Honda Foreman 500 Service Manual 2012 Trx500

User Manual: Honda Foreman 500 Service Manual 2012 Trx500

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HOW TO USE THIS MANUAL

A Few Words About Safety
Service Information
The sel"llice and repair infonnatiofl contained in this manual is intended fO( use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others . It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated eqUipment. Any person who Intends to use a replacement part. service
procedure or a tool thai is not recommended by Honda, must determine Ihe risks to their personal safety and the safe operation of
the vehICle.
If you need to replace a part. use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
thai you do not use replacement parts of inferior quality.

For Your Customer's Safety
Proper servIce and maIntenance are essential to the customer's safety and the reliability of the vehicle Any error or oversight whIle
servicing a vehicle can resull in faulty operation, damage to the vehlde, or Injury to others.

AWARNING
tmproper service or repaIrs can create an unsafe
conditIon that can cause your customer to be
seriously hurt or killed
Follow the procedures and precautions in this
manual and other service materials carefully.

For Your Safety
Because this manual is Intended for the professIon al service techniCIan, we do not provIde wamings about many basic shop safety
practIces (e.g .. Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend thai you do not attempt to perfOf'1l1 the procedures described in this manual.
Some of the most important general service safety lX9Cautions are given betow However, we cannot warn you of every
conceivable hazard that can ansa in performing service or repair procedures. Only you can decide whether or not you should
perfoon a given task.

AWARNING
Failure to property follow instructions and
precautions can cause you to be seriously hurt or
killed
Follow the procedures and precautions
manuat carefully

In

this

Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are weanng appropriate clothing and
using safety equipment. When perfooning any service task, be especially careful of the fol lOWIng
Read aU of the Instructions before you begin. and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and complelely
Protect your eyes by using proper safety glasses. goggles or face shields any time you hammer, drill. grind, pry or work around
pressurIZed air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
bums or cu ts. Before you grab something that looks like it can hun you, stop and put on gloves.
Protect yourself and others whenever you have the vehicle up in the air. Any IJme you lift the vehicle. either with a hOist or a Jack,
make sure that II is always securely supported. Use jack stands.
Make sure the engine is off before you begin
help eliminate several potential hazards:

any servictng procedures unless the instructIon tells you to do otherwise. ThiS wilt

Carbon monoxide poIsoning from engine exhaust. Be sure there IS adequate ventllatJon whenever you run the engine.
, Burns from hot parts or coolant. Let the engine and exhaust system cool before WOr1-

~ F=~~~==~=============================
FUEL SYSTEM
-'
w F=======================================~
o
COOLING SYSTEM

~ F=~==~=============================
LUBRICATION SYSTEM

~ F=C~Y~L~I=N~D=E=R=H=E=A=D=N=A=L=V=E=======================
>- F=~~~~~========================

w
CYLINDER/PISTON
~ F=~~~~====~==~================
CLUTC H/GEARSHIFT LINKAGE
o0::

WF=A~L~T=E=R~N~A=T=O=R=/S=T=A=R=T=E=R=C=L~U=T=C~H~===============

Z f======================================
Cl
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Z

w

ENGINE REMOVAUINSTALLATION
FRONT WHEEUSUSPENSION/STEERING

II>

REAR WHEE USUS PENSION

~ F==B=R~A=K=E=S~Y=S=T=E=
M============================

J:

(J

FRONT DRIVING MECHANISM
REAR DRIVING MECHANISM
BATIERY/CHARGING SYSTEM
LIGHTS/METERS/SWITCHES
ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
ELECTRIC POWER STEERING (EPS: FPM/FPE models)
WIRING DIAGRAMS
INDEX

MEMO

J

1. GENERAL INFORMATION

SERVICE RULES .... ······································ 1·2

LUBRICATION & SEAL POINTS ··············· 1·19

MODEL IDENTIFICATION ···························· 1·3

CABLE & HARNESS ROUTING················· 1·23

SPECIFICATIONS ········································· 1·6

EMISSION CONTROL SYSTEMS ·········· ···· 144

TORQUE VALUES· .. ··································· 1·13

1-1

GENERAL INFORMATION

SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lubricants or their equi....alents. Parts that don't meet Honda's design
specifications may cause damage to the vehicle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle. Metric botts, nuts and screws are not interchangeable with English fasteners .
4 . Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or Inner bolt first. Then tighten to the specified torque diagonally in
incremental sleps unless a particular sequence is specified.
6. Clean parts in deaning solvent upon disassembly. lubricate any sliding surfaces before reassembly.
7 After reassembly, check all parts for proper installation and operation.
8 Route all electrical wires as shown In the Cable & Harness Routing (page 1-23).
9. Do not bend or twist control cables. Damaged control cables will not operates smoothly and may slid( or bind.
10. Do not tow your ATV behind a car or other vehicle.

ABBREVIATION
Throughout this manual, the following abbreviation are used to identify the respective parts or systems.

L ""n;",Abbrev. term
,- CKP sensor
LCD
DLC
DTC
PCM (FEfFPE models)

Full term
Crankshaft Position sensor
liquid Crystal Display
Data link Connector - Diagnostic Trouble Code
Powertrain Control Module

==i~E~n~g~ine Control Module

ECM (FMfFPM modelstl
ECT sensor
-~
EEPROM
EPS
ESP
ECU
HDS

l

Engine Coolant Temperature sensor
ElectncaUy Erasable Programmable Read Only Memory
Electnc Power Steering
Electric Shift Program
Electric Control U~
Honda Diagnostic System

IACV
_======~',dle Air Control Valve
IAT sensor
Intake Air Temperature sensor
MAP sensor _ __ _ __
Manifold Absolute Pressure sensor
MIL
Malfunction Indicator Lamp
PGM-FI
Programmed Fuel Injection
SCS service connector
I Service Check Short service connector
TP sens:~o~,_ _ __ _ __ ~I Throttle Position sensor
VS sensor ____ _ __
Vehicle Speed sensor
_ _ _ __ _ _ _J -4 Wheel Drive
4WD

1·2

t

!

=-_____

GENERAL INFORMATION

MODEL IDENTIFICATION
This manual covers 4 types of TRXSOO models:
FM - 4WD/Left fool operated gearshift
FE - 4WDfElectric shift program (ESP)
• FPM - 4WD/Left foot operated gearshift/Electric Power Steering (EPS)
• FPE - 4WDfElectric shift program (ESP)fElectric Power Steering (EPS)
Be sure to refer to the procedure that pertains to the appropriate version of the TRX500.

SERIAL NUMBERS
The Vehicle Ideo(;fi08tloo N,mbe, (VI N) [1) Is stamped 00 the Imot "de 01
the frame through the front fender.

The engine serial o,mbe' [11 Is stamped 00 the leh side of the 'ea,
crankcase.

I

I

1-3

GENERAL INFORMATION
The throttle body identification number (1) is stamped on the lower side of
the throttle body.

LABELS
The certification label [1] (U.S.A. type) or safety certification label [2]
(Canada type) is attached on the left front frame down pipe.

The color label 11] is attached on the left front frame down pipe. When
ordering color-coded parts. always specify the designated color code .

1-4

GENERAL INFORMATION
The vehicle emission control information label (11 is attached on the left f ront
frame pipe .

U.S.A. and Canada type :

111

Canada type only:

1-5

GENERAL INFORMATION

SPECIFICAliONS
GENERAL SPECIFICATIONS
DIMENSIONS

- -- - ITEM
Overall length
Overall width
Overall height
Wheelbase
Front tread
Rear tread
Seat height
Footpeg height
Ground clearance
Curb weight

FMJFPM:
FElFPE:
FM :
FE:
FPM :
FPE:

FRAME

ENGINE

Maximum weight capacity
Frame type
Front suspension
Front wheel travel
Front damper
Rear suspension
Rear wheellravel
Rear damper
Front tire size
Rear tire size
Front rim size
Rear rim size
Front tire brand
Rear tire brand
Front brake
Rear brake
Caster angle
T ra il length
Camber angle
Fuel tank capacity
Fuel tank reserve capacity
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train
opens: at 1 mm (0.04 in) lift
Intake valve
closes: at 1 mm (0.04 in) lift
Exhaust
opens: at 1 mm (0.04 in) lift
valve
closes: at 1 mm (0.04 in) lift
lubrication system
Oil pump type
Cooting system
Air filtration
FMlFPM:
Engine dry weight

FUEL DELIVERy
V - -TT"yp" eC
SYSTEM _ _~_T
"h",
rott!e bore

1-6

SPECIFICATIONS
2,127 mm (83.7 in)
1,205 mm (47.4 in)
1,197 mm (47.1 in)
1,281 mm (50A in)
915 mm (36.0 in)
925 mm (36.4 in)
881 mm (34.7 in)
365 mm ( 14.4 in)
355 mm (14.0 in)
194 mm (7.6 in)
U.S.A.: 284 kg (626 Ibs)
Canada: 286 kg (631 Ibs)
U.S.A.: 285 kg (628 Ibs)
Canada: 286 kg (631 Ibs)
U.S.A.: 291 kg (642 Ibs)
Canada : 293 kg (646 Ibs)
U.S.A. : 292 kg (644 Ibs)
Canada: 294 kg (648Ibs)
220 kg (48Slbs)
Double cradle
Double wishbone
171 mm (6.7 in)
Double tube
Swingarm (trailing type)
174 mm (6.9 in)
Double tube
AT2S x 8-12 .. -

AT2S x 10-12
12x6.0AT
12x7.5AT

**

M975 (MAXXIS )
M978 (MAXXIS)
Hydraulic disc brake
Mechanical drum brake

3·
11 rnm (0.4 in)

O·

15.0 lilers (3.96 US gal , 3.30 Imp gal)
4 .6 liters ( 1.22 US gal, 1.01 Imp gal )
Single cylinder, longitudinally installed
92.0 x 71.5 mm (3.62 x 2.81 in)
475 cm l (29.0 cu-in)
9.5 ' 1
OHV
7" BTOC
43" ABOC
44 " BBOC
1· ATOC
Forced pressure and wet sump
Trochoid
liquid cooled
Oiled double urethane foam
U.S.A .: 51.4 kg (113.3Ibs)
Canada: 52.5 kg (115.7Ibs)
FElFPE:
U.S.A.: 52.3 kg (1l5.3Ibs)
Canada: 53.4 kg (117 .7Ibs)
- -- - -- - - - hpGM.FI (Programmed Fuel Injection)

36 mm (1.4 in)_ _

1

GENERAL INFORMATION
ITEM'---_ _ __
DRIVE TRAIN

Clutch system
Clutch operation system
Transmission
Primary reduction
Secondary reduction
Final reduction

Gear ratio

SPECIFICATIONS
Centrifugal and multi-plate, wet
Automatic
Constant mesh, 5-speeds with reverse
2.103 (61/29)
1.875 (30/16)
3.231 (42/13)

Front
Rear

3.154 (41/13)

1st

41h
51h
Reverse

4.230 (55fI3)
2.388 (43/18)
1.608 (37/23)
1.178 (33/28)
0.848 (2S(33)
5.743 (48/13 x 2af18)

FM/FPM:

Left foot operated return system

2,d
3,d

R - N-I-2-3-4-5

Gearshift pattern

ElECTRICAL

--"F"EI"F",P",E'c'_~-:EO",;:eC,"I~ric__s"h'";f~(left
t
hand operated) return sys__l"em
" '--_---"
Ignition system
Starting system

Full transistorized ignition
Electric starter motor
Electric starter motor and emergency recoil slater
Triple phase output alternator
FET shorted , triple phase full wave rectification
Battery

U.S.A.:
Canada:

Charging system
Regulator/rectifier
Lighting system

PGM-FI SYSTEM SPECIFICATIONS
ITEM
tAT sensor resistance (20°C/68 F-' ) - - - - - - - - -EeT sensor resistance (40 ± 5 Cf104 ± 4 1°F)
+
Fuel injector resistance (20°C/6,oS,,·F:l)_ _ _ _ _ _ _ _~+

SPECIFICATIONS

Q

2.2
0.86

6

2.7 kO
1.55 kO

11.6-12.40

IGNITION SYSTEM SPECIFICATIONS

--=====:- ===+==
+ ___

ITEM
Spark plug
____
Spark plug g~p
________
Ignition coil primary peak voltage
Ignition pulse generator peak voltage
_ Ignition timing ("F" mark)

SPECIFICATIONS

--'S"'K"'RSE-l1 (NGK), KI6PR-Ul1 (DENSO)
1.0-1.1 mm (0.039-0.043 in)
100 V minimum
0.7 V minimum
10 BTDC al idle

1

6

ELECTRIC STARTER SPECIFICATIONS
ITEM
-----starter motor brush length

_ _~~~ Unit: mm (in)

STANDARD
12.0 (0.47)

_ _+-,;;S..
ER
o;,VICE LIMIT
6.5 (0.26)

FUEL SYSTEM SPECIFICATIONS
ITEM
Throttle body identification number
Idle speed
Throttle lever freeplay
Fuel pressure at idle
Fuel pump flow (at 12 V)

SPECIFICATIONS
GQ3RA
1,400 ± 100 rpm
3-8mm(0. 1-0.3in)
316 387 kPa (3.2 3.9 kgf/em2, 46 56 psi)
125 em (4.2 US oz, 4.4 Imp OZ) minimum/ l0 seconds

1-7

GENERAL INFORMATION
COOLING SYSTEM SPECIFICATIONS
Coolant capacity

ITEM
Radiator and en"9i,n,,
,0 ______--f__
==::-:R
.::e"s",
erve tank

1.51lters (1.6 USqt. 1.3 Imp qt)
0.3 liter (0.3 US ql. 0.31mp qt)
108-137 kPa (1 .1 - 1.4 kgffcm 2, 16 20 psi)
Radiator cap relief pressure
--==========:1==-Thermostat
~gin to open
80 84'C 1176 183' F)
9S' C (203' F)
Fully open
-o
8 ~m~mOff(0~.3~i~n~)m~in~imumat9~S"'C'"12~0~3"'F~)-----, Valve lift
Recommended a~n"
tif;:;re"eC;ze-;:----"-'
Pro Honda HP Coolant or an equivalent high quality ethylene

~=====_______= == = = : - '-

Standard coolant concentration

1

---==:;::;;:~S~
P~
EC~I~F~ICATIONS;;:;::;;;====-j

glycol antifreeze containing silica;te;~-f~ree
~CO~rrtOS~io~n~i~n~hi~b~
ito~rs=---t
1:1 mixture with di~illed water

LUBRICATION SYSTEM SPECIFICATIONS

1

Unit: mm (in)
SERVICE LIMIT
STANDARD
Engine oil capacity
After draining
+--;2.9 liters (3.1 US ql. 2.6 Imp ql)
3.0 liters (3 ,2 US qt, 2.6 Imp ql)
After draininglfilter change
,-;;;;-;;;o==,-'-~
After disassem
~b~I~
Y ________+--i3;o:
.3 liters (3 .5 US qt, 2.9 Imp ql)
;r+--------------'
Recommended engine oil
Pro Honda GN4 4-stroke oil (U.S,A. and
Canada) or Honda 4-stroke oil (Canada
only), or equivalent motor oil
API service classification: SG or higher
(except oils labeled as energy
conserving on the circular API service
label)
JASO T 903 standard: MA
_________--f--;Viscosity: SAE 10W-30
Oil pump
0~20J0008 ~
L!!Pclearance
0.15 (0.006) ""'''''''''''_ _
~y clearance
0.15 -0.24 (0.006 0.009)
0.25 (0.010)
___________L
: .'S"'i
de clearance
0,02 - 0.09 (0.001 - 0.004)
0.11 (0.004)

::;::==~fT~E~MC::;~

,""= ==o--__

CYLINDER HEADNALVE SPECIFICATIONS
ITEM
Cylinder compression at 400 rpm
Valve clearance
Valve, valve
9 uide

Valve stem 0 .0 .
Valve guide 1.0 .
Stem·to-guide clearance

~
EX
IN
EX
IN/EX
IN

Unit: mm (in)
STANDARD
SERVICE LIMIT
600 kPa (6 .1 kgf/cm3, 87 psi)
0.15±0.02(["006To.001)
0.23 :t 0.02 (0.009 ± 0.001)
5,975 5.9-90 (0.2352 0.2358)
5.95 (0.234)
5.955 - 5. 970(0.2344 - 0.2350)
5.93 (0.233)
6.000 6. 012 (0.2-362 - 0.2367 f-)---+-'6"'.;::02"1"'0~.2"37':)'--0.010 O. 037 (0.0004 - 0.0015)
0.12 (0.005)

~~;1:'j~;c~~:t===~E~X~=~0.030

Valve sprin9
Rocker arm

Camshaft and
cam follower

Valve guide
above
i
Valve seat width
Free length

Arm 1.0.
Shaft 0.0.
r---Arm-to-shaft
Cam lobe height

Cam follower 0 .0 .
Follower bore 1.0.
Follower-to-bore
Cylinder head warpage

1·8

IN/EX

- 0.057
(0.00
12 - 0.0022)
14.8 -15.0
(0.58
- 0.59)

0.14 (0.006)

GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS
Cylinder

Piston,
pis-ton pin,
piston ring

i

Unit: mm (in)
SERVICE LIMIT
92 .10@:626)
0.10 (0,004)
0.10 (0.004)
0.10 (0.004)
91 .90 (3.618)
19.04 (0.750)"
18.96 (0.746)
0.08 (0.003)
0.5 (O.02)
0.6 (0.02,,)_ _
0.9 (0.04)
0.09 (0.064-)-0.09 (0.004)
I 0 10 (0.004)-----1
19.07 (0.751)
I
0.10 (0.004)

STANDARD
--.-~---,ITEM
1.0.
92.000' -9"'2".0"1"'0'"'(3.6220 _ 3.6224)
Out-of·(ound
Taper
Warpage
Piston 0.0. at 15 (0.6) from bottom
91.970 - 91.990 (3.6209 - 3.6216)
Piston pin hole l.O.
=~~t-'19.002 -19.008 (0.7481 - 0.7483)
Piston pin 0.0 .
18.994 19.000 (0.7478 - 0.7480)
0.002 - 0.014 (0.0001 - 0.0006)
Piston-Ie-piston pin clearance
Piston ring end
L.!op
0.15- 0.30 (0.006 0.012) ~~~_
gap
, Second .~;:=:=~O. 30 - 0.45 (0.012 0.018)
~~_-,Oil (side r~il)
0.20 - 0.70 (0.008 0.028)

I

_-_-_-_-=--=-+f-

Piston ring-to-ring

Top

groove clearance

------second

~~~+-O.030 - 0.060 (0.0012 - 0.0024)

0.030 - 0.060 (0.0012 - 0.0024)
0.010 _ 0.040 (0.0004 - 0.0016)
19.020 - 19.041 (0.7488 - 0.7496)
0.020 - 0.047 (0.0008 - 0.0019)

Cylinder-to-piston clearance
Connecting rod small end 1.0 .
Connecting rod-to-piston pin clearance

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
UOII: mm (in)
STANDARD
SERVICE LIMIT
ITEM
Centrifugal
Drum 1.0.
150.0 - 150.2 (5.906 - 5.913)
150.4 (5.9c=2~)_ _
clutch
Weight lining thickness
2.0 (0.08)
1.3 (0.05)
Clutch spring height
-t- 2.96 (0.1 17)
~~~-+- 2.84 (0.112)
.=;;;-~~C::;;lutCh weight spring free len"g"th,---~~~I 24.72 (0.973)
~~_ _ 25.7 (1.01)
Change clulch
Spring free length
FM/FPM
52 .2 (2.06)
_-=;:=:;:=:=- 50.7 (2.00)
FElFPE
46.8 (1.84)
45.3 (1.78)
Disc thickness
_ _~~~ 2.62 - 2 ..78 (0.103 0.109)
~~_-;2.3 (0.09)
Plate warpage
0.20 (O.O~L
Outer [0. _--=;:=:==29.000 - 29.021 {1.1417 - 1.1426)~--;29. 05 (1 .144)
Outer guide
1.0 .
22.000 - 22.021 (0.8661 - 0.8670)
22.05 (O.868).

1

0.0.
Primary drive
gear

- 28.980 (1.1401 21 .967 - 21.980 (0.8648 29.000-29.021 (1. 1417 28.959 - 28.980 (1.1401 -

~~_ 28 . 959

Mamshaft 0 .0 . at clutch outer guide
Gear 1.0
Crankshaft 0 .0 . at drive gear

1.1409)
0.8654)
1.1426)
1.1409)

28.93
21 .93
- t -29 .05
28.93

(1 .139)
(0.863)
(1 .144 )
(1.139)

AL TERNATORISTARTER CLUTCH SPECIFICATIONS
Unit: mm (in)

:::-;:;;::;:==_tltTEM _ _---,"'_
Starter driven gear boss
0.0.

1.0.
i

Crankshaft 0.0. at starter driven gea=,~~~_

~ .705

STANDARD

=.---~_...,S~E"iR"
VICE L1M IT

51.718 (2.0356 - 2.0361)

~946 - 31.962 (1.2577 - 1.2583)

1-

31.884 - 31.900(1.2553-1.2559)

51 69 (2.035)
31 .90 (1.256)
31.85(1.254)

1-9

GENERAL INFORMATION
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER SPECIFICATIONS
Unit: mm (in)

~=~~ :::::r,T!iE[jM
'==--_--rc
STANDARO
1.0.
Front, re"'
a,c -- ' - 13.00
= 0- "3."
' 02:C,CC(O.5118 0.5126)
Center -==t~'~3.000 13.018 (0.5118 - 0.5125)

SERVICE LIMIT
13.04 (O.5~
13.04 (O.S13)
_
4,93 5.00(0.194 - 0.197)
4.5(0.18)
Claw thickness
12.966
12.984
(O.5105-0.5112)
12.96 (0.510)
= = -1-' Shaft 0 .0 .
M3
---+-25.000 25.021 (0.9843 - 0.9851)
25.05 (0.986)
Transmission
i Gear LD.
M5
20.000 - 20.021 (0.7874 - 0.7882)
20.05 (0.789)
CTC2, C4, CR
28.020 28.041 (1 .1031-1 .1040)
28.07 (1.105)
Reverse idle
13.000 13.021(0 .5118-0.5126)
13.04(0.513)
M3
24.959 24 ,980 (0,9826 - 0.9835)
24.93 (0.98 1)
Gear bushing
0.0.
M5
!
19.966 19.984 (0.7861 0.7868)
19.94 (0.785)
C2
27.984 28.005(1 .1017-1 .1026)
27.94 (1.100)
"C4' CR
27.979 28.000(1 .1015 - 1.1024)
27.93(1 .100)
M3
~
I 0.020 0.062 (0.0008 - 0.0024)
0.10 (0.004)
GeaHo-bushing
clearance
M5
0.016 0,055 (0.0006 - 0. 0;;0~2~2)t:::=:t 0.10 (0.004)
C2
0.D15 0.057 (0.0006 - 0 . ~~22)
0.08 (0.003)
Cl. C4 , CR
0.020 0.OS2 (0.0008 - 0.0024)
0.10 (0.004)
Gear bushing 1.0.
M3
22 .000 22.021 (0.8661 - 0.8670)
22.04 (0.868)
M5
I 17.016 17.034 (0.6699 0.6706)
17.06 (0.672)
_ _-'-'_:C4
25.000 25.021 (0.9843 0.9851)
25.05 (0.986)
Mainshaft 0 .0 .
at M~21 '959 21.980 (0.8645 - 0.8654)
21 ,93 (0.863)
I at M5
16.976 - 16.987 (0.6683 0.6688)
16.93 (0.667)
I Countershaft 0 .0 . I a t C4
24 .959 24.980 (0.9826 - 0.9835)
24 .93 (0.98 1)
~erse idle shaft 0 .0 .
12,966 - 12.984 (0.5105 - 0.5112)
12,94 (0.S09)
Bushlng-to-shaft
M3
0.020 0.062 (0.0008 0.0024)
0.10 (0.004)
clearance
M5
0.029 0.058 (0.0011 - 0.0023)
0.10 (0.004 )
C4
0.020 0.062 (0.0008 - 0.0024)
0.10 (0.004)
Reverse idle gear-tcrshaft clearance
0.016 0.055 (0.0006 0.0022)
0.10 (0.004)
Crankshaft
Runout
0.15 (O.OOS)
Big end side clearance
0.05 0.65 (0.002 - 0.026)
0.8 (0.03)
Big end radial clearance
0.006 0.018 (0.0002 - 0.0007)
0.05(5J)02)

Shift fork

t

~

1

j

I

t

-f

t

ENGINE REMOVAUINSTALLATION
Engine dry weight

ITEM
FMIFPM
FElFPE

Et

SPECIFICATIONS

U.S,A.
Canada

51.4 kg (113.3 tbs)
52.5 kg (115.7 !bs)

U.SA

52.3 kg (llS.3Ibs)

Canada
53.4 kg (117.7Ibs)
After draining
2.9 liters (3. 1 US ql.
After draining/fille~
Change
3.0 liters (3.2 US qt.
After disassembly
3.31iters (3.5 US ql.
Coolant capacity (radiator and engine)
__ 1.5 liters (l.G US qt,
Engine oifcapadty

Reverse selector lever freeplay

2

4 mm (0.1

1
2,6 Imp qt)f -_ _
2.6 Imp ql)
2.9 Imp qt)
1.3 Imp qt)

4
4
t

j

0.2 in)

FRONT WHEEUSUSPENSION/STEERING SPECIFICATIONS
_ _, -oo,'""Unll: mm (in)

~

ITEM

Minimum tire tread dePth~~~==Cold tire
L Standard
pressure
[ With cargo
Tie-rod distance between the ball joints
_ _ _
Toe
- -

1-10

-.:::;;;::~S~T.ANDARD_-:;;;===

".
,--::
30 kPa (0.30 kgffcm2. 4.4:c'P:OS;~)_
30 kPa (0.30 kgflcm', 4.4 psi)
+~3~83.1 (15",.0;;08,,)=,Toe-oul: 28± 15 (1.1:t0.6)

j, 4.0 (0.16)

SERVICE liMIT

_
I

L

1

GENERAL INFORMATION
REAR WHEEUSUSPENSION SPECIFICATIONS
ITEM
Minimum lire tread depth
Cold tire pressure

Unit: mm (in)
_ _-"S ERViCE LIMIT

STANDARD

I

Standard
With cargo

_ _+-4.0 (0.16)

-==+p
~3'O kPa (0.30 kgf/cm7, 4.4 psi)
-

~ kPa (0.30 kgf/cm 2 , 4.4 psi)

BRAKE SYSTEM SPECIFICATIONS
ITEM
Front b"',"'ak"e:--

Recommended brake fluid

STANDARD
Honda DOT 4 brake fluid

Disc th,ckne,"s~s_ __

3.8 - 4.2 (0.15 - 0.17)

Unit: mm (in)
_ _ _ _ SERViCE LIMIT

Disc runout
Master cylinder 1.0.
Master piston 0.0.
Caliper cylinder 1.0.
:-_~C;a!iper piston 0.0. Rear brake
Drum 1.0.
Shoe lining thickness
Oa"""i"o9")"b",.,"ke lever freeplay'--_ _
Rear (p
Rear brake ~al freeplay

14.000 - 14.043 (0.5512 - 0.5529)

r

13.957 - 13.984 (0.5495 - 0.5506)
32.030 - 32.080 (1.2610 - 1.2630)

I 31 .984 - 31.998 (1.2578 - 1.2598)

180.0 - 180.2 (7.086 - 7.094)
5.3 (0.21)
15
15

3.0(0.12)
0.30 (0.012)
_~'4 055 (0.5533)
13.945 (0 5490)
32.090 (12634)
31.94 (1.257).
181.0 (7 13)
To index mark

t

20rnm(O.6 -0. 8in)
20mm(O.6 -0.8 In)

FRONT DRIVING MECHANISM SPECIFICATIONS
VOl!. mmJin)
ITEM

STANDARD

SERVICE LIMIT

Front final
drive

Oil capacity
After draining
200 em' (6.8 US oz, 7.0 Imp ozl
="".--'A"ft",e,-"disassembly_..--'2~5:v0"icm3 {8.S US 02, 8.8 Imp ozl
Honda shaft drive oil or equivalent
Recommended oil
hypoid gear oil. SAE # 80
Gear backlash
0.4 (0.02)
0.05 0.25 (0.002 - 0.010)
Backlash"'d"iff"e'c,e"'oce=-0.2 (0.01)
Slip torque
14 - 17 N·m (145 - 1.75 kgfm ,
12Nm
10 - 13lbfft)
(12 kgfm. 9lbfft)
Face cam-to-housing distance
3.3 3.7(0.13 -0. 15)
3.3 (0.13)
Differential ring gear depth
6.55 6.65 (0.258 - 0.262)
_---+_6:.55 (0.258)
2.6 (0.10)
2.8(0.11)
_ _ _ _--"
Cone spring free heighl

REAR DRIVING MECHANISM SPECIFICATIONS
ITEM

Axle runout
Rear final drive

Oil capaCIty --!A~.~e;:,d~'2'a~lning
After disassembly
Recommended oil

Gear backlash
Backlash difference
_~-"
R~in,g gear-Io-stop pin clearance

STANDARD

75 em l (2.5 US oz, 2.6 Imp oz)
100 cm 3 (3.4 US oz. 3.5 Imp ozl
Honda shaft drive oil or eqUivalent
hypoid gear oil, SAE # 80
0.05 - 0.25 (0.002 - 0.0 10)

Unit mm (in)
SERVICE LIMIT
3.0 (0. 12)

0.4 (0.02)

0.2 (0.01)
0.3 - 0.6 (0.01 - 0.02)

,
,
i

1·11

GENERAL INFORMATION
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM

SPECIFICATIONS

GYZ16H
12V-16Ah

Battery

_ _-,;0",
,62 mA,o
m:caCi'._ _ _ __ _

--:::=::;!'~3.0
-11~.4
; ,3~.2~VV7:=======_
Below

Capacity
Charging coil resistance (20°C/68°F)

Al temator

_ _ _ _ _ __ ~
' .~6Ax5 ~
'0~h~-­
- n:;-i"".OiiA x 1 .0~h=_ _
0.416 kWfS,OOO rpm

0.1-1.00

--====_

LIGHTS/METERS/SWITCHES SPECIFICATIONS
Bulbs

t

ITEM
Headlight (high/low beam)
Assist headlight

BrakeJtaitlighl
Neutral indicator
Reverse indicator
Coolant temperature indicator

[ MIL

4WD indicator

Meterlighl

Fuse

EPS indicator (FPMlFPE)
,
Main fuse
FMlFPM

t FElFPE

Sub-fuse
EPS fuse (FPMfFPE)

1-12

SPECIFICATIONS

12 V - 30/30 W x 2

12V-45W
LEO
LEO
LEO
LEO
LED
LED
LEO
LEO
30A
30Ax2
15Ax2,10Ax2
40A

l

GENERAL INFORMATION

TORQUE VALUES
STANDARD TORQUE VALUES
FASTENER TYPE
5'-m
=
m~b~o~lt~
and nul
6 mm bolt and nut
8 mm bott and nut
10 mm bolt and nut
12 mm bolt and nut

+-

TORQUE
N'm (kgf'm, IbHt)

.t-I_-,5'i.2~
(O . 5 , 3.8)
10(1 .0, 7)

_+t--_..2;;-2j;(2.2, 16 )

+

34 (3.5. 25)
54 (5.5, 40)

TORQUE

_tJ~~~F~AwSTENER TYP_E_ --1i-._ .N·m (kgf'm, Ibf-ftl----j
5 mm screw

4.2 (0.4, 3.1)

6mmscrew

_j
9(0 .9. 6.6) - -

6 mmflange bolt

10 (1. 0, 7)~

(8 mm head , small flang ~
. ),---_ _ __
6 mm flange bolt
(8 mm head, large flange)'--_ __
6 mm flange bolt
(10 mm head) and nul
8 mm flange bolt and nul
10 mm flange boll and nut

12 (1 .2, 9)

-==1==--

12 (1 .2, 9)
27 (2 .8. 20)

39 (4 .0. 29)

ENGINE & FRAME TORQUE VALUES

. Torque specifications listed below are for important fasteners .
. Others should be lightened to standard torque values listed above .

FRAME/BODY PANELS/EXHAUST SYSTEM

ITEM

a'TV
4
8
2
2
3
1
1
2

Rear carrier bolt
no!

band bolt
screw (front side)
screw (rear side)
stud bolt

THREAD

TORQUE
N'm (kgf 'm , IbHt)
74 (7.5 . 55)

DIA. (mm)

10
8
8
6

8

REMARKS

32_(3.3. 24)

J

23
22
2 .0
2.0

(2 .3,
(2.2.
(0.2,
(0 .2.

17)
16)
1.5)
1.5)

~

3.2 (0.33, 2.4 )
6.0 (0.6. 4.4 )

See page 2·15

MAINTENANCE
ITEM
Spark plug
Valve adjusting screw lock nut
Valve adjusting hole cap
Timing hole cap
Engine oil drain bolt
Rear final gear case oil check bolt
Rear final gear case oil filler cap
Rear final gear case 011 drain boll
Rear final gear case skid plate bolt
oil filler cap
case oil drain bolt
cover bolt
reservolf cap screw
II
(knuckle side)
(steering arm side)

a'TV
1
2
2
1

1
3

14
6
36
14
12
8
30
8
8

1
3
2
2
2

30
8
6
4
12
12

1
1

THREAD
DIA. (mm)

TORQUE
N·m (kgf·m , IbHt)
22 (2.2. 16)
17 (1.7, 13)
12 (1 .2. 9)
10 (1 .0. 7)

REMARKS

25 (2.5. 18)
12 (1.2 . 9 )
12 (1.2. 9 )
12 (1.2. 9 )
32 (3.3. 24)
12 (1 .2. 9 )
12 (1 .2. 9)
10 (1 .0. 7)
2 .0 (Q.2. 1.5)
54 (5.5. 40)
54 (5.5. 40)

I
I

b

ALOe bolt: replace
with a new one.

age3.26
Left hand threads .
See page 3·26

PGM·FI SVSTEM
ITEM
Sensor unit tone screw (T25)
EeT sensor
Bank ang~sensor mounting bolt

3

THREAD
DIA. (mm)
5

2

10
6

Q'TV

+

,

i

TORQUE
N·m (kgf·m . IbUt)
3.4 (0 .3, 2.5.)
12 (1.2 . 9 )

REMARKS

10 (1 .0. 7)

1-13

GENERAL INFORMATION
IGNITION SYSTEM
- -'T-E-M- - - - - - - i - - , - - -a- '-T-Y--,-

JT~im~i~n~g~h~O'~e~ca~pP-----=_ _ _ _

L'

TORQUE

THREAD

REMARKS

DIA.1~
(;m~m~)j:~N~.mi2
lk~gi'·m
Qj,'lb~'.ft~):j======-_~
10(1
.0,7)

_t

ELECTRIC STARTER

----ITEM
__

a 'TY

THREA
~TORQUE

+~;-+--,O:cI"A'-i'(mm)

s;;:,at.rtiie'~m~o~'~o'~"'~"'idbo~'~'
W---====~~tj2=i=-_
N~alive brush set screw
1
55

N'm

I

REMARKS

(k9['~.mj'~'ba,·~ft~)± = = == == - - j

4.9 (0.5,
3.7
(0.4, 3.6)
2.7)

FUEL SYSTEM

---

Q'TY
THREAD
TORQUE
+ ---,.----t-=::
DIA. F"'---,----'N
c:...m
~ (kgf'm, IbHt)

ITEM

REMARKS

-~=~=-~:~(~Oi
·9~.6~.5~)c==t~
S~
~p:a~ge~1.~2~0==-1
!~9.
66)
34 (0.3. 2.5)

_~~==~~t-=-=-~r=~~34~0·E3.~2:5)==~~~B1I=~1
See page 7-25
See page 7-26

5

1.8 0.2.1.3)
2.1 (0.2, 1.5)
5.1 (0.5. 3.8)

COOLING SYSTEM

,----

ITEM

_ _ _ _ _+_

I Cooling fan nul

Q'TY
THREADQ TORQUE
,_ + -DIA. (mm)
N'm (k~.!:m , !bHt)

5

2.7 (0.3. 2.0)

REMARKS

Apply locking agenllo
the threads.

1

52
===r-=-=j
; (0.5.
(0.9, 3.8;t) =:t==-:===:::1
t

Fan motor bolt
Fan motor stay bolt

_ : t:j3=
: : - --j56
3

jde)

Rear fina!gear case oil seal I;;
I~·
i

Rear final gea"
.
Left axle
I 1 5-ring
Left axle I
I ld"t,eal llp,

--------r---------------~

lri'~llwneel "oel

Fron

'.""'n 'P";~',;~r pl,ot!
pper arm pl,ot
I 1 inner

grease

II • ,haft)

j

lShaitsPline

"pllne

EPS """ ,

'e."hoCk
I
Front
"ont I

I

'.

,I lip'

~

I

I land d,,"ealllp'

'I,ot d"t ,eal lip,
II "haft boo"lp
II
t ,pllne, (both "de,)
'~ pinion joint splines

c,,".:_
89

~ ....: :
,s_h_~ft side: 5
\0.2 - 0.3 0')
5 - 8 g (0.2 - 0.3 oz;

-

II
j
,I jOint 'pllne, ,oth ,Ide,)

Rear

II

Rear

II

"pllne, (gear
O-ring

Rear axle 'pllne, (3 I
; (Kyodo Y"hl)

Front

I

~Irrtl

50 - 70 g (1 .8 - 2.5 oz;

1-21

GENERAL INFORMATION

Honda Handgrip Ce,me,nt
(U.S.A. only) or equivalent

Engine

nullhreads
t

J

1-22

GENERAL INFORMATION

CABLE & HARNESS ROUTING
THROTTLE CABLE

REAR (pARKING)
BRAKE CABLE

FRONT BRAKE HOSE A

HANDLEBAR
SWITCH WIRE

REVERSE

REVERSE SELECTOR

CABLE

SELECTOR
CABLE

HANDLEBAR
SWITCH WIRE
FRONT SUB-WIRE

':)..'::>--r\ HARNESS
REAR
(PARKING)
BRAKE CABLE

Front

REAR BRAKE LIGHT SWITCH (Lever side)

/

IGNITION
SWITCH WIRE

II~

1

BAND
(Secure at the tape position)

o

HANDLEBAR
SWITCH WIRE

REVERSE

REAR (PARKING)
BRAKE CABLE

FRONT SUB·WIRE
HARNESS
Front

1·23

GENERAL INFORMATION

HAN DLEBAR SWITCH WIRE
(To front brake/light switch)

HANDLEBAR SWITCH WIRE

Front

Front

t

t
FUEL TANK
BREATHER HOSE

IGNITION SWITCH

B3

Ol,--!{I

REAR BRAKE LIGHT
SWITCH WIRE

(lever side)

FRONT BRAKE
INHIBITOR SWITCH

GRAY TAPE

I
BRAKE
LIGHT SWITCH

1·24

j

GENERAL INFORMATION

t
~

IGNITION SWITCH WIRE

FRONT SUB-WIRE

HARNESS

Up

MAIN WIRE
HARNESS

BANK ANGLE SENSOR 3P
(Black) CONNECTOR
SIPHON HOSE

HANDLEBAR
SWITCH WIRE

Front

ACCESSORY
SOCKET WIRE
HEAOLIGHT WIRE

WATER HOSE
(Thermostat-Io-radlator)

PAINT
MARK

Up
,

I

45"

-----..

FAN MOTOR 2P
(Natural) CONNECTOR

4WD SElECT
SWITCH WIRE

~Hr_r~

-

Lett
PAINT

MARK
FMfFPM : HANDLEBAR SWITCH 10P (Green) CONNECTOR
FElFPE : HANDLEBAR SWITCH 14P (Green) CONNECTOR

FRONT SUS-WIRE HARNESS
14P (Gray) CONNECTOR

1-25

GENERAL INFORMATION
ACCESSORY SOCKET
2P (Black) CONNECTOR

I
3P
(Black) CONNECTOR

Reverse side of radiator:
FAN MOTOR

FAN MOTOR 2P
(Natural) CONNECTOR

PAINT
MARK

•

~
_.

PAINT
MARK

4WD SELECT SWITCH WIRE

1-26

FAN MOTOR
BREATHER HOSE

45"

"

.. Right

_

WATER HOSE
(Radiator-Io-waler pump)

GENERAL INFORMATION

FRONT BRAKE PIPE

4WD SELECT SWITCH WIRE

FRONT FINAL GEAR CASE
BREATHER HOSE

FRONT BRAKE HOSE B

o

0

o

FRONT FINAL GEAR CASE
BREATHER HOSE

4WD SELECT

WIRE

4WD SELECT SWITCH

1·27

GENERAL INFORMATION

Inside of front fender:
FRONT FENDER

LID

HEADLIGHT HOUSING

H"""LI~'" WIRE

GROOVE

GROOVE

HEJ'DL.IG>n WIRE

SOCKET

1·28

SOCKET WIRE

GENERAL INFORMATION

FUEL VAPOR RETURN HOSE

FRONT BRAKE HOSE A

J

~"'-~~~~~~~~~~S~~~~i=:::FUEL
'\

I

1

LEVEL SENSOR
2P (Red) CON NECTOR

FUEL OVERFLOW HOSE

FCOot~

-~

3 - 8 mm (0.1 - 0.3 in)

3-Bmm(O.1-0 .3in)

PAINT MARK

Align pain t mark wi th arrow

1-29

GENERAL INFORMATION

FRONT BRAKE HOSE B

STOPPER

RIGHT FRONT BRAKE CALIPER

FRONT BRAKE HOSE B

STOPPER

LEFT FRONT BRAKE CALIPER

1-30

GENERAL INFORMATION

FUEL VAPOR
RETURN HOSE

Front

FUEL VAPOR RETURN
HOSE (From fuel lank)

FUEL HOSE

SUB-fUEL TANK!
FUEL PUMP

FUEL FEED
HOSE

:..L'---

L _ _---'-_ _

PAINT MARK

FRONT FINAL GEAR CASE
BREATHER HOSE
SIPHON HOSE
FUEL HOSE

REAR (PARKING )
BRAKE CABLE
REVERSE
SELECTOR CABLE

fAN MOTOR

MAIN WIRE

BREATHER HOSE (Pink)

HARNESS

o
THROTTLE CABLE

HEATGUI'RD
PLATE

Eer SENSOR!
IGNITION COIL WIRE

1-31

GENERAL INFORMATION
FPM/FPE :

TORQUE SENSOR 3P
(Gray) CONNECTOR

SHIFT CONTROL
MOTOR WIRE (FPE only)

TORQUE
SENSOR WIRE

FRONT FINAL GEAR
CASE BREATHER HOSE

~

FAN MOTOR
BREATHER
HOSE (Pink)

EPS SUB-WIRE

I

EPS MOTOR

EPS UNIT

EPS MOTOR 2P
(Gray) CONNECTOR

All models (FPMIFPE shown):

2WD/4WD SELECTOR
CABLE

1-32

GENERAL INFORMATION
FM/FE :
REVERSE
SELECTOR CABLE

REAR (PARKING)
BRAKE CABLE

WATER HOSE

WATER HOSE

SHIFT CONTROL MOTOR
WIRE (FE only)

Up

•

Up
WATER PUMP
BREATHER HOSE

•

SHIFT CONTROL MOTOR 2P
(Black ) CONNECTOR (FE only)

SHIFT CONTROL
MOTOR WIRE (FE only)

SHIFT CONTROL
MOTOR WIRE
(FE only)
FAN MOTOR

BREATHER
HOSE (Pink)

FRONT FINAL
GEAR CASE
BREATHER HOSE

FUEL HOSE

FAN Mo-roR
FUEL

HOSE

FRONT FINAL GEAR CASE

BREATHER HOSE (Pink)

BREATHER HOSE

1-33

GENERAL INFORMATION
FPMIFPE :
WATER HOSE

WATER HOSE

REVERSE
SELECTOR CABLE

~=J~~~j~~~i~~1~-~~~:~:~-::-=S''::.-:
~

)_~~

WATER
BREATHER HOSE

WIRE (FPE ooly)
SHIFT CONTROL MOTOR
Up

•

\

EPS ECU 21 P (Gray)
CONNECTOR

SHIFT

MOTOR 2P

(Black) CONNECTOR (FPE only)

SHIFT CONTROL

MOTQRWIRE

TORQUE

(FPE only)

SENSOR WIRE

FAN MOTOR

BREATHER

EPS ECU 2P (Gray)

HOSE (Pink)

CONNECTOR

FINAL
BREATHER HOSE

FUEL HOSE

FUEL FEED HOSE

Mo-rOR 2P
(Gray) CONNECTOR

1-34

EPS ECU

GENERAL INFORMATION

Clamp tab position

/

PAINT MARK

0-3 mm
(0-0.1 in)

FUEL VAPOR RETURN HOSE

J:;;;;;;Q:;T

FUEL HOSE
(To be butted to the

fuel joint)

FUEL TANK

Up

•

(it

·,'·T:·-

FUEL JOINT

0-3 mm

FUEL JOINT

PAINT MARK

(0-0.1 in)

~

FUEL VAPOR
RETURN HOSE

~

~

lHOSE

0- 10mm

0-5 mm

(0 - 0.4 in)

(0-0. 2in)

rrn

(j

(

,

I

D=-

~.

Me;

1;

I

~

rrn

OD

I

I

SUB-FUEL TANK/FUEL PUMP

1-35

GENERAL INFORMATION
FUEL INJECTOR 2P (Gray)

FUEL FEED HOSE

THROTTLE CABLE

CONNECTOR

SENSOR UNIT 5P

CONNECTOR

REAR BRAKE PANEL

BREATHER HOSE

REAR FINAL GEAR
CASE BREATHER HOSE

INTAKE AIR DUCT

IACV 4P (Bllao.,j CONNECT'OR

FRONT FINAL GEAR
CASE BREATHER HOSE

FAN MOTOR BREATHER
HOSE (Pink)

FAN MOTOR BREATHER
HOSE (Pink)

FRONT FINAL GEAR
CASE BREATHER HOSE

REAR BRAKE PANEL
BREATHER HOSE

REAR FINAL GEAR
CASE BREATHER HOSE

1-36

GENERAL INFORMATION

IGNITION COIL PRIMARY WIRE
CONNECTOR
II

Eel SENSOR 2P
(Black) CONNECTOR

SPARK PLUG W IRE

Up

Right

IGNITION COIL PRIMI,R" WIRE
CONNECTOR (BlaCk/red)
WATER HOSE
(Thermostat-la-radiator)
Right

•,

Front .. ~ -

..

••

THROTTLE
BODY

BANDS

AIR CLEANER HOUSING
CONNECTING TUBE BAND

INTAKE AIR DUCT
CONNECTING TUBe BAND

AIR CLEANER HOUSING
CONNECTING TUBe BAND
Up

t
Right ..
AIR CLEANER SUB CHAMBER
CONNECTING TUBe BAND
Up

t

le"
13·

~o

§

O~

I
1-37

GENERAL INFORMATION
GEAR POSITION SWITCH
BP (Gray) CONNECTOR

FMlFPM; ENGINE SUB-WIRE HARNESS 3P (Btack) CONNECTOR
FElFPE: ENGINE SUB·WIRE HARNESS 6P (Black) CONNECTOR

REVERSE
SELECTOR CABLE

SIPHON HOSE

REAR (PARKING)
BRAKE CABLE
REVERSE
SELECTOR

CABLE

FRAME

GROUND
POINT

SIPHON

Ql,~--HOSE

REAR

ALTERNATOR 5P
(Natural) CONNECTOR

LIGHT

SWITCH WIRE

REVERSE
SELECTOR CABLE

Righi

•

STARTER MOTOR
CABLE

REAR FINAL

GROUND CABLE
(Engine-to-frame)

REAR (pA.RKING)
BRAKE CABLE

BATIERY
NEGATIVE
HCABlE

Up

WIRE

HARNESS

SIPHON HOSE

GEAR CASE
BREATHER HOSE

BATIERY
NEGATIVE H

CABLE

~~?l. ~i~~~~~~~~;~~~E~~r~
~

MAIN WIRE HARNESS
STARTER MOTOR CABLE
REAR BRAKE LIGHT SWITCH
2P (BlaCk) CONNECTOR

REAR BRAKE

REAR FINAL GEAR
CASE BREATHER HOSE

Up
t

GROUND CABLE
(Engine-la-frame)

IAT
2P
(Black) CONNECTOR
BATIERYNEGATlVE
HCABLE

STARTER MOTOR
CABLE

1-38

REAR BRAKE PANEL
BREATHER HOSE

ENGINE SUB-WIRE HARNESS:
- FM/FPM: To VS SENSOR
- FE/FPE: To SHIFT ANGLE SENSORNS SENSOR
GEAR POSITION
SWITCH WIRE

GENERAL INFORMATION

GEAR POSITION
SWITCH WIRE
SHIFT ANGLE SENSOR
WIRE (FElFPE only)

ENGINE SUB·WIRE HARNESS:
- FMfFPM. To VS SENSOR
- FElFPE: To SHIFT ANGLE
SENSORNS SENSOR

ALTERNATOR
GROUND CABLE
(Engine-ta-frame)

WIRE
Up

BATTERY
NEGATIVE (-)
CABLE

STARTER
MOTOR

CABLE
CLAMP

VS SENSOR 3P
(Black) CONNECTOR

GEAR POSITION
SWITCH WIRE

f\-~~;;-:;,'ll-=~ ~;f:~~~ ~ijCJ'l--.J

REAR BRAKE PANEL
BREATHER HOSE

REAR FINAL GEAR
CASE BREATHER HOSE

REVERSE SELECTOR
CABLE

SHIFT ANGLE SENSOR 3P (Gray) CONNECTOR
(FElFPE only)

CRANKCASE BREATHER HOSE

fM IFPM :

\
\

~

h

VS SENSOR 3P
(Black) CONNECTOR

CLAMP

VS SENSOR 3P
(Black) CONNECTOR

1·39

GENERAL INFORMATION
Clamp at paint mark position

LEVER REAR (PARKING)
BRAKE CABLE

PEDAL REAR BRAKE CABLE

REAR FINAL
GEAR CASE

BREATHER HOSE

BREATHER HOSE

REAR BRAKE UGHT SWITCH

REAR BRAKE UGHT
SWITCH WIRE

REVERSE SELECTOR CABLE

PEDAL REAR BRAKE CABLE
PEDAL RETURN SPRING

Spring installation direction:

BRAKE LIGHT SWITCH SPRING

FRAME

BRI'KE PEDAL

1-40

GENERAL INFORMATION

MAIN WIRE

HARNESS
STARTER MOTOR

CABLE

REAR FENDER
SUB-WIRE HARNESS

REAR FENDER
SUB-WIRE HARNESS

MAIN WIRE

HARNESS
SA TTERY NEGATIVE
CONDENSER 2P (Natural)
CONNECTOR (Canada type )

(-)CABLE

BATTERY

REAR FENDER SUB-WIRE HARNESS
lOP (G ray ) CONNECTOR

RECTifiER 2P (Black)
CONNECTOR (Canada type)

Ole

(Red)

RADIATOR RESERVE TANK
BREATHER HOSE

CONDENSER
(Canada type)

RECTIFIER
(Canada type)

REAR
FENDER

REGULATOR!
RECTIFIER WIRE

SIPHON HOSE
RECTIFIER

CONDENSER WIRE
(Canada type)

RECTtF IERWIRE
(Canada type)

1-41

GENERAL INFORMATION
FM/FE :
FM: MAINfFAN FUSE 1P (Natural ) CONNECTOR
FE: MAIN FUSE 2P (Natural) CONNECTOR

BRAKEfTAILLIGHT 3P
(Black) CONNECTOR

STARTER RELAY SWITCH
2P (Green) CONNECTOR

~~ __ DIODE

~

MAIN WIRE

HARNESS

FUSE BOXf
DIODE

PCI.vEC;M ';P (Bla"')
CONNECTOR

L
=li1
,

. -_.-

'''1l''' ,'.','",1,

'"

_..... ....

~ .

"'" ..'..
,

" ,
'

.v.~

"

,

f

[- &
t{!-

"

TAB

7
'ig;;ri1~ mm

No interference

f Up

Up

i-~

I
3,2 N' m (0,33 kgf-m,
2.4 IbHI)

in)

MUFFLER
COVER

Up

I

Left

6 mm bolts and washers
, ~Nm(22kgfm.'6Ibfft)

MUFFLER BAND

... ,. - ..... --- .---- -_. -- _._-

!--i£:1~J Left
2.0 N'm (0.2 kgf·m, 1.5Ibf·ft)

2·15

MEMO

3. MAINTENANCE

SERVICE INFORMATION ············ ·················3·2

2WD/4WD SELECT SYSTEM ····················· 3·19

MAINTENANCE SCHEDULE ··················· ·····3·3

BRAKE FLUID ······································ .... ·· 3·20

FUEL LINE······························ ·······················34

BRAKE SHOES WEAR ························· .... · 3·21

THROTTLE OPERATION ······························ 34

BRAKE PADS WEAR ........... ...................... 3·21

AIR CLEANER·················· ·· ···························3·5

BRAKE LIGHT SWITCH ·························· ···3·21

AIR CLEANER HOUSING DRAIN TUBE ······ 3·7

BRAKE SYSTEM ············ ···························· 3·22

SPARK PLUG ················································ 3·8

REVERSE LOCK SySTEM ························· 3·23

VALVE CLEARANCE ····································3·9

GUARDS .......... ........... ................................ 3·24

ENGINE OIL ················································ 3·12

CLUTCH SYSTEM ······································3·24

ENGINE OIL FILTER ···································3·14

SUSPENSION ············· ··· ······ ···················· ··· 3·25

ENGINE IDLE SPEED ·································3·15

SPARK ARRESTER ··································· 3·25

RADIATOR COOLANT ······························· 3·15

NUTS , BOLTS, FASTENERS ..................... 3·25

COOLING SYSTEM·· ··································· 3·16

WHEELSITIRES ............................. .......... ... 3·25

DRIVE TRAIN BOOTS ································ 3·17

TIE·ROD AND JOINT BOOTS ····················3·26

REAR FINAL GEAR CASE OIL AND
DIFFERENTIAL OIL ····································3·17

STEERING SHAFT HOLDER BEARING ···· 3·26
STEERING SySTEM··································· 3·26

3-1

MAINTENANCE

SERVICE INFORMATION
GENERAL
• Place the vehicle on level ground before starting any work.

TORQUE VALUES
ITEM

f

a 'TV

Spark plug
Valve adjusting screw lock nut
Valve adjusting hole cap
Timing hole cap
Engine oil drain bolt
Rear
i1
Rear
i1
Rear
i1
Rear
case

1
2
2
1
1
1
1
1
3

Front final gear case oil filler cap
Front final gear case oil drain bolt
Final clutch arm cover bolt
Front master cylinder reservoir cap screw
Tie-rod lock nut (knuckle side)
Tie-rod lock nut (steering arm side)

1
3
2
2
2

THREAD
DIA. (mm)

+--

TOOLS
Adjusting screwdriver
07GMA-KTB0110

3·2

Valve adjusting wrench
07GMA·ML70120

14
6
36
14
12
8
30
8
8
30
8
6
4
12
12

TORQUE

N'm (kgf'm, IbHt)

REMARKS

22 (2.2, 16)
17 (1.7, 13)
12 (1.2,9)
10 (1.0, 7)

25 (2.5,18)
12 (1.2, 9)

12 (1.2, 9)
12 (1.2, 9)
32 (3.3, 24)

ALoe boll: replace
with a new one.

12 (1.2, 9)
12 (1.2. 9)

HlJ1Jl, 7)
2.0 (0.2, 1.5)

54 (5.5, 40)
54 (5.5, 40)

See page 3-26
left hand threads.
See page 3-26

MAINTENANCE

MAINTENANCE SCHEDULE
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and dean. adjust. lubricate or replace if necessary. C: Clean. R: Replace. A : Adjust. L: Lubricate.

FREQUENCY WHICHEVER
COMES
FIRST

INITIAL

;f

AI NTENANCE

FUEL LINE

150
1

~;==~_ ===~H~O~URS

,",

THROITlE OPERATI..,.O",N'-----II--.,
AIR CLEANER
NOTE 1

i~~T~~~~~R HOUSING
SPARK PLUG

VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FilTER

1i:

4=

RADIATOR COOLANT _ __

"N~OTE 3

COOLING SYSTEM

NOTE 2

AND DIFFERENTIAL Oil
• __ 2WD/4WD SELECT SY STEM
• BRAKE FLUID
NOTE 3
NOTE 1, 2• BRAKE SHOES WEAR
• . BRAKE PADS WEAR
NOTE1 .2
BRAKE LIGHT SWITC H
BRAKE SYSTEM
REVERSE LOCK SYSTEM
GUARDS
CLUTCH SYSTEM
SUSPENSION
SPARK ARRESTER
NUTS, BOLTS. FASTENERS
•• WHEELSfTlRES
~~:t===
.. TIE·ROD AND JOINT BOOTS,-+_ __
•• STEERING SHAFT HOLDER
BEARING
. . I STEERING SYSTEM

••

_"

2,000
12

_-r---_~2ooI

C

12 months: R

+

I
I

+

+
t

3-4

3-9
3·ti'
~

3·14

~

I
I
I
I
I
I
C

3·t5

L

I
I

+

3-4

-t-:l:15

~ (RE,e'Y
2 years)

+

REFER
TO
PAGE

" 1 ~:: ;

I
C

-===;::.;:;:-

-DRIVE TRAIN BOOTS
REAR FINAL GEAR CASE "O"IL~'---­

~

- + - - -'00

-+==~'1,200

I
I
I
INITIAL 100 mi (150 km), 20 operating hours or 1 month : R
REGULAR = Every 600 mi (1.000 km), 100 operating hours or

-I-

ENGINE IDLE SPEED

20

1.000
6

+

NOTE 2

REGULAR MAINTENANCE
INTERVAL

100~=:;:::=~'600

mi
km
MONTH

ITEMS

I

1
[

I
I
I
I
I
I
I
I
I
I
C
I
I

3·20
3·21
3·21
3·21
3-22

3·23
3-24

3-24
3-25
I 3-25

3-25
3-26
3·26

I

I

t- 3.25'--j

3·26

Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
In the interest of safety, we recommend these items be serviced only by a dealer.

NOTES:
1. Service more frequently when riding in dusty areas, sand or snow.
2. Service more frequently after riding in very wet or muddy condi tions.
3. Replace every 2 years. Replacement requires mechanical skill.

3-3

MAINTENANCE

FUEL LINE
Remove the fuel tank (page 7-20).

Check the fuel lines III for deterioration , cracks,
damage or leakage .
Replace the fuel hose if necessary.

THROTTLE OPERATION
Check for any deterioration or damage to the throttle
cable. Check the throttle lever 11] for smooth operation .
Check that the throttle opens and automatically closes
in all steering positions
If the throttle lever does nol return property, lubricate
the throttle cable and overhaul and lubricate the throtlle
housing (page 16-11).
If the throttle lever still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure that the idle speed does nol
change. If idle speed increases, check the throttle lever
free play and the throttle cable connections.

Measure the throttle lever freeplay at the tip of the
throttle lever.

THROITLE LEVER FREEPLAY:
3-8 mm (0.1 - 0.3In)

Throttle lever free play can be adjusted al either end of
the throttle cable . Minor adjustments are made with the
upper adjuster.
Slide the rubber boot (1 J off the adjuster [2].
Loosen the lock nut (3). lum the adjuster as requIred
and tighten the lock nut.
Install the rubber boot securely.

3-4

MAINTENANCE
Major adjustments are made with the lower adjuster.
Remove the throttle body cover (page 7-13).
Slide the rubber boot (1] off the adjuster (2].
Loosen the lock nut (3]. turn the adjuster as required
and tighten the lock nut.
Install the rubber boot securely.
Recheck the throttle operation and install the throttle
body cover (page 7-13).

AIR CLEANER
NOTE :
• If the vehicle is used in dusty areas, sand or snow.
more frequent inspections are required.

Remove the seat (page 2-4).
Release the four retaining dips [lJ and remove the air
deaner cover (21 .

Loosen the band screw [1) and remove the air cleaner
element assembly 121.
Remove the dust filter [3] from the element holder in the
air cleaner housing.
Check the dust filter for dirt. and clean it if necessary.

3-5

MAINTENANCE
Remove the element band (1] and the element core [2J
from the air cleaner element 131.

I1J

'"

[3[

[2J
Wash the element and filter In non-flammable or high
flash point solvent.

Squeeze out the solvent thoroughly. and allow the
element and filter to dry.

Wash

Squeeze out

Apply approximately 20 9 (0.7 oz) of Pro Honda Foam

Filler Oil [11 or equivalent oil from the inside of the
element.

......_ _ [1[

Place the element into a plastic bag [2J and spread the
oil evenly by hand.

[2J

Install the element core
[21 properly.

III into the

air cleaner element

[2J '---...

Install the element band [3] onlo the element flange.

[3[

3-6

MAINTENANCE
Clean the inside of the air cleaner housing and cover.
Make sure the rubber seal in the cover is in position and
in good condi tion.
Install the dust filler [1) into the housing port.
Install the element assembly [2) over the connecting
tube on the housing.
Be sure to rest the element onto the stepped area [3} of
the housing and tighten the band screw [4].

Install the air cleaner cover [1] with the arrow [2) facing
forward by aligning the stepped area (3) with the
element.
Secure the cover wi th the four retaining clips [4].

~~~~~~~~IlIII~~~I~'I~"""""""""""

Install the seat (page 24).

~

~' ~ I .

. .

~ ~.- ~
141

AIR CLEANER HOUSING DRAIN TUBE
NOTE '
• If the vehicle is used in very wet or muddy
conditions , more frequent inspections are required.

Remove the drain tube (1) from the bottom of the air
cleaner housing to empty any deposits.
Install the drain tube securely .

3-7

MAINTENANCE

SPARK PLUG
Remove the left side cover (page 24).
Clean around the
sparK plug base
with compress&(l air
before removing the
plug. end be sure
thaI no debris is

Disconnect the spark plug cap (1) and clean around the
spark plug base.

Remove the spark plug (2).

a/lowed to enter into
the combustion
chamber.

Check the insulator [1 ) for cracks or damage, and the
electrodes for wear, fouling or discoloration. Replace
the plug if necessary.

~~111111111111111111~~~"""'''''''''''==::~
12J

13J

RECOMMENDED SPARK PLUG :
BKR5E·11 (NGK). K16PR·U11 (DENSO)

Clean the spark plug center electrode (2) and side
electrode (3] with a wire-type brush or special plug
cleaner.

]1J
Check the spark plug gap between the center and side
electrodes with a wire-type feeler gauge.

SPARK PLUG GAP: 1.0 - 1.1 mm (0.039 - 0.043 in)

If necessary, adjust the gap by bending the side
electrode carefully.

Thread the spark plug in by hand to prevent crossthreading and tighten it to the specified torque with a
spark plug wrench .
TORQUE : 22 N'm (2.2 kgf'm , 16 tbHtl

Connect the spark plug cap and install the left side
cover (page 2-4).

3-8

:==================~
1.0-1.1mm

(O.039 - 0.043 in)

MAINTENANCE

VALVE CLEARANCE
NOTE
Inspect and adjust the valve clearance while the
engine is cold (below 35°C/9S0F),
• Check the engine idle speed after the valve
clearance inspection (page 3-15).
Remove the following:
-

fuel tank (page 7-20)
intake air duct (page 7-22)
right mudguard (page 2-6)

Remove the following:
- rubber plug [lJ (from the heat guard plate)

-

intake valve adjusting hole cap 121

Release the cables [3], wire harness and hoses {4] oul
of the heat guard plate [5].

Be careful not /0
damage the fuel

lift Ihe right side of the heat guard plate up (1) and
remove the exhaust valve adjusting hole cap [2J.

hooe.

Remove the following:
-

three bolls [1]
crankshaft hole cap [2]
timing hole cap [3]

3·9

MAINTENANCE
If the ...,. marl( is
passed when trymg
/0 align il with the
Index mark.

Rotate the crankshaft clockwise to align the ~T· mark 111

on the flywheel with the index mark 121 on the

crankcase.
Make sure the piston is at TDC (Top Dead Center) on

contmue to rotate the compression stroke.
This position can be obtained by confirming that there is
to align. slack in both rocker arms. If there is no slack, rolale the
Do not rotate the crankshaft one full tum and match up the
mark
crankshaft again .
the crankshaft

cIockwlS6

-r

counterclockwise.
This ;s 10 prevent
the one-way

decompressor
system from
functlOfllflg. whICh
would cause an
in~valve

clearance

measurement
W'hen checking the

clearance. slide the
feeler gauge from
the center toward
the outside.

Check the valve clearances by inserting a feeler gauge
(1) between the adjusting screw and valve stem,
VALVE CLEARANCE :

IN : 0.15:t: 0.02 mm (0.006:t: 0.001 in)
EX : 0.23:t: 0.02 mm (0.009 :t: 0.001 in)

Adjust by loosening the lock nut {1] and turning the
adjusting screw [2] until there is a slight drag on the
feeler gauge.
TOOLS:

(3] Valve adjusting wrench
[4] Adj usti ng screwdriver

07GMA·ML70120
07GMA·KTS0110

Hold the adjusting screw and tighten the lock nut to the
specified torque.
TORQUE : 17 N'm (1.7 kgf'm, 131bHt)

After tightening the lock nut, recheck the valve
clearance.

3-10

111

MAINTENANCE
Coat new O-rings [1J with engine oil and install them
into the groove in each valve adjusting hole cap.
Install the valve adjusting hole caps and tighten them to
the specified torque.
TORQUE : 12 N'm (1.2 kgf'm, 9 tbHt)

Coat a new D-ring 111 with engine oil and install il onlo
Ihe timing hole cap 121.
Inslall the liming hole cap and tighten it 10 the specified
torque.
TORQUE: 10 N'm (1 .0 kgf'm, 7 lbHt)
Coat a new a-ring [31 with engine oil and Install It into
the crankcase cover groove.

Install the crankshaft hole cap {11 and tighten the three
bolts [2].
Install the removed parts in the reverse order of
removal.

Install the heat guard plate (1) on the frame while
rouling the cables (2). wire harness and hoses (3) into
the guides of the plate properly, being careful not to
damage them.

~:::::::::::;;=:::~

Install the rubber plug [4).
Be sure the routing items are in place and install the
following:
- right mudguard (page 2-6)
- intake air duct (page 7-22)
- fuel tank (page 7-20)

3-11

MAINTENANCE

ENGINE OIL
LEVEL CHECK
NOTE:
Check the oil level after starting the engine and
allowing the oil to circulate through the engine
thoroughly. It is especially important on a dry sump
engine . due to the comparatively large volume of oil.

Do nol snap the throttle while idling or the oil level
reading will be inaccurate.
Remove the left side cover (page 2-4).
Place the vehicle on level ground.

III

Start the engine and let it idle for 3 - 5 minutes.
If the air temperature is below lOoe (50°F). lei the

engine idle for an additional 5 minutes (a tolal of 10
minutes).
Slop the engine and wait 2 - 3 minutes.

Remove the oil filler capfdipSllck [1 J and wipe it clean.
Check the oil level by inserting the oil filler cap/dipstick
into the engine without screwing it in.
The engine contains a sufficient amount of oil if the oil
level is between the upper level [21 and lower level (3)
marks on the dipstick.
If the oil level is near or below the lower level mario:, add
the rerommended engine oil to the upper level mario;.
RECOMMENDED ENGINE OIL:
Pro Honda GN4 4·stroke 011 (U .S.A . and Canada)
or Honda 4·stroke oil (Canada only), or equivalent
motor 011
API service classification: SG or higher
(except oils labeled as energy conserving on the
circular API service label)
JASO T 903 standard: MA
Viscos ity: SAE 10W·30
NOTE ·
Other viscosities shown in the chart may be used
when the average temperature in your riding area is
wi thin the indicated range .

OIL VISCOSITIES

Reinstall the oil filler capfdipstick.
lDW·30

Inslalilhe left side cover (page 2-4 ).

10W·40

SW·30

ow
--30~ ,, '0
·20

3-12

0 -20

30

0

'0
40

••
•

20 :10
10 to

~50'C

.Go

,2o·F

MAINTENANCE
OIL CHANGE
NOTE '
• Change the oil with the engine warm to assure
complete and rapid draining.
Remove the left side cover (page 2-4).
Place the vehicle on level ground.
Start the engine and let it idle for a few minutes.
Slop the engine.
Remove the drain 0011111 and the oil filler cap/dipstick
[2J to drain the engine oiL
After the oil has drained, install the drain bolt with a new
sealing washer (3] and tighten it to the specified torque.

TORQUE : 25 N'm (2.5 kgf'm, 181bHt)

\

Pour the recommended oil (page 3-12) into the engine
to the upper level mark on the dipstick.

OIL CAPACITY:
2.9 liters (3. 1 US qt, 2.6 Imp qt) after draining
3.0 liters (3.2 US qt, 2.6 Imp qt) after draininglfllter

change

3.3 liters (3.5 US qt, 2.9 Imp qt) after disassembly
Install the filler cap/dipstick.
Check the oil level (page 3-12).
Resel the 011 change indicator after changing the engine
oil as follows.

OIL CHANGE INDICATOR RESET
To reset the indicator [1] , press and hold the odometerl
tripmeter/hourmeter select button [2] and turn the
ignition switch ON for more than 5 seconds. The
indicator message win disappear.

[X2~2 [0)
'-, - ,

(R2~N2

(~

-1\1

If the oit is changed before the oil change indicator
appears, be sure to reset the oil change indicator after
changing the oil, except after the initial oil change.
Press and hold the odometerflripmeter/hourmeter
select button and tum the ignition switch ON for more
than 5 seconds . When the indicator lights for 2 seconds
and then turns off, the oil change indicator is reset.

L'

ouo

n:

--

1...... 1

2 "'l.I.

/
121

\

!;

111

- il

f>l E . .

)

~

3-13

MAINTENANCE

ENGINE OIL FILTER
Remove the right side cover (page 2-4 J.
Drain the engine oil (page 3-13).
Remove the following:
three bolts [1]
cover because oil - filter cover [2] and O-ring

Pface shop towels

under the filter

-

will flow out

-

oil filler [1j
selting spring (2)
D-ring (3]

Coat new a-rings [1] with engine oil and install them
into each groove in the filter cover [2J and front
crankcase cover.
Installmg the oil
filter backwards will
resul/insevere
engine damage.

Install the selling spring onto the lugs and a new oil filler
with the rubber seal [3] facing Qui, away from the
engine ("OUT.SIDE- mark [41 on the filler is visible).
then set the filter cover onto the filter and lighten the
bolls while holding the cover.
Fill the crankcase with the engine oil (page 3-13).
Install the right side cover (page 2-4).

3-14

MAINTENANCE

ENGINE IDLE SPEED
INSPECTION
NOTE:

Inspect the idle speed after all other engine
maintenance Items have been performed and are
within specifications.
Before checking the idle speed, check the following:
- OTC or MIL blinking (page 4-11)
- spark plug condition (page 3-8)
- air cleaner condition (page 3-5)
The engine must be warm for accurate idle speed
inspection.

This system eliminates the need for manual idle
speed adjustment compared 10 previous designs.

Use a tachometer with graduations of 50 rpm or
smaller thai will accurately indicate a 50 rpm
change.

Remove the left fuel lank side cover (page 2-5),

Start the engine and warm it up until the coolant
temperature rises to

ao°c (176°F ).

SlOp the engine and connect a tachome ter according to
the tachometer manufacturer's instructions.
Start the engine and let it idle. Check the Idle speed.
ENGINE IDLE SPEED : 1,400 ± 100 rpm

If the idle speed is out of the specification, check the
following:
~ throttle operation and throttle lever free play
(page 3-4).
- intake air leak
- engine top-end problem (page 10-6)
- IACVoperation (page 7-26)

RADIATOR COOLANT
Check the coolant level of the reserve tank [11 with the
engine running at normal operating temperature.
The level should be between the upper 121 and lower
level lines [3] wi th the vehicle upright on a level surface.

If the level is low, add coolant as follows
Remove the rear fender cover (page 2-9).
Remove the reserve tank cap [41 and fill the lank up to
the upper level line with a 1:1 mixture of distilled wa ter
and antifreeze (coolant preparation: page 8-6).
RECOMMENDED ANTIFREEZE:
Pro Honda HP coolant or an equivalent high
quality ethylene g lycol antifreeze containing
silicate-free corrosion inhibitors

NOTICE
Using coo/ant with silicate corrosion inhibitors may
cause premature wear of w8ter pump se8/s 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 Ihe reserve tank becomes completely emply, there is
a possibility of air getting Into the cooling system.
Be sure to remove any air from the cooling system
(page 8-7).

3-15

MAINTENANCE

COOLING SYSTEM
NOTE:
• If the vehicle is used in very wei or muddy
conditions, more frequent inspections are required.
Remove the front grille (page 2·7).
Remove the side covers (page 2-4).

Be careful not /0 Remove the radiator grille under cover 11] by releasing
damage the radiator the four tabs {2] .
fins.

Remove the following :

-

connector and wire [3J (from right side air guide
plale)

-

two trim cUps [4J (from each side air guide plate by
pushing the center pin )
side air guide plates (by releasing each lab)
radiator grille (by releasing the two tabs)

-

121

Check for any coolant leakage from the water pump (1) .
water hoses [21 and hose joints.

Check the water hoses for cracks or deterioration and
replace if necessary.
Check that aU hose clamps are light.

Check the radiator air passage for clogs or damage.
Straighten bent fins with a small, fiat blade screwdriver
and remove insects, mud or other obstructions with
compressed air or low water pressure.
Also, clean the radiator grille thoroughly.
Replace the radiator if the air flow is restricted over
more than 20% of Ihe radiating surface.
Install Ihe removed parts in the reverse order of
removal.

NOTE :
When installing the trim clip, carefully align the clip
holes in the radiator, grille and air guide plate.

3-16

111

MAINTENANCE

DRIVE TRAIN BOOTS
Raise all the wheels off the ground by supporting the
frame securely
Remove the left side cover (page 2-4).

Check the drive shaft boots (1), propeller shaft boots [2]
and universal Joint boot [3] for cuts, damage or leaking

grease.

If the boot is damaged , replace it
- front driving mechanism (page 19-2)
- rear driving mechanism (page 20-2)

121

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 11) and check that the oil
flows out of the check bolt hole.
Check for leaks if there is no oil flow.

Remove the oil filler cap [2) and pour the oil slowly
through the filler hole until oil starts to flow out of the
check bolt hole.
RECOMMENDED OIL: Honda shaft drive gear oil or
equivalent hypoid gear oil,
SAE # 80
Install the check bolt with a new sealing washer [3] and
tighten it to the specified torque .

TORQUE: 12 N'm (1.2 kgf·m, 9lbHt)
Coat a new O-ring [41 with grease and install it into the
cap groove.
Instan the filler cap and tighten illo Ihe specified torque.

TORQUE: 12 N·m (1 .2 kgf·m, 9lbHt)

3-17

MAINTENANCE
OIL CHANGE
Place the vehicle on a level surface.
Remove the three bolts {1] and fear final gear case skid
plate {2}.

Remove the drain bolt (1] and sealing washer [2J. and

the filler cap 13J to drain the oil.
When the oil is completely drained, install the drain bolt
with a new sealing washer and lighten ilia the specified
torque.
TORQUE : 12 N'm (1 .2 kgf'm , 9lbHt)
Fililhe gear case with the recommended oil

(page 3-17).

OIL CAPACITY:

75 em 1 (2.5 US OZ , 2.6 Imp oz) after draining
100 em) (3.4 US OZ, 3.5 Imp oz) after dis assembly

Inslal1 the skid plate with new three bolts and tighten the

bolts to the specified torque.

TORQUE : 32 N'm (3.3 kgf-m, 24 IbHt)

DIFFERENTIAL OIL
LEVEL CHECK
Place the vehicle on a level surface.
Remove the oil filler cap (1] and check that the ailteval
is up to the lower edge of the oil filler hole 12].
Check for leaks if the oil level is low.
Pour the oil into the filler hole until it reaches the lower
edge of the hole.
RECOMMENDED OIL: Honda shaft drive gear o il or
equivalent hypoid gear o il ,
SAE # 80
Coat a new O-ring /31 with grease and install il into the
cap groove.
Install the filler cap and tighten it to the specified torque.
TORQUE: 12 N'm (1.2 kgf'm, 9lbHt)

3-18

L _ _ _ _-'-_ _- 'L _

MAINTENANCE
OIL CHANGE
Place the vehicle on a level surface.

Remove the drain bolt [1] and sealing washer [21 . and
the oil filler cap [3] to drain the oil.
When the oil is completely drained , install the drain bolt
with a new sealing washer and tighten it to the specified
torque.
TORQUE: 12 N'm (1.2 kgf-m, 9lbHt)
Fill the gear case with the recommended oil
(page 3-18),

OIL CAPACITY:
200 cm 3 (6.8 US oz, 7.0 Imp oz) after draining
250 em 3 (8.5 US oz, 8.8 Imp 02) after disassembly

2WD/4WD SELECT SYSTEM
2WD/4WD SELECTOR CABLE
ADJUSTMENT
Remove Ihe boll [11 and the clutch arm cover 121 by
releasing the two tabs [3].
Shift the select lever to the 2WD position.
Be sure the clutch arm [4] position is between the 2WD
marks [5].

Temporarily loosen the adjusting nut [6J by turning it
counterclockwise.
Tum the adjusting nut clockWise until the joint pin (7)
just touches the clutch arm slot (8) with the nut ends (9)
are contacted the joint pin (cutout is not seated). Then
further turn it clockwise 1f4 of a turn to seat Ihe cutout in
the nul onto the joint pin.
Make sure that the clearance between the joint pin and
arm slot is 0.25 - 2 mm.

I
13J

Ir~
\
12J

I1J

After adJuslmenl. check the select lever for smooth
operation .
Install the arm cover by aligning the slits with the tabs
and tighten the bolt to the specified torque.
TORQUE : 10 N 'm (1.0 kgf'm , 7 Ibf-ft)

...

Touches
the slot

O.2S-2mm

3-19

MAINTENANCE

BRAKE FLUID

I

NOTICE

Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the

system Is serviced.
NOTE :

Do not mix different types of fluid, as they may not
be compa tible with each other.

Do nol allow foreign material to enter the system
when filling the reservoir.
When Ihe fluid level is low, check the brake pads for
wear (page 3-21 ). A low fluid level may be due to
wear of the brake pads. If the brake pads are worn
and the caliper pistons are pushed Qui, this accounts
for a low reservoir level. If the brake pads are nol

worn and the fluid level is low. check the entire
system for leaks (page 3-22).
Tum the handlebar to the left side so the reservoir is , - - - - - - - - - - - - -- ---...,
level and check the reservoir fluid level through the
121
sight glass.

If the fluid level is near the "LOWER" level mark [11.
remove the reservoir cap [2], set plate and diaphragm
and fill the reservoir with DOT 4 brake fluid from a
sealed container to the casting ledge [3].
Install the diaphragm , set plale and reservoir cap. and
tighten the cap screws 14] to the specified torque.
TORQUE : 2.0 N'm (0.2 kgf'm, 1.5 IbHt)

3-20

MAINTENANCE

BRAKE SHOES WEAR
Replace the brake shoes if the wear Indicator plale [1]
aligns with the reference mark [2) on the brake panel
when the feaf brake lever or brake pedal is applied.
See Brake System section for brake shoe replacement

(page 18·16).

BRAKE PADS WEAR
Replace the brake pads if the wear indicator [1 ) aligns r------:---:-?;l:;;;~;r
with the reference mark (lug) [2] on the caliper body
-:when the front brake is applied.

111 1

See Brake System section for brake pad replacement
(page 18-8).

BRAKE LIGHT SWITCH
NOTE
The front brake light switch cannot be adjusted. If
the front brake light switch actuation and brake
engagement are oul of synchronization, either
replace the switch unit or the malfunctioning parts of
the system.
Check that the brake light comes on just prior to the
brake actually being engaged .

I

If the light fails to come on, adjust the rear brake light
SWitch PI so that the light comes on at the proper time.
Hold the switch body and tum the adjustmg nut [21. Do
not tum the switch body.

3·21

MAINTENANCE

BRAKE SYSTEM
FRONT BRAKE
Firmly apply the front brake lever and check that no air

has entered the system.
If the brake lever feels soft or spongy when operated,

bleed the system.
See Brake System section for

alf

bleeding procedures

(page 18-7).
Inspecllhe brake hoses (1) and fittings for deterioration,

cracks, damage or signs of leakage.
Tighten any loose fittings.
Replace hoses, pipes and fittings as required.

REAR BRAKE
Check the brake cable, brake lever and brake pedal for
brake pedal loose connections, excessive play or other damage.
operatos smoothly Replace or repair if necessary.
Make sure the

and that the broke
pedal position is
correct.
Make sure the

brakes do not drag

For cable lubrication: Disconnect the brake cable at the
brake lever or pedal. Thoroughly lubricate the cables
and their pivot points with a commercially available
cable lubricant or a lightweight oil.
Measure the rear brake lever free play at the end of the , - - - - ,....-..,,.,
lever.
FREEPLAY: 15 - 20 mm (0.6 - 0.8 in)

Measure the rear brake pedal freeplay at the end of the
pedaL
FREEPLAY: 15 - 20 mm (0.6 - 0.8 i n)

3·22

MAINTENANCE
Make sure the
indent In the

adjusting nut is
seated on the brake

arm pin.

Adjust the brake lever freeplay by turning the upper
adjustmg nut [11 at the brake arm.
Adjust the brake pedal free play by turning the lower
adjusting nut [21 at the brake arm.

121

REVERSE LOCK SYSTEM
Check the reverse selector cable and lever for loose
connections , excessive play or other damage.
Replace or repair if necessary.
Release the dust cover [1] .
Measure the lever free play at the lever end near the
cable.

FREE PLAY: 2 - 4 mm (0.1 - 0.2 in)
NOTE
If necessary, watch the reverse selector arm on the
crankcase to see when it moves white determining
freeplay.

Slide the rubber boot [1] off the adjuster [2J.
Adjust by loosening the lock nut [31 and turning the
adjuster.
Tighten the lock nut.
Install the dust cover properly.

3-23

MAINTENANCE

GUARDS
Check the outboard guard [1 1. inboard guard (2), engine
guard [31 and rear final gear skid plate [41. for cracks,
damage or looseness.

Tighten any loose fasteners. Replace the skid plates or
guard as required .

CLUTCH SYSTEM
Remove Ihe left side cover (page 2-4).
Loosen the lock nut [11 and turn the adjusting screw [2]
one fuiliurn clockwise.
Slowly turn Ihe adjusting screw counterclockwise until
resistance is felt, then tum the adjusting screw 1/4 tum
clockwise.

Hold the adjusting screw and tighten the lock nul.
Start the engine and check for proper dutch operation.
Inslalithe side cover (page 2-4)

3-24

MAINTENANCE

SUSPENSION
Loose. wom Of Check the action of the front and fear shock absorbers
damaged by compressing them severatlimes ,
suspension pans Check the entire shock absorber assembly for signs of
impair vehicle leaks, damage or loose fasteners ,
stability end control.

Replace damaged components which cannot be
repaired
Tigh ten aU nuts and bolts.

Raise the rear wheel off the ground by supporting the
frame securely.
Check for worn swingarm beanngs by grabbing the rear
axle hOUSing and attempting 10 move the wheels side to
side.
Replace the bearings if any looseness IS noted
(page 17-8)

SPARK ARRESTER
Remove the arrester bolt [ 1].
Block the end of the muffler with a shop toweL
Start the engine with the transmisSIOn In neutral , and

purge accumulated carbon from the muffler by
momentarily revving the engine several times.
Stop the engine and allow the exhaust system to cool.
Install the boll and lighten it securely.

NUTS,BOLTS,FASTENERS
Check thai all chassis nuts and bolts are tightened to
Iheir correct torque values (page 1.13).
Check that all coller pins. safety clips , hose damps and
cable sl ays are in place and properly secured

WHEELS/TIRES
Tire pressure Check the tire pressure with a tire pressure gauge.
should be checked
when the tires are RECOMMENDED TIRE PRESSURE
cold
Front:Standard : 30 kPa (0.30 kgflcm 1 , 4.4 psi)
With cargo: 30 kPa (0.30 kgflcm1 , 4.4 psi)
Rear: Standard : 30 kPa (0 .30 kgfl cm J , 4.4 psi)
With cargo: 30 k Pa (0.30 kgflcm1, 4.4 psi)

Check the tires for cuts, embedded nails, or other r~::'i:i;".ii~
damage.
•
Measure the tread depth at the center of the tires
Replace the tires when the tread depth reaches the
following limits.
MINIMUM TREAD DEPTH (Front/Rear) :
4.0 mm (0.16 in)
Raise the wheel off the ground and check the bearings
in the knuckle for excessive play or abnormal noise.

3-25

MAINTENANCE

TIE-ROD AND JOINT BOOTS
Check the lie-rod joint nuts {1] and the suspension arm

ball Joint nuts [21 for looseness,
Check the ball joint boots [3J of the tie-rod and
suspension arm for tears or other damage.
Check for looseness of the tie-rocl ball joints [41 or
bearings by grabbing each front wheel side to side with
the wheels on the ground.

If any looseness is noted, inspect the following .
-

lie-rod (page 16-40)
knuclde bearing (page 16-16)

[4]

-===::::::1J'4

STEERING SHAFT HOLDER BEARING
Make sure the
cables do not
interfere with the
rot8tfO(l of the

handlebar.

Raise the front wheels off the ground and support the
vehicle securely.

Check that the handlebar moves freely from side to
side.

If the handlebar moves unevenly, binds, or has
horizontal or vertical movement, inspect the steering
shaft holder bushing and bearing.
-

FMfFE model (page' 6-27)
FPM/FPE model (page 16-32)

STEERING SYSTEM
Place the vehicle on level ground with the front wheels , - - - - - - - - - - - - - - , - - - - ,
facing straight ahead.
Mark the centers of the tires with chalk to indicate the
axle center height.
Align the toe-gauge (1] with the marlc;s on the tires as
shown.
Check the readings on the gauge scales.

3-26

MAINTENANCE
Slowly move the vehide back until the wheels have
turned 180· so the marks on the tires are aligned with

Front

t

the gauge height on the rear side.
Measure the toe on the rear part of the tires at the same
points with no load on the vehicle.

Toe-out: 28 ± 15 mm (1.1 :t 0.6 in)
NOTE-

Toe-In means the rear measurement is greater than
the front measurement.

Toe-out means the front measurement is greater
than the rear measurement.

When the loe is out of specification, adjust it by
changing the length of the lie-rods [1) equally by
loosening the lock nuts [2] and turning the tie-rods while
holding the ball joints [3J.

r

{11
[3)

After
lie-rod
rotate both
the
sameadjusting
direction,each
along
the ,lie-rod
axis ball
unliljoints
theyinstop
against the ball joint stud.

[2]

~:~l~~~~r:1~~~~~~~~;~

131
Using a 22 mm wrench , hold the ball joint ends (flats)
(1) so that the relative angle of both ball joints may tum
into specified angle. Then, tighten each lock nut (2)10
the specified torque, making sure nol to force the ball
jOint end against the ball joint slud [3].

[21
[11

TORQUE : 54 N·m (5.5 kgf·m, 40 Ibf·ft)
After lightening the lock nuts, rotate 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 knuckle
bearings or tie-rod ball joints for excessive play or
abnormal noise.

Steering arm side

121

{11

Front __
'""' loglll bIufI
,~

, ".,.

~~
IG,.~)

CONNECTOR

4-3

PGM·FI SYSTEM

SERVICE INFORMATION
GENERAL
This section covers servICe of the electrical system of the PGM· FI system. For mechanical system service of the PGM-FI system
and the fuel supply system, see Fuel System section (page 7-2).
Bending or twisting the control cable will Impair smooth operation and could cause the cable to slick or bene!. resulting in loss of
vehicle control.

Work in a well ventilated area . Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
Do not damage the throttle body. It may cause incorrect throttle valve operation .
Prevent dirt and debris from entering the sensor hole . Clean them using compressed air.
The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
Do not loosen or lighten the white painted screws and nut of the throttle body. Loosening or tightening them can cause throttle
body malfunction.
Tighten the yellow painted screws of the throttle body to the specified torque.
A faulty PGM-FI system is often related \0 poorty connected or corroded connectors. Check those connections before
proceeding.
When disassembling the PGM-FI parts, note the location of the O-rings. Replace them with new ones upon reassembly.
Use a digital tester for PGM-Fl system Inspection.
The engine stop switch line is connected to the PCMlECM on this vehicle. lis signal permits the PCMfECM to control the fuel
pump, injector and ignition coil.

SPECIFICATIONS

~E~M~~~~~======~==============~SP~0.86
E~C~I~F-I~C1.55
~AT~I~kOO~N~S=============3
rf-;~~~~~~~~IT
ECT sensor resistance (40 :i: SOC/104 :i: 41 °F)
~AT sensor resistance

Fuel in'

(20"Cf68"F)

tor resistance (20· C/66°F)

TORQUE VALUES

h en

2.2 - 2 .7 kO

ITEM

sor unit torx screw T25)
sensor
Bank angle sensor mounting bolt

~

11 .6 - 12.4 0

1

Q'TY

THREAD
OIA. (mm)

TORQUE
N'm (kgf'm , IbHt)

3
1
2

5
10
6

3.4 (0.3. 2.5)
12 (1 .2. 9)
10(1 .0. 7)

REMARKS

I

TOOLS
SCS service connector
070PZ-ZY30100

4-4

Test probe
07ZAJ-RDJA110

HDS pocket tester
TDS 3557-0112-01 (U.S.A. Only)

PGM·FI SYSTEM

SYMPTOM TROUBLESHOOTING
When the vehicle has one of these symptoms. check the Ole or Mil blinking, refer to the Ole index (page 4-13) and begin the
appropriate troubleshootmg procedure. If there are no DTCfMll blinking stored in the PCM/ECM memory. do the diagnostic
procedure for the symptom. in the sequence listed below, until you find the cause.

Symptom
Engine cranks but won't start
(No OTC and Mil blinking)

Diagnosis proce'~
d~u~,e--:-;:::;:::=+=::::;~
Also check for
1. Check the spark plug (page 3-8).
Sparl< plug condition
2. Inspect the ignition system
Faulty ignition system
(page 5-5).
No fuella fuel injector
3. Inspect the fuel supply system.
- Pinched or clogged fuel tank breather hose
- fuel pressurelflow (page 7-11)
- Pinched or clogged fuel hose
- fuel pump (page 7-13)
- Pinched or clogged fuel feed hose
4. Inspect the cylinder compression
- Clogged fuel tank strainer screen
(page 10-7)
- Clogged fuel pump fitter
- Faulty fuel pump circuits
- Faulty fuel pump
Intake air leak
Contaminatedfdeteriorated fuel
Faulty fuel injector
IACV stuck closed
Low cylinder compression
- blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston nng or cylinder
1. PCMfECM powerlground cl~,cu=iI~'--"" Open circuit in the power input andlor ground
malfunction (page 4-35).
wire of the PCMIECM

Engine cranks but won't start
(Gear position indicator
continuously blinking .-.)=.-~.
Engine crank s but won'l start
1.
(No fuel pump operation
sound when turning the
2.
ignition switch ON and engine
stop switch "0")
Engine stalls, hard to start,
1,
rough idling
2,

Engine stalls, rough idling,
lacks power (after warm up
the engine)

Backfiring or misfiring during
acceleration
Poor performance
(driveabillty) and poor fuel
economy

PCMIECM engine stop switch
circuit malfunction (page 4-36).
Inspeclthe fuel supply system
(page 7- 13).

Open circuit in the engine stop sWitch wire of
Ihe PCMIEC M
Faulty fuel pump relay or related cirCUit
Faulty fuel pump or related circuits

Check the spark plug (page 3-8)
Check the air cleaner (page 3-5).
Check the Idle speed (page 3-15).
Check the IACV (page 7-26).
Insped the fuel supply system.
- fuel pressurel flow (page 7-11)
- fuel pump (page 7-13)
Inspect Ihe cylinder compression
(page 10-7)

Spark plug condition
Air cleaner condition
3.
Restncted fuel feed hose
4.
Contaminaledldeterioraled fuel
5.
Intake air leak
Restricted fuel lank breather hose
Faulty ignition system
6.
low cyhnder compression
- blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston ring or cylinder
' Troubleshoot the fuel line ( pa·~g~e~7"'5)'.--"Pinched or clogged fuel tank breather hose
Pinched or clogged fuel hose
Pmched or clogged fuel feed hose
Clogged fuel tank strainer screen
Clogged fuel pump filter
Faulty fuel pump or related circuits
Inspect the ignition system
Faully igrlltion system
(page 5-5),
1. Check the brake system
Brake dragged
(page 3-22).
Clogged muffler tail (spark arrester)
2. Check the muffler lail (spar!<
air cleaner condition
Pinched or clogged fuel tank breather hose
arrester) (page 3-25)
Pinched or clogged fuel hose
3. Check the air cleaner (page 3-5).
Pinched or clogged fuel feed hose
4. Inspecl the fuel supply system.
Clogged fuel tank strainer screen
- fuel pressurefflow (page 7-11)
Clogged fuel pump filter
- fuel pump (page 7-13)
Faulty fuel Injector
5. Inspect the ignition system
(page 5--5).
Faully ignition syslem
6. Inspect the cylinder compression
Low cylinder compression
(page 10-7)
- blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston ring or cylinder

4·5

PGM -FI SYSTEM
Symptom

Diagnosis procedure

Also check for

h '''
dI''e-:s::C
pe:::ed ";~s'ibe:5.:'o;;wc----+-·1, -"C"he"c"k,",l!:he='idle speed (page 3- f5 '),-+-,--O
s p:::a:::"= p'':::
g-:co:Cn3dilio"n""==- - -specifications or fast Idle too
low (No DIG and Mil blinking )

2.
3.
4.
5.

Check the spark plug (page 3-8).
Check the air cleaner (page 3-5).
Check the IACV (page 7-26).
Inspect the fuel supply system.
- fuel pressure/flow (page 7-11)
- fuel pump (page 7-13)
6. Inspect the ignition system

air cleaner condition
IACV stuck closed

Faulty fuel supply system
Faulty ignition system

5-5). -c;;===="".-f-:
- ====-----I-"';;-;;====
Idle speed is above ___-+---.-_(~p"age
1. Checktheidle
speed (page 3-15).
IACVSluck
opened
specifications or fas t idle too
high (No DTC and MIL
blinkmg)

2. Check the throttle operation and
lever freeplay (page 3-4).
3. Check the tACV (page 7-26).
4. Inspect the ignition system

Faulty ignition system
Intake air leak
Engine top end problem

,oc~~~-::::~~~___.~(p~age~5~),~~""-::::~
~..--,r-~Faulty MI L~~'-----------------1
Inspect the Mil circuit (page 4 ~29).
circuit

Mil stays on but no OTCs set.
or MIL never comes ON at all

hM:;,;'L~s~t=ay~s~o;n~a~t~a~lIr.t~;m~e~s""""'-'--;'=n=sp=e=c"'"th=e~D~L~C-=c=irc=u"'it (page 4-2"9"),--+~~S"hort Circuit in the OlC related,c;;w;;;;'~e-----1
(No OTC sel)

4-6

PGM -FI SYSTEM

PGM-FI CONNECTOR LOCATION
NOTE 1: Remove the front fender/carrier (page 2-8).

m

..A.

m

f 0)
BANK ANGLE SENSOR 3P (Black) CONNECTOR
(NOTE 1)

NOTE 2: Remove the throttle body cover (page 7-13).

FUEL INJECTOR 2P (Gray) CONNECTOR
(NOTE 2)

SENSOR UNIT 5P (Black) CONNECTOR
(NOTE 2)

IACV 4P (Black) CONNECTOR
(NOTE 2)

4-7

PGM·FI SYSTEM

IAT SENSOR 2P (Black) CONNECTOR

NOTE 1: Remove the left fuel tank side cover (page 2.5).

EeT SENSOR 2P (Black) CONNECTOR
(NOTE 1)

4-8

PGM·FI SYSTEM
NOTE 1: Remove the seat (page 2-4 ).

OLe (NOTE 1)

NOTE 2: Remove the rear fender cover (page 2-9).

B33

B23

PCM/ECM 33P (Gray) CONNECTOR
(NOTE 2 )

A33

A23

PCMlECM 33P (Black) CONNECTOR
(NOTE 2)

4-9

PGM-FI SYSTEM

PGM-FI TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure
The term -intermittent failure" means a system may have had a failure , but it checks OK now. If the Mil does not come on, check
for poor contact or loose pins at all connectors related to the circuil with the trouble. If the Mil was on , but then went oul, the original
problem may be intermittent.

Opens and Shorts
·Opens· and ·Shorts· are common electrical terms. An open is a break In a

Wife

or al a connection. A short is an accidental

connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With peM/
ECMs this can mean something will work, but not the way it's supposed to.

If the MIL has come o n
Refer to DTe READOUT (page 4-11 ).

If the Mil did not stay on
If the MIL did not stay on , but there Is a driveability problem, do the SYMPTOM TROUBLESHOOTI NG (page 4-5).

SYSTEM DESCRIPTION
SELF·DIAGNOSIS SYSTEM
The PGM·FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system , the PCMfECM turns
on the MIL and stores a OTC In its erasable memory.
FAll·SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system. When any abnormality is detected by the self-diagnosis function, running capability is maintained by pre-programed value
in the simulated program map. When any abnormality is detected in the fuel injector and crankshaft position (CKP) sensor, the failsafe function slops the engine to protect it from damage.
OTe (Diagnost ic Trouble Code)
The oTC is composed of a main code and a sub code and it is displayed as a hyphenaled number when retrieved from the
PCMlECM with the HDS pocket tester.
The digits in front of the hyphen are the main code, they indicate the component of function failure.
The digits behind the hyphen are the sub code, they detail the specific symptom of the component or function failure.
For example . in the case of the TP sensor:
- OIC 08 - 1 = (TP sensor voltage) - (lower than the specified value)
- OIC 08 - 2 = (TP sensor voltage) - (higher than the specified value).
The MAP, ECT, TP and JAT sensor diagnosis will be made according to the voltage output of the affected sensor.
If a fallure occurs , the PCMfECM determines the Function Failure , compares the sensor voltage output to the standard value.
and then outputs the corresponding oTC to the HDS Pocket Tes ter.
For example:
- If the output voltage line (A) on the MAP sensor is opened, the PCMfECM detects the output voltage is about 5 V. then the
OIC 1-2 (MAP sensor circui t high voltage) will be displayed.
- If the input voltage line (8) on the TP sensor is opened, the PCM fECM detects the output voltage Is 0 V, then the OIC 8-1 (TP
sensor circuit low voltage) will be displayed .
5V
5V

MAP SENSOR

5V

TP SENSOR

.--9-- 18)--<:>--'
,....,..-<;>-

(A)-

-<)-- + -

OUTPUT VOLTAGE

--9-----<>--;~

OUTPUT VOLTAGE

5V

~

tAT SENSOR

ECTSENSQR

*
4-10

~ ": V

....

OuTPUTVOlTAGE

-Jo

*

OU TPUT VOLTAGE

-Jo

PGM-FI SYSTEM
MIL Blink Pattern

If Ihe HDS pocket tester

IS

not available, OTG can be read from Ihe . - - - - - - - - - - - - - - - - - ( '1- ,

PCM/ECM memory by the MIL [1) blink pattern.
The number of MIL blinks is the equivalent the main code of the OTG
(the sub code cannot be displayed by the MIL).

The MIL will blink the current DIG , in case the PCMJECM detects Ihe
problem at present, when the ignition switch ON or idling. The MIL will
stay ON when driving.
The MIL has two types of blinks, a long blink and short blink. The long
blinking lasts for 1.2 seconds, the short blinking lasts for 0.4 seconds.
One long blink is the equivalent of ten short blinks. For example, when
two long blinks are followed by five short blinks, the MIL is 29 (two long
blinks = 20 blinks, plus nine short blinks).
When the PCMIECM stores more than one OTC , the MIL will indicate
them by blinking in the order from the lowest number to highest number.
MIL Check

,-, --,
(~

(R) (N)

-[\1

-

- il
'-,
,. " II!!!!
2

vvO

I

(I) ~ (qJ

1...... 1

WI LE

)

\(5" /

I

When the ignition switch is turned ON and engine stop switch "0", the MIL will stay on for a few seconds , then go off. If the MIL
does not come on, troubleshoot the MIL circuit (page 4-29),
CURRENT DTC/STORED DTC
The DTC is indicated in two ways according to the failure status .
In case the PCM/ECM detects the problem at present, the MIL will come on and the MIL will start to blink as its DTC. It is
possible to readout the MIL blink pattern as the current OTC.
In case the PCM/ECM does not detect any problem at present but has a problem stored in its memory, the MIL will not light and
blink. If it is necessary to retrieve the past problem. readout the stored DTC by following the OTC readout procedure.

HDS POCKET TESTER INFORMATION
• The HOS can readout the DTC , stored data, current data and other PCMfECM condition.
How to connect the HDS Poc ket Tester
Turn the ignition switch OFF.
Remove the seal (page 2-4).
Remove the OLC 11) from the dummy connector [2] .
Connect the HDS pocket tester to the Ole.
Tum the ignition switch ON and engine stop switch ·0·, check the OTC and
stored data.
NOTE '
• Stored data indicates the engine conditions when the first malfunction
was detected.

PCM/ECM reset
The HDS can reset the PCMfECM data including the OTC , stored data and
some learning memory.

DTC READOUT
When the ignition switch is turned ON and engine stop switch "0·, the
Mil (1) will stay on for a few seconds, then go off.
After performing diagnostic troubleshooting, erase the problem code(s)
(page 4-12) and test-ride the vehicle to be sure that the problem{s) have
been removed.
If the MIL stays on or blinks, connect the HDS Pocket Tester to the OLC
(page 4-11 ).
Read the OTC, stored data and follow the troubleshooting index
(page 4-13).
To read the DTC with the Mil blinking, refer to the following procedure.

'-----------------:I~
'J--,

I

-,
'-, -

I (R) (N)

If$)

-f\I

II

2 "'11..E

vvv

(5"

(X)

(~(OJ

1....... 1

/

\

-il
,. " II!!!!

)

4-11

I

PGM-FI SYSTEM
Reading DTC with the MIL
Start the engine and lei it idle. Read Ihe MIL blinking thai is indicated as Ihe , - - - - - -- - - - - - - - - -- - --,
currenl DIG and refer to the troubleshooting index (page 4-13).
When retrieving the stored DI C, refer to the following procedure.
Remove Ihe OLe from Ihe dummy connector (page 4-11).
Short the OLe [11 terminals using the special tool.

TOOL
[2] SCS service connector

070PZ-ZY30100

Connection : Brown/red - Green
Tum the ignition switch ON and engine stop switch ·0·, read , note the MIL
blinks and refer to the troubleshooting index (page 4-13).
NOTE :
• If the PCMfECM has any DTC in its memory. the MIL will start blinking.

ERASING DTC
Connect the HDS Pocket Tester to the OLC (page 4-11).
Erase the OTC with the HOS while the engine is stopped .
To erase the DTC without HDS, use the fOllowing procedure.
How to erase the OTC without HOS
1. Remove the OLC from the dummy connector (page 4-11 ).
2. Short the OLC [1J terminals using the special tool.
TOOL:
(2] SCS service connector

11]

12]

070PZ-ZY30100

Connection : Brown/red - Green
3. Tum Ihe ignition switch ON and engine stop switch ·0·,
4 . Remove Ihe special tool from the OLe.

5. The MIL will light for approximately 5 seconds. While Ihe MIL lights,
short the OLe terminals again with Ihe special tool. The self-diagnostic
memory is erased if Ihe malfunction indicator goes off and starts
blinking .
NOTE:
The OLe must be shorted while the MIL lights. If not, the MIL will not start blinking.
• Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking.

CIRCUIT INSPECTION
INSPECTION AT PCM/ECM CONNECTOR
Always clean around and keep any foreign material away from the PCMI
ECM connector before disconnecting it.
A faulty PGM-FI system is often related to poorly connected or corroded
connections. Check those connections before proceeding .
Do not pull the wire harness while disconnecting the PCM/ECM
connectors.
In lesting al PCMfECM connector (wire harness side) terminal, always
use the test probe. Insert the test probe into the connector terminal , then
attach the digital multimeter probe to the test probe.
TOOL:
[1] Test probe

4-12

07ZAJ·ROJA 110

{1]

PGM-FI SYSTEM

PGM-FI DTC INDEX
orc
(MIL
bUnks)
1-1 (1)

1-2 (1)

7-1 (7)

Refer

Symptom/Fail-safe function

Function Failure

10

MAP sensor circuillow voltage (less than 0.19 V)
Engine operates normally
4· 14
• MAP sensor or its circuit malfunction
Fail-safe value: 29 kPa
- + -'MAP sensor circuil high vollage (more than 3.9 V') ---t--:--~E~n~g;;;n~.~o~pe:::;;,"~,~.,;C:;;n~m;;;Cm'~II~y---t-• Loose or poor contact of the MAP sensor connector
Fail-safe value: 29 kPa
4·15
• MAP sensor or its circuit malfunction
--I--1h E"'C"r;csensor circuit low voltage (less than 007 V)'- - - - - - : -H=ard to start='t~'''-Iow=---­
• ECT sensor or its circuit malfunction
temperature
4-16
Fall-safe value: 78 .6°Cl173.5"F
' ' ' '_ _ __ : -COOling fan~tu~m~s~o~n;;;-_ _ _
ECT sensor circuit high voltage (more than 4.93 V)
Hard to start at a low
• loose or poor contact of the ECT sensor connector
temperature
4-17
ECT sensor or its circuit malfunction
Fail-safe value: 78.6"C/173.5·F
Cooling fan turns on
TP sensor circuit low voltage (less than 0.22 V) - - - - - - : -:Poor engin~.~,~cc~.~'~.~""U~o~n--• loose or poor contact of the TP sensor connector
Fail-safe value: D·
4-18
o
TP sensor or its circuit malfunction
ESP does not work
Poor engine:e,~cce=~t.~"~t~k>=n-:---""'TP sensor circuit high voltage (more than 4.93 V)
• TP sensor or its circuit malfunction
Fail-safe value: 0"
4-19

.
C t
8-1 (8)

8-2 (8)

ESPdoesnotwo~~~ITn"I,-____-+I~~~
tAT sensor circuit low voltage (less than 0 07 V)
• tAT sensor or its circuit malfunction
r------ - -+-'IAT sensor circuit high vottage (more t'~h~
a ~n'4',9V3~V')~
9-2 (9)
• loose or poor contact of the tAT sensor connector
4-22
• IAT sensor or its circuit rnatfuncllOn
-----+-'V7

8

Ii,)

11)

PGM-FI SYSTEM
TP SENSOR RESET PROCEDURE
NOTE

Make sure that the DIG is nol stored in the PCMf
ECM memory. If the DIG is stored, the reset mode
will not start.
1. Remove the following:
-

111

seal (page 2-4)
left fuel tank side cover (page 2-5)

121

2. Turn the ignition switch OFF .

3. Remove the Ole from the dummy connector
(page 4· 1 1).
4 . Short the DLe 11jlerminals using the Special tool.

Connection: Brown/red - Green

TOOL:
(2] SCS service connector

070PZ-ZY30100

5. Disconnect the EeT sensor 2P (Black) connector

11 I·

~;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;::=------.:===~
Green/red

Short the wire harness side connector terminals with
a jumper wire [2].

Connection: Black/blue - Green /red
6. Turn the ignition switch ON and engine stop switch
·0·, then disconnect the jumper wire from the EeT
sensor 2P (Black) connector wi thin 10 seconds
while the MIL is blinking (reset receiving pattern).

121
7. When the reset procedure is complete. the MIL blinking changes from Reset Receiving Pattern to
Confirmation Pattern.
Turn the ignition switch OFF .
If more than 10 seconds elapse or the procedures are incorrect. the MIL stays on . Repeat the reset
procedures from the step 4.

tti
----""""-'="---tp -,
UI;
Within 10 sec.

"1.3sec'
• 0.1 sec.'··'·
.'
• ,
I

MIL

0:: ~ -_ -_ -_ -_-_ ~-- -- n n,-----,n
Reset Receiving Pattern
ON - - - - - -

IGNITION
SWITCH

I

03
03 sec.
. sec.,~
, •.

nJUl_
Reset Confirmation Pattern
(Stay on: Reset procedure is not complete)

+-___________________

OFF _ _ _-'

8. Connect the ECl sensor 2P (Black) connector.
g. Disconnect the special toot from the OLC.
10.ln5tall the dummy connector to the OLC (page 4-11 ).
11.Check the engine idle speed (page 3-15).
12.ln51all the removed parts in the reverse order of removal.

4-31

PGM·FI SYSTEM

ECT SENSOR
REMOVAUINSTALLATION
Drain the coolant (page 8-6).

Remove the left fuel lank side cover (page 2-5),
Disconnect Ihe spark plug cap [1] and Eel sensor 2P

(Black) connector [21.
Replace the ECT Remove Ihe EeT sensor [3J and O-ring 14].

sensor while the Install the a new O-ring onto Ihe Eel sensor.
&ngine is cok:J.

Install Ihe Eel sensor to the cylinder head and lighten
it to the specified torque.
TORQUE: 12 N'm (1.2 kg f-m, 9I bHt)
Connect the Eel sensor 2P (Black) connector and
spark plug cap.

Fill the cooling system with recommended coolant
(page 8-6).
Install the left fuel tank side cover (page 2-5).

INSPECTION
Remove the Eel sensor (I] (page 4-32).
Wear;nsulated
gloves and

Heat Ihe coolant (1:1 mixture) with an electric heating
element.

adequate eye

Suspend the ECT sensor in heated coolant and check

121

protection. the continuity through the sensor as the coolant heats

Keep "ammable
materials away from

me burner,

up.
NOTE :

HI

Soak the ECT sensor in coolant up to its metal area
••
thoroughly with at least 40 mm (1.6 in) from the
bottom of the pan to the bottom of the sensor.
Slowly stir the coolant while heating and keep
temperature constant for 3 minutes before testing. A
sudden change of temperature will result in incorrect
[1]
readings. Do not let the thermometer {2] or ECT L _ _ _ __ '-'-_ _ _ _ _ __ _ __ _.J
sensor touch the pan .
Measure the resistance between EeT sensor terminals.
Temperature
Resistance

40 ± 5°C (104 ± 41 °F)
0.86 1.55 kO

Replace the ECT sensor if it is out of specifications .
Install the ECT sensor (page 4·32).

4·32

PGM·FI SYSTEM

BANK ANGLE SENSOR
REMOVAL/INSTALLA n ON
Remove the front fender/carrier (page 2·6).
Disconnect the bank angle sensor 3P (Black) connector

[11·
Remove the two mounting bolts [2] and bank angle
sensor [3J from the frame.

Inslalilhe bank angle sensor [1] with its MUpM mark [2]
facing up.

It I

Install the removed parts in the reverse order of
removal.
TORQUE:
Bank angle sensor mounting bolt:
10 N·m (1.0 kgf·m , 7lbHt)

[21

OPERAT[ON INSPECTION
NOTE
• Before you perform this inspectJon. check that the
engine idle speed is normal (page 3·15).
Remove the bank angle sensor [1) with the bank angle , - sensor 3P (Black) connector is connected (page 4-33).
[lJ
• Do not disconnect the bank angle sensor 3P (Black)
connector during inspection.
Befora you perform
this test. first tum
the Ignition switch
OFF, then tum Ihe
Ignition switch ON
and engine stop
swirch ·0 ·

Place the bank angle sensor is horizontal (normal
position) as shown, and turn the ignition SWitch ON and
engine stop switch

orr.

Start the engine.
Incline the bank angle sensor 60- ± 5- to the left or right
with keeping with the engine running.
The bank angle sensor is normal if the engine stops
after a few seconds when the bank angle sensor
Inclined .

l

60· ± 5° BANK ANGLE POSITION

HORIZONTAL

''
9/!
."Ii
,

'\

60· ± 5·

If you repeat this test, first turn the ignition switch
OFF, then turn the ignition switch ON and engine
stop SWitch RO".

4·33

PGM-FI SYSTEM
INSPECTION WITH HOS POCKET
TESTER
Connect the HOS pocket tester (page 4.11).
Remove the bank angle sensor [1) with the bank angle
sensor 3P (Black) connector is connected (page 4-33).

60· ± S· BANK ANGLE POSITION

[11

Place the bank angle sensor horizontal as shown .

'ii',.

Turn the ignition switch ON and engine stop switch ·0·,
Read the vollage with the HOS pocket tester.

60· ± 5°

Standard : 3.6 - 4.4 V
Incline the bank angle sensor 60· ± 5° to the left or right

with keeping the ignilion switch ON and engine slop
switch -0 · ,
Read the voltage with HOS pocket lester.

Standard : 0.7 - 1.3 V
If you repeat this test, first turn the ignition switch
OFF, then tum the ignition switch ON and engine

stop switch ·0·.

PCM/ECM
REMOVALIINSTALLATION
Remove the rear fender cover (page 2-9),
Release the following :

-

fuse box (I]

-

brake/taillight wire [2) from the wire guides (3]

Release the tabs (4J of the connector holder plate [SJ
from the rear fender, then remove the connector holder
plate.

Turn the ignition switch OFF.
Remove the PCM/ECM [11 from the rear fender,
Disconnect the 33P (Gray) connector [2J, 33P (Black)
connector (3J and SP (Black) connector (4] from the
PCM/ECM.
Installation is in the reverse order of removal.

4-34

~
',.

HORIZONTAL

f'

~
~ J
"\ I

60. ± 50

PGM·FI SYSTEM
POWERIGROUND LINE INSPECTION
Before starting the inspection, check for loose or
poor contact on the PCMfECM 33P (Gray)

connector.
1. PCM/ECM Power Line Inspection
Turn the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) connector (1).

81

Turn the ignition switch ON and engine stop switch
"0 ".
Measure the voltage between the wire harness side
PCM/ECM 33P (Gray ) connector terminal and
ground .
Connection: 81 (+) - Ground H

TOOL:
Test probe

07ZAJ·RDJA 110

Does the battery voltage exis t?
YES
NO

- GO TO STEP 2.
Open circuit

In

the Black/red wire ' - - - _ _ _ _ __ _ _ _ _ _ _ _ _ _.1

between the fuse box and PCM/ECM .

Open circuil in the Black wire between
the ignition switch and fuse box .
Blown IGN fuse (10A)
Inspecllhe ignition switch (page 22-11 ).

2. PCMIECM Ground Line Inspection
Turn the ignition switch OFF.
Check for continuity between the wire harness side
PCM/ECM 33P (Gray) connector [1J terminal and
ground .

810

07ZAJ·ROJA 110

Is there continuity?
YES

- Replace the PCM/ECM with a known good
one (page 4·34), and recheck.

NO

- Open circuil in the Green wire.

813

~~~~~

Connection: 810 - Ground
B13 - Ground
821 - Ground

TOOL :
Test probe

821

Q

Q

4-35

PGM·FI SYSTEM
ENGINE STOP SWITCH LINE
INSPECTION
Before starting the inspection, check for loose or
poor contact on the PCM/ECM 33P (Black) and
(Gray) connectors.

ENGINE DOES NOT START (NO FUEL PUMP
OPERATION SOUND)

1. Fuse Inspection
Check the IGN fuse (10 A) for blown.

Is the fuse blown ?
YES

- Replace the fuse.

NO

- GO TO STEP 2.

2. Engine Stop Switch Line Inspection

Turn the ignition switch OFF .
Disconnect the PCMfECM 33P (Black) connector
[1 J.
Tum the ignition switch ON and engine Slop switch
·0·,
Measure the voltage between the wire hamess side
PCM/ECM 33P (Black) connector terminal and
ground.

Connection : A4 (+) - Ground
TOOL:
Test probe

H
07ZAJ·RDJA 110

Does the battery voltage exist?
YES

Inspect the fuel supply system

(page 7-13).
NO

4·36

- ' Open circuit in the Black/while wire
between the engine stop switch and
PCM/ECM.
Open circuit In the Black/red wire
between the fuse box and engine stop
switch.
Inspect the engine stop switch
(page 22-11).
Open circuit in the Black wire between
the ignition switch and fuse box.
Inspect the ignition switch (page 22-11).

[1 [
A4

5. IGNITION SYSTEM

COMPONENT LOCATION ····················· .... ··· 5-2

IGNITION COIL ............................................. 5-7

SYSTEM DIAGRAM ··········· ·········· ················· 5-2

IGNITION TIMING ......................................... 5-8

SERVICE INFORMATION ····························· 5-3

CONDENSER (Canada Iype) ....................... 5-8

TROUBLESHOOTING ··································· 5-4

RECTIFIER (Canada type) ......................... 5-10

IGNITION SYSTEM INSPECTION ················ 5-5

5·1

IGNITION SYSTEM

COMPONENT LOCATION
ENGINE STOP SWITCH

FUSE BOX:
- FMfFPM: MAINFUSE (30 A)
- FElFPE: MAIN FUSE 1 (30 A )
- IGN FUSE (to A)

IGNITION SWITCH

CONDENSER
(Canada type)

PCMJECM

SPARK PLUG

RECTIFIER
(C anada type)

SYSTEM DIAGRAM
r--------,

"""",eM

•

CONDENSER

'

~
G

Canada type



t

I,
I,
I

1-------1

,

'

I
I

LR_~ R.i

I
R

RIBl ~ RIBl -

BIIW

i

u

~'"'--0-ENGINE STOP
SWITCH

1

- - - - --------- ______ 1

I- ----- - ._._ ..........,
I
I
G G

W While
y Yellow

I-- --._._._.

!
!

,-

R Red

R

I,
I
I,

BuIY OfW G G!Y BUR 81M'

BI Black
BuBtue
G Green

R~o--BI
IGNlTION
SWITCH

IGN FUSE (lOA)

---<0>--

FMlFPM MAIN FUSE (3OA)
FEJFPEc MAIN FUSE 1 (3OA.)

BATIERY

5-2

IGNITION SYSTEM

SERVICE INFORMATION
GENERAL

NOTICE
The PCMIECM may be damaged if dropped. Also, if the connector is disconnected when current is "owing, the excessive
voltage may damage the PCMIECM. Always tum the ignition switch OFF before servicing.
Use spark plugs with the correct heat range. Using spark plugs with an incorrect heat range can damage the engine.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present
When servicing the ignition system, always follow the checks described in the troubleshooting chart (page 5-4).
This ignition system is controlled by PCM/ECM .
The transistorized ignition system uses an electrically controlled ignition timing system. No adjustments can be made to the
ignition timing.
A faulty ignition system is often related to poor connections. Check those connections before proceeding.
Make sure the battery is adequately charged . Using the starter motor with a weak battery results in a slower engine cranking
speed as well as no spark at the spark plug.
The engine stop switch line is connected to the PCM/ECM on this vehicle . Its signal permits the PCM/ECM to conlrollhe fuel
pump, injector and ignition coil.
Refor to each section for the following components information.
- CKP sensor (page 13·6).
- Ignition switch (page 22-11).
- Engine stop switch (page 22-11).

SPECIFICATION

T

ITEM
Spark plug
Spark plug gap
Ignition coil primary peak voltage
Ignition pulse generator peak voltage
Ignition timing CF" mark)

SPECIFICATIONS
BKR5E-11 (NGK), K16PR-U11 (DENSO)
1.0 1.1 mm (0.039 0.043 in)
100 V minimum
0.7 V minimum
10' BTDC at idle

+

+
~

TORQUE VALUES
ITEM
;

Timi"9 hole cap

Q' TV

THREAD

DIA. (mm)

1

TORQUE
(~

,
1
1

:h

N·m (kgf-m , IbUt)

14 _ - 1 _ - - ,1 0

l,

REMARKS

7)

TOOLS
IgnitionMate peak voltage tester
MTP07-0286 (U.S.A. on ly)

Peak voltage adaptor
07HGJ-0020100

Test probe
07ZAJ-RDJA110

(not available in U.S.A .) with
commercially available digital
multimeter (impedance 10 MOIOCV
minimum)

5·3

IGNITION SYSTEM

TROUBLESHOOTING
Inspect the following before diagnosing Ihe 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)
"Initial voltage" of the ignition primary coil is Ihe battery voltage with the ignition switch turned ON. (The engine is not cranked by
Ihe starter motor)

No spark at spark pl ug

;

iI
voltage

ignition switch
ON.
(Other electrical componen ts
are normal.)

2. An open circuit in the Black/red wire between the ignition coil and
ignition switch.
3. l oose or poor connection of the primary terminal, or an open circuil in
the primary coil.

~~~;~~~~;~:~.::,:~;;-t_4~.~~~P~C~M~'~E~C~M~(;~n~c~ase when the initial voltage is njormal with the

I drops by 2 - 4 V while cranking
the engine.

Initial voltage is normal but
there is no peak voltage while
cranking the engine.

Initial voltage is normal but
peak voltage is lower than the
standard value.

CKP sensor

r---rnilial and peak voltages are
normal but no spark jumps.
Low peak voltage.

t--No peak voltage.

5-4

voltage is over
specifications
reverse connections)
2. Battery is undercharged. (Voltage drops largely when the engine is
started)
3. No voltage at the Black/red wire of the PCM/ECM (Gray) connector,
or loose or poorly connected PCM/ECM (Gray) connector
4. Loose or poor connection, or an open circuit in the Green (ground)
wire of the PCM/ECM .
5. Loose or poor connection, or an open circuit in the Green/yellow wire
between the ignition coil and PCM/ECM.
6. A short circuit in the ignition primary coil.
7. Faulty engine stop switch.
8. No voltage at the Blacklwhite wire of the PCM/ECM (Black)
connector, or loose or poorly connected PCM/ECM (Black) connector.
9. Faulty CKP sensor. (Measure the peak voltage)
10.Faulty PCMfECM (in case when above No. 1 through 9 are normal).
1. Incorrect peak voltage adaptor connections. (System is normal if
measured voltage is over the specifications with reverse connections)
2. Faulty peak voltage adaptor.
3. Faulty engine stop switch .
4. Faulty CKP sensor. (Measure the peak voltage)
5. Faulty PCM/ECM (in case when above No. 1 and 4 are normal).
1. The mullimeter impedance is too low; below 10 MOIOCV.
2. Cranking speed is too slow. (Battery is undercharged)
3 . The sampling timing of the tester and measured pulse were not
synchronized . (System is normal if measured voltage is over the
standard voltage at least once)
4. Faulty PCM/ECM (in case when above No.1 through 3 are normal).
1. Faulty spark plug or leaking ignition coil secondary current.
2. Faulty ignition coil.
1. The multimeter impedance is too low; below 10 MO/OCV.
2. Cranking speed is too slow. (Battery is undercharged)
3. The sampling timing of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once)
4. Faulty CKP sensor (in case when above No. 1 through 3 are normal) .
1. Faulty peak voltage adaptor.
2. Faulty CKP sensor.

IGNITION SYSTEM

IGNITION SYSTEM INSPECTION
NOTE:
If there is no spark at Ihe plug, check aU connections
for loose or poor contact before measuring the peak
voltage.
Use a commercially available digital mullimeler with
an impedance of 10 MO/DCV minimum.

The display value differs depending upon the
internal impedance of the multimeter.
Use the peak voltage tester or connect the peak voltage , - - - - adaptor [1] to the digital multimeter [2].

121

TOOL:
Ig nition 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 MO/DeV minimum)

111
IGNITION COIL PRIMARY PEAK
VOLTAGE
NOTE :
Check all system connections before this inspection.

Poor connected connectors can cause incorrect
readings.
Check thai the cylinder compression is normal and
the spark plug is installed correclly in the cylinder
head.
Remove the left fuel tank side cover (page 2- 5).
Disoonnectthe spark plug cap [1) from the spark plug .
Connect a known good spark plug [2) to the spark plug
cap and ground the spark plug to the cylinder head as
done in a spark test.

5·5

IGNITION SYSTEM
With the connector connected, connect the peak
voltage tester or adaptor probes to the ignition coil
primary terminals.

Connection: Green/yellow (+) - Black/red

H

Turn the ignition switch ON and engine stop switch

-ct.

Check the initial voltage al this time.

The battery voltage should be measured.

If the initial voltage cannot be measured, follow the
checks in the troubleshooting chart (page 5-4).
Shift the transmission into neutral.

Crank the engine 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 chart
(page 5-4).

CKP SENSOR PEAK VOLTAGE
NOTE:
Check that the cylinder compression is normal and
the spark plug is installed correctly in the cylinder
head.
Remove the rear fender cover (page 2-9).
Seal the PCMlECM
connecfor with tape
/0 prevent dirt and
oil from en/enng Ihe
ronneclor after
disconnecting il.

Canada type shown"

Turn the ignition switch OFF and disconnect the PCM!
ECM 33P (Gray) connector [1].
NOTE:
When reconnecting the PCM!ECM connector, check
that there is no dirt and oil in the connector.

Connect the peak voltage tester or adaptor [1] probes to
the wire harness side PCM/ECM 33P (Gray) connector
[2J terminals
Connection:
B23 (Blue/yellow) (+) - B12 (Green /white) (-)
TOOL:
Test probe

07ZAJ-RDJA110

121

912{-)

~~
823 (+)

Shift the transmission into neutral.
Tum the ignition switch ON.
Crank the engine with the starter motor and measure
the CKP sensor peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the voltage measured at the PCM/ECM connector is
abnormal, measure the peak vo!tage at the a!ternator
connector.

5-6

[1)

IGNITION SYSTEM
Remove the right side cover (page 2-4).
Turn the ignition switch OFF and disconnect the
alternator 5P (Natural) connector (1).
Connect the peak voltage tester or adaptor [2J probes to
the alternator side connector terminals.
Connection : BluefyeUow (+) - Green (-)
In the same manner as at the PCMfECM connector,
measure the peak voltage and compare it to the voltage
measured at the PCMfECM connector.
If the peak voltage measured at the PCM/ECM
connector is abnormal and the one measured at the
alternator connector is normal, the Blue/yellow or
Greenlwhile wire has an open or short circuit, or
loose connection.
If both peak voltages are abnormal. follow the
checks described in the troubleshooting chart (page
5-4).
If the CKP sensor is faulty, replace the alternator stator/
CKP sensor assembly (page 13-6).

Blue/yellow (+)
Green (-)

[2)

[1)

IGNITION COIL
REMOVALIINSTALLATION
Remove the left fuel tank side cover (page 2-5).
Disconnect the spark plug cap [1] from the spark plug.
Disconnect the ignition coil primary wire connectors {2J.
Remove the bolls [3] , spacers {4J and ignition coil (5].
Installation is in the reverse order of removal.

5-7

IGNITION SYSTEM

IGNITION TIMING
NOTE:

• Before you performing this inspection, check Ihe
engine idle speed (page 3-15).
Remove the fonowing:

-

right mudguard (page 2-6)
left fuel tank side cover (page 2-5)

Start Ihe engine and warm
temperature.

it up to operating

SlOp the engine and remove the timing hole cap from
the rear crankcase cover.
Connect the timing light (1) and tachometer.
Start the engine, let it idle and check Ihe ignilion timing.

The ignition liming is correct if the ~F" mark (2] on the
flywheel aligns with Ihe index nolch [3] on the rear
crankcase cover at idle.
Coat a new O-ring [1 J with engine oil and install it onto
the liming hole cap [2).
Install and tighten Ihe timing hole cap to the specified
torque.

TORQUE : 10 N-m (1 .0 kgf'm , 7lbHt)

Install the removed parts in the reverse order of
removal.

CONDENSER (Canada type)
REMOVAUINSTALLA nON
Remove the seat (page 2-4).
Disconnect the battery negative (-) cable (page 21-8).
Disconnect the condenser 2P (Natural) connector [1].

5·8

I

IGNITION SYSTEM
Release the condenser wire [1] from the wire guide [2)
of the rear fender.
Remove the condenser [3].

Installation is in the reverse order of removal.

INSPECTION
NOTE:
• Perform this inspection using a fully charged battery.

Disconnect the condenser 2P (Natural) connector [lJ
(page 5-8)
Connect the battery negative (-) cable (page 21-8).

Measure the voltage between the wire harness side
condenser 2P (Natural) connector terminals.

Green

Red

[11

Connection : Red (+) - Green (-)
Standard : Battery voltage at all time
If there is no voltage, check the following:
-

-

FM/FPM : main fuse (30A), FE/FPE: main fuse 1
(30A ) andlor related circui ts
open circuit in the Red or Green wires
rectifier and/or related circuits (page 5-10)

If there is voltage, check the condenser as following:
1. Disconnect the battery negative (-) cable (page 21-8)
and connect the condenser 2P (Natural) connector

111

111.
2. Connect the battery negative (-) cable for a few
seconds and charge the condenser.
3. Disconnect the battery negative (-) cable and
discharge the condenser.
4. Disconnect the condenser 2P (Natural) connector
and check the resistance between the condenser
side connector terminals.
Select the kD range
of the tester.

Q

The condenser is normal if the resistance comes
near 00 once and eventually becomes 
16 N'm
(1.6 kgf'm, 121bHt)

12-2

CLUTCH/GEARSHIFT LINKAGE

SERVICE INFORMATION
GENERAL
This section covers service of the clutch (centrifugal clutch and change clutch) and gearshift linkage. To service the gearshift
spindles of the FMlFPM models and reverse stopper shaft, the engine must be removed from the frame .
The crankcase must be separated when the transmission, shift drum and shift forks require service (page 14-2).
Engine oil viscosity and level and the use of otl additives have an effect on clutch operation . Oil additives of any kind are
specifically not recommended. When the clutch does nol disengage or the vehicle creeps, inspect the engine oil and oil level
before servicing the clutch system.
Engine lubricating oil is fed through the oil passages in the front crankcase cover. Clean the oil passages before installing the
crankcase cover.
The FEiFPE models are equipped with the electric shift program (ESP). ESP service (page 23· 30).

SPECIFICATIONS
Unit: mm

clutch

gear

TORQUE VALUES
ITEM
Clutch spring bolt
Centrifugal clu tch lock nut

'--

Change clutch lock nut

Q 'TY

4

1

THREAD
DIA. (mm)

6
20

TORQUE
N'm (kgf'm, Ibf·ft)
13 (1.3 , 10)
118 ( 12.0 , 87)

18

108 (11 .D, 80)

REMARKS
Lock nut: replace with
a new one.
Apply engine oil to the
threads and seating
surface. Stake.
Lock nut: replace with

a new one.

I Shin drum stoppe' a,m p;,o' bott
I

Gearshift cam bolt

+ -6
1

Gearshift spindle return spring pin
Gearshift spindle A stopper bolt (FM/FPM)

1

12 (1.2. 9)

6

16 (1 .6. 12)

8

22 (2.2. 16)

8

27 (2 .8. 20)

:J

Apply engine oil to the
threads and seating
surface. Stake.
Apply locking agent to
the threads.
Apply locking agenllo
the Ihreads.
Apply locking agent to
the threads.
Apply locking agent to
the threads.

12-3

CLUTCH/GEARSHIFT LINKAGE
TOOLS
Remover weight

07741-0010201

--------r-I

Attachment, 32 x 35 mm

07746-0010100

Driver, 22 mm 1.0.
07746-0020100

or 07936-371020A or 0793&3710200
(U.S.A. only)
Pilot, 15 mm

- - -- -----,f-D"":-:
'e::', - - - - - -------+"P'"
ul""e:O'.'3"5-:X;C'OC.Oi>Cmm~--------1
07749-0010000

07746-0040300

;;;;;---t--;= =====~~~_ _ +

Bearing remover shaft, 1S- mm
07936-KC10100

Bearing remover head, 15 mm
07936-KC10200

07933-HA80000

or 07933-HB3000A (U.S.A. only)

Bearing remover, 15 mm
07936-KC 10500 (U .S.A. only)

CIUlch>C;;ce"o",e","h;oo'-'d"'e'C,- - -- -- +-,Clutch holder sel
07JMB-MN50302

07ZMB-HN20001

0'
07HGB-001010B or 07HGB-001010A
(U .S.A . only) with
07HGB-001020B or 07HG8-001020A

or 07ZMB-HN2A 101 (U.S.A. only)

(U.S.A. only)

12-4

i

CLUTCH/GEARSHIFT LINKAGE

TROUBLESHOOTING
Clutch slips when accelerating
Incorrect clutch adjustment (page 3·24)
Worn clutch discs
Weak clutch springs
Faulty clutch lifter
Improper oil viscosity or oil additive used

Clutch will not disengage
• Faulty clutch lifter
• Warped clutch plates
The vehicle creeps
• Faulty centrifugal clutch
Clutch operating feels rough

Worn clutch outer and center grooves
Warped clutch plates
Loose clutch lock nul
Faulty clutch lifter
Improper oil viscosity or oil level

Hard to shift
Incorrect clutch adjustment (page 3-24)
Worn or damaged gearshift linkage componen ts
Faulty clutch lifter
Improper engine oil viscosity
Faulty gearshift spindle
Faulty shift forks/shaft or shift d rum (page 14·6)
Transmission jumps out of gear
Broken shift drum stopper arm
Weak or broken shift linkage return springs
Worn or damaged gearshift cam
Faulty gearshift spindle
Faully shift forks/shaft or shift drum (page 14-6)
Faulty transmission gears (page 14-6)

12-5

CLUTCH/GEARSHIFT LINKAGE

FRONT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-13).
Drain the coolant (page 8-7).

Remove the following:
- mudguards (page 2-6)
- front propeller shaft (page 19-12)

-

FElFPE models only: shift control molor and
reduction gears (page 23-30)

Disconnect the waler hoses (1) from the front crankcase
cover.

Remove the following:
-

fifteen bolls [lJ
front crankcase cover (2)

-

lifter cam plate [1 J
two dowel pins [2)
joint coliars and O-rings [3]
O-ring [4]

-

output shaft oil seal [IJ
gearshift spindle oil seal (FElFPE models only) (2]

121

12·6

CLUTCH/GEARSHIFT LINKAGE
CRANKSHAFT BEARING
REPLACEMENT
Check the crankshaft bearing [1J.
If the inner race does not turn smoothly. quietly. or if the
outer race fils loosely in the cover, replace the bearing
as follows.

Remove the crankshaft bearing with the special tools ,
TOOLS:

[2] Remo ver shaft, 15 mm
[3] Remover head , 15 mm
[4] Remover weight
U.S.A. TOOLS :
Bearing remover, 15 mm

Remover weight

07936·KC1010a
07936·KC10200
07741-0010201
07936·KC10500
07936·371020A or
07936·3710200

Apply engine oil 10 a new bearing .

Drive a new bearing squarely with the sealed side
facing down until it is fully sealed .

I-_.-

r

TOOLS :
11] Driver
(2J Attachment, 32 x 35 mm
(3J Pilot, 15 mm

07749-0010000
07746-0010100
07746"()040300

CLUTCH LIFTER
Check lhe clutch lifter plale assembly and cam plate for
wear or damage , replace them if necessary.

r..,,-- - -

Remove the lock nut (1) and washer [2).

Remove Ihe adjusting bolUHfter plate assembly [1 ) and
O-nng [2) .
Remove the adjusting boll from the lifter plate
assembly.

~~~~~~~!!!~~~~~

Install the adjusting bolt into the lifter plate assembly.
Coat a new O-ring with engine oil and Install It onto the
adjusting bolt.
Instalilhe adjusting bolUlifter plate assembly by aligning
the groove with Ihe stopper pin [3]
Temporarily Install the washer and lock nut.

12-7

CLUTCH/GEARSHIFT LINKAGE

CENTRIFUGAL CLUTCH
REMOVAL
Remove the front crankcase cover (page 12-6).
Be careful not 10 Unslake the clutch lock nut (11.
damage lhe

crankshan threads

Hold the clutch drive plale using the special 1001 [I J and
loosen the lock nul 12].

TOOL:
Clutch holder set
- holder plate
- holder pin

07ZMB-HN20001
07ZMB-HN20101
07ZMB·HN20200

U.S.A. TOOL:
Clutch holder

07ZMB-HN2A 101

Remove the lock nut and washer PI.

Remove the centrifugal clutch assembly 111 using the

special tool.
TOOL:
[2] Puller, 35)( 1.0 mm

~=====

07933-HASOOOO or
07933-HB3000A
(U .S.A . only)

DISASSEMBLY/INSPECTION
ONE·WAY CLUTCH

You should be able 10 turn the clutch weight assembly
[I) counterclockwise smoothly, but the assembly should
nollurn clockwise.

.-1-'1- - - - - - - - - - - - - - - '

Remove the clutch weigh t assembly from the clutch
drum (2] while turning it counterclockwise .

)
121

12-8

CLUTCH/GEARSHIFT LINKAG E
CLUTC H DRUM

Check the weight contacting surface for scratches or
abnormal wear
Measure the drum 1.0.
SERVICE LIMIT: 150.4 mm (5.92 In)

Check the sprag clutch for abnormal wear, damage or
irregular movement.
Remove the sprag clutch [1] from the clutch drum.

[11

Check the sprag clutch contacting surface [1] for
abnormal wear or damage.

~==--;;;;;;;;;;;;;;;;;;;;;. c----,

DRIVE PLATE

Check the sprag clutch contacting surface [1) for
abnormal wear or damage

1

CLUTCH WEIGHT LINING
Replace the clUtch
wfJlghfs as a set

Measure the lining thickness
SERVICE LIMIT : 1.3 mm (0.05 in)

12-9

CLUTCH/GEARSHIFT LINKAGE
CLUTCH SPRING

Remove the E·chps 111 uSing a screwdriver while
compressing the clutch spring 121.

[31

Remove the following :
- outer plate (3)
- clutch spring

-

inner plate [4J

Measure the clutch spring height.
SERVICE LIMIT: 2.84 mm (0.112 In)

WEIGHT SPRING

Replace the S(lnngs Check the weight springs [11 for wear or damage.
as 8 set. Remove the dutch weights [2J and springs from the
drive plale.

1

(2(
Measure the spring length.
SERVICE LIMIT; 25.7 mrn (1 .01 in)

12·10

(1)

CLUTCH/GEARSHIFT LINKAGE
ASSEMBLY
CLUTCH WEIGHTS

DRIVE PLATE

WEIGHT SPRINGS
CLUTCH SPRING
OUTER PLATE

CLUTCH DRUM

INNER PLATE

E-CUPS
SPRAG CLUTCH
Install with the
spring's open ends
facing In

Install the clutch weights [1] and springs [2] onto the , -- -- - - - -- -- - - - - - - ,
drive plate as shown.
[t}

[21
InSlall the inner plate [1] with flange side facing up.
Install the clutch spring [2] with concavity side facing
down .

[1)

[21

12-11

CLUTCH/GEARSHIFT LINKAGE
Install the outer plate [1] with the pins [2] facing up.

[11

Be careful not to

Inslall the E-clips [3J into the spindle grooves with its
damage the clutch gap facing towards the pin by using the phers while
weights while compressing the clutch spring
compressmg

Apply engine oil 10 the whole surface of the sprag dutch
(1] and the sprag dutch contacting surface of the clutch

~=============~.O~U=T~S~'=D=E~.~

drum.
Install the sprag dutch into the clutch drum with the
"OUT SIDE" mark facing up.

Apply engine oil the sprag clu tch contacting surface ~=================1:::;
10

of the drive plale boss.

Install the clutch weight assembly [1] while turning it

counterclockwise.

[11

INSTALLA T[ON
Sel the centrifugal clutch assembly (1] onto the , - - - - crankshaft by aligning the splines of the drive plate and

crankshaft, and the splines of the clutch drum and
primary drive gear.

Be careful not to Tap the drive plate 10 seat it.
damage the
TOOL:
crankshafi threads.
[2) Driver, 22 mm 1.0 .

12-12

07746.{)020100

CLUTCH/GEARSHIFT LINKAGE
Install the washer (1].
And apply engine oil 10 the threads and seating surface
of a new lock nul [2) and install II.

Hold the drive plale of the centrifugal clutch assembly
with the special tool and tighten the lock nut to the
specified torque

TOOL:
(3) Clutch holder set
- holder plate
- holder pin

07ZMB ·HN20001
07ZMB· HN20101
07ZMB· HN20200

U.S.A. TOOL:
Clutch holder

07ZMB·HN2A101

TORQUE : 118 N'm (12.0 kgf'm, 87 Ibf·h)
Be careful not to
damage/he
crankshaft Ihreads

Stake the lock nut into the crankshaft groove .

Install the front crankcase cover (page 12-23).

CHANGE CLUTCH
DISASSEMBLY
Remove the following:
-

centrifugal clutch assembly (page 12-8)
FEJFPE models: gearshift linkage (page 12-19)
FMfFPM models: dutch lifter lever (page 12-20)
lifter bearing (1] and collar [2]

Loosen the dutch spring bolts [1] in a crisscross pattern
in several steps, and remove Ihe bolls, lifter plale [2J
and dutch springs [3].

~~~;:!!;;=~=~::~~

12-13

CLUTCH/GEARSHIFT LINKAGE
Be careful nollo
damage/he

Unstake the clu tch cen ter lock nul [1).

mainshaft threads

Install the clutch center holder 111 onlo the pressure
plale bosses with the four clutch spring bolts (2).

TOOL:
Clutch center holder

07JMB·MN50302

U.S.A . TOOLS :
Holder plate

07HGB-001010B

or

07HGB·001010A
Holder collar A

with
07HGB-001020B
07HGB-001020A

or

Hold the clutch center and loosen the dutch center lock

nut (3].
Remove the lock nul and washer [4].

Remove the following:

12-14

-

clutch cen ter [1)
clutch discs and plates [21

-

pressure plale (3J

-

thrust washer [1]
clutch outer (2)

~;::;;:;;:;~

CLUTCH/GEARSHIFT LINKAGE
-

clutch outer guide [1]

Remove the pnmary drive gear
the crankshaft.

111 and washer 121 from

INSPECTION
CLUTCH LIFTER

Tum the inner race of the lifter bearing
finger.

111

with your

~~~~~~

F

FElFPE models shown:

[1J

The bearing should tum smoothly and quietly_
Replace if necessary.
Check the tifter cam plate [21, lifter plate (3] and oollar
[4) for deformation or damage

13J

{4J

CLUTCH SPRING
Replace the clutch

spnngs as a sel

Measure the clu tch spring free length
SERVICE LIMITS : FM /FPM : 50.7 mm (2.00 in)
FElFPE : 45.3 rnm (1 .78 In)

12-15

CLUTCH/GEARSHIFT LINKAGE
CLUTCH DISC
Replace the clutch
discs and plales as
s set

Check the clutch discs for signs of scoring 0'
discoloration.

I

Measure the clutch disc thickness.
SERVICE LIMIT: 2.3 mm (0.09 in)

CLUTCH PLATE
Replace the clutch
diSCS and plates as

a sel

Check the plates for discoloration .

Check the plate warpage on a surface plate using a

feeler gauge.
SERVICE LIMIT: 0.20 mm (0.008 in)

CLUTCH CENTER

Check the clutch center and pressure plate for nicks,
Indentations or abnormal wear made by the plates.

CLUTCH OUTER

Check the pnmary driven gear teeth for wear or
damage.
Check the slots in the dutch outer for nicks, indentation
or abnormal wear made by the clutch discs.

Measure the clutch outer I D.
SERVICE LIMIT: 29.05 mm (1 .144 in)

12-16

r - -- - - - - - - - - - -- - - - ,

CLUTCH/GEARSHIFT LINKAGE
CLUTCH OUTER GUIDE
Check the outer guide for wear or damage .
Measure the clutch outer guide 1.0 . and 0 .0 .
SERVICE LIMITS : 1.0 .: 22.05 mm (0.868 In)
0 .0 .: 28.93 rnm (1 .139 in)

PRIMARY DRIVE GEAR

Check the gear teeth for wear or damage.
Measure the drive gear 1.0.
SERVICE LIMIT: 29.05 mm (1.144 in )

MAINS HAFT AND CRANKSHAFT
Measure the mainshaft 0 .0 at the clutch outer gUIde.
SERVICE LIMIT: 21 .93 mm (0 .863 in)
Measure the crankshaft 0 .0 . at the primary dnve gear.
SERVICE LIMIT: 28.93 mm (1.139 in)

ASSEMBLY
Apply engine oil to the primary drive gear Slidmg
surface of the crankshaft.
Install the thrust washer (11 and the primary drive gear
(2J onto the crankshaft.

12-17

CLUTCH/GEARSHIFT LINKAGE
Apply molybdenum oil solution to the inner and outer
surfaces of the clutch outer guide Pl.
Instalilhe outer guide onto the mainshaft (2).

Instalilhe clutch outer [11 and thrust washer (21

Coal the clutch discs with clean engine oil.
Install the followi ng:
pressure plate [1]
- clutch discs and plates 12]
Set/he outside - clutch center [4J
clutch dISC tabs mto
the Shallow slots (3)
Ins/all the discs and
plaIa alternately.
staffing with a disc

In

the dutch

-

outer,

Install the washer [1 J to the malnshaft.
Apply engine oil 10 the threads and seating surface of a
new lock nul 12]. and install it.

r.:;;......,..-

Install the clutch center holder [31 onlo the pressure
plate bosses with the four clutch spring bolts.

TOOL :
Clutch center holder

07JMB·MN50302

U.S.A. TOOLS :
Holder plate

Holder collar A

07HGB..Q01010B or
07HGB.(I01 01 OA
with
07HGB-001020B or
07HGB-001020A

Hold the dutch center holder and tighten the lock nut to
the specified torque.

TORQUE : 108 N'm (11 .0 kgf'm , 80 IbUt)

12-18

j

CLUTCH/GEARSHIFT LINKAGE
Be careful not to
damage the

Stake the lock nul [1J into the mainshaft groove.

mamshaft fhrosds

Install the clutch springs [lJ and the lifter plate [2J Wtth
the ·our mark facing out.
Install the clutch spring bolls [3] and lIghten them to the
specified torque In a crisscross paltern in several sleps.

~=;;=::

TORQUE : 13 N'm (1.3 kgf'm, 10 IbHt)

Apply engine 01110 the lifter bearing 11], and install the
lifter collar [21 and bearing .
Install the following.
- FEJFPE models: gearshift linkage (page 12-22)
- FMfFPM models: liftarlever (page 12-22)
- litter bearing and collar
- centrifugal clutch assembly (page 12-12)

GEARSHIFT LINKAGE
REMOVAL
NOTE'
• To service the reverse stopper shaft. engine removal
is required (page 14-7).
Remove the centrifugal clutch (page 12-8).
Remove the following:
FElFPE models.

-

-

angle sensor (page 23-26)
shift arm spring 111
gearshift spindle assembly [2J and washer (3)

12-19

CLUTCH/GEARSHIFT LINKAGE
FMlFPM models: -

clutch lifter lever (1)

-

shift arm spring [2J
return spring 13] and gearshift arm 14]

-

washer [5)

To service the gearshift spindles 16J , remove the rear
crankcase cover (page 12-22).

-

0011[1)

-

guide plate (2)

-

gearshift plaia [1J
FM/FPM models only: washer from the gearshift

-

gearshift cam [2) (while holding stopper arm with a

spindle
screwdriver)

12-20

-

bolt [1]
stopper arm (2]

-

washer (3)
return spring (4]

-

gearshift spindle return spring pin [5]

CLUTCH/GEARSHIFT LINKAGE
INSTALLATION
Apply locking agent to the threads of the gearshift
return spring pin [1J.
Install the gearshift return spring pin and tighten it to the
specified torque.

TORQUE : 22 N·m (2.2 kgf'm , 16 1bHt)
Apply locking agent to the threads of the stopper arm

boll 121 .
Install the return spring [3], washer (41 (between the arm
and crankcase), stopper arm IS] and bolt, and tighten
the bolt to the specified torque.

TORQUE: 12 N'm (1 .2 kgf'm, 9lbHt)

Hold the stopper arm [1] with a screwdriver (2] and
install the gearshift cam [3] by aligning the pin hole (4)
with the dowel pin [5].

FM/FPM models only: Install the washer onto the
gearshift spindle
Inslallthe gearshift plate [1] onto the cam (2) as shown.

Install the guide plale [3] by aligning the tab with the
groove in the cam.

Apply locking agenllo the threads of the cam bolt (1).
Inslalilhe cam bolt and tighten it to the specified torque.
TORQUE : 16 N'm (1.6 kgf'm , 121bHt)

12-21

CLUTCH/GEARSHIFT LINKAGE
FEJFPE models: Install the washer (1 ) behind the gearshift plate and

insert the gearshift spindle assembly [2} into the
crankcase.
Align the relum spring ends (3) with the stopper pin [41.

Hook the shift arm spring [5) to the gearshift arm and

plate.
Install the angle sensor (page 23-28).

FMlFPM models

Insert the gearshift spindle [1] from the rear crankcase
side, then instalilhe washer [21 in between the gearshift

;"'''=~:::~~=~~~:':'~~~:':'~~~~

plate [31 and crankcase.
Install the gearshift arm (4) and re turn spring (51.
aligning the spring ends with the stopper pin.
Hook the shift arm spring 16] to the gearshift arm and

plate.
Install the lifter lever £7] by aligning the wide groove with
the wide tooth of the splines.

Install the rear crankcase cover (page 13-9).
All models:

Inslallthe centrifugal clutch (page 12-12).

171
GEARSHIFT SPINDLE A (FM/FPM
models only)
Remove the rear crankcase cover (page 13-6)
Remove the stopper bolt (1), washer 12) and gearshift
spindle A 13] from the rear crankcase cover (4).
Remove the oil seal IS] from the rear crankcase cover.

121

111

cg

141

Install a new oil seal.
Apply engine oil to the oil seal lip and Install the
gearshift spindle A.
Apply locking agent 10 the stopper bolt threads.
Install the washer and stopper bolt, and tighten the bolt.
TORQUE: 27 N·m (2.8 kg f 'm, 20 IbUt)
Install the rear crankcase cover (page 13-9)

131

12-22

tI~ 151

CLUTCH/GEARSHIFT LINKAGE

FRONT CRANKCASE COVER
INSTALLATION
Clean the mating surfaces of the front crankcase cover
and crankcase thoroughly, being careful nol to damage
them.

Blow through the oil passages in the front crankcase
cover with compressed air.
Apply engine oil to the boss of the adjusting plate.

Install a new output shaft oil seal [1[ into the front
crankcase cover.

;:=~~===;::~~==~~::::~~

FElFPE models only: Install a new gearshift spindle oil
seal 12] into the front crankcase cover

Install the joint collars [1] and dowel pins [2].
Coal new O-rings 131 with engine oil and install them.
InSlalithe lifter cam plate 14].

Apply liquid sealant (TB1215 or equivalent) to the
mating surface (shadowed area) of the front crankcase
cover as shown.

~==

12-23

CLUTCH/GEARSHIFT LINKAGE
Apply engine oil to the tips of the oil seal

Be careful nollo
drop the lifter cam
plate.

111.

Install the crankcase cover 121. being careful not to
damage the oil seal lips.

Install the fifteen bolts (3] and lighten them in a
crisscross pattern in several sleps.

Connecllhe water hoses (lJ to the crankcase cover.

Inslallthe following:
- FElFPE models only: reduction gears and shift
control motor (page 23-31)
- front propeller shaft (page 19-37)
- mudguards (page 2-6)
Adjust the clutch system (page 3-24).
Fill the engine with recommended oil (page 3-13).
Fill and bleed the cooling system (page 8--6).
Check the engine oil level (page 3-12).

12-24

13. ALTERNATORISTARTER CLUTCH

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

RECOIL STARTER (Canada type) ............ 13-6

SERVICE INFORMATION .......................... ·13-4

ALTERNATOR STATOR ............................ 13-6

TROUBLESHOOTlNG .... · ...... · .................... ·13-5

FL YWHEEUSTARTER CLUTCH ............ · 13-11

•

13-1

ALTERNATOR/STARTER CLUTCH

SYSTEM COMPONENTS
U.S.A. type :
FElFPE models shown:

108 N-m (11 .0 kgf-m, 80 IbfftJ

13·2

AL TERNATORISTARTER CLUTCH
Canada type:
FElFPE models shown:

t08N ·m(11 .0

13-3

ALTERNATOR/STARTER CLUTCH

SERVICE INFORMATION
GENERAL
This section covers service of the alternator stator, flywheel and starter clutch . To service these parts. the engine must be
removed from the frame (page 15-2).
Transmission lubricating oil is fed through the oil passages in the rear crankcase cover. Ctean the oil passages before installing
the cover.
For alternator stator inspection, see Battery/Charging System section (page 21 -10)
For starter motor servicing. see Electric Starter section (page 6-6).

SPECIFICATIONS
ITEM
Starter driven gear boss

= = =---'-

STANDARD
51 .705 - 51 .718 (2 .0356 - 2.0361)

0 .0 .
I.D. ~._

_ _ -!--.;;31.946- 31 .962 (1 .2577 - 1.2583)

Crankshaft 0.0. at starter driven gear

31 ,884

31 .900 (1 ,2553 - 1.2559)

Unit: mm (in)
SERVICE LIMIT

51.69 (2.035)
31 .90 (1.256)
31.85 (1 .254)

TORQUE VALUES

I Starter clutch bolt
~

ITEM

C 'TY

6

Flywheel bolt (U.S,A. type)

FtywheeVdriven pulley bolt (Canada type)

I CKP sensor boll

13-4

1
2

THREAD
DIA. (mm)

TORQUE
N'm (kgf'm , tbUt)

8

37 (3 .8. 27)

12

108 (11 .0, 80)

+

12

I

108(11 .0. 80)

~644)

REMARKS
Apply tacking agent to
the threads.
Apply engine oil to the
threads and seating
surface.
Apply engine oit to the
threads and seating
surface.
Apply locking agent to
the threads.

AL TERNATORISTARTER CLUTCH
TOOLS
Flywheel holder

07725-0040001

Rotor puller
07733-0020001

or 07933-3950000
Attachment, 52 x 55 mm

Attachment, 24 x 26 mm

07746-0010400

07746-0010700

Remover weight

07741-0010201

or 07936-37 1020A or 07936-3710200
(U.S.A. only)
Pilot, 10 mm
07746-0040100

8
Pilot. 25mm
07746-0040600

Driver

Bearing remover shaft, 10 mm

07749-0010000

07936-GE00100

Bearing remover head , 10 mm
07936-GE00200

Bearing remover, 10 mm
07936-GEOAOOO (U .S.A. only)

Recoil pulley holder
07SMB-HM70100

TROUBLESHOOTING
Starter motor turns, but engine does not turn
Faulty starter clu tch
• Damaged starter reduction gear andlor driven gear

13-5

ALTERNATOR/STARTER CLUTCH

RECOIL STARTER (Canada type)
REMOVAUINSTALLA TION
Remove the mudguards (page 2-6),
Remove the following:

111 and clamp [2]

-

four bolts

-

recoil starter assembly [3}

Apply locking agent to the boll threads.
Instalilhe recoil starter assembly with the four bolts and

clamp, and lighten the bolts in a crisscross pattern In

several sleps.
Secure the wire with the cramp properly.
Install the mudguards (page 2-6).

STARTER ROPE REPLACEMENT
When the

rope has Pull the starter rope (1) fully to align the rope holes in

broken or the pulley
has rewound, align
the rope holes by
fUming the pulley 6-

112 tums
counterclockwise

and hold it

the drive pulley [2J and housing [3J, and secure the
pulley with a vise pliers or equivalent 1001 to prevent Ihe
pulley from rewinding.

I [4]

Untie Ihe slarter rope and remove the rope.
Insert a new slaner rope Ihrough Ihe pulley, housing
and grip (4], and tie the rope ends in a square knot. Sel
the pulley side rope end into the cavily as shown.
Carefully release the pulley and check the recoil slarter
for smooth operation by pulling the grip.

Rope ends:

~

ALTERNATOR STATOR
REAR CRANKCASE COVER
REMOVAL

1

I

Remove the following:
- engine from the frame (page 15-4)
- Canada type only: recoil starter (page 13-6)
- FElFPE only: shift angle sensor (page 23-28)
Canada type. Hold the recoil starter driven pulley using the special , -- - -- - - - - - - - - - - - - - ,
tool and loosen the boll.

TOOL:
[ 1] Recoil pulley holder

13·6

L

ALTERNATORISTARTER CLUTCH
Canada type:

Remove the following:
bolt (1) and O-ring [2)
- driven pulley 131
- oil seal [4]

The cover (stalor) is magnetically -

,'"

(31

J

thirteen bolls (1)
rear crankcase cover [2)

aflracted to the

flywheel, be careful
during removal.

-

two dowel pins [1]
oil joint pipe and O-ring [2]
countershaft thrust washer [3J
reverse stopper shaft thrust washer (4]

-

output shaft oil seal11J
reverse lock lever oil seal [2)
FElFPE models only: gearshift spindle oil seal [3]

13-7

ALTERNATOR/STARTER CLUTCH
STATOR AND CKP SENSOR
REMOVAL
Remove the following :
-

two CKP sensor bolts (1]
four stator bolts (2)

-

grommet (3]

-

slator/CKP sensor assembly [4]

[3)

[4[

STATOR AND CKP SENSOR
INSTALLAT[ON

.c:u:a

Set the stator/CKP sensor assembly [1] onto the 0;::---:=- - - - --:[=2): -----:
"tmI.
::::,: --alternator cover,

Apply seatanllo the sealing surface of the grommet [2]
and install the grommet into the cover groove securely,

(3)

\,\!'--l.>>¥""'~;':"

_

?"'''''''''

Apply locking agent to the threads of the CKP sensor

boll [3[ .
Install the stator bolts [4J and CKP sensor bolts, and
lighten them to the specified torque.
TORQUE :

CKP sensor bolt: 6.0 N'm (0.6 kgf'm, 4.4IbHt)

[4J .....~:E:J:;~

[1 [

OUTPUT SHAFT BEAR[NG
REPLACEMENT
Turn the inner race of the bearing 11]

with your finger.

The bearing should turn smoothly and quietly.

Also check that the bearing outer race fits tightly in the
rear crankcase cover.
Replace the bearing if the inner race does not turn
smoothly, quietly or if the outer race fits loosely in the
cover.
Drive the bearing out of the cover.
Apply engine oil to a new bearing .
Drive the bearing into the cover with the marked side
facing up.
TOOLS :
Driver
Attachment, 52 x 55 mm
Pilot, 25 mm

13·8

07749..()010000
07746-0010400
07746"()040600

!

1

ALTERNATOR/STARTER CLUTCH
REAR CRANKCASE COVER
INSTALLATION
Clean the mating surfaces of the crankcase and rear
crankcase cover thoroughly, being careful nol to
damage them.

Blow through the oil passage in the rear crankcase

cover with compressed air.
Install the following:
- new output shaft oil seal [1]
- new reverse lock lever oil seal (2)
- FE/FPE models only: new gearshift spindle oil seal

131
Apply engine oil to the oil seal lips.

Apply liquid sealant (T81215 or equivalent) to the
mating surface (shadowed area) of the rear crankcase
cover as shown.

;::=====~~~~~~~
I

Install the two dowel pins [1] and oil joint pipe 12].
Coat a new O-ring [3) with engine oil and install it onlo
the oil joint pipe.
Install the thrust washers (4J onto the countershaft and
reverse stopper shaft.

Shift the transmission into neutral to align the groove in
the shift drum [1J with the lug [2J on the crankcase.
Align the long end (3] of the gear position switch pin
with the "N" mark [4J (lug [5]) on the rear crankcase
cover.
Install the rear crankcase cover aligning the switch pin
with the shift drum groove properly, being careful not to
anracled to the damage the switch pin and oil seal lips.
"ywheel, be careful
not to get anything NOTE·
FMfFPM models only: Align the arm of gearshift
caught between
'Phindl~ A, W,,!th t,hhe arm hole in the gearshift spindle
Ihese parts when
w en inS a mg e cover.
installing.

~~~~111~=~~~~~~=
/ ~"
"\.

[31

The cover (stalor) is
magnetically

-,...

7"-"1~'
:~
,'-'>

Itl

141

151

If the cover doesn't install easily, remove it and check '-'--'--_ __ _ _ _ _---'--'-_ _ _ _ _ _-'-'~
Ihe alignment of the switch pin and the shift drum or the
switch for damage.

13·9

ALTERNATOR/STARTER CLUTCH
After installing the crankcase cover, make sure that the
oil seals in the cover are nol turned inside out.

Install the thirteen bolls [11 and tighten them in a
crisscross pattern in 2 or 3 sleps.

Canada type '

Apply specified grease to the lips of a new oil seal (1]
and inslall it into the crankcase cover unlil it is fully

sealed .
SPECIFIED GREASE: Mobilith SHe 100 (EXXON)
Coal a new O-ring 12] with engine oil and install it onto
the pulley bolt nanga.

[3[

Apply engine oil to the threads and sealing surface of
the pulley boll (3).
Install the driven pulley (4] with the bolt, aligning the
bosses with the grooves in the crankshaft.

1

Canada type: Hold the driven pulley using the special tool and tighten
thebett.

TOOL :
(1] Recoil pulley holder

07SMB·HM70100

TORQUE: 108 N'm (11 .0 kgf'm , 80 Ibf-ft)

Install the following:
- FElFPE only: shift angle sensor (page 23· 28)
- Canada type only: recoil starter (page 13·6)
- engine into the frame (page 15·9)

13-10

\

(

\

ALTERNATOR/STARTER CLUTCH

FL YWHEELISTARTER CLUTCH
REMOVAL
Remove the rear crankcase cover (page 13-6),
Remove the starter reduction gear shaft [1] and gear
{2{ .

U.S.A. type: Hold the flywheel using the special 1001111 and remove
the flywheel bolt 121 and collar (3J .

TOOL:
Flywheel holder

07725-0040001

Hold the f1~heel [1 J and remove it from the crankshaft
using the speciallools.

1":'::""11"""'::;;;;;0

TOOL:
(2) Rotor puller

07733-0020001 or

07933·3950000

Remove the woodruff key [1] from the crankshaft.

13-11

AL TERNA TOR/STARTER CLUTCH
STARTER CLUTCH DISASSEMBLY
Make sure that the starter driven gear (1] turns
dockwise
smoothly
and
does
not
turn
counterclockwise.

r c-- - -- - - - - - - - - - - - - - ,
l1 I

$

RemOlle the driven gear while turning it clockwise.

Hold the flywheel with the special tool (11 and remove
the starter clutch bolts (T40) [2].

TOOL:
Flywheel holder

11)

07725-0040001

Remove the starter clutch assembly from the flywheel.

121
INSPECTION
Check the starter driven gear teeth for wear or damage. , - - - - - - --

- - --

------,

Measure the driven gear boss 0.0. and 1.0.

SERVICE LIMITS : 0 .0 .: 51 .69 mm (2 .035 In)
1.0.: 31 .90 mm (1 .256 In)

Measure the crankshaft 0 .0 . at the starter driven gear.
SERVICE LIMIT: 31 .85 mm (1 .254 in)

13·12
J

ALTERNATORlSTARTER CLUTCH
Remove the sprag clutch [lJ from the clutch outer (2J.

Check the starter clutch outer and sprag dutch for
abnormal wear or damage.

(11

Check the starter reduction gear and shaft for wear or
damage,

~================;

STARTER CLUTCH ASSEMBLY
Lubricate the sprag clutch [1J with engine oil and install ,
it into the clutch outer [2J with the flange facing the
flywheel side.
Inslalithe starter clu tch onto the flywheel.

Apply locking agent to the threads of the starter clutch
(T401 bolt (11.

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

~12=1===============~

Align the bolt holes in the flywheel and staner clutch ,
and inslalilhe bolts.
Hold the flywheel with the special tool [2] and tighten
the bolts to the specified torque.
TOOL;

Flywheel holder

0772S'{)040001

TORQUE : 37 N'm (3.8 kgf'm , 27 IbHt)

13-13

ALTERNATOR/STARTER CLUTCH
Install the starter driven gear (1] while turning it
clockwise.

INSTALLATION
Install the woodruff key [1] into the key groove.
Apply molybdenum oil solution to the starter driven gear
sliding surface of the crankshaft.
Clean any oil from the tapered portions of the
crankshaft and flywheel.

Apply engine oil to the starter driven gear boss inner
surface.
Instalilhe flywheel ttl aligning the key way with the key
on the crankshaft.

u.S.A. type:

Apply engine oil to the threads and seating surface of
the flywheel bolt [1] and install it with Ihe collar 121.
Hold the flywheel using the special tool 131 and lighten
Ihe flywheel bolt.

TOOL:
Flywheel holder

07725-0040001

TORQUE : 108 Nom (11 .0 kgf·m, 80 IbHt)

13-14

11 I

ALTERNATOR/STARTER CLUTCH
Canada type:

Temporanly tighten the pulley bolt to seal the flywheel
as follows.
Apply engine oil to the threads and sealing surface of
the pulley bolt [t).
Install the driven pulley (2] . aligning the bosses wi th the
grooves in the crankshaft, and secure it with the bolt.
Hold the driven pulley using the special tool and tighten
the bolt.

TOOL:
(3] Recoil pulley holder

,

07SMB·HM70100

TORQUE: 108 N'm (11 .0 kgf'm , 80 IbHt)

loosen the pulley bolt. Remove the tool, bolt and
pulley.
Apply molybdenum oil solution to the starter reduction
gear shaft [11.
Apply engine oil to the reduction gear teeth [2] .
Inslalithe gear and shaft.
Inslall the rear crankcase cover (page 13-9).

13·15

ALTERNATOR/STARTER CLUTCH
STARTER MOTOR BEARING
REPLACEMENT
Remove the rear crankcase cover (page 13-6).
Remove the starter reduction gear shaft

111

and gear

(21.
Turn the inner race of the bearing [3] with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tighlly in the
rear crankcase cover.
Replace the bearing if the inner race does not turn
smoothly, quietly or if the outer race fits loosely in the
cover.
Remove the bearing using the special tools.
TOOLS :
Bearing remover shaft, 10 mm
Bearing rem over head, 10 mm
Remover weight
U.S.A. TOOLS:
Bearing remover, 10 mm
Remover weight

07936-GE00100
07936-GE00200
07741-{l010201
07936-GEOAOOO
07936·371020A or
07936·3710200

Apply engine oil to a new bearing.
Drive a new bearing into the crankcase with the marked
side facing out. using the special tools.
TOOLS :
Driver
Attachment, 24
Pilot, 10 mm

x 26 mm

07749-{l010000
07746-{l010700
07746-{l040100

Apply molybdenum oil solution to the starter reduction
gear shaft, and install the gear and shaft.
Install the rear crankcase cover (page 13-9).

13-16

14. CRANKCASEfTRANSMISSION/CRANKSHAFT/BALANCER

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

TRANSMISSION ...... · .................................. 14-8

SERVICE INFORMATION .......................... ·14-3

CRANKSHAFT/BALANCER · .. · .. · .......... · .. · 14-15

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

CRANKCASE BEARING .......................... 14-18

CRANKCASE SEPARATION ...... ·· ...... ........ 14-7

CRANKCASE ASSEMBLY ...................... · 14-21

14-1

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER

SYSTEM COMPONENTS

14-2

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER

SERVICE INFORMATION
GENERAL
The crankcase halves must be separated to service the transmission and crankshaft. To service these parts . the engine must be
removed from the frame (page 15-4).
Be careful not to damage the crankcase mating surfaces when servicing.
Engine lubricating oil Is fed through the oil passages in the crankcase. Clean the oil passages before assembling the crankcase
halves.

SPECIFICATIONS

_____

Shift fOrk.~
D

\1~==:::::;:::~

ITEM

Front. rear
Center

Claw thic'kko:e:,:,=~~~~==
I--= = = =_ - ;Shaft O.~
Transmission
Gear 1.0 .
M3
M5
C1 , C2. C4 , CR
Reverse idle
Gear bushing
M3
0 .0 .
M5
C2
C1 , C4 , CR
r---Gear-Io-bushing
M3
clearance
M5
C2
C1, C4. CR
Gear bushing 1.0.
M3

r

M5
~=",,,_+-;;'i'C4,

Malnshaft 0 .0 .

Cou::;nl"'e:;o
"iCha'"ft~O".o'.-+

I

Crankshaft

~

Reverse idle gear-to-shaft
Runoul
Big end side clearance
Big end radial clearance

13.000
13.000

13.021 (0.5118 - 0 5126)
13.018 (0.5118 - 0.5125)

4.93 5.00 (0.194 0.197)
12.966 12.984 (0.5105 - 0.5112)
25.000 25.021 (O.9843 - 0.985 1)
20.000 20.021 (0.7874 - 0.7882)
28.020 28 .041 (1.1031 - 1.1040)
13.000 13.021 (0.5118 - 0.5126)
24.959 24 .980 (0.9826 - 0.9835)
19.966 19.984 (0.7861 - 0.7868)
27 .984 28.005( 1'.1017-1 .1026)
27.979 28.000 (1 .1015-1.1024)
0.020 0.062 (0.0008 - 0.0024)
0.016 0.055 (0.0006 - 0.0022)
0.015 - 0.057 (0.0006 - 0.0022)
0.020 0.062 (0.0008 0.0024)
22.000 22.021 (0.8661 0.8670)

1304 (0 51=!)
13.04 (0.513)

4.5 (D.'!!)
12.96 (0.510)
25.05 {O.9861_
20.05 (0.789f
28 .07 (1 .105)
13.04 (0. 51~)
24.93 (0.981)
19.94 (0.785)
27.94(1 .100)
27.93 (1 .100)
0.10 (0. 004 )t-_--1
0.10 '({f""{}Q4
0.08 (0.003)
0-:10 (0.QQ±l
22.04 (0 .868)

1---:==~!lr7.~01~6~-~'
~7~.0~34~(0~
. 66;.9:9~0].6;706~)==~:17.06
25.000 - 25.021
(0.9843
- 0.9851)
25.05 (0.672)
(0.986)

at M3
at M5
at C4

Reverse idle shaft 0 .0 .
BUShing_tO-Shaft
. M3
clearance
M5
C4

~:::;;;::;:::::;;::.;;~~.
--::::===~
Unit:LIMIT
mm (in).
STANDARD
,.
SERVICE

_

21 .959 - 21 .980 (0.8645 - 0.6654)
16.976 -16.987 (0.6683 - 0.6688)
--+--i2T4.ii95'"9~24.980 (0.9826 - 0.9835)
12.966 -12.984 (0.5105 - 0.5112)
0.020 - 0.062 (0.0008 - 0.0024)
0.029 - 0.058 (0.0011 - 0.0023)
0.020-0.0620.0008 - 0.0024)

I

21 .93 (0.863)
16.93 (0.667)
24 .93 (0.981)
12.94 (0.509)
0.10 (0.004)
0.10 (0.004)
0.10 (0.004)

clearan",c",e'=1~
0~.0~'6~-;0~.0~S:5:10:.~00~0~6~-:0~.~00~2~2~)===S0.15
O. 10 (0.004)
(0.006)
0.05 - 0.65 (0.002 - 0.026)
0.006 - 0.018 (0.0002 - 0.0007)

0.8 (0.03) 0.05' (0.002)

THREAD

REMARKS

TORQUE VALUE
ITEM

,c;o.;= , . -- --'-

Mainshaft bearing selling plate bolt

Q'TY

TORQUE

-.,_+-coO"IA,,·t1m=mL) -t~
N .m (kgf'm , Ib"'.ft,,)' -i--,====== c-'
2
6
12 (1 .2. 9)
Apply locking agent to
the threads.

14-3

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
TOOLS

I

Universal bearing puller

Remover weight

Attachment, 32 x 35 mm

07631-0010000

07741 -00 10201

07746-0010100

o

I

orequivalenl commercially available in

U.S.A.

or Q7936·371020A or 07936·3710200

=-______~~(U~.S~.~A=.o=n~'y)

~~--------~..,~~,.~~~--------~

Attachment, 37 x 40 mm

Attachment, 42 x 47 mm

Attachment, 62 x 68 mm

07746-0010200

07746-0010300

07746-0010500

Attachment, 72 x 75 mm ----------hp>Oi"'o't,<''""lIers~h~a'ft-------------------r'R~e~mo~,~e~'h~a~n~d~leC--07931-HB3020A (U.S.A. only)

07931-ME4010B (U.S.A. only)

07936-3710 100

:J
Bearing remover, 17 mrn

Bearing remover, 20 mm

07936-3710300

07936-3710600

Bearing remover head, 15 mm
07936-KC10200

07936-KC1 0500 (U.S.A. only)

Assembly collar
07965-VM00100

TI BeaMng ..mo,., shaft, 15 mm
Q7936-KC10100

Beanng-o'e=m
=o='''eO"',' I''S-Om=m=-----------j-' Attachment. 45x50 mm
07946-6920100

------------r,P~"'"""ershaftand'cn="71-------------+-.
Th='=e=ad7e~d~a~d~a=pl~.='--Q7965-VM00200

07965-VM00300

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

14-5

CRANKCASEITRANSMISSION/CRANKSHAFT/BAlANCER
Attachment, 78 x 90 mm
07GAO-S040101

Pilol, 32 mm
07MAD-PR90200

11

TROUBLESHOOTING
Excessive engine noise
Worn , seized or chipped transmission gears
Worn transmission bearings
Worn connecting rod big end bearing
Worn crankshaft. main journal bearing
Worn balancer bearing
Improper balancer installation

Transmission Jumps out of gear
Worn gear dogs or dog holes
Worn shift drum guide groove
Worn shift fork guide pin
Worn gear shifter groove
Worn shift fork
Bent shift fork shaft
Faulty gearshift linkage (page 12-5)

Hard to sh ift
Damaged shift fori<:;
Benl shift fork shaft
Damaged shift fork guide pin
Damaged shift drum guide groove
Benl gearshift spindle
Faulty gearshift linkage (page 12-5)

Abnormal vibration
• Improper balancer timing

14-6

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER

CRANKCASE SEPARATION
Remove the following:
- engine (page 15-4)
cylinder head (page 10-9)
cylinder and piston (page 11-4)
gearshift linkage (page 12.19)
change clutch (page 12-13)
oil pump (page 9-4)
flywheel and starter clutch (page 13-11)
reverse stopper shaft assembly 11]
output shaft drive gear [2J, driven gear [3J and output
shaft [4]

Loosenthe

crankcase bolts in a
cnssClOSS pattem in
several steps.

Do not PlY the
cnmkCBS6 apart

with

-

two front crankcase bolts [1]

-

fifteen rear crankcase bolls (1)

Place the crankcase assembly with the rear crankcase
down.

Remove the front crankcase while tapping It at several
locations with a soft hammer.

a screwdriver. Remove the three dowel pins (1).
Remove any sealant material from the crankcase
mating surfaces.

111

14·7

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
OIL STRAINER CLEANING
Remove the oil strainer (1] and strainer plate (2).
Wash the strainer thoroughly in non-flammable or high

flash point solvent unlil all accumulated dirt has been
removed.
Blow dry the strainer with compressed air completely.

Before installing the strainer, the screen mesh should
be examined closely for damage.

Install the strainer and plate with the wedge facing the

crankcase.

[2[

TRANSMISSION
DISASSEMBLY
Separate the crankcase (page 14-7).
Remove the following:
- shift fork shaft [1]
- shift forks [21

PoSitlOfllhe crank
weights so rnat they
do not interfere with
the m8inshat!

-

shift drum [3J

-

reverse idle shaft [1) and idle gear [2J

-

mainshaft (1], countershaft [21 and washer [3J as an
assembly

~~~~~~~~~~=I.I:~IIIl~~~

gears.

14-8

j

CRANKCASEITRANSMISSIONfCRANKSHAFTfBALANCER
Do not expand the
snap ring more thall
necessary for
removal.

Disassemble the mainshaft (1) and counlershaft (2].

1'1

Clean all disassembled parts in solvent thoroughly.
NOTE:
Keep track of the disassembled parts (gears,
bushings. washers and snap ring) by sliding them
onto a 1001 or slipping them onto a piece of wire.

111
INSPECTION
GEARIBUSHINGISHAFT

Check the shifter groove [1) for abnormal wear or
damage .
Check the gear dogs [21. dog slots [3) and teeth for
abnormal wear or damage.

r - - -- -- - -1c31:--:- -- - ---:cIc':-I'

Measure the 1.0. of each gear.
SERVICE LIMITS :
M3 : 25.05 mm (0.986 in)
M5: 20.05 mm (0.789 in)
C1, C2, C4, CR : 28.07 mm (1 .105 in)
Reverse idle: 13.04 mm (0 .513 i n)

Measure the gear bushing 0 .0 .

SERVICE LIMITS :
M3 : 24.93 mrn (0.981 i n)
M5: 19.94 mrn (0.785 in)
C2 : 27.94 mm (1 .100 in)
C1 , C4, CR : 27.93 mm (1 .100 in)
Calculate the gear-to-bushing clearance.
SERVICE LIMITS:
M3, MS, C1 , C4, CR: 0.10 mm (0.004 in)
C2 : 0.08 mm (0.003 in)

-8-

Measure the gear bushing 1.0 .
SERVICE LIMITS:
M3: 22.04 mm (0.868 in)
MS: 17.06 mm (0.672 In)
C4: 25.05 mm (0.986 in)

14-9

CRANKCASEfTRANSMISSION/CRANKSHAFT/BALANCER
Check the mainshaft and counlershafl for abnormal

wear or damage.
[31

Measure the shaft 0 .0 .
SERVICE LIMITS:
At M3(11 : 21 .93 mm (0.863 in)
At M5 (21 : 16.93 mm (0.667 in)
At C4 [31 : 24.93 mm (0.981 in)
Reverse Idle: 12.94 mm (0.509 in)
Calculate the bushing-(O+shatt clearance.

SERVICE LIMIT: 0.10 mm (0.004 in)

[1[

12[

OUTPUT SHAFT/GEAR

Check the output shaft drive gear [1), driven gear (2]
teeth and each gear, output shaft [3] splines for
abnormal wear or damage.

13[

SHIFT FORK/SHAFT
Check the shift forks for abnormal wear or damage.

Measure each shift fork 1.0.
SERVICE LIMIT: 13.04 mm (0.513 in)
Measure the claw thickness of each shift fork.
SERVICE LIMIT: 4.5 mm (0.18 in)

Check the shift fork shaft for damage or bending .

Measure the shift fork shaft 0 .0 .
SERVICE LIMIT: 12.96 mm (0.510 in)

14·10

J

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
SHIFT DRUM

Check the gUide grooves [l J for abnormal wear or

r-----------c-11~1----------,

damage.
Check the shift drum journals for scoring. scratches or
evidence of insufficienllubrication.

ASSEMBLY
NOTE
Always install the thrust washers and snap ring with
the chamfered (rolled) edge facing away from the
thruslload.
Install the snap ring 111 so its ends aligns With the
grooves in the splines.
Make sure the snap ring is fully seated in the shaft
groove after installing it

Ends aligned
with grooves

Correct

Ends aligned
with splines
Incorrect

Clean all parts in solvent and dry them thoroughly.
Apply molybdenum oil solutIOn to lhe gear and bushing

sliding surfaces.
Assemble lhe mainshaft and counlershaft.

[11

14-11

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
MAINSHAFT
M3 BUSHING
THRUST WASHER

M5 GEAR (33T)

\

M2IMR GEAR (18T)

MAINSHAFT

r

SPECIAL WASHER

M5 BUSHING

THRUST WASHER

SNAP RING

M4 GEAR (28T)
MS GEAR (33T )

SPLINE WASHER

M3 GEAR (23T)

M4 GEAR (28T)

M3 GEAR (23T)

---"78 :Gear and bushing sliding surfaces

SPLINE WASHER

SNAP RING
Washer and snap ring direction:

14-12

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
COUNTERSHAFT
C 1 GEAR (SST)
CR GEAR (48T)

l

C21CR GEAR SHIFTER

C2 GEAR (43T)

~

,~ ,

THRUST WA:SHE.R

C3 GEAR (37T)

C4 GEAR (33T)

-+- '11('

SPLINE COLLAR

C1 GEAR (SST)
C4 GEAR (33T)
CR GEAR (48T )

C3 GEAR (37T)

C2 GEAR (43T)

~

C5

(28T)

: Gear and bushing sliding surfaces

THRUST WASHER
Washer direction:

14-13

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Check the gears for freedom of movement or rota tion
on the shaft.

121

Apply engine oil to the journals of the mainshaft [1 J and
counlershaft [2].
Engage the mainshaft and counlershaft gears.

111

Position the crank weights so Ihalthey do not interfere
with the mainshaft {1].

;:'===:==========:=::====

Inslall the mainshaft, counlershafl. [2] and washer (3]
assemblies as a set into the rear crankcase.

Apply molybdenum oil solution to the sliding surface of , ......
the reverse idle gear [11.

..

Install the reverse idle gear and shaft [2] .

Each shift fork has an identification mark; "RR" [1] for
Ihe rear fork . ·C· (2) for the center fork and "FR" [3] for
the front fork.

14·14

~"""IIIIIIIIIIIIIIIIII"""'IIIIIIIIIIII"""'::~=~=I11111~==~

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Apply engine oil 10 the shift drum guide pin grooves and
install the shift drum 11].
Install each shift fork into the gear shifter grooves and
shift drum groove with their identification marKs facing
up (front crankcase side).
-

rear shift fork into the M4 gear
center shift fork into the C3 gear
front shift fork into the C2Ireverse gear shifter

Apply engine oil 10 the fork shaft [2].
Install the fork shaft through the shift forks [31 and into
the crankcase.

Assemble the crankcase halves (page 14-21).

CRANKSHAFT/BALANCER
REMOVAL
Separate the crankcase halves (page 14-7).
Remove the transmission (page 14-8).

Be careful not to
damage the
crankcase mating
surface and
crankshaft
assembly.

Remove the crankshaft (1] and balancer (2J from the
feaf crankcase using a hydraulic press.

Be sure to hold the crankshaft and balancer while
pressing them out of the crankcase.

Remove the rear crankshaft bearing [11 using the
bearing puller [2J wi th a suitable protector [31 and
discard the bearing.

TOOL:
Universal bearing puller

07631-0010000 o r
equivalent commerci ally
available in U.S.A.

NO TE'

Always replace the rear crankshaft bearing with a
new one when the crankshaft is removed.

INSPECTION
Check the balancer drive and driven gears for wear or , - - - - - - - - - - - - - - - - - ,
damage.

14-15

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Sel the crankshaft in a stand or V-blocks (1] and
measure the runoul using a dial indicator (2).
SERVICE LIMIT: 0.15 mm (0.006 in)

Measure the side clearance between the connecting
rod big end and crank weight with a feeler gauge.

[2[

[2[

,----===============

SERVICE LIMIT: 0.8 mm (0.03 in)

Measure Ihe radial clearance at the connecting rod big , - - - - -- - - - - - - - - - - - end in an X and Y directions.
SERVICE LIMIT: 0.05 mm (0.002 in)

INSTALLAT[ON
Apply engine oil to a new rear crankshaft bearing.
Drive the crankshaft bearing into Ihe rear crankcase
with the marking side facing up.

TOOLS:
[1] Driver
[2] Attachment, 72 x 75 mm
[3] Pilot, 32 mm

[1 [

07749-0010000
07746-0010600
07MAD·PR90200

Other bearing replacement in the crankcase halves
(page 14-18).

[2[

14-16

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Install the special 1001111 onto the rear crankshaft end .

TOOL:
Threaded adapter

07965·VM00300

or

07931·KF00200
(U.S.A. only)

111

Be careful nollO
disengage the
gears.

Take care thai the
crankshaft and
balan~r do not fall
out of/he
crankcase when
installing the
speclalloo/s.

Engage the balancer and cranksha ft by aligning the
index lines [1 ] on the crank weight [2) and balancer
driven gear [3), and install them together In to the rear
crankcase.

~=================~
[3]

Install the special tools onto the crankshaft and
crankshaft bearing .
TOOLS :
[1) Assembly collar
[2J Puller shaft and nut

07965-VM00100
07965·VM00200 or
07931·ME4010B and

07931·HB3020A
(U.S.A. only)
88 careful nOllo Ie/

Draw the crankshaft into the bearing inner race.

the connecting rod
13} press against the
crankcase mating

surface.
After installing the crankshaft, make sure the index lines
[1) on the crank weight (2) and balancer driven gear (3)
are aligned.
Install the transmission (page 14-11).
Assemble the crankcase halves (page 14-21).

14-17

CRANKCASEITRANSMISSIONICRANKSHAFTIBALANCER

CRANKCASE BEARING
INSPECTION
Remove the crankshaft and balancer (page 14-15).
Tum the inner race of each crankcase bearing with your
finger. The bearing should tum smoothly and quietly.
Also check that the bearing outer race fits tighlty in the
crankcase.

Replace any bearing if the inner race does not turn
smoothly, quietly or if the outer race fils loosely in the
crankcase.

(

FRONT CRANKCASE BEARING
REPLACEMENT
Remove the balancer bearing [11 and counlershaft
bearing [21 with the special tools.

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

TOOLS:

Countershaft bearing:
[3J Remover handle

[4] Bearing remover, 20 mm
[5) Remover weight

07936-3710100
07936-3710600
07741-0010201 or
07936-3110200 or
07936·371020A
(U.S.A. only)

Balancer bearing :
Remover handle
Bearing remover I 17 mm
Remover weight

07936·3710100
07936·3710300
07741-0010201 or
07936·3710200 or
07936·371020A
(U.S.A. only)

Drive the crankshaft bearing (6]. output shaft bearing [7]
and shift drum bearing [8] out of the fron t crankcase.

Remove the two bolts (1 ] and mainshaft bearing setting
plale [21.

Drive the mainshaft bearing [3J oul of the front
crankcase.

14-18

~~=~==~~==:;:=====-=~

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Apply engine oil 10 new bearings.
Drive the bearings in with the marked side facing up.

TOOLS:
Crankshaft bearing:
[1] Driver
[2] Attachment, 78 )( 90 mm

[3] Pilot, 40 mm
Balancer bearing :
(1] Driver
[2] Attac hment, 37 )( 40 mm

[3] Pilot, 17 mm
Mainshaft bearing:
[1] Driver
(2] Attachment, 45 x 50 rnm
(3] Pilot, 22 mm
Countershaft bearing :
(1] Driver
[2] Attachment, 42 x 47 mm

(3) Pilot, 20 mm
Output shaft bearing :
{1] Driver
(21 Attachment, 42 )( 47 mm
(3) Pilot, 22 mm
Shift drum bearing :
(1} Driver
(2] Attac hment, 42 x 47 mm

[3] Pilot, 35 mm

07749-0010000
07GAD·SD40101

07746-0040900
07749-0010000
07746-0010200
07746-0040400
07749-0010000
07946-6920100
07746.{l041 000
07749·0010000
07746-0010300
07746-0040500
07749-0010000
07746-0010300
07746-0041000
07749-0010000
07746-0010300
07746-0040800

Apply locking agent to the threads of the selling plate
bolts [1].
Install the mainshaft setting plate [21 with the bolts and
tighten them to the specified torque.
TORQUE : 12 N'm (1.2 kgf'm, 9 IbHt)

14-19

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
REAR CRANKCASE BEARING
REPLACEMENT
Remove the mainshaft bearing/plate {1] and camshaft
bearing [2] with the special tools.

TOOLS :
Mainshaft bearing :
[3] Bearing remover, 17 mm
[4J Remover handle
[5] Remover weight

07936·3710300
07936-3710100
07741-0010201 or
07936·3710200 or
07936-371020A
(U.S.A. only)

Camshaft bearing :
Bearing remover shaft, 15 mm 07936·KC10100
Bearing remo ver head , 15 mm 07936· KC10200
Remover w eight
07741-0010201
U.S.A . TOOLS:
Bearing remover, 15 mm
Remover weight

07936· KC10500
07936·3710200 or
07936·371020A

Drive the countershaft bearing [6] and balancer bearing
(7) out of the rear crankcase.

Apply engine oil to new bearings .
Drive the bearings in wi th the marked side facing up.

TOOLS :
Balancer bearing :
[1] Driver
[2J Attachment, 37 x 40
[3] Pilot, 17 mm
Malnshaft bearing:
[1] Driver
[2J Attachment, 37 x 40
Countershaft bearing :
[1) Driver
[21 Attachment, 62 x 68
[3J Pilot, 25 mm
Camshaft bearing:
[11 Driver
[2] Attachment, 32 x 35
[3] Pilot, 15 mm

14·20

mm

mm

07749-0010000
07746-0010200
07746-0040400
07749-0010000
07746-0010200

mm

07749-0010000
07746-0010500
07746-0040600

mm

07749-0010000
07746-0010100
07746-0040300

.-------,""c-::.----~--------,

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER

CRANKCASE ASSEMBLY
Clean the front and rear crankcase mallng suriaces
thoroughly, being careful not to damage them,

I.

__

~
~~
":.~.c'<~>:::::~,

Blow through the oil passages in the crankcases with

h'

compressed air.

/J

Apply liquid sealant (TB1215 or equivalent) to the

....-I.
, 1

mating surface (shadowed area) of the front crankcase

as shown.

c,

:j.

'\.

~

'
0
~
Install the thcee dowel pin, 11 1to the ceac ccankc",e.

I

Make sure all the parts are installed in the rear

crankcase.
Install the fronl crankcase over the rear crankcase.

111
Install the fifteen rear crankcase bolts [1)

111

InslaUthe two front crankcase bolls [1}

Tighten aU the bolts in a crisscross pattern In several

steps.

14-21

CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
Insert the output shaft (I] Inlo the crankcase unlil it
seals against the bearing in the front crankcase.

Instal! the output shaft drive and driven gears [2).
Apply engine oil to the journal surfaces of the reverse

stopper shaft 13].
Install the reverse stopper shaft assembly into the
crankcase as shown.
Install the following:

-

fl~heel

and starter clutch (page 13-14)

oil pump (page 9-5)
change clutch (page 12- 17)
gearshift linkage (page 12-21)

cylinder and piston (page 11-8)
cylinder head (page 10-16)
engine (page 15-9)

j

14-22

15. ENGINE REMOVAUINSTALLATION

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

ENGINE REMOVAL························ ·······.... · 15-4

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

ENGINE INSTALLATION .. ···· ·· ····················15·9

15·1

ENGINE REMOVAUINSTALLATION

SYSTEM COMPONENTS
FE model shown:
44 N'm (4 .5 kgf'm, 32Ibf-ft)

~
44 N'm (4.5 kgf-m, 32 IbHt)

54 N m (55 kgfm. 40 Ibf·tt)

~,

32 N'm (3.3 kgf·m. 24 Ibf·ft)

~

- """,--'

1
15-2

ENGINE REMOVAU INSTALLATION

SERVICE INFORMATION
GENERAL
When removing and installing lhe engine, tape the frame around the engine beforehand for frame protection ,
The following components require engine removal for service
- alternator/slaner clutch (page 13-2)
- crankcase/lransmission/crankshaftlbalancer (page 14-2)

SPECIFICATIONS
~~ ~

I Engine dry weight

SPECi'FICAT10NS

-+--~~.4 kg (113.3Ibs)

U.S.A.

Canada
U.S,A,
~=~ Canada
Engine oil capacity
After draining
After draining/filter change
After disassembly
Coolant capacity (radiator and engine)- ~se seleclor1eVer freeplay

52_5 kg (115.7 Ibs)
523kg(11S-:-3 Ibs)
53.4 kg (117.7Ibs)
2,ghlers (3.1 US qt, 2.6
3,0 liters (3.2 US qt, 2.6
3,3 liters (3.5 US qt, 2.9
TII"li9rs (1.6 US""Cjt1.3

Imp
Imp
Imp
Imp

ql)
qt)
ql)
qt)- -

2 - 4 rnm (0. 1 - 0.2 in)

~~

TORQUE VALUES
r - --

~

-

ITEM

C'TY

~~~~~~~;~~~1;~~~~~ 2~

THREAD

-t=

'~o-=~~_
54 (5.5, 40)
N'm (kg f'm, lbHt),_

OIA.1~
(mm)
2
8
1 --+6
2
10

1

TORQUE

=t==
I

54 (5.5, 40)

32 (3.3.24)
20 (2.0, 15)
44 (4.5, 32)

_

REMARKS

_

lock nut: replace with
a new one.

15-3

ENGINE REMOVAUINSTALLATION

ENGINE REMOVAL
Remove the following :

-

mudguards (page 2-6)
engine guard (page 2.7)

Drain the engine oil (page 3-13).
Drain the coolant (page 8·7).

FMlFPM models:

[21

Remove the following:
- heal guard plale (page 10·7)
- throttle body (page 7-23)
- exhaust system (page 2·14)
- bal1ery H cable (page 21.8)

FMfFPM only: Remove the pinch bolt [1[ and the
gearshift pedal 12]

[11
Disconnect the following :
-

VS sensor 3P (Black) connector [1]
FElFPE only: shift angle sensor 3P (Gray) connector

[21
-

sub-wire harness (from the clamp (3])

-

wire band [I)

-

bolt 121 and ground cable [3]
nut 14] and starter motor cable 15J

-

-

two bolls [6) and battery (-) cable [7J
starter motor [8J

gear position switch 8P (Gray) connector [IJ
(remove from the frame and disconnect it)
alternator 5P (Natural) connector (2) (remove from
the frame and disconnect it)

15-4

ENGINE REMOVAUINSTAllATION
Loosen the adjuster of the reverse selector cable (page
3-23).

Remove the following:
-

-

bolt (1] and selector arm
selector cable)

12J

(10 disconnect the

selector cable [3] (from the cable holder 14] of the
engine)

-

spark plug cap (11
bolts [2J and ignition ooillbrackel [3]
water hose [4]

-

water hose (1]
shift control motor connector [2) (FElFPE only)

-

bolt [1] and clutch arm cover [2J (release from the
two tabs [3])

1~=!IIIII!IIIII!IIIII~1~3 I!IIIII!IIIII!IIIII!IIIII~~~"""!IIIII!IIIII~
f

(1)

--

15-5

ENGINE REMOVAL/INSTALLATION
-

adjusting nul {1J
cable retaining plale (21

-

2WO!4WD selector cable (3] (remove from the cable
holder [4] and joint pin (5))

-

cable spring [61

-

joint pin

-

final gear case mounting nuts 11] and bolts 12)

-

two bolts [31 and mounting bracket (4)

Move the gear case assembly (11 forward for maximum
clearance between the propener shaft joint and engine.
NOTE
Turn the handlebar aU the way to the right to move

the gear case assembly.
Put some cloth on the gear case to avoid scratch or

damage the lie-rod end [21.

15-6

ENGINE REMOVAUINSTALLATION
Pull the shaft joint [1] out of the output shaft [2] from the
engine .
Remove the O-ring [3] from the output shaft.

Remove the boot band [ 1J and release the propeller
shaft boot [2] off the pinion joint [3] of the gear case
assembly.
Pull the propeller shaft [4] to force the stopper ring [5)
past the groove in the pinion joint to remove the
propeller shaft.
Remove the stopper ring from the propeller shaft.

Remove the following from the engine upper mount:
- tvo engine hanger bolts [11 (engine side)
- engine hanger nut and bolt [21 (frame side)
- hanger bracket (3)
- mounting rubbers [4]

15·7

ENGINE REMOVAUINSTALLATION
Set suitable

wooden blocks
between the engine

and lower frame
pipe

to support the

Remove the following from each engine lower mount:
-

-

engine hanger nut [1] and bolt (2)
spacer [3)
mounting rubbers [4]

engine.

Move the engine forward and disconnect the output
shaft [1] from the universal joint 121.
Hold the engine
securely and take
care 001 to damage
the frame and

Remove the engine out of the frame from the left side .
Remove the O·ring [3] from the output shaft.

engine.

Remove the engine mounting bushings [1] and dust
seals (2).

15·8

ENGINE REMOVAUINSTALLATION
Check the mounting rubbers [1], bushings 12] and dust
seals for deterioration, wear or damage.

[2[

[1 )

ENGINE INSTALLATION
Install the lower engine mounting bushings [1] into the
engine.

(3)

(3)

Install the dust seals (2J with the lip side [3) facing out.

P)

Hold the engine

securely and be
careful not to
damage the frame
and engine.

Place the engine in the frame from the left side and
support it with suitable wooden blocks.

~;:::7===::=~:===:;;____iiiiiiii~

Coat a new O-ring [1] with molybdenum disulfide
grease and install it into the output shaft [2] groove.
Apply molybdenum disulfide grease to the splines of the
universal joint [3}.
Carefully move the engine and engage the output shaft
with the universal jOint.

15-9

ENGINE REMOVAL/INSTALLATION
Be sure the
universal join/IS not
disengaged.

Install the mounting rubbers [1] onto the lower mounting
bushing with the larger I.D. side facing in .
Install the spacer [2] and the hanger bolt 13] (from the
front side) while aligning the bolt holes carefully.
Loosely install the hanger nut [4] .
Install the other side mounting fasteners in the same
manner as above.

Install the mounting rubbers [1] onto the upper
mounting bushing in the hanger bracket [2] wi th the
large I.D. side facing in.
Inslalilhe hanger bracket with the 10 mm hanger bolt
[3] (from the front side) and nul [4] .
Inslall the two 8 mm hanger bolts [5] .
After installing all the mounting fasteners and seal
them, tighten the fasteners to the specified torque in
order as follows:
- left and right lower engine hanger nuts
TORQUE : 54 N'm (5.5 kgf'm , 40 Ibf-ft)
-

engine side upper engine hanger bolts

TORQUE : 32 N'm (3.3 kgf·m , 24 Ibf·ft)
-

frame side upper engine hanger nut

TORQUE: 54 N'm (5.5 kgf·m , 40 Ibl-ft)

Install a new stopper ring (1] into the groove in the
propeller shaft [2] end.
Apply 5 - 8 9 of molybdenum disulfide grease to the
splines of the pinion joint [3}.
Apply molybdenum disulfide grease to the front end of
the propeller shaft.
Place the boot band [4} over the pinion joint temporarily.
Install the propeller shaft into the pinion joint. aligning
the splines until the stopper ring seats in the groove.
Make sure the stopper ring is seated properly by pulling
the propeller shaft lightly.
Install the boot [5] over the pinion joint groove securely
and the boot band into the boot groove.

15-10

ENGINE REMOVAUINSTALLATION
Coat a new O-ring [1) with molybdenum disulfide
grease and install it into the output shaft [2) groove.
Apply molybdenum disulfide grease to the splines of the
propeller shaft joint [3).
Move the gear case assembly [4] forward for maximum
clearance between the shaft jOint and output shaft.
NOTE ·
Turn the handtebar all the way to the right to move
the gear case assembly.
Put some ctoth on the gear case to avoid scratch or
damage the tie-rod end [5) .
Engage the shaft joint over the output shaft and move
the gear case assembly rearward.

[5]

[4[
Align the rear mounting bolt holes in the gear case [1]
and frame, then install the mounting bolt [2] from the
right side and a new mounting nut (3).
Install the mounting bracket [4] with the two bolts [5].
Install the front mounting bolt [6] from the right side and
a new mounting nut (7).
Tighten all the gear case mounting fasteners in the
following sequence.
-

Rear mounting nut
Mounting bracket bolts
Front mounting nut

TORQUE:
Rear mounting nut: 44 N·m (4.5 kgf-m, 32 IbUt)
Front mounting nut: 44 N·m (4.5 kgf-m , 32 IbHt)

15-11

ENGINE REMOVAUINSTALLATION
Install the spring [1] onto the selector cable (2J.
Insert the cable into Ihe cable holder (3J and connect it
to the clutch arm [4] with the Joint pin [5] and adjusting
nut 16].
Sellhe groov8 in the cable grommet [7] onto the cover
base end properly.
Install the retaining plate [8] onto Ihe cable with the
concave side facing the cable holder to secure the
cable.

Inslalilhe water hose [1].
Connect the shift control molor connector [2] (FElFPE
only).

Inslallthe water hose [1].
Inslallths ignition coil/bracket [2) and bolts [3].
Tighten the bolts securely,
Connect Ihe spark plug cap {4J .

Connect the following and install them onto the frame:

15-12

-

alternator SP (Natural ) connector 111

-

gear position switch 8P (Gray) connector [2]

ENGINE REMOVAU[NSTALLAT[ON
Install the reverse selector cable (lJ into the cable
holder [2] of the engine.
Connect the cable to the selector arm [3] and install the
arm by aligning the flat surlaces. and tighten the bolt
[4[.

Install the starter motor [lJ (page 6-6).
Connect the ground cable [2) to the engine with the
bolts [3]. Tighten the bolt securely.
Secure the wires and cables with the wire band [4].
[4[

[l[
Connect the fOllowing and secure the wire with the
clamp [1 1:
~

FEIFPE only: shift angle sensor 3P (Gray) connector

-

VS sensor 3P (Black) connector [3]

i~~~~=~~j~~~~~iiii~

[2[

FMlFPM only:

. . .......';

=.,.~======:""

Install the gearshift pedal (1] so thai the bottom surface ;"'":"............
of the pedal joint [21 is parallel with the frame pipe [3].
FM/FPM models:
Install the pinch bolt [4J and lighten it to the specified
[l[
torque.
TORQUE : 20 N'm (2.0 kgf'm , 151bHt)
Adjust the following:
- reverse selector cable (page 3-23),
- 2WO/4WD selector cable (page 3-19)
Install the following:
- exhaust system (page 2-14)
throttle body (page 7-25)
engine guard (page 2-7)
mudguards (page 2-6)
heat guard plale (page 10-19)
battery (- ) cable (page 21-8)

[2[

Fill the engine with recommended oil (page 3-13).
Fill and bleed the cooling system (page 8-6).
Check the engine oil level (page 3-12).

15-13

MEMO

16. FRONT WHEEUSUSPENSION/STEERING

SYSTEM COMPONENTS····························16-2

WHEEL HUB AND KNUCKLE········ ··········16-16

SERVICE INFORMATION ········ ··················· 16-4

SUSPENSION ARM ·····························.. ·.. 16-23

TROUBLESHOOTING································· 16-7

FRONT SHOCK ABSORBER· .. ················ 16-26

HANDLEBAR ·········· ······· ··· ····· ····················· 16-8

STEERING SHAFT (FM/FE models) ····· ··· 16-27

THROTTLE HOUSING ······························16-11

STEERING SHAFT/EPS UNIT
(FPM/FPE models) ····· ······························ 16-32

FRONT WHEEL······················ ··· ················ 16-13
TIE-ROD ················································· ··· 16-40
TIRES························································· 16-13

16-1

FRONT WHEEUSUSPENSION/STEERING

SYSTEM COMPONENTS
FM/FE mo dels
FE model shown:

39 N'm (4 0 kgf-m, 291bHt)

1

i

/--------

34 N'm (3.5 kgl'm, 251bHt)

/
,,-

54 N'm (55 kgf-m, _ _-::,,£...;;-

401bHt)

11 Nm (1.1 kgf'm,
BlbHt)

39 N'm (4.0 kgf'm,
29Ibf-ft)
108 N m

kgf-m, 80 Ibf ftl

29 N'm (3.0 kgf'm, 211bHt)

V
78 N 'm (8.0 kgf m, 58lbHt)

30 N'm (3.1 kgf-m . 22Ibf·ft)

64 N'm (6.5 kgf'm, 47 IbHI)

16-2

FRONT WHEEUSUSPENSIONISTEERING
FP M/FPE models
FPE model shown :

39 N'm

kgf-m. 29 IbHt)

32 N'm (3.3 kg"m , 24 IbUt)

22 N'm (2.2 kgfrn.
161bHt)

60 N'm (6.1 kgf'm,

44 IbHt)

34 N·m {3.5 kgf-m,

25 Ibf ttl

39 N'm (4.0

11 N'm (1.1 kgf-m,
8IbH!)

291bHt)
108 N'm (1 1.0 kg! m , 80 Ibf-ft)

.-

/
1/

\.

-

- .... \

\

78 N'm (B.O kgf 'm , 58lbf tt)

I

64 N m (6.5 kgf-m, 47Ibf-ft)

16·3

FRONT WHEEUSUSPENSIONfSTEERING

SERVICE INFORMATION
GENERAL
This seclJon covers service of the front wheel , suspension and steering (including EPS unit; FPM/FPE models). For electrical
system servICe of the EPS. see Electric Power Steering (EPS) section (page 24-2).
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agel'll.
A Jack or other support is required to support the vehicle.
Adjust toe whenever the tie-rod , knuckle or steering shaft are replaced or removed (page 3-26).
00 not twist or bend the brake hose when servicing.
Use Honda Genuine replacement bolts and nuts for all suspension pivots and mounting points.
For brake system service , see Brake System section (page 18-2).
For each sWitch inspection. see LightslMeterslSwitches section.
- handlebar switch (page 22-11)
- front brake sWitch (page 22·12)
- rear brake light sWitch (page 22-13)
FPMfFPE model only: Perform the torque sensor initialization when you service the following components (page 24-13)

t

Service Location
Cables and harness around handlebar

Replacement
INITIALIZE

Removal/Installation
INITIALlZE:_ _ _ _---1

;~:f!~~~=:!=I~N~IT~'~A~LI~ZjE=:=
INITIALIZE
_~::;::~INITIALI~E
IN~'tTI~A~LlZ;,Et===:::j

Handlebar
Sleenng shaft and steenng shaft bushing
Steenng arm and nul
EPS unit
EPS ECU

INITIALIZE
INITIALIZE
INITIALIZE

_ _ _~'Nc.ITIAlIZE;..-----l
___ '.i'N"ITIALlZc-E~____ j
_ __ L-'N-",O NEE0c--_ _ _ --'

SPECIFICATIONS
1J
1T~EjlMC=:-~___===:--===~S~
TA"NDAR,!O'-.::===
Minimum tire tread depth
Cold tire

pressuredistance between the ball joints
Tie-rod
Toe
_ ______

16-4

;.-----+--0""""=",=='"

I Standard

With~ca=,g~oC---

30 kPa (0.30 kgf/cm , 4 .4ic'OPS~;~)- - -

i

Unit: mm (in)
SERVICE LIMIT
4.0 (0.16)

4~4~PS~;~)===~-t==~===-

30 kPa(15.08)
0.30 kgf/cm2,
383.1
Toe-out:28±15(1 .1 to.6)

1

FRONT WHEEUSUSPENSION/STEERING
TORQUE VALUES
C 'TY

ITEM

THREAD
DIA. (rnm)

-,-+~

~3t::==- 4

_2

5
1
6
2
•
8;---+-_ _.'0

~~~~~~st~ay~~--

r Frontwheel

nute =,---_

2

Front wheel hub nut

16

TORQUE ~ REMARKS
N'm (kgf'm, Ibf.ft)

-~~,

r 64
I

1.5(0 .2, 1.1)
4.2(04, 3.1)( -_ _
7.0 (0.7. 5.2),_ _ _ _
32 (3.3, 24) _ _ _ _
(6.5. 47):_ _ -,-:;.
78 (8.0. 58)

---~

Castle nut: tighten to
the specified torque
and further lighten

until its grooves align
with Ihe cotter pin

~~_,-'hOIe .

Front brake disc bolt

8

8

Splash guard bolt

6

6

4

10

39 (4 .0, 29)

2

10

34 (3.5. 25)

' Lower arm pivot nut

4

10

39 (4 .0, 29)

Upper and lower arm ball jOint nut

4

12

29 (3.0. 21)

7

6

12 (1.2 . 9)

Shock absorber mounting nut
Upper arm pivot nut

==t

Brake hose clamp bolt
Tie-rod joint nut
7teering shaft end nut

I Steering shaft holder bolt
I
Steering shah ","ch bolt (FPMlFPE)

=-+i

EPS unit mounting nut (FPMIFPE)
Handlebar switch housing screw (FMfFPM)
Handlebar switch housing screw (FElFPE )
Rear brake lever bracket holder screw
Front master cylinder holder bolt
Front brake caliper mounting bolt

4

2
2
2
3
2
2
4

- - + - -'2
14
8
10

~331)

ALoe bolt: replace
with a new one.

11(1 . 1.8)

54 (5.5, 40)
108 (11 0 . 80)
3-2 (3.3. 24 )
60(6 .1, 44 )

ALOe bolt: replace

with a new one.
lock nut: replace with

I

a new one.
lock nut. replace with
a new one.
lock nut: replace with
a new one.
Castle nut: lighten ~
the specified torque
and further tighten
unliliis grooves align
with the coller pin
hole.
ALOe bolt: replace
with a new one.
Lock nut: replace with
a new one.
Lock nut replace wltha new one

"'--A LOC bolt· replace
with a new one.

t6~

8
:
22(2 .2.
f f i4.2 (0.4. 3.1)
5
4.2 (0.4, 3.1)
5
4.2 (0.4 , 3.1)
6
I
12 (12, 9)
8
30 (3. 1. 22)

ALOe bolt: replace
wi th a new one.

16-5

FRONT WHEEUSUSPENSION/STEERING
TOOLS
Attachment, 42 x 47 mm
07746-0010300

Attachment, 52 )( 55 mm
07746-0010400

Attachment, 20 mm I,O·- -07746·0020400

- - + -OP'-ilo"t,-,2m
O-;;m"m;;07746-0040500

Pilot. 22----rnm- - - - - - - - I - - - cOriver
07746-0041000
07749-0010000

r

I

Fork seal driver attachm"."'
n't
07947-KA40200

&

- ---t-I-DriC'eC::;'- -07949-3710001

Attachment, 40 x 42 mm
07746·0010900

---r'Phljlo~t~
, 30mm~----07746-0040700

---- - I

I

Attachment, 28 x 30"m=m, -07946-1870100

--

/'
Compressor boll assembly
07GAE-PG40200

o
07GAE-PG4020A (U.S.A. only)

16·6

FRONT WH EEU SUSPENSION/STEERING
Oil seal driver attachment
07JAD-PH80101

Ball jOint

Clutch compressor attachment

Ball joint remover, 28 mm

07LAE·PX40100

07MAC-SLOO201

removerlinst;alo;;le~,-----+- Attachment. 34 mm- - -

07WMF·HNQ0100

----t

07MAC-SL00202

07ZMD·MBW0100

I
~

TROUBLESHOOTING
Hard steering
Steering shaft holder too tight
Damaged steering shaft bearing/bushing
• Insufficienllire pressure
• Faulty EPS (FPM/FPE models) (page 24-9)

Steers one side or does not track straight
Incorrect wheel alignment

Unequal Ure pressure
Ben' tle·rod, suspension arm or frame
Worn or damaged knuckle bearing or wheel hub beanng
Weak shock absorber

Front wheel wobbling
Benl rim
Worn or damaged knuckle bearing or wheel hub bearing
• Faulty lire
• loose wheel hub nul
Soft suspens ion
• Weak shock absorber spnng
• Dilleakage from damper unit
Stiff suspension
Damaged shock absorber damper
Faulty shock absorber pivot bushings
• Improperly Installed suspension arms
• Faulty suspension arm bushings
Front sus pension noise
Faulty front shock absorber
loose front suspension fasteners
Wom front suspension Piliot bushings
Damaged suspension components

16-7

FRONT WHEEUSUSPENSION/STEERING

HANDLEBAR
REMOVAL
Remove the assist headlight cover (page 22-4).
Remove Ihe fuel tank breather hose [1] from the meter
cover (2).
Remove the screw (3] and meter cover.

Disconnect the 21P connector [1) from the combination

meier.
Remove the following:
- two wire bands (2)
- two bolts and collars (3]
- meter cover stay (4J

Remove the

two screws [1J. throttle housing holder [2)

and throttle housing 13].

~~=~~;~~==::"'~~==~~~~

Disconnect the connectors [4].

Keep the mas/ar Remove Ihe two bolls 151, master cylinder holder [6] and
cy//fldef reservoir brake master cylinder (7).
upngfll to p!8ven/
81r from enlenng the
hydraulic system

Remove the two screws [1 j, lever bracket holder (2J and
rear brake lever brackel(3).

FElFPE mod&/s.

Remove the three screws [4J and handlebar sWitch [5].

FMlFPM models:

Remove the two screws and handlebar switch .

16·8

~~~""':::=~=========~=~

FRONT WHEEUSUSPENSIONfSTEERING
Remove the grip ends (1) (tum the grip end to release
the setting tabs (2) and pry it using a screwdriver).
Remove the handlebar grips {3J.

Remove the four bolts
handlebar {3] .

(11.

upper holders

121

and

INSTALLATION
AJign the punch
mark on the

handlebar with the
top edge o( the
lower holder.

Install the handlebar and upper holders with the punch
mark (4] facing forward. Tighten the front bolls first, then
tighten the rear botts.

Apply Honda Bond A or Pro Honda Handgrip Cement r-----------1~~a~~J
(U.S.A. onty) to the inside surface of each handlebar
grip (1J and to the ctean surfaces of the handlebar.
Allow rne adhesive Wait 3 - 5 minutes and install the grips. Rotate the grip
to dry for an hour for even application of the adhesive .

I

befo", uSlf1g.

Install new grip ends (2) by aligning the tabs [3] with the
holes in the handlebar.

FMlFPM models:

Install the handlebar switch (1). Tighten the upper screw
first, then tighten the lower screw to the specified
torque.

Align the Iocalrng

pin on the switch
housing with the

nole in the
handlebar

~I=
F==P
MIf =M
c-m
-od-=.'='=h=O
=
W
='='========='~
~

[2J
,"t.
Align
~/. W-~y

TORQUE , 4 .2 N·m (0.4 kgf'm, 3.1 'bf·ftl

Ir " r~
,.#~'7

Install the brake lever bracket 121 and holder [3] with the
punch marl< [4] facing up.
Tighten the upper screw first, then lighten the lower
handlebar. screw to the specified torque.

A lign the edge of
the bracket with the
punch mark on the

~

TORQUE : 4.2 N'm (0.4 kgf'm , 3.1tbHt)

r

/

[4]

'\

P]

[11

Align

16-9

I,
FRONT WHEEUSUSPENSION/STEERING
FEJFPE models: Install the handlebar switch [1). Tighten the inside
Allfln the seam of
the switch with the
punch mark on/he
handlebar.

screw [21 first, then tighten the outside screws [3] to the
specified torque.

[11

FElFPE models:

TORQUE: 4.2 N'm (0.4 kgf·m. 3.1Ibf·ft)

FElFPE models: Instalilhe brake lever bracket (1] and holder [2) with the
Align the locating punch mark (3) facing up. Tighten the upper screw fi rs t,
pm Of! the bracket then tighten the lower screw to the specified torque,
with the hole in the
switch housing. TORQUE : 4.2 N'm (0 .4 kgf-m, 3.1 Ibf-ft)

Align the edge of
the mas/ef cylinder

Inslall the brake master cylinder (1] and holder [2) with
the "UP· mark [3) facing up. Tighten the upper boll first,
then tighten the lower bolt to the speCified torque.

with the punch
mark {4} on the
handlebar. TORQUE : 12 N'm (1.2 kgf'm , 9lbHt)

COOneG't the gray Connect the connectors [1J to the inhibitor switch [2J
tape (4) Wlf9 and brake tight switch (3J.
connectors 10 Ihe
upper terrmna/s.

11[

[4[

/

121

131

16-10

FRONT WHEEUSUSPENSION/STEERING
Al,gn the lug {5Jon
tile throttle housing
with the mating line
01 the master
cylinder and holder.

Inslall the throttle housing [1] and holder (2] against the
master cylinder 13]. Tighten the front screw first, then
lighlen the rear screw 14] to the specified torque.
TORQUE: 4.2 N'm (0.4 kgf'm, 3. 1 IbHt)

Install the meter cover stay (lJ with the two bolts and
collars (2J, and tighten them to the specified torque.
TORQUE : 32 N'm (3.3 kgf'm, 24 Ibfoft)
Secure the wires with the two wire bands (3].
Connect the 21P connector (4] to the combination
meter.

Install the meter cover (1) and tighten the screw 12).
Install the fuel tank breather hose [31 into the meter
cover.
Install the assist headlight cover (page 22--4).
FPMlFPE only:
Refer to "Service
Information" for

Perform the torque sensor initialization (page 24-13).

serviCe location of
the initializatiOn
(page 16-4).

THROTTLE HOUSING
DISASSEMBLY
Remove the following:
- three SCl'ews (11
- throttle housing cover 12]
- gasket (3]
Slide the boot 141 off the throttle cable adjuster.

16-11

FRONT WHEEUSUSPENSION/STEERING
Loosen the lock nut [1] and cable adjuster [2).
Bend down the lock washer tab and remove the
fallowing:
- pivot nut [3]
- lock washer [4]
- throttle lever [5] and plastic washer [6]
- return spring [7]
- throttle arm [8] (by disconnecting the cable [9])
- dust seal (from the housing)

ASSEMBLY
Coat the lips of a new dust seal [1] with grease and
install it into the housing until it is fully seated .
Apply grease to the throttle lever pivot in the housing
and to the throttle cable end.
Connect the cable (2) to the throttle arm (3] .
Insert the throttle lever [4] with the plastic washer (5)
into the housing.
Install the throttle arm with the spring (6) over the
throttle lever pivot by aligning the flat surfaces .
Install a new lock washer [7] and the nut [8]. and tighten
the it to the specified torque.
TORQUE : 7.0 N·m (0.7 kgf·m, 5.2 IbHt)
Bend up the lock washer tab against the nut.

Install the housing cover (1) with a new gasket [2] and
tighten the three screws (3) to the specified torque.
TORQUE : 1.5 N·m (0 .2 kgf·m, 1.1IbHt)
Adjust the throttle lever freeplay (page 3-4).

16-12

~---­

FRONT WHEEUSUSPENSION/STEERING

FRONT WHEEL
REMOVAL
Loosen the wheel nuts [1].

Support the vehicle using a hoist or equivalent and
raise the front wheels off the ground.
Remove the wheel nuts and wheel.

INSTALLATION
Do nol interchange
the left and right
wheels

Install the front wheel with the lire valve facing out and
the arrow mark [2J facing in the normal rotating
direction .
Inslatl the wheel nuts with the lapered side (3] facing
inward and tighten them to the specified torque.
TORQUE : 64 N'm (6.5 kgf-m, 47 tbf-ft)

TIRES
REMOVAL
NOTE"

This service requires the A TV Bead Buster
(KLS379024).
Remove and install the tire from the rim side
opposite the valve slem.
Remove the core from the valve stem.
Use a pneumatic lire 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 [1] to the proper rim
size. Align the flat side of the support with the
corresponding rim size indicator.
Useonlywaleras8
lubricant when
removing ex
mountmg /Ires.
Soap or some
mountmg lubricants

lube the bead area of the tire with water, pressing
down on the tire sidewaltlbead area in several places to
allow the water to run into and around the bead.

111

o

.....

~

~ ./
_ ,-,

o

may leave a
slippery residue that
can cause the lire 10

00

j

shift on the rim and
lose tire pressure
during nding.

Place the wheel assembly over the center shaft (1] and , - -use the correct size cone (2) to keep the wheel centered
during operation.
Instal! the bottom hold down nut [3J. bearing side down.
and finger tighten it so the wheel can rotate freely
during operation.

- - - -- --

111------...

131

121

I~

(,

I'

U;:.
l'I
\

~.

'-------'

16-13

FRONT WHEEUSUSPENSION/STEERING
Install the breaker arm assembly [1) over the center
shaft and adjust the upper rim supports {2] to fit the
outside rim diameter.
Install the top hold down nut (3] and tighten it finger
tight.

[1)

Failure to back out Puilihe leverage bar 11 J down so the breaker shoe [2] is
the breaker shoe just below the rim lip, Turn the crank [3) to fully push the
two tums will cause breaker shoe between the tire bead and rim . Once the
the shoe to scratch shoe contacts the rim, back the crank out two turns to
the bead lock, allow the shoe to clear the rim's bead lock.
whICh may cause
the tire to leak.

Push down on the leverage bar [1J to push the lire bead

over the bead lock. Use only short strokes on the
handle. While the shoe (2] is still engaged , turn the
wheel as far as it will go between strokes as you break
the bead around Ihe rim .
Remove Ihe breaker arm assembly and flip Ihe wheel
over. Inslall the breaker arm assembly, adjust the shoe
property and break the other bead by following the
above procedures.
Remove the tire from the rim using a tire changing
machine or lire irons and rim protectors.

~

_ _ _ [1)

1
[2)
~---

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 here.

Check the lire for puncturing objecls.
Chalk mark the punctured area and remove the
puncturing object.
Inspect and measure the puncture hole.
Tire repairs for puncture holes larger than 15 mm (0.6
in) should be a section repair.
Section repairs should be done by a professional tire
repair shop.
If the puncture hole is smaller than 15 mm (0.6 in).
proceed with the repair as described here.

16·14

FRONT WHEEUSUSPENSION/STEERING
Install a rubber plug into the puncture hole as follows:

Apply a cement to a plug inserting needle and work the
needle into the puncture hole to clean and lubricate it.
00 this three limes.
Do not let the cement dry.

Be careful not /0
push the plug all the
way into the tire 10
prevent it from
falling inside

Insert and center a rubber plug through the eye of the
inserting needle.
Apply cement to the rubber plug .
Push the inserting needle with plug Into the puncture
hole untillhe plug is slightly above the lire.
Twist the needle and remove it from the tire; the plug
will slay in the tire.

Trim the plug 6 mm (0 .2 in) above the tire surface.
Repeat the above procedure if the puncture is large.
Do not use more than two plugs per puncture hole.

Allow the repair to dry. Drying lime will vary with air
temperature. Refer to the tire repair kit manufacturer's
recommendations.
Inflate the tire and test the seal by dabbing a small
amount of cement around the plug . Escaping air will
cause a bubble in the cement. If there is leakage.
remove the tire (page 16-13) and apply a cold patch to
the inside of the tire as described below.

If a plug has been inserted , trim it even with the inner
tire surface.

~~
~I=====:....:===========~

Temporarily place a rubber patch thai is alleas! twice
the size of the puncture hole over 1I. Make a mark
around the patch. stightly 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
unlil tacky.
Do not touch the cement with dirty or greasy hands.
Remove the lining from the patch and center it over the
puncture hole.
Press the patch against the puncture hole using a
special roller.

I

16-15

FRONT WHEEUSUSPENSION/STEERING
ASSEMBLY
Install the lire onto the rim, where the rim shoulder , -- - - -- - - width is the narrowest, to simplify installation.
Clean the rim bead seal and flanges.
Use only water 8S 8

Apply clean water to the rim fl anges. bead seal and
lubricant when base.
removing or
Install the valve core in the valve slem.
mountmg tires.
Install the lire with the arrow mark facing in the normal
Soap or some
rotating direction.
mounting lubncants
Inflate the tire to seat the lire bead .

may !eave a
slippery residue Deflate the tire. Wail 1 hour and inflate the lire to the

whICh can causa the
tire /0 shift on the
rim and /0$8 8;r

pressure dunng
riding.

specified pressure.
RECOMMENDED TIRE PRESSURE
Front: Standard: 30 kPa (0.30 kgflcm 2 , 4.4 psi)
With cargo: 30 kPa (0.30 kgf/cm 2, 4.4 psi)
Rear: Standard : 30 kPa (0.30 kgflcm 2, 4.4 psi)
With cargo: 30 kPa (0.30 kgfl cm l , 4.4 psi)
Check for air leaks and install the valve cap.

WHEEL HUB AND KNUCKLE
REMOVAL
Remove the engine guard if the suspension arm will be
removed (page 2-7).
Remove the front wheel (page 16-13).
Remove the two hose clamp bolts (1) from the upper
arm.

Remove the two selling bolts [1] and outboard guard (2).
Support the caliper
so that it does nol
hang from the brake
hose. Do not (WiSf or
bend the brake

"""".

16-16

Remove the following:
two mounting bolts [3J
brake caliper [4J

-

FRONT WHEEUSUSPENSION/STEERING
-

cotter pin [1]

-

hub nul (2]

-

wheel hub [3]

-

three socket bolts [1J
splash guard [2]

11J

-

coller pin [1 J (from the lie-rod ball joint stud)

-

ball jOint nul {2] (by holding the joint stud nat
surfaces [3])
tie-rod [4]

-

cotter pins [1]

Loosen the ball joint nuts [2) . but do not remove them
yet.

16-17

FRONT WHEEUSUSPENSION/STEERING
Release the ball joints, using the special tool according
to the following instructions.

TOOL:

(1] Batt joint remover, 28 mm

07MAC·Sl00201 o r
07MAC·Sl00202
(U.S.A. only )

111
Apply grease to the ball joint remover at the point (1)
shown.
This will ease installation of the tool and prevent
damage to the pressure bolt [2J threads.

~=================~
\2)

Insert the jaws carefully, making sure that you do not
damage the ball joint boot.
If necessaty. appJy
penetf1ltmg type
lubricant /0 loosen

Adjust the jaw spacing by turning the pressure boll.

,

the bal/pnt.

To prevenllhe tool from dropping, tie the strap [ 1] on a

neighboring solid part such as the suspension arm, tierod , etc. before operation.

;:=================~

NOTE :
Do not tie the strap on the brake hose, brake pipe,
rubber boot. and other parts that can be damaged
easily.

Once the 1001 is in place, turn the adjusting bolt [1] as

necessary to make the jaws parallel.

;:======::::==========~

Then hand-lighten the pressure bolt [2] and recheck the
jaws to make sure they are still parallel [3].
Tighten the pressure bolt with a wrench until the ball
joint stud pops loose.
Remove the ball joint nuts and the knuckle from the
upper and lower arms.

I

I \31

L

\11

16-18

FRONT WHEEUSUSPENSION/STEERING
INSPECTION
Remove the dust seals (1J from the knuckle [2] .

Turn the inner race of each bearing (3) in the knuckle
with your finger. The bearings should turn smoothly and
quietly. Also check that the bearing outer race fils tightly
in the hub or knuckle.
Inspect the knuckle for damage or cracks.
Inspect the ball jOint boot [4] for tears or other damage
by moving the ball joint stud.
It should move freely and smoothly.

BRAKE DISC REPLACEMENT
Remove the four disc bolts [1] and brake disc \21 from
the wheel hub [3].

$I

Do not get grease Inslall a new brake disc with new disc bolts and lighten
on the brake disc or them to the specified torque.

stopping power will

be reduced.

TORQUE : 42 N'm (4.3 kgf'm , 31 IbHt)

121

BEARING REPLACEMENT
Remove the inner dust seal [1) and Quter dust seal (2]
from the knuckle.

16-19

FRONT WHEEUSUSPENSIONfSTEERING
Remove the snap ring (1) and drive the bearings [2] out
of the knuckle.

TOOLS ;
Driver
Attachment, 40 x 42 mm
Pilot, 30 mm

07749-0010000
07746-0010900
07746-0040700

Pack the cavities of a new bearings with grease.
Drive in the bearing squarely with the marked side
facing up until l hey are fully sealed .
TOOLS :
(3] Driver
[4] Attachment, 52 x 55 mm

(51 Pilot, 30 mm

07749-0010000
07746-0010400
07746"()040700

Inslall the snap ring into the knuckle groove with the
chamfered side facing in .

13]

14]

Apply grease to the lips of new inner dust seal [1) and
Quter dust seal [2] and install each seal until it is fl ush
with the knuckle, being careful not to damage the lip.

TOOLS:
Inner dust seal:
[3] Driv er
[4} Oil seal driver attachment
Outer dust s eal:
Fork seal dr iv er attachment

(31

07749-0010000
07 JAD·PH801 01
07947·KA40200

Pack the seal lips of the inner dust seal with 2.5 - 3 g of
grease.

(2.S - 3g)

16-20

FRONT WHEEUSUSPENSIONfSTEERING
BALL JOINT REPLACEMENT
Remove the snap ring (1) from the ball jOint [2).

Set the knuckle [11 and speciallools with "A" mark [21
side of the remover/installer facing to the ball joint in the

vise as shown,
Press the ball jOint [3) out of the knuckle.

TOOLS :
[4] Ball joint remover/installer
[5J Attachment, 28 x 30 mm

07WMF·HN00100

07946·1870100

Set the knuckle [1] and special tools with "8" mark [2]
side of the removerlinstaller facing to the ball joint [3] in
the vise as shown.
Press the ball joint into the knuckle until it is fully

sealed .
TOOLS :
[4] Ball joint remover/installer

07WMF·HN00100

[5] Attachment, 20 mm 1.0.

07746-0020400

I

NOTICE

I

If you feel strong resistance when compressing the
vise, stop. Reset the attachment of the tool so that the
ball joint head can go into the hollow of the attachment
and try again.
Install the snap ring [1] with the chamfered edge facing
in.

16·21

FRONT WHEEL/SUSPENSION/STEERING
iNSTALLATION
Inslallthe knuckle [1] onto the drive shaft [2]. and lower
and upper arms with the ball jOint nuts {3J .

[1J

Tighten each joint nut to the specified torque and further
tighten unlil its grooves align with the cotter pin hole.

[2[

TORQUE : 29 N'm (3.0 kgf-m , 21 IbHt)
Install new cotter pins [4].

[4J

I!t

Inslall the tie-rod [1 J into the knuckle with a new joint nul

[2i·

Tighten the nut to the specified torque by holding the
joinl stud flat surfaces [3] .
TORQUE : 54 N'm (5.5 kgf'm , 40 IbHt)
Install a new cotter pin [41.

Install the splash guard [1] with new bolts [2J and
tighten them to the specified torque .

TORQUE : 11 N'm (1.1 kgf'm, 8lbHt)

[2J

I!t

[1i

Apply molybdenum disulfide grease to the drive shaft
splines.

~;;;;;;;;;;;;;;;;;;;;;;;;;;;;;.;,;;;;;;;=======~

Pack the dust seal lips with 2.5 ~ 3 9 of grease.

(2.5 -3 g)

16-22

FRONT WHEEUSUSPENSION/STEERING
Install the wheel hub 11) and hub nut [2].

Tighten the nut to the specified torque and further
lighten until its grooves align wi th the cotter pin hole.
TORQUE: 78 N'm (8.0 kgf'm, 58 IbHt)
Install a new cotter pin [3].

111

Install the brake caliper [1] with new mounting bolls [2]
and lighten them to Ihe specified torque.

;========;,;;;;;;;;;;;,;;;;;;;;;;;;;;;;

TORQUE: 30 N'm (3.1 kgf-m , 22 Ibf·ft)
Install the outboard guard {3] and lighten the bolts [4].

~ 12J

Install the hose clamps (1] with new clamp bolts [2) and
tighten t hem to Ihe specified torque.
TORQUE: 12 N'm (1 .2 kgf-m , 9 IbUl)
Install the front wheel (page 16-13).

SUSPENSION ARM
REMOVAL
Remove the wheel hub and knuckle (page 16-16).
Remove the following :
- pivot nuts [1] and bolls [2]
- lower arm [3]

16-23

FRONT WHEEUSUSPENSION/STEERING
-

shock absorber lower mounting nut [11 and bolt (2]
pivot nut [3] and bolt [4]
upper arm [5J
dust seal caps [6J

INSPECTION
Check the pivot bushings [1) for wear or damage.
Inspect the ball joint boot (2] on the upper arm [3J for
lears or other damage by moving the ball joint stud [4).
It should move freely and smoothly.

IrI1i]1~======:::~foi;----l

:) . @)

I

Remove the bolt [5) and inboard guard [6] from the
lower arm [7] if necessary.

131
14J
16J

BALL JOINT REPLACEMENT
Remove the snap ring [1] from the ball joint [2] .

16·24

FRONT WHEEUSUSPENSION/STEERING
Sel the upper arm (1) and special tools with "A" marl< 12)
side of the remove r/installer facing to the ball joint [3) in
the hydraulic press as shown.
Press the ball ;oint out of the upper arm.

TOOLS :
[4) Ba ll joint remover/installer

07WMF·HN001 00

(5J Attachment, 28)( 30 mm

07946-1870100

Set the upper arm PI and special lools with "8" mark 121
side of t he remover/installer facing to the ball joint (3] as
shown.
Press the ball joint into the upper arm until it is fully

seated.
TOOLS:
(4) Ball joint remover/installer

07WMF·HN00100

[5] Attachment, 20 mm I.D.

07746-0020400

I

NOTICE

I

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 again.

Install the snap ring (1) with the chamfered edge facing
in .

INSTALLATION
Apply molybdenum disulfide grease to the inner
surfaces of the pivot bushings (1 J and install the pivot
collar (2) into the upper arm.

~~

Apply molybdenum disulfide grease to the lips of new
dust seal caps (3) and inslalilhem onto the upper arm .

j

131

111 ~

,- 131 ~
121

16·25

FRONT WHEEUSUSPENSION/STEERING
Insert the bolts from
the front skie.

Install the upper arm [1] into the frame with the bolt (2]
and a new nut (3]10 the specified torque.

TORQUE : 34 N'm (3.5 kgf-m, 25 IbHt)
Insert the bolt from
the rear side.

Connect the shock absorber to the upper arm with the
bott (4J (10 x 45 mm) and a new nut [5] to the specified
torque.
TORQUE : 39 N'm (4.0 kg f'm , 29 IbHt)

Insert the bolts from
the front side.

Instalilhe lower arm (1) with the pivot bolts [2] and new
nuts [3]. and loosely lighten them.
Install the knuckle and wheel hub (page 16-22).

Install the front wheel (page 16-13).
Place the vehicle on level ground and tighten the lower
arm pivot nuts to the specified torque.
TORQUE : 39 N'm (4.0 kgf-m , 29 IbHt)
Install the engine guard (page 2-7).

FRONTSHOCKABSORBER
REMOVAL
Support the vehicle using a hoist or equivalent and
raise the front wheels off the ground.
Support the lower arm. Remove the mounting nuts and
bolts (1), and front shock absorber [2).

INSPECTION
Remove the pivot coilar 11).
Check the pivol bushings [2] for wear or damage.
Check the damper unit for leakage or other damage.
Replace the shock absorber assembly if necessary.

16-26

FRONT WHEEUSUSPENSION/STEERING
INSTALLATION
Install new dust seals [1] into the lower pivot with the lip
side facing the bushing until they are fully seated.
Apply molybdenum disulfide grease to the lower pivot
bushing [2] and dust seal lips.

Install the pivot collar [3].

12)
[3)

Insert the bolts from

/herearside.

Install the shock absorber [ 1] with the mounting bolls
(upper: 10 x 42 mm, lower: 10 x45 mm) and new nuts
[2], and tighten them to the specified torque.

~

~:!iiilliiiiiii_.illiiiiiii~;;;;;;;;;;rr::::;;;::ir.!~

TORQUE: 39 N'm (4.0 kgf'm , 29 IbHt)

STEERING SHAFT (FM/FE models)
REMOVAL
Remove the following:
- mudguards (page 2-6)
- front fender/carrier (page 2-8)
- front wheels (page 16-13)
- meier cover stay (page 16-8)

Release the wire clip [1J.
Remove the following connectors from the frame and
disconnect them :
- FM model : handlebar switch 10P (Green) [2]
FE model: handlebar switch 14P (Green) [2]
- ignition switch 4P (White) [3]
- front sub-wire harness 14P (Gray) [4J

Remove the following :
-

colter pins [1J (from the tie-rods )
joint nuts [2] (by holding the joint stud flat surfaces)
tie-rods [3] (from the steering arm)
cotter pin [4J (from the steering shaft)
shaft end nut and washer [5]
steering arm [6]

16-27

I

FRONT WHEEUSUSPENSION/STEERING
Supporllhe

-

handlebar securely

-

whi~ keeping the

-

master cylinder
reservoir upright.

-

hose clamp bolt [1]
wire band [2]
cables [3) and wires [4] (from the upper guide IS])
two nuts and washers [6)
handlebar assembly (7] (from the steering shaft)

-

brake hose (1) (from the clamp [2])
connector clip [31

-

cables [4J and wires [5J (from the lower guide)

-

two holder bolts (6]

-

steering shaft holder [7]

1'1

131

16-28

-

steering shaft [1] (from the shaft bearing)

-

shaft bushing [2J

-

dust seals [1]

1'1

FRONT WHEEUSUSPENSION/STEERING
INSPECTION
SHAFT BUSHING

Check the shaft bushing for wear or damage.

STEERING SHAFT

Check the steering shaft for distortion or damage.

STEERING SHAFT BEARING

Turn the mner race of the sleermg shaft bearing with
your finger.

The bearing should turn smoothly and quietly. Also
check thai the bearing ouler race fits tightly in the
frame.

BEARING REPLACEMENT
Remove the snap ring (11.

111

\

16-29

FRONT WHEEUSUSPENSION/STEERING
Assemble the special toots and a 10 mm washer (1 ]
onto the steering shaft bearing [21.
Remove the bearing by tightening the nut (3].

[51-

TOOLS :
[4] Clutch compressor
07LAE·PX40100
aHachment
[5] Compressor bolt assembly 07GAE·PG40200 or
07GAE·PG4020A
(U.S.A. only)
[6] Attachment, 34 mm
07ZMD·MBW0100

--n

I[6}-

[4[

-n
,

I
[2[

fV

, -_ _

['I
[3}

Drive a new bearing into the frame with the marked side
facing up.
TOOLS:
[1] Driver
[2] AHachment, 42 x 47 mm
(3] Pilot, 22 mm

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

07949·37 10001
07746-0010300
07746-0041000

Make sure lhe snap Install the snap ring into the groove properly with the
nng Is firmly sealed chamfered edge facing down.
in /he groove

[NSTALLATION
Coa' 'he Hp, of "ew dust ,eal, with 9,ea,e.

I

Install each dust seal [1] with the flat side facing oul so
that it is flush with the frame edge.

"
~~~ce~

- 3 g of grease to the shaft bushing inner

InstaH the shaft bushing [1] onto the steering shaft (2]
with the arrow mark (3] facing up.
Install the steering shaft into the bearing.

16-30

"\'

~=======~=['=[=_=~
=~=(2=-=3=9=1~

FRONT WHEEUSUSPENSION/STEERING
Temporarily install
the handlebar
assembly onto the
sleenng shaff.

Inslall the steering shaft holder (1] with the guide 121
facing down while rouling the wires and cables into the
guide. Inslall the two holder bolts (3).

Install the brake hose [4] into the damp 151 .
Install the 2P (Red) connector [6) onlo the shaft holder.
Tighten the holder bolts alternately in several sleps.

TORQUE : 32 N'm (3.3 kgf·m. 24 IbHt)

161

Apply molybdenum disulfide grease to the steering
shaft spline 111.

Install the steering arm [21 over the steering shaft with
the marked side facing down by aligning the wide looth
with the wide groove.
Inslallthe washer and a new end nul (3). and lighten the
nut to the specified torque.

TORQUE : 108 N'm (11 .0 kgf'm,80 IbHt)

.

Install a new cotler pin (4].
Install the tie-rods [5] into the steering arm.
Install new joint nuts [61 and tighten them to the
specified torque by holding the joint stud flat surfaces.

,

Align

,

----'-\

121

TORQUE : 54 N·m (5.5 kgf·m, 40 Ibf-ft)
Install new coller pins (7) into the ball joint studs.

Install the handlebar assembly (1] onto steering shaft
with the washers and new lower holder nuts [2].
Tighten the nuts.
Install the wires (3] and cables 14] into the guide [5].

!

Secure the wires to the guide with the wire band [6].
Install the hose clamp 171 with a new clamp bolt [8] and
tighten it to the specified torque.

TORQUE : 12 N·m (1.2 kgf·m, 9 tbl-fl)

Connect the following connectors and install them onto
the frame.

•

-

front sub·wire harness 14P (Gray) {1]
ignition switch 4P (White) 12]
FM model : handlebar switch 1QP (Green) (3]
FE model : handlebar switch 14P (Green) 13]

Secure the wires with the wire clip (4] .
Install the following:
- meter cover stay (page 16-9)
- front wheels (page 16-13)
- front fender/carrier (page 2-8)
- mudguards (page 2-6)

131

12J

111

16-31

FRONT WHEEUSUSPENSION/STEERING

STEERING SHAFT/EPS UNIT (FPM/FPE
models)
REMOVAL
Remove the following:

-

mudguards (page 2·6)

-

-

front wheels (page 16-13)
meter cover slay (page 16-8)
bolt [11 and clutch arm cover (2] (release from the

-

adjusting nut (4]

-

cable retaining plate (5]
2WD/4WD selector cable (6) (remove from the cable
holder [7) and joint pin [8])
cable spring (9J

front fender/carrier (page 2-8)

131 I!

two tabs (3])

-

jOint pin

121
[7J "{

16J
\',:- --

18J
Release the wire clip [1).
Remove the following connectors from the frame and

disconnect them:
- FPM: handlebar switch 10P (Green) [2)
FPE: handlebar switch 14P (Green) [2]
- ignition switch 4P (While) [3]
- front sub-wire harness 14P (Gray) [4)

Remove the following:
-

EPS

motor 2P (Gray) connector (1]

- torque sensor 3P (Gray) connector 121

,
16-32

1

FRONT WHEEUSUSPENSIONfSTEERING

Suppor1the
handlebar securely
while keeping the
master cylinder
reservoir upright.

-

cotler pins (1J (from Ihe lie-rods)
Joint nuts (2J (by holding the joint stud flat surfaces)
tie-rods (3] (from the steering arm)
cotler pin (4] (from the steering shaft)
shaft end nut and washer [5]
sleering arm (6]

-

hose clamp bolt (1)
wire band [2]
cables [3] and wires [4] (from the upper guide (5])
two nuts and washers [6]
handlebar assembly 17] (from the steering shaft)

-

brake hose [1] (from the clamp)
connector clip [2] (from the shaft hOlder)
cables [3] and wires (4] (from the lower guide)
two holder bolts (5]
steering shaft holder [6J

131

16-33

FRONT WHEEUSUSPENSION/STEERING
-

steering shaft pinch bott [11

Loosen the EPS unit mounting fasteners [2].
Hold the EPS unit Remove the following:
securely and - steering shaft [3]
maneuver it auto! - shaft bushing [41
the frame to the left - mounting nuts and bolts [2]

side, being careful nor to damage lhe

EPS unit [51

shaft splines.

-

dust seals [1)

INSPECTION
STEERING SHAFT
Check the steering shaft for distortion or damage.

16·34

FRONT WHEEUSUSPENSIONfSTEERING
SHAFT BUSHING
Check the shaft bushing for wear or damage.

EP$ UNIT

Check each shaft [11 of the EPS unit for wear or , - - - - - - - - -- - - -- - ----,
damage.

111
STEERING SHAFT BEARING

Turn the inner race of the steering shaft bearing with

your finger.
The bearing should turn smoothly and quietly. Also
check that the bearing outer race fits lighUy in the
frame.

BEARING REPLACEMENT
Remove the snap ring (I].

16-35

FRONT WHEEUSUSPENSION/STEERING
Assemble the special tools and a 10 mm washers [1J
onto the steering bearing {2J.
Remove the bearing by tlgh tening the nut [3).

151 __ .
1

141

TOOLS :
[4] Clutch compressor
07LAE·PX40100
attachment
[5] Compressor bolt assembly 07GAE·PG40200 or

07GAE·PG4020A
[6) Attachment, 34 mm

(U .S.A. only)
07ZMD-MBW0100

(6)

- - '1:=cf-__

11 I

(3)

Drive a new bearing into the frame with the marked side
facing up.
TOOLS:
[1J Driver
{21 Attachment, 42 x 47 mm
[3) Pilot, 20 mm

01949·3710001
07746-0010300
07746-0040500

Make sure the snap Install the snap ring [1] into the groove properly with the
nng is firmly sealed chamfered edge facing down.
in the groove.

INSTALLATION
Pack the seal lips of new dust seals [1] wi th grease.
Install each dust seal with the flat side facing out so that
it is flush with the frame edge.

16-36

~=================~
(21

FRONT WHEEUSUSPENSION/STEERING
Hold the EPS unil
securely and
carefully maneuver
i/ into place, being
careful nolto
damage the dust
seal in the frame
and shaft splines_

Place the EPS unit [1] into Ihe frame and install it into
the bearing.
Install the mounting bolts [2] from the right side and Ihe
nuts [3]. but do not lighten them yet.

Apply molybdenum disulfide grease to the splines.

Inslall the steering arm [1) with Ihe marked side [21
facing down by aligning Ihe wide tooth with the wide
groove in the shaft.
Inslallthe washer [3J and a new end nut [4}, and tighten
it to the specified torque.
TORQUE: 108 N'm (11 .0 kgf'm , 80 tbUt)
Install a new cotter pin [5].

16·37

FRONT WHEEL/SUSPENSION/STEERING
Apply 2 - 3 9 of grease to the shaft bushing inner

surface.
Install the shaft bushing [1] onto the steering shaft [2)
with the arrow mark [3] facing up.
Install the steering shaft over the input shaft [4] of the
EPS unit by aligning the wide tooth with the wide
groove. Install a new pinch bolt (5] .

Temporarily install
the handlebar
assembly onto the
steering shaft.

Install the steering shaft holder (1] with the guide [2]
facing down while routing the wires and cables into the
guide. Install the two holder bolts (3].
Install the brake hose [4] into the clamp [5].
Install the 2P (Red) connector (6] onto the shaft holder.

Be sure the steering shaft is fully seated onto the EPS
unit. Install and lighten a new pinch bolt (7] to the
specified torque.
TORQUE : 60 N'm (6.1 kgf'm, 44 IbHt)
Tighten the holder bolts alternately in several steps.

TORQUE : 32 N'm (3.3 kgf'm , 24 IbHt)
Tighten the EPS unit mounting nut [11 to the specified
torque.

TORQUE : 22 N·m (2.2 kgf·m , 161bHt)

16-38

1

FRONT WHEEUSUSPENSIONfSTEERING
Install the tie-rods 11J into the sleering arm [21.

Install new joint nuts [3] and lighten them to the
specified torque by holding the joint stud flat surfaces.

TORQUE : 54 N'm (5.5 kgf'm, 40 IbHt)
Install new cotter pins (4J into the ball joint studs.

Install the handlebar assembly [11 onto steering shaft
with the washers and new lower holder nuts [21 .
Tighten the nuls.
Install the wires (3] and cables [4) into the guide 151.

Secure the wires to the guide with the wire band {61 .

Install the hose clamp [71 with a new clamp bolt [8J and
lighten it to the specified torque,
TORQUE: 12 N'm (1.2 kgf-m , 9Ibf-ft)

Connect the torque sensor 3P (Gray) connector !1] and
the EPS motor 2P (Gray) connector [2].

Connect the following connectors and install them onto
the frame.
-

front sub-wire harness 14P (Gray) [11
ignition switch 4P (White) [2]
FPM : handlebar switch 10P (Green) 13]
FPE : handlebar switch 14P (Green ) [3]

Secure the wires with the wire clip [4].

[3J

[2J

16-39

FRONT WHEEUSUSPENSIONfSTEERING
Install the spring [1] onto the selector cable [2] .

Insert the cable into the cable holder [3] and connect it
to the clutch arm with the joint pin {4] and adjusting nut

[51·
Set the groove in the cable grommet [6J onto the cover
base end properly.

Install the retaining plate [7J onto the cable with the
concave facing the cable holder to secure the cable.
Adjust the 2WQ/4WD selector cable (page 3-19).
InstaU the following:
- meier cover stay (page 16-9)
- front wheels (page 16-13)
- front fender/carrier (page 2-8)
- mudguard (page 2-6)
Referto ·Service

Perform the torque sensor initialization (page 24-13).

Information" for
service location of
the initialization
(page 16-4).

TIE-ROD
REMOVAL
Remove the following :
-

mudguards (page 2-6)
front wheel (page 16-13)

Remove the cotler pins [1J.
Remove the joint nuts [2] by holding the jOint stud flat
surfaces [3] with an open end wrench.
Remove the lie-rod (4] from the steering arm and
knuckle.

16-40

[1 I

[41

FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Inspecllhe lie-rod [1] for distortion or damage.
Inspecllhe ball joint boots 12J for tears or other damage
and the ball joints [3] for looseness by moving the ball

jOint studs [4J.
They should move freely and smoothly without binding.

111
[41

DISASSEMBLY/ASSEMBLY
loosen the lock nuts (1), and remove the ball joints and r - - - - - - - - - - - - - - - - -- ,
lock nuts from the tie-rod.

Install the right-hand threads nul and unmarked ball
joint on the flat (wrench holding area for loe adjustment)
side [2) of the lie-rod, and the lefl-hand threads nut and
"L" marked [3) ball joint on the opposite side.

[11

131

121

Note the reference distances (between the lock nut and
thread end).

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

REFERENCE DISTANCES:
A: 8.0 rnm (0.3 1 in)
B: 8.0 mm (0.3 1 in)
A difference between distances A and B should be 3
mm (0.12 in) max.
Tighten these nuts
after installing the
tie-rod and
adjusting the too.

Temporarily tighten the lock nuts while the ball joint
positions are approximately 180' from each other.

1-

B

A

16-41

FRONT WHEEUSUSPENSIONISTEERING
Install the tie-rod [11 with the flats (2] of the rod toward
the knuckle [3).

Install new joint nuts (4) and lighten them to the
specified torque by holding the joint stud flat surfaces

15J.
TORQUE: 54 N'm (5.5 kgf'm , 40 IbHt)
Install new cotter pins {6].

Install the front wheel (page 16-13).
Adjust the loe (page 3-26).

Inslalilhe mudguards (page 2-6).

16-42

17. REAR WHEEUSUSPENSION

SYSTEM COMPONENTS····························17-2

REAR WHEEL .. ··········································· 17·6

SERVICE INFORMATION··· ········ ················ 17-3

REAR SHOCK ABSORBER ·······················17-6

TROUBLESHOOTING·································17 -5

SWINGARM ················································ 17-8

17-1

REAR WHEEUSUSPENSION

SYSTEM COMPONENTS
39 N'm (4.0 kgf·m, 29Ibf-ft)

64 N'm (6.5 kg f·m. 47 IbUt)

39 N'm (4 0 kgf'm, 29Ibf.ft)

118 N'm (12.0 kgf-m. 87Ibf-ft)

17-2

REAR WHEEUSUSPENSION

SERVICE INFORMATION
GENERAL
This section covers service of the rear wheel , rear shock absorber and swingarm.
A jack Of other support is required to support the vehicle.
Use Honda Genuine replacement bolts and nuts for all suspension pivots and mounting points.
For tire information . see Front Wheel/Suspension/Steering section (page 16-13).
For brake system service, see Brake System section (page 18-2).
For driving mechanism service , see Rear Driving Mechanism section (page 20-2).

SPECIFICATIONS
ITE M

-

E standard
With cargo

STANDARD

r-

-

_~ ERV I C E LIMI T
4.0mm 0.16 in)

30 kPa (0.30 kgf/cm2, 4.4 psi )
30 kPa (O .30- kgf/cm1, 4:4 psi )

TORQUE VALUES
ITEM

Q'TY

THREAD

TORQUE
N'm (kgf'm, IbHl)
64 (6.5, 47)
39 (4 .0, 29)

Rear wheel nut
Shock absorber upper mounting nut

6
1

OIA. (mm)
10
10

Shock absorber lower mounting nut

1

10

Universal joint guard bolt

2

6

10 (1 .0 , 7 )

2

12

118 (12.0, 87 )

t -Swingarm pivot bolt

--

39 (4 .0 , 29)

REMARKS
Lock nut: replace with
a new one.
Lock nut: replace with
a new one.
ALOe bolt: replace with a new one.
ALoe bolt: replace
with a new one.

17·3

REAR WHEEUSUSPENSION
TOOLS
Attachment, 24 x 26 mm

Pilol, 12 mm

Pilot, 20 mm

07746-0010700

07746-0040200

07746-0040500

B
Pilot, 25 mm

Driver

Attachment, 28 )( 30 mm

07746-0040600

07749·0010000

07946-1870100

Driver

07949-3710001

)

17-4

REAR WHEEUSUSPENSION

TROUBLESHOOTING
Rear wheel wobbling
Bent rim
Worn or damaged rear axle bearings
Faulty lire
Loose wheel hub nut
Faulty swingarm pivot bearings
Rear wheel hard to turn
Faulty rear axle bearings
• Bent rear axle
• Rear brake drag

Soft suspension
• Weak shock absorber spring
• Oil leakage from damper unit

Stiff suspension
Damaged shock absorber damper
• Faulty shock absorber pivot bushings
• Damaged swingarm pivot bearing

Rear suspension noise
Faulty rear shock absorber
• Loose rear suspension fasteners
• Worn rear suspension pivot bearings or bushings
Steering is heavy
Steering shaft nut or holder too tight
• Damaged steering shaft bushing
• Damaged steering shaft bearing

Any wheel is wobbling
Excessive knuckle or hub bearing play
Bent rim
Improperly installed wheel hub
Loose suspension arm
Bent frame
Vehicle pulls to one side
Tire air pressure incorrect
Faulty shoCk absorber
Bent tie-rod
Incorrect tie-rod adjustment
Improper wheel alignment
Bent frame

17·5

REAR WHEEUSUSPENSION

REAR WHEEL
REMOVAL
Loosen the wheel nuts [1].

Support Ihe vehicle using a hoist or equivalent and
raise the rear wheels off the ground .
Remove the wheel nuts and rear wheel.

For life removal/installation and repair, see Front
Wheel/Suspension/Steering section (page 16-13).

INSTALLATION
Do not interchange
the left and right
wheels

Install the rear wheel with the tire valve facing out and
the arrow mark. [2] facing in the normal rotating
direction.

Install the wheel nuts wi th the tapered side facing
inward and tighten them to Ihe specified torque.

TORQUE : 64 N'm {6.S kgf'm, 47 IbHtl

REAR SHOCK ABSORBER
REMOVAL
Remove the skid plate (page 3-18).

Support the vehicle using a hoist or equivalent and
raise the rear wheels off the ground.
Support the swingarm. Remove the nuts and bolts [1[,
and the shock absorber [2).

17-6

REAR WHEEL/SUSPENSION
INSPECTION
Check the upper pivot bushing [1] for wear or damage.
Check the damper unit [2] for leakage or other damage.
Replace the shock absorber assembly jf necessary.
Remove the lower pivot collar [3).

Check the lower pivot bushing [1] and collar (2) for wear
or damage.

~;;;;;;;;;;;:::;:=============~

INSTALLATION
Inslall new dust seals (1] into the lower pivot with the flat
side facing out unlillhey are fully seated.
Apply molybdenum disulfide grease to the lower pivot
bushing [21 and dust seal lips.
Inslall the pivot collar [3].

131~

121 ~

17·7

REAR WHEEUSUSPENSION
Insert/he bolts from
the right side.

Instal! the shock absorber [1) with the mounting bolls (2)
and new nuts [3]. and tighten them to the specified
torque.
TORQUE :
Upper: 39 N-m (4.0 kgf'm, 29 Ibf·tt)
Lower: 39 N'm (4.0 kgf'm, 29 IbHt)
Ins18llll'le skid plate (page 3-18) .

SWINGARM
REMOVAL
Remove the mudguards (page 2-6)

Remove the final gear assembly (page 20-9) ,
Remove the following:
- breather hose [1] (from the clamp [2])
- pivot nuts and bolts [3]

-

swingarm [4]

-

two bolts (1) and universal joint guard [2]

-

pivot collars [3]
dust seals [4J

Check the bearings in the pivots for wear or damage.

/

131

17-8

\J

131

REAR WHEEL/SUSPENSION
BEARING REPLACEMENT
REMOVAL
Press the needle bearing out of the right pivot using the
special tool.

[1[~_.

TOOLS :

[1] Driver
[21 Attachment, 24 x 26 mm
(3] Pltot, 20 mm

side (needle

07949·3710001
07746..(}010700
07746"(}040500

Press the ball bearing and setting collar oul of the left
pivot.
TOOLS :

[4] Driver
[5] Attachment, 24 x 26 mm

[6) Pilot, 12 mm

07949·3710001
07746..(}010700
07746"(}040200

14[ _ _
[51_~

INST ALLA liON
Apply molybdenum disulfide grease to the rollers of a ~'~~ilill.~~~--------l
new needle bearing.
~
Press in the bearing
wilhthemarked
side facing up.

Press the needle bearing into the right pivot until the
depth from the Quter surface is 7.0 - 7.5 mm (0.280.30 in).
TOOLS :
(1) Driver

(2] Attachment, 24 x 26 mm
(3] Pilot, 20 mm

07749-0010000
07746-0010700
07746-0040500

Pack molybdenum disulfide grease into the cavity of a
new ball bearing [11.
Press in /he bearing
with the marked
side facing up.

7.0 - 7.5 mm
(0.28 - 0.30 in)

II~~~~~iiiiiii~i~===l

Press the ball bearing and the collar [2] into the left
pivot until they are futly seated .

[31

TOOLS :
Bearing :
[3] Driver
[4] Attachment, 28 x 30 mm

141

Pilot, 12 mm
Collar:
Driver

Attachment, 28 x 30 mm
[5] Pilot, 25 mm

07749·0010000
07946·1870100
07746-0040200

[21

07749-0010000
07946·1870100
07746-0040600

17-9

REAR WHEEUSUSPENSION
INSTALLATION
Pack molybdenum disulfide grease into the seal lip
cavity of each new dust seal

Pl.

Install the dust seals until the depth from the outer

'u.".",

r - - -- - - - -- - - -- - - -- ~~ ,
~", ~
...... ~

lllliil'

1)\11

mm.

~

{11

I

l
1 mm
(4 places)
Left side:

Right side:

Install the pivot collars [11 in position as shown.

Install the universal joint guard [2] with new bolts [3] and
tighten them to the specified torque.

TORQUE : 10 N'm (1 .0 kgf'm, 7 IbHt)

~\f
111

Insert the bolts from

the outside.

Install the swingarm [1 1 with new pivot bolls [2J and nuts
(3], and tighten them to the specified torque.

Install the following:
- final gear assembly (page 20-22)
- mudguards (page 2-6)

17-10

{11

~==========~=====:::;::;

TORQUE : 118 N'm (12.0 kgf'm , 87 IbHt)
Install the breather hose [4J into the damp [5].

{21

111

18. BRAKE SYSTEM

SYSTEM COMPONENTS .... ··· .. · .. ················ 18-2

BRAKE PAD/DISC ·················· ··············· .... · 18-8

SERVICE INFORMATION ···························18-4

FRONT MASTER CYLINDER ··················· 18-10

TROUBLESHOOTlNG ·································18-6

FRONT BRAKE CALlPER········ ················18-12

BRAKE FLUID REPLACEMENT/AIR
BLEEDING ······· ······· ····································· 18-7

REAR BRAKE DRUM/SHOES ················· 18-16
REAR BRAKE PEDAL··········· ··················· 18-20

18-1

BRAKE SYSTEM

SYSTEM COMPONENTS
12 N'm (1.2 kgf-m, 9lbHt)

2.0 N'm (0.2 kgf·m, 1.5IbHt)

I
34 N'm (3.5 kgf-m, 251bHt)

~v
2.4 N'm (0.2 kgf-m, 1.8 IbHt)
17 N'm (1.7 kgf-m, 13 IbHt)

34 N'm (3.5 kgf-m, 251bHt)

30 N'm (3.1 kgf'm, 221bHt)

18-2

BRAKE SYSTEM

20 N"m (2.0 kgf-m, 1SlbHt)

137 N·m (14.0

• 101 Ibf-ft)

18-3

BRAKE SYSTEM

SERVICE INFORMATION
GENERAL

ACAUTION
Frequent inhalation of brake pad or lining dust, regardless of material composition could be hazardous to your health.
Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

~~~--------~

NOTICE

I

Spilled brake fluid will severely damage the plastic parts and painted suriaces. It is a/so harmful to some rubber parts. Be careful
whenever you mmove the reservoir cap; make sure the front reservoir is horizontal first.
A contaminated brake disc, pad, drum or shoe reduces stopping power. Discard contaminated pads or shoes. and clean a
contaminated disc or drum with a high quality brake degreasing agent.
Never allow contaminants (dirt, water. etc.) to get into an open reservoir.
Once the hydraulic system has been opened. or if the brake feels spongy. the system must be bled.
Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as
they may not be compatible.
Always check brake operation before riding the vehicle.

SPECIFICATIONS

I .

Rear brake

~I
18-4

BRAKE SYSTEM
TORQUE VALUES
ITEM

O'TY

Brake hose oil 00"'''.---- Front brake caliper bleed valve
Front master cylinder reservoir cap s...
Pad pin
Pad pin plug
Front brake lever pivot bolt
Front brake lever pivot nut
Front brake lighVinhibilor switch screw

"'".w'"--__

l

I
(mm1a'
m

THREAD

TORQUE

OlA.

(kgf'm , Ibl-ft)

3
10
2 = = =18
2 _ _ _.4
4 -+_--;'0
4_
1
6
1 ---+_ _:6
1
4

Front master cylinder holder bolt
Front brake caliper mounting bolt

4

6
8

Front brake caliper slide pin

2

;---Front brake caliper bracket pin_ _ __
~ar brake arm pinch bolUnul _ __ _
Rear wheel hub nul

34 (3.5. 25)
5.4 (0.6. 4.0)f =:::::= =2.0 (0.2. 1.5)_ _ _
17 (1 .7, 13)
,

~==-'~O

1

2

tEE
2

Rear brake panel drain bolt
Brake pipe joint bott

REMARKS

1.8)~

2.4
1.0 (0.2.
(0.1. 0.7)
5.9 (0.6. 4.4)
1.2 (0.1. 0.9)

-+I

Apply locking agent to
the threads .

12 (1.2,9)

30(3T22-) -

ALOe- boil: replace
with a newone.

8

22 (2.2. 16)

Apply locking agent to
the threads.

8
8
20

20 (2 .0. 15)
137 (14.0, 101)

8
10

14 (1.4, 10)

17 (1 .7, 13)
Castle nul' tighten to
the specified torque
and funher tighten
until Its grooves align
with the cotter pin
hole.

12 (1.2. 9)

TOOLS
Oil seal driver
070MF-MEG0300

---~'Attachment

72 x 75 mm
07746·0010600

~

I
\

Driver
07749-0010000

)

18-5

BRAKE SYSTEM

TROUBLESHOOTING
FRONT DISC BRAKE
Brake lever soft or spongy
Air in hydraulic system
leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake pad/disc
Contaminated caliper

Contaminated master cylinder
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warpedldeformed brake disc
Slickinglwom caliper piston
Slicking/worn master cylinder piston
Bent brake lever

Brake lever hard
Clogged/restricted brake system
Slicking/wom caliper piston
Slickinglwom master cylinder piston
Caliper nol sliding properly
Bent brake lever

Brake drags
Contaminated brake pad/disc
Badly worn brake pad/disc
Warped/deformed brake disc
Caliper nol sliding properly
Clogged/restricted fluid passage
Slicking caliper piston

REAR DRUM BRAKE
Poor brake periormance
Brake not adjusted properly
Worn or oontaminated brake shoes
Worn or oontaminated brake drum
Water in brake drum
Inoorreclly installed rear brake arm
Worn rear brake cam

18-6

BRAKE SYSTEM

BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
Turn the handlebar to the left until the reservoir is level
before removing the reservoir cap.
Remove the screws [1J. reservoir cap [2), set plate and
diaphragm .

Connect a bleed hose [1} to the front brake caliper
bleed valve [2J.
Loosen the bleed valve and pump the front brake lever
until no more fluid flows out of the bleed valve.

Perform above procedure for the other side bleed valve.

BRAKE FLUID FILLING/BLEEDING
Close each brake caliper bleed valve.
Fill the master cylinder reservoir with DOT 4 brake fluid
from a sealed container.
Follow the
manufacturer's
operating

Connect a commercially available brake bleeder [1J to
the bleed valve.

instructions. Operate the brake bleeder and loosen the bleed valve

121.

Check the fluid level
often while bleeding
the brake to prevent
air from being
pumped into the

If an automatic refill system is not used, add fluid when
the fluid level in the reservoir is low.

system.
If air enters the

bleeder from
around the bleed
valve threads, seal
the threads with
teflon rape.

Perform the bleeding procedure until the system is
completely flushed/bled.
Tighten the bleed valve to the specified torque.
TORQUE : 5.4 N-m (0.6 kgf·m , 4.0 Ibf·ft )
Perform air bleeding for the other side bleed valve.
After bleeding air, operate the front brake lever. If it still
feels spongy, bleed the system again.

18-7

BRAKE SYSTEM
If the brake bleeder is not available, perform the
following procedure;
Pump up the system pressure with the front brake lever
until the lever resistance is felt.

Connect a bleed hose [I] to the front brake caliper
bleed valve (2) and bleed the system as follows:

bleed valve has

1. Squeeze the brake lever all the way and loosen the
bleed valve 1/4 of a turn. Wail several seconds and
then close the bleed valve.

been Closed.

2. Release the brake lever slowly and wail several

Do not releaSJJ the
brake /everunti/ the

seconds after it reaches the end of its travel.

3. Repeal the steps 1 and 2 until there are no air
bubbles in the bleed hose.
Tighten the bleed valve to the specified torque.
TORQUE: 5.4 N'm (0.6 kgf'm, 4.0 IbHt)

Perform air bleeding for the other side bleed valve.
After bleeding air, operate the front brake lever. If it still
feels spongy, bleed the system again.
Fill the master cylinder reservoir to the casting ledge
with DOT 4 brake fluid from a sealed container.

[11

Install the diaphragm, set plate and reservoir cap. and
tighten the screws to the specified torque.
TORQUE: 2.0 N'm (0.2 kgf'm , 1.5IbHt)

BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Remove the front wheel (page 16-13).
Remove the pad pin plugs.
Loosen the pad pins (1].
Remove the two mounting bolts

(3].

121

and brake caliper

Check the fluid level Push the caliper piston all the way in by prying the
In the master brake pads to allow installation of new pads.
cylInder reservoir as
this operatIOn

causes the fluid
leve/to rise.

18-8

BRAKE SYSTEM
Pull the pad pins (1) oul of the caliper while pushing the
brake pads (2] in againslthe pad spring [3], and remove
the pads.
Make sure the pad
spnng is installed

correctly.
Always rep/ace the
brake pads in pairs
to ensure even disc
pressure.

Install new brake pads into the caliper body.
Align the pad pin holes in the caliper body and pads by
pushing the pads in against the pad spring , and install
the pad pins.

Install the brake caliper (1] so the disc is positioned
between the pads. being careful not to damage the
pads.
Install new mounting bolts [2J and tighten them to the
specified torque.
TORQUE: 30 N'm (3.1 kgf·m. 221bHt)
Tighten the pad pins (3] to the specified torque.
TORQUE: 17 N-m (1 .7 kgf'm , 13 IbHt)
Install the pad pin plugs and tighten them to the
specified torque.
TORQUE : 2.4 N-m (0.2 kgf'm , 1.8 IbHt)
Squeeze the front brake lever to seat the caliper piston
against the pad .
Install the front wheel (page 16-13).

BRAKE DISC INSPECTION
Remove the brake caliper without disconnecting the
brake hose (page 18-12).
Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness al several points.
SERVICE LIMIT: 3.0 mm (0.12 in)
Replace the brake disc if the smallest measurement is
less than service limit.

Check the brake disc for warpage.
SERVICE LIMIT: 0.30 mm (0.012 in)
Check the knuckle bearing for excessive play, if the
warpage ex.ceeds the service limit.
Replace the brake disc if the bearings are normal.
Brake disc replacement (page 16-19).

18-9

BRAKE SYSTEM

FRONT MASTER CYLINDER
REMOVAL
Drain the brake fluid (page 18-7).
Remove the dust cover [1[ and disconnect the
connectors [21 from the switches .
When removing the Disconnect the brake hose by (emoving the oil boll [3)
oil boll, cover the and sealing washers 14].
end of the hose to
Remove the two bolts (5] , holder [61 and master cylinder
prevent
con/emine/IOII.

[II-

DISASSEMBLY/ASSEMBL Y

SEPARATOR

~
CUP

I

MASTER
PISTON

SNAP RING

5.9 N·m (0.6 kgf-m .

4.4 Ibf-ft)

----::~~
SWITCHES

PISTON BOOT

BRAKE LEVER

18·10

1,2 N 'm (0.1 kgf-m, 0.9Ibf-ft)

BRAKE SYSTEM
INSPECTION
Check the piston cups and boot for wear, deterioration , - - - - - - - - -- - - - - -- - - - - - ,
or damage.
Check the spring for damage.
Check the master cylinder and piston for scoring.
scratches or damage.
Measure the master cylinder 1.0.

SERVICE LIMIT : 14.055 mm (0.5533 in)
Measure the master piston O.D.
SERVICE LIMIT: 13.945 mm (0.5490 in)

INSTALLATION
Align the edge of
the master cylinder
with the punch
mark {51 on the
handlebar.

Instalilhe brake master cylinder [1] and holder [2] with
the "UP· mark facing up. Tighten the upper bolt f3J first,
then lighten the lower bolt [4] to the speCified torque.

~=------------__.._--,

TORQUE : 12 N'm (1.2 kgf-m , 9 IbUt)
Set the brake hose joint between the stopper groove in
the master cylinder.
Connect the brake hose with the oil bolt [6] and new
sealing washers (7] . and tighten the oil bolt to the
specified torque,
TORQUE: 34 N'm (3.5 kgf'm , 25 Ibf-ft)

Connect the gray
Jape (4J wire

connectors 10 the
upper terminals.

Connect the connectors [1] to the switches [2].
Insta!1 the dust cover {3] properly.
(1(

Fill and bleed the hydraulic system (page 18-7).

[21 (for starting inhibitor)

I(4(

~?!IJ;;" ~

_

131

(21 (for brake light)

18-11

BRAKE SYSTEM

FRONT BRAKE CALIPER
DISASSEMLBY
Remove the front wheel (page 16-13).
Drain the brake fluid (page 18-7).
Remove the two bolts [1] and outboard guard [2].
Remove the slide pin plug [3] .

Disconnect the brake hose by removing the oil bolt [1]

and sealing washers [2J.

loosen the slide pin [3].
Remove Ihe brake pads (page 18-8).

Remove the following:
- caliper brackel11] (loosen the slide pin)
- spring washer (2]
- pad spring (3[
- slide pin (4) (by releasing the boot rib from the pin
groove)
- slide pin boot [5J
- bracket pin boot [6J

Take care nOl to
damage the PIs/on

Remove caliper piston [1] out of the cylinder by pushing
it through Ihe fluid inlel.

with the caliper
body.

Release the piston boot [2] from the piston groove to
remove them.

18-12

161

,---~_"",,;;:---========~

BRAKE SYSTEM
Be careful not to
damage the piston
sliding surface.

Push the piston seal [1) in and lift it out.
Clean the seal and boot grooves , caliper cylinder. and
piston with clean brake fluid.

INSPECTION
Check the caliper cylinder and piston for scoring,
scratches or damage.

~----------------.

Measure the caliper cylinder 1.0.
SERVICE LIMIT: 32.090 mm (1 .2634 in)
Measure the caliper piston 0.0.
SERVICE LIMIT: 31.94 mm (1 .257 in)

ASSEMBLY

...-'iiSioI '1m

CALIPER BODY

SLIDE PIN
22 N·m (2.2 kgf·m , 16 1b,",t)

PISTON SEAL

SLIDE PIN PLUG

~
PAO SPRING

I
e" ...-'iiSioI
PISTON BOOT

~,

CALIPER PISTON

~

cr6

~:::l~~

I

BRACKET PIN
17 N·m (1.7 kg f·m, 131bHt)

e" ...-'iiSioI

(

SLIDE PIN BOOT
SPRING WASHER
CALIPER BRACKET

18-13

BRAKE SYSTEM
Coal a new piston seal (lJ with dean brake fluid and
install it into the seal groove in the caliper cylinder.

Apply 0.2 9 of silicone grease to the inside and seal
areas (boot ribs) of a new piston boot [21.

Install the inside boot rib of piston boot into the boot
groove in the caliper cylinder properly.
Coat the caliper piston [3] with dean brake fluid and
place it into the caliper body with the open side toward
the brake pad. Cover the piston with the boot carefully.
then push the piston and sel the outside boot rib into
the boot groove in the piston to seallhe piston.

fII [l[
fII [2[

I

Install a new bracket pin bool [1) into the caliper body
and pack the inside of the boot with 0.4 9 of silicone

~~

grease.
Install a new slide pin boot [21 into the groove in the
caliper body.
Apply 0.4 9 of silicone grease to the grease groove and
sliding area of the slide pin (3] . Install the slide pin and
set the boot rib into the boot groove in the stide pin.

[3J

,

Q-----=- [2J fII

18-14

BRAKE SYSTEM
Inslalithe pad spring [1] as shown.

"1m
[3[ _ __

Install the spnng washer (2] onlo the slide pin with the
concavity toward the bracket side.
Apply locking agent to the slide pin threads.
Inslalithe caliper bracket (4] ovef the caliper body and
thread the slide pin [5] into the bracket, being careful
not damage the slide pin boot (6).

Make sure the boot ribs are sealed into the boot
grooves in the slide and bracket pins properly.

InslaUthe brake pads (page 18-9).

--

f-B~,-a-'k-e-t---'
[l[

SideJ
[2[

-

Tighten the slide pin [1]10 the specified torque.

TORQUE : 22 N'm (2.2 kgfm, 16Ibf-ft)
Rest the brake hose joint onto the stopper on the
caliper body_
Connect the brake hose with the oil bolt [21 and new
sealing washers [3), and tighten the oil bolt to the
specified torque.
TORQUE : 34 N'm (3.5 kgf'm, 25 IbHt)

Inslallthe slide pin plug [1].
Inslalithe outboard guard 121 and lighten the bolts [31.
Fill and bleed the hydraulic system (page 18-7).
Inslallthe front wheel (page 16-13),

18-15

BRAKE SYSTEM

REAR BRAKE DRUM/SHOES
BRAKE DRUM REMOVAL
Remove the right rear wheel (page 17-6),
Remove the following:

-

coUerpin(1)

-

hub nut (2]
wheel hub (3)

-

six bolts 111

-

drum cover [2J

-

dust seal [3]

-

Q-ring [lJ
brake drum [2]

(2)

INSPECTION
Measure the brake drum 1.0.

SERVICE LIMIT: 181 .0 mm (7.13 in)

L
18-16

BRAKE SYSTEM
DISASSEMBLY
Always repJace the
brake shoes in
pairs.

Remove Ihe following:

-

cotter pins [1)

-

selling plale [2J
brake shoes 13]
springs [4]

-

131
-

adjusting nuts [ 1]
brake cables [2)
joint pins [3J

-

springs [4)

-

brake panel drain bolt [5J and washer [61

-

nut and bolt [lJ
brake arm [2]
wear indicator [3]
return spring (4]
brake cam (5)
felt seal
dust seat

121 ~

I

f---(5)

j
ASSEMBLY
Apply grease to the lips of a new dust seal [1) and
install it with the flat side facing toward the brake arm
until II is fully seated.
Apply 0.2 - 0.3 9 of grease to the brake cam [2] spindle
and install it.

18·17

BRAKE SYSTEM
Apply engine oil to a new felt seal [1] and Install it over
the brake cam.

Installthe return spring (2) by aligning its end wi th the
hole [3] .
InslaUthe wear indicator (4J by aligning the wide teeth
with the wide groove altha brake cam (5).

Install the brake arm (1] by aligning the punch marks
(2( .

Install the pinch bolt [3] from the punch mark side and
the nut (4]. and lighten ilia the specified torque.

TORQUE: 20 N'm (2.0 kgf'm , 151bHt)

Install the brake cables 11] into the cable holders on the
brake panel (upper holder for lever brake cable and
lower holder for pedal brake cable).
InslaUthe cable springs (2] onto the cables and the jOint
pins (3)Inlo the brake arm. Connect the brake cables to
the brake arm with the adjusting nuts [4).

Install the brake panel drain bolt with a new searing
washer [5) and tighten the bolt (6] to the specified
torque.
TORQUE : 12 N'm (1.2 kgf'm , 9lbHt)

Apply 0.2 - 0.3 g of grease to each anchor pin groove
and the brake cam sliding surfaces.
Do not get grease
OIl/he shoe linings.

Assemble the brake shoes 11] and springs [2] so that
the spring ends are facing outside as shown and install
the assembly onto the brake panel.

The cotter pins are

Install the setting plate (3) with the chamfered side
(rolled edge side) facing in and secure it with new cotter
pins (4].

installtKJ from the
front side.

18-18

;::~~::':':::;;;;:

BRAKE SYSTEM
BRAKE DRUM INSTALLATION
Apply molybdenum disulfide grease to the axle splines.

Donotgetgrnase

Inslalithe brake drum [1] onto the axle until il is fully

on the brake drum

seated.

and shoes.

Coal a new D-ring [2J with grease and install it into the
groove in the brake panel [31.

[1[

Pack the seal lips of a new dust seal

grease.

[1J with

3 - 4 9 of

;::=================~
[2J

Install the dust seal into the drum cover so thai it is flush
with the cover surface.

TOOL:

[3J Attachment 72 x 75 mm

07749-0010000
07746-0010600

[4J Oil seal driver

070MF·MEG0300

[2J Driver

[3[
[4[

[1)

......

111

(3 - 4g)

Install the drum cover [1]. aligning the bolt holes.
Install the six bolts [2] and tighten them.

Apply grease to the lips of a new dust seal (1) and
install it into the wheel hub (2J with the flat side facing in
until it is fully seated.
Do nol getgfl3ase
on the axle threads.

Install the wheel hub onto the axle.

18-19

BRAKE SYSTEM
Install the hub nul (1) and tighten it to the specified
torque and further tighten until its grooves align wi th the

coller pin hole.
TORQUE : 137 N'm (14.0 kgf'm, 1011bHt)
Install a new cotter pin 12).
Inslall the rear wheel (page 17-6).
Adjust the rear brake (page 3-22).

REAR BRAKE PEDAL
REMOVAL
Remove the right mudguard (page 2-6).

Disconnect the pedal brake cable from the brake arm
(page 18-17).
Remove the following:
- switch spring [1)
- return spring [2)

-

brake cable (3) (from the cable holder [4] and pedal

[511

-

cotter pin [1]

-

washer [2]
brake pedal [3)
dust seals (4]

,

[NSTALLAT[ON
Apply grease to the lips of new dust seals (1).
Install the dust seals with the flat side facing out so that
they are flush with the pedal [2j.
Apply grease to the groove In the pivot shaft and install
the brake pedal.

18-20

BRAKE SYSTEM
Install the washer (1] and a new cotter pin (21.

Install the brake cable [11 into the pedal [21 and cable
holder [3/.
Install the return spring [41 and switch spring [51 in the
direction as shown.
Connect the brake cable to the brake arm (page 18-18).
Adjust the brake pedal freeplay (page 3-22).
Install the right mudguard (page 2-6).

Spring installation direction:

___ Front

[4[

18-21

MEMO

19. FRONT DRIVING MECHANISM

SYSTEM COMPONENTS ·· .... · .. · ............ · .... ·19-2

FRONT FINAL CLUTCH .......................... · 19-16

SERVICE INFORMATION .......................... ·19-3

FRONT FINAL GEAR DISASSEMBLYI
INSPECTION · .. · ........ · .. ·· ...... · ................ · .. ·· 19-22

TROUBLESHOOTlNG ........ .............. · .. · .. · .... 19-6
FRONT DRIVE SHAFT ...................... .......... 19-7

GEAR CASE BEARING
REPLACEMENT ........ .. ............................ · 19-30

FRONT FINAL DRIVE REMOVAL ............ 19-12

FRONT FINAL GEAR ASSEMBLY .......... 19-33

FRONT PROPELLER SHAFT .................. ·19-14

FRONT FINAL DRIVE INSTALLATION "" 19-37

19-1

FRONT DRIVING MECHANISM

SYSTEM COMPONENTS

44 N'm (4.5 kgf'm,

~ \

321bHt)

--1--- 44 N'm (4.5 kgf-m,

,

32 Ibf-ft)

10 N'm
7Ibf-ft)

19·2

kgf'm,

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 nol clamp it too tight as it could damage the gear

case.
When using the lock nul wrench , use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the
torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The
specification given is the actuallorque applied 10 the lock nut, not the reading on the torque wrench. Do not overtighten the lock
nut. The specification later In the text gives both actual and indicated.
Replace the ring and pinion gears as a set.
Replace the cam followers (12 pieces) as a set, and the cam followers, face cams and differential housing as an assembly if the
face cam or differential hOUSing IS faulty.
Do not confuse the left and right drive shaft parts.

SPECIFICATIONS

~

Front final
drive

ITEM
Oil capacity

- - -- -,--.c;; Unit: mm (in)
STANDARD
SERVICE LIMIT
200 em {6.S US
7.0 Imp OZ)C==t:::~'::;=--==---i
250 em (S.5 US
8.8 Imp oz)
Honda shaft drive oil or equivale~n"I-----hypoid gear oil. SAE # 80
0.4 (0.02()_ __
0.05 0.25 (0.002 - 0.010)

OZ,
OZ,

After draining
After disassembly

Recommended oil
I--Gear backlash: - -- - -- - Backlash diffe~'e~n~c~e----­
Slip torque
Face cam-to-housing distance
Differential ring gear depth
_.L~
C~o~
n=
e spring free height

0.2 (0.01)
14-17N·m(1.45 - 1.75kgf·m,
10 - 13 IbHt)

t2N 'm
(1.2 kgf·m. 9lbHt)

----.:J

------[i'3 - 3.7 (033 - 0.15 )=..---_ _ _-!-C3 ·3 (0.13)
ii (0.258)
_
} ~ . 55 -=-~,65 (0.258 - 0.262)
6.55
~--,2",.8~( 0.11)
2.6 (0.10)

~

TORQUE VALUES

60

TORQUE
N'm (k gf'm, IbHt)
98 (10.0, 72)

11

8

49 (5.0. 36)

Front final gear case cover bolt

2

10

47 (4.8, 35)

Front final clutch shift fork bolt

4
1

8
6

25 (2 .5. 18)
10(1 .0. 7)

Front final clutch hOUSing bolt
Front final gear case moun\lng nul

3
2

8
10

25 (2.5, 18)
44 (4.5, 32)

12 (1.2. 9)

1
3

10
6
6

ITEM

THREAD
DIA. (mm)

Q'TY

Front final gear pinion bearing lock nut
Differential ring gear bolt

r

4WD select switch
4WD select switch wire clamp bolt
Final clutch arm cover bolt

+

4-

-I-

10 (1.0, 7)
10 (1 .0, 7)

REMARKS
Lock nul ,ePla~
a new one Stake.
AlOe boll replace
--t-flth a new one
Apply locking agent to
the threads.

I

AlOe bolt: replace
with a new one.
lock nut: replace with
a new one.

J

-----=:j

19-3

FRONT DRIVING MECHANISM
TOOLS
Bearing clip compressor, 25 mrn
070ME·HNB0100

Threaded adaptor
070MF·HP50100

Remover weight

07741·0010201

,

r

Of 070ME-HN8Al00 (U.S. A. only)

or 070MF·HPSA100 (U.S.A. only)

or 07936-371 020A or 07936.3710200
(U.S.A. only)

Attachment, 52 x 55 mm

07746-0010400

Attachment, 22 x 24 mm
07746-0010800

Attachment, 30 mm 1.0.

07746-0030300

1

=

"P~i~ ,·,·'"2~m=mo-----------------r,P~i~'O'I."<5~m~m~----------------1-'P~iI~o",'30" m~mC---------------- j
07746-0040200

07746-0040300

07746-0040700

h F"o""""."a'"d"'n"'v"e'"we""'' gh'' '- ----------+nOOiri,,''.'''";;a"tta'' c'>h;;;m''.;;;n.I.'3'3 m"m;;T'.D".- ---- -1-'0'-'"",.=,- -07747·0010100

19-4

07747-0010501

07749-0010000

FRONT DRIVING MECHANISM
lock nul wrench, 34 x 44 mm
07916-ME50001

Special nut
07931-HB3020A (U.SA only)

~puller shaft
0793 1-ME4010B (U.SA only)

I

/

Bearing remover, 12 mm
07936-166010A (U.S.A. only)

Remover head , 12 mm
07936-1660110

Remover shaft, 12 mm

Remover handle

Remover shaft, 15 mm

07936-37101 00

07936-KCl 01 00

Remover head, 15 mm
07936-KC10200

h B"e"a"ri"ng;c-;;re"m
"o"';;;e;r, <'''S-;;m''m
;;-- - - - +' Altachment. 45 x 50 mm
07936-KC10500 (U.SA only)

07946-6920100

07936-1660120

-----r-~;~~:~--3-7-'O-O-O-,------I

I

 ~ I

Coast side

REAR DRIVING MECHANISM
Replace the pinion shim [1] with a thinner one if the
contact pattern is too tow, toward the flank.

Too Low:

[1]

The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in)
when the thickness of the shim [1] is changed by
0.12 mm (0.005 in),

Pinion shims:

A: 1.82 mm
B: 1.88 mm
c: 1.94 mm
0 : 2.00 mm
E: 2.06 mm

(0.072
(0.074
(0.076
(0.079
(0.081

in)
in)
in)
in)
in)

F: 2.12
G: 2.18
H: 2.24
t: 2.30

mm
mm
mm
mm

(0.083
(0.086
(0.088
(0.091

in)
in)
in)
in)
Drive side

Pinion shim replacement (page 20-16).

I~ ~ I

Flank

Coast side

Flank

PINION GEAR REMOVAL
Remove the oil seal [1) from the gear case.

Be careful that
melal particles do

Unstake [1] the bearing lock nul [2J with a drill or
grinder.

~==~IIII!IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII~=~~IIIIIIIIIIII=~

not enter the
bearing and the
threads of the case

are not damaged

Remove the lock nut [1] and discard it.

TOOL:
[2] Lock nut w ren ch, 30 x 64 mm

121

07916·MB00002

20-15

REAR DRIVING MECHANISM
Install the special lools onto the pinion gear shaft and

gear case.
TOOLS:
[1] Puller shaft and nut
[2] Pinion puller base
U.S.A. TOOLS:
Puller shaft

07931 ·ME40000
07HMC·MM80110

Special nut

07931·ME4010B
07931·HB3020A

Pinion puller base

07HMC·MM8011A

12J

Pull the pinion assembly [3] out from the gear case.

13J

PINION BEARING AND SHIM
REPLACEMENT
Pull the bearing from the shaft with a commercially , - - - - - - - - - -- - -- - . . . ,
available bearing puller.
Remove the bearing and shim.

Install the shim [1] and bearing [2] onto the pinion gear

131·
NOTE:
When the gear set, ring gear bearing , and/or gear
case has been replaced. use a 2.00 mm (0.079 in)
thick. shim for initial reference.

Press the pinion gear into a new bearing until It is fully
seated by supporting the bearing inner race.

TOOL:
[1] Attachment, 35 mm 1.0.

20·16

07146-0030400

~~~":':'::===:':'::=====::::~

REAR DRIVING MECHANISM

GEAR CASE BEARING REPLACEMENT
RING GEAR BEARING
Remove the oil seals [1] from the gear case and cover.
Drive the bearings [2) out of the gear case and cover.

Drive new bearings into Ihe gear case and cover.

TOOLS :
Cover Side;

(1J Driver

07749-0010000

[2) Attachment, 62 x 68 mm

07746-0010500

(3] Pilot, 35 mm

07746-0040800

Case Side:

[1J Driver

07749-0010000

[4] Oil seal driver attachment

07JAO·PH80101

[3J Pilot, 35 m m

07746-0040800

Case Side:

131- -

20-17

REAR DRIVING MECHANISM
Apply grease to the seal lips of new oil seals [1].
Inslall each oil seal with the flat side facing oul so thai it
is flush with the cover or case .

TOOLS :
(2] Driver:
[3] Attachment

07749-0010000
07946·3290000

PINION NEEDLE BEARING
Rotate the stopper ring

[tl

until its end appears in the , - - -

access hole [2].

Strike gently near the end of the ring with a punch to
bend the end upward.
Grasp the end of the ring with needle-nose pliers and

pull the stopper ring 01..11through the access hole.
Remove the oil filler cap.

eo·e

(176"F) and remove
Be sure /0 wear Heat the gear case to about
heavy gloves to the needle bearing (3] , using the speciallools.
avoid bums when

handling Ihe healad TOOLS:
gear case Remover head, 15 mm
Usmg 8 loreh to Remover shaft, 15 mm
heal the gear case Remover weight
may cause
warpage U.S.A. TOOLS:
Bearing remover, 1S mm
Remover weight

07936·KC10200
07936-KC1 01 00
07741-0010201

07936·KC10S00
07936-371 020A or
07936-3710200

....

Install a new stopper ring [1J into the groove in a new , - - - - - - - - - - - - - Make sure Ihe
stopper ring slays in
the groove.

install the beating into the compressor [2J until ihe
stopper ring is nush with the end of the tool.
TOOL:
Bearing clip compressor, 26 mm

070ME-HPS0100

121

20-18

~

(11 ¢!~

beaciog.

REAR DRIVING MECHANISM
Place the driver, attachment and pilot on the top of the
bearing and tape the driver to the compressor [1J.
TOOLS :

[2J Driver
[3] Attachment, 24 x 26 mm
[4] Pilot, 15 mm

07949-3710001
07746-0010700
07746-0040300

Place the bearing and tool assembly into a freezer for at
least 30 minutes.
Heat the gear case to

aooe (176"F).

Remove the bearing and tool assembly from the freezer
and drive the bearing into the gear case using the
special lools.
Only strike the driver once . If you slrlke it more than
once, the stopper ring [5] may slip oul of the groove. If
this happens, remove the stopper ring and bearing , and
install a new stopper ring.
Make sure the stopper ring is securely set in the groove
of the gear case.

REAR FINAL GEAR ASSEMBLY

g

_..s;;;;;

OIL SEAL
(35 x 49 x 6)

$I

~jjff
T.(JJ)c

(35x60)(14)

STOPPER RING

RING GEAR

PINION NEEDLE
BEARING
(15x26x 17)

RING GEAR BEARING
(6007)
BmmBOLT
25 N'm (2.5 kgf-m,
18 Ibf·tt)

g~
OIL SEAL
(39x70xI2)
SHIM

PINION BALL BEARING
(6007)

~

98 N'm (10.0 kgf'm,
72 Ibf tt)

GEAR CASE COVER

cu

10 mm BOLT
47 N'm (4 .8 kgf'm, 35 1bHt)

OIL SEAL
(35 x 49 x 6)

20-19

,

REAR DRIVING MECHANISM
PINION GEAR INSTALLATION
Blow compressed air through the breather hole [1] in , - - - - - - - -...,.. ,--.._

the gear case.

Drive the pinion gear assembly [I] into the gear case.
TOOLS:
(2] Driver
(3] Attachment, 42 x 47 mm
[4] Fork seal driver weight

07749-0010000
07746-0010300
07747-0010100

InstaU a new lock nul [I] and tighten it to the specified
torque.

TOOL :
(2) Lock nut wrench, 30 x 64 mm
Referto "Service
fnformatJon"for
torque wrench
reading information
(page 20-3).

Be careful not to
damage the threads
arrha case.

20-20

~====~;II""IIIIIIIIIIIIIIIIII~~====~
[2]

01916·MB00002

TORQUE: Actual: 98 N'm (10.0 kgf'm , 72 IbHt)
Indicated: 89 N'm (9.1 kgf'm, 66 1bHt)

Slake [I] the lock nut into the case groove.

[1[

REAR DRIVING MECHANISM
Apply grease to the lips of a new oil seal [1] and install it
so that it is flush wilh Ihe gear case.

RING GEAR CLEARANCE
INSPECTION
Install the ring gear [1) with the left shim into the case
cover [2].
Measure the clearance between the ring gear and stop
pin [3] with a feeler gauge.

CLEARANCE: 0.3 - 0.6 mm (0,01 - 0 .02 in)
Remove the ring gear.
Be sure to wear
heavy gloves 10
avoid bums when
handling the heated
case cover.
Using a lorch 10
heal the cover may
cause warpage.

If Ihe clearance exceeds Ihe standard value. heat the
case cover to approximately 80°C (176°F) and remove
the stop pin by tapping the cover.
Install a stop pin shim [4] to obtain the correct
clearance.
Stop pin shims:

A: 0.10 mm (0.004 in)
B: 0.15 mm (0.006 in)
Inslall the shim and drive the stop pin inlo the case
cover.

FINAL GEAR CASE ASSEMBLY
NOT E:
When the gear sel, bearing, and/or gear case has
been replaced, check the following:
- looth contact pattern (page 20-13)
- gear backlash (page 20-12)
Keep dusl and dirt
out of the case and
cover.

Clean Ihe mating surface of the gear case and cover.
being careful nol to damage them.

~-----------------~

12J

Inslall the proper ring gear shims [1] onto Ihe ring gear
[2] and install them into the gear case.

I1J

20·21

REAR DRIVING MECHANISM
Apply liquid sealant (T81215 or equivalent) to the
[11

mating surface of the case cover 11).
Inslallthe cover onlo the gear case 121.

1/ is important /0
tum the pinion while
'lfIflfening the bolts.

/( the nng gear shim
is too thick, the
gear$ will lock after
only Il!Iht lighfenmg.

Apply locking agent to the threads of the two 10 mm
bolts [1].

Install the eight bolts and tighten them several steps
until the cover [2] evenly touches the case. Then. while
rotating the pinion gear. lighten the bolts to the
specified torque In a crisscross pattern in several steps.

TORQUE: 10 mm bolt: 47 N'm (4.8 kgf'm, 35 IbHt)
8 mm bolt: 25 N'm (2.5 kgf'm, 181bHI)
Make sure that the gear assembly rotales smoothly
without binding .

REAR FINAL DRIVE INSTALLATION
Coal a new O-ring [1J with molybdenum disulfide
grease and install it into the groove in the output shaft.
Apply molybdenum disulfide grease to the splines of
both sides in the universal joint [21.

InstaJl with the small Install the universal joint onto the output shaft until it is
0.0. side facing the fully seated.
engine.

Coat a new O-ring 111 with molybdenum disulfide
grease and install it into the groove in the propeller
shaft [2).
Install the propeller shaft into the universal joint until it is
fully seated .

20-22

~=============~~==;~
PJ

REAR DRIVING MECHANISM
Install the joint spring [11 into the propeller shaft firmly.
Apply molybdenum disulfide grease to the splines of the
propeller shaft.

Coat a new O-ring 11] with grease and install it into the
gear case groove_
Install the axle housing [2] onto the gear case with new
nuts 13] and temporarily tighten them.

Support the swmgarm securely.
Insert the OoIts from
the nght side

Install the gear case assembly Into the swingarm while
connecting the propeller shaft [1). then install the four
bolts [2] and new nuts [3). Temporarily tighten the nuts.
Connect the breather hose [4] to the gear case.
Tighten the four (axle housing-to-swingarm ) nuts (3) to
the specified torque.
TORQUE : 52 N'm (5.3 kgf-m, 38 IbHt)
Tighten the four (axle housing-to-gear case) nuts [5] to
the specified torque.
TORQUE: 47 N-m (4.8 kgf·m. 351bHt)

Insert the bolt from
the right side

Connect the shock absorber with the bolt [6J and a new
nut [7] and tighten it to the specified torque.
TORQUE: 39 N'm (4.0 kgf'm, 29 IbNt)
Install the breather hose (8] into the clamps [9J on the
axle housing .

12J

20-23

REAR DRIVING MECHANISM
Inslallthe skid plate (11 with new bolts [21 and lighten
them to the specified torque.
TORQUE : 32 N'm (3.3 kgf'm , 24 IbHt)
Install the rear axle (page 20-24).

REAR AXLE INSTALLATION
Apply molybdenum disulfi de grease to the center
splines [11of the axle (2J.
Inslall the axle into the final gear case from right side
until it is fully seated.

121

Coat a new O-ring 111 with grease and install it into the
groove in the left axle housing.

Install the side collar 12J onlo the rear axle wIth the
tapered side facing inward.

~===:::::===::;:=======~
111

121
Install the axle housing [11 into the gear case.

Installihe four new nuts 121 and tighten the them to the
specified torque.
TORQUE : 47 N'm (4.8 kgf'm , 35 IbHt)

20·24

REAR DRIVING MECHANISM
Apply grease to the lips of a new dust seal (11 and
install it into the wheel hub 121 with the flat side facing in
until it is fully seated.
Apply molybdenum disulfide grease to the axle splines
13].
Do nol get grease
on the axle /hreads.

Install the wheel hub onto the left side of the axle.

- 13)

Do not tighten it yel. Install the hub nut loosely.

~
12)

Apply grease to the lips of a new dust seal [1 ].

Install the dust seal into the brake panel so that it is
flush with the brake panel.
Coal a new O-ring [21 with grease and install it into the
brake panel groove.
Do nol get grease
the brake shoe

Install the brake panel assembly onto the axle.

OIl

limngs.

Install four new nuts [1] and tighten them to the
specified torque.
TORQUE : 47 N'm (4.8 kgf'm, 35 IbUt)

Install the brake cables 121 into the cable holders on the
brake panel (upper holder for lever brake cable and
lower holder for pedal brake cable).
Install the cable springs [3] onto the cables . Connect
the brake cables to the brake arm with the joint pins {41
and adjusting nuts [5].
Connect the breather hose [6].
Whenever
removingbolhhub
nuts, firs/lighten
nght sKie, then
tighten the /eft side.

Install the rear brake drum (torque Ihe hub nut)
(page 18- 19).

Tighten the hub nut [11 to the specified torque and
further tighten untit its grooves align with the cotter pin
hole.

' -----::::::0

I

TORQUE: 137 N'm (14.0 kgf'm , 101 IbHt)

Install a new cotter pin 12].
Inslall the left rear wheel (page 17-6).
Fill the gear case with Ihe recommended oil
(page 3-17).

....

12) ~

20-25

MEMO

21. BATTERY/CHARGING SYSTEM

COMPONENT LOCATION ··························21-2

CHARGING SYSTEM INSPECTION ··········21-9

SYSTEM DIAGRAM ····································21-2

ALTERNATOR CHARGING COIL ············ 21-10

SERVICE INFORMATION ···························21-4

REGULATOR/RECTIFIER ........................ 21·10

TROUBLESHOOTING·································21-6

POWER RELAY (Canada type) ···············21·11

BATTERY ····················································21-8

21-1

BATTERY/CHARGING SYSTEM

COMPONENT LOCATION
FUSE BOX:
- FMfFPM: MAINFUSE (30 A )
- FElFPE: MAIN FUSE 1 (30 A )

BATIERY

PO.,ERRELA Y
(Canada type )

PCMIECM

RECTIFIER

I I
(Canada type )

SYSTEM DIAGRAM
U.S.A. type :

FMfFPM : MAIN FUSE (30A)
FElFPE : MAIN FUSE 1 (30A)
RlBI ----Q....../"O RlBI

ALTERNATOR

REGULATOR/RECTIFIER

21-2

BATTERY

BATTERY/CHARGING SYSTEM
Canada type:
PCMIECM

POWER RELAY

POWER RELAY

--0 ( " " 0 -

WIBIBIIR

R W/BI

BIIR RlBI

R W/BI BIIR RlBI

I

BIIR

---<:r-.....O-

BI]

IGN FUSE (lOA)

R~~al
~ R

[EJ
RECTIF IER

IGNITION
SWITCH

RlBI ~

RlB I
8 1: Black

G Green

~

rrrI

R: Red
Y: Yellow
W:Wh ite

FMlFPM, MAIN FUSE (30A)
FE/FPE ' MAIN FUSE 1 (30A)

b

I

-

RlBI

--+-

R

J:1o:'- '

-~-n=t__

G

8

ALTERNATOR
REGULATOR/RE CTIFIER

BATIERY

21-3

BATTERY/CHARGING SYSTEM

SERVICE INFORMATION
GENERAL

AWARNING
The battery gives off explosive gases; keep sparks, flames and cigarettes away . Provide adequate ven tilation when
charging.
The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
- If electrolyte gets on your skin , flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
Electrolyte is poisonous.
- If swallowed . drink large quantities of water or milk and call your local Poison Control Center or a physician immediately .

NOTICE

I

Always tum OFF the ignition switch before disconnecting any electrical component.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
For extended storage , remove the battery, give it a full charge, and store it in a cool , dry space.
For a battery remaining in a stored vehicle, disconnect the negative battery cable from the battery.
The maintenance free battery must be replaced when it reaches the end of its service life.
The battery can be damaged if overcharged or undercharged . or if left to discharge for long period. These same conditions
contribu te to shortening the "life span" of the battery. Even under normal use, the performance of Ihe battery deteriorates after
2 - 3 years .
Battery voltage may recover after battery charging , but under heavy toad, the battery vol tage will drop quickly and eventually die
out. For this reason. the charging system is often suspected as the problem . Battery overcharge often results from problems in
the battery itself, which may appear to be an overcharging symptom . If one of the battery cells is shorted and battery voltage
does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level
goes down quickly.
Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight on for long periods of time without riding the vehicle.
The battery will self-discharge when the vehicle is not in use. For this reason , charge the battery every two weeks to prevent
sulfation from occurring.
When checking the charging system , always follow the steps in the troubleshooting (page 21-6).
For alternator removallinstallation, refer to Alternator/Starter Clutch section (page 13-6).
BATIERY CHARGING
Turn power ON/OFF at the charger, not at the battery terminal.
For battery charging, do not exceed the charging current and time speCified on the battery. Using excessive current or extending
the charging time may damage the battery.
Quick charging should only be done in an emergency; slow charging is preferred.
BATIERY TESTING
Refer to the instructions in the Operation Manual for Ihe recommended battery tester for details about battery testing. The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
Recommended battery t ester: Mic ro 404XL (U.S.A . only)

SPECIFICATIONS
Battery

Alternator

21-4

ITEM
Type
r----tapacily
Current leakage
Vol tage
Fully charged
(20°C/6S"F)
Needs charging
Charging
Normal
current
Quick
Capacity
Charging coil resistance (20· Cf6BOF)

,
-

t-

SPECIFICATIONS
GYZ16H
12V 16 Ah
0.62 mA max .
13.0 13.2 V
Below 12.4 V
1.6Ax5 10 h
8.0Ax1 .0h
0.416 kWI5,OOO rpm
0 .1 1.00

BATIERY/CHARGING SYSTEM
TOOLS
--..M"'
ot;;;
o,o;cy;;octehb""'
"' t"'te"'
''''"'a'''na"t'yz
= e', ------,''Chh.''ist
"'fui.' '''
batlery
= ch"a';;',g"eCC
, - -- Micro 404XL (U.S.A. only)

,

MC1012/2T (U.S.A. only)

21·5

BATTERY/CHARGING SYSTEM

TROUBLESHOOTING
BATIERY IS DAMAGED OR WEAK
1. Battery Test
Remove the battery (page 21-8).
Check the battery condition using Ihe recommended battery tester.
Recommended battery tester: Micro 404XL (U.S.A. only)

Is the battery in good condition?
YES

- GO TO STEP 2.

NO

- Faulty battery.

2. Current Leakage Test
tnstallthe battery (page 21-8).
Check the battery current leakage (page 21 -9).

Is the current leakage be/ow 0.62 mA ?
YES

- GO TO STEP 4.

NO

- GO TO STEP 3.

3. Current Leakage Test With Regulator/Rectifier Connector Disconnected
Disconnect the regulatorlrectifl8r connector and recheck the battery current leakage.

Is the current leakage below 0.62 mA ?
YES

- Faulty regulator/rectifier.

NO

- ' Shorted wire harness .
• Faulty ignition switch .

4. Alternator Charging Coli Inspection
Measure the alternator charging coil resistance (page 21 -10).
Standard : 0.1 -1.0

n (20°CI68°F)

Is the alternator charging coli resistance within the standard value?
YES

- GO TO STEP 5.

NO

- Faulty charging coil.

5. Charging Voltage Inspection
Measure and record the battery voltage using a digital multimeter (page 21-8).
Start the engine.
Measure the charging vol tage (page 21-9).
Compare the measurements to the results of the following calculation .
Standard : Measured BV < Measured CV < 15.5 V
• BV = Battery voltage (page 21-8)
• CV:: Charging voltage

Is the measured charging voltage within the standard voltage ?
YES

- Faulty battery.

NO

- Canada type: GO TO STEP 6.
U.S.A. type : GO TO STEP 7.

6. Power Relay In spection (Canada type)
Check the power relays and their circuits (page 21-11).

Are the relay and circuits normal?
YES
NO

21-6

- GO TO STEP 7.
Faulty power relay.
Loose or poor con tacts of related connector terminal.
Open or short circuit in related wire.
Faulty PCMJECM.

BATTERY/CHARGING SYSTEM
7. Regulator/Rectifier Wire Harness Inspection
Perform the regulator/rectifier wire harness inspection (page 21-10).

Are

the measurements correct?

YES

- Faulty regulator/rectifier.

NO

-

'

Open circuit in related wire.
loose or poor contacts of related terminal.
Shorted wire harness.

21-7

BATIERY/CHARGING SYSTEM

BATTERY
REMOVAUINSTALLATION
Remove the rear fender cover (page 2-9).

Tum the ignition switch OFF and disconnect the
negative (-) cable (1J first, then disconnect the positive
(+) cable (21 by removinglhe terminal bolts.
Remove the battery holder band (3].
Remove the battery [4) and battery rubber (51.
Installation is in the reverse order of removal.
NOTE

Connect the positive (+) cable first and then the

negative H cable.

VOLTAGE INSPECTION
Remove the rear fender cover (page 2-9).

Measure the battery voltage using a commercially
available digital multimeter.

VOLTAG E (20 ~C f6 8 ° F ) :

Fully charged: 13.0 - 13.2 V
Under charged: Below 12.4 V

BATIERY TESTING
Remove the battery (page 21-8).

Refer to the instructions that are appropriate to the
battery testing equipment available to you.

TOOL:

Battery tester

Micro 404XL (U.S.A. only)

BATIERY CHARGING (U .S.A. only)
Remove the battery (page 21-8).
Refer to the instructions that are appropriate to the
battery charging equipment available to you.

TOOL:
Christie battery charger MC 1012/2T (U .S.A. only)

21-8

BATTERY/C HARGING SYSTEM

CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Remove the rear fender cover (page 2-9).

Tum the ignition switch OFF and disconnect the
negative (-) cable [1) from the battery.

Connect the ammeter (+) probe [2] to the negative (-)
cable and the ammeter (-) probe [3] to the battery H
terminal (4].
Wi th the ignition switch turned OFF , check for current
leakage .
NOTE '

When measuring current using a lesler, set It to a
high range , and then bring the range down to an
appropriate level. Current now higher than the range
selected may blowout the fu se in the tester.
While measuring current, do not turn the ignition
switch ON . A sudden surge of current may blowout
the fuse In the tester.
SPECIFIED CURRENT LEAKAGE :
0.62 rnA maximum
If current leakage exceeds the specified value , a
shorted circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the current.

CHARGING VOLTAGE INSPECTION
NOTE :
• Be sure the battery is in good condition before
performing this test.

Remove the rear fender cover (page 2-9).
Warm up the engine to normal operating temperature.
Connect the multimeter between the battery positive (+)
and negatIVe (-) terminals.
NOTE:
To prevent a short, make absolutely certain which
are the positive (+) and negative (-) terminals or
cables.
Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tester or electrical components.

Restart the engine and turn the headlight on .
Measure the voltage on the multimeter when the engine
runs at 5,000 rpm.
Standard :
Measured BV < Measured CV < 15.5 V
• BV = Battery voltage (page 21-8)
• cv = Charging voltage

21-9

BATIERY/CHARGING SYSTEM

ALTERNATOR CHARGING COIL
INSPECTION
Remove the right side cover (page 24).
Disconnect the alternator 5P (Natural) connector (1] .
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

a (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 continui ty to ground.
For alternator stator replacement (page 13-6).

REGULATOR/RECTIFIER
REMOVAUINSTALLATION
Release the regulator/rectifier wire [1) from the wire

Canada type shown:

Remove the two mounting bolts (3] and regulatorl

(6) ~

band (2].

rectifier 14).

Disconnect the regulator/reclifier 3P (Gray) [5] and

[2J

[11

-:::::S;::;;11~~

[5[

-

(Black) 16] connectors.

Installation is in the reverse order of removal.

13J

[4J

WIRE HARNESS INSPECTION
Disconnect the regulator/rectifier 3P (Gray) [1] and , - - - - - - - - - - - - - - - - - - ,
(Black) [2) connectors (page 21.10).

Check the connectors for loose contacts or corroded
terminals.
Check the
connectors.

following

at the

wire

hamess

and ground.
There should be battery voltage at all times.

Ground Une (Black connector):
Check for continuity between the Green wire terminal
and ground.
There should be continuity at all times.

Charging Coil Line (Gray c onnector) :
Measure the resistance between the Yellow wire
terminals.

a (20°C/68- F)

Check for continuity between each Yellow wire terminal
and ground.
There should be no continuity.

21-10

Yellow

Yellow

[11

side

Battery Une (Black connector) :
Measure the voltage between the Red wire terminal

Standard : 0.1 - 1.0

Yellow

1Xi

}X~

Gcee"

Red

[2J

BATTERY/CHARGING SYSTEM

POWER RELAY (Canada type)
RELAY INSPECTION
Remove the rear tender cover (page 2-9).
Disconnect the power relay BP (Gray) connector [1J.
Remove the power relay [2J from the rear fender.

Connect an ohmmeter to the power relay side 8P
connector [1] terminals as shown.

I
r--S~~I;~~~~::::

Connection : C
A (Red/black)
(Red/black) -- B
(Red)
0 (Red)

111

Connect the 12 V battery (2] to the power relay side 8P
connector terminals as shown.
Connection : E (Black/red) - F (White/black)
G (BlaCk/red) - H (White/black)
There should be continuity wi th the battery connected
and no continuity with the battery disconnected.
If the test result is abnormal , replace the power relay.

CIRCUIT INSPECTION
Olsconnect the power relay 8P (Gray) connector (1) r - - (page 21-11).

Check the following al the wire harness side power
relay 8P (Gray) connector.
Charging Line (Battery side):

Redlblack
Rod

Red

Redlbfack

111

Measure the voltage between the Red/black wire
terminal (+) and ground (-),
There should be battery voltage at all times.

Charging LIne (Regulator/rectifier side):
Measure the voltage between the Red wire terminal (+)
and ground (- ).
There should be battery voltage al all times.

Whitelblack

Black/red

Black/red
White/black

Relay Coil Input Line :
Measure the voltage between the Black/red wire
terminal (+ ) and ground (-).
There should be battery voltage when the ignition
switch is turned ON.
Relay Coli Ground Une:
Check for continuity between the White/black wire
terminal and ground.
There should be continuity when the engine speed is
more than 100 rpm.

21-11

MEMO

f

22. LIGHTS/METERS/SWITCHES

COMPONENT LOCATION ···················.. ·····22-2

HANDLEBAR SWITCH ····························· 22 -11

SERVICE INFORMATION ······················ ·····22-3

FRONT BRAKE SWITCH ········· ················ 22 -12

ASSIST HEADLIGHT ·································· 22-4

REAR BRAKE LIGHT SWITCH· ·········· ····· 22-13

HEADLIGHT ········································· ·······22-5

GEAR POSITION SWITCH ....................... 22-14

BRAKEfTAILLIGHT ............................... ······ 22-6

COOLING FAN ·········································· 22-15

COMBINATION METER ······························22-6

4WD SELECT SWITCH ···························· 22-17

ACCESSORY SOCKET ···························· 22-10

FUEL GAUGE/FUEL LEVEL SENSOR .... 22-18

IGNITION SWITCH ····················· ····· ··········22-11

22·1

LIGHTS/METERS/SWITCHES

COMPONENT LOCATION

COMBINATION METER

FRONT BRAKE LIGHT SWITCH
FRONT BRAKE INHIBITOR SWITCH

REAR BRAKE LIGHT

SWITCH

SIDE)
IGNITION
SWITCH

HANDLEBAR SWITCH

GEAR pmilTl(]N SWITCH

WE;e+h
0000000

LIGHTS/METERS/SWITCHES
SPEEDOMETER
Speedometer does not operate
1. Combination Meter Power/Ground Line
Inspection

Check the odometer/trip meier and indicators
functions .

Do they function properly?
YES

- GO TO ST EP 2.

ND

- Check the combination
ground lines (page 22-7).

meter powerl

2. ESP System OTe Inspection
Check the ESP system OTe (page 23-11).

Is DTe 11-1 indicated?
YES

- Perform the DlC 11-1 troubleshooting
(page 23-14).

NO

- GO TO STEP 3.

3. Speedometer Line Open Circuit Inspection
Remove the left side cover (page 2-4).
Disconnect the VS sensor 3P (Black) connector [1].

Disconnect the combination meter 21 P connector
(page 22-6).
Check the continuity between the combination
meter 21P connector [1) and VS sensor connector
[2]lerminals.

Connection : Pink/green - Pink
Is there continuity?
YES
NO

- Replace the combination meter
(page 22-6).
Open circuit in the Pink/green or Pink
wire.
Loose or poorly connected related
connectors.

~----------=--------,
[2[

[1 1

0000000
000 000
OO( 000

Pink/green

Q

Pink

22-9

LIGHTS/METERS/SWITCHES

ACCESSORY SOCKET
INSPECTION
Remove the accessory sockel2P (Black) connector (1)
from the frame and disconnect it.
Measure the voltage between the While/black (+) and

Green (-) wire terminals of the wire harness side
connector.
There should be battery vollage with the ignition switch
turned ON .
If there is no voltage, check for brown ACe fuse (10 A)
and an open cirruil in the wire harness.

Remove the accessory socket cap [1].

Check for continuity between the White/black wire
terminal of the socket side 2P connector and bottom
center terminal 121 of the sockel, and between the
Green wire terminal and side wall terminal [3).
There should be continuity.

If there is no continuity, replace the accessory socket
(page 22-10).

REPLACEMENT
Remove the left fuel tank side cover (page 2-5).
Disconnect the accessory sub harness 2P (Black)
connector (1) from the accessory socket (2).
Remove the nut (3) and inner spacer [4]. accessory
socket, outer spacer [5).
Assemble the outer spacer and a new accessory socket
by aligning the groove with the lug, and place them into
the fender.
Install the inner spacer while aligning the holes with the
outer spacer bosses.
Install the nut and tighten it securely.
Connect the
connector.

accessory

sub

harness

2P

(Black)

Install the left fuel tank side cover (page 2-5).

tftJ'~

141

22-10

131

[11

LIGHTS/METERS/SWITCH ES

IGNITION SWITCH
INSPECTION
Remove the front fender/carrier (page 2-8).
Remove the ignition switch 4P connector (1] from the
frame and disconnect it.
Check for continuity between the switch side connector

terminals in each switch position.
Continui ty should exist between the color coded wires
as follows:

~

Position
ON

RIBI

P

0- r-o

R

BI

0--0

OFF

REPLACEMENT
Disconnect the ignition switch 4P connector
(page 22-11).
Remove the meter cover (page 22-6),

Release the ignition switch wire from the wire band ,
wire dips and wire guides.
Remove the ignition switch [lJ from the meter cover by
pushing in the two stoppers (21 .
Install a new ignition switch by aligning the locating tab

PI with the covef groove.

Install the removed parts in the reverse order of

removal.

HANDLEBAR SWITCH
INSPECTION
Remove the front fender/carrier (page 2-8),

Remove the handlebar switch connector [1) from the
frame and disconnect it.
-

FMlFPM : 10P (Green)
FElFPE: 14P (Green)

111

22-11

LIGHTS/METERS /SWITCHES
For gearshift
swl/ch inspectIOn

(page 23-29)

Che ck for continuity between the switch side connector
term; nals in each switch position.
Conti nuity should eXist between the color coded wires
hown below:

FEJFPE shown:

."

lIG HTING

""

SWITCH (1]/OIMMER SWITCH [2]

Color

Color

B,

BlIBr

w

Position

Posilion

•
-IT-

liD
(N)

','

~D

ENG INE

""

STOP SWITCH (3)/STARTER SWITCH 14]

Color

BUR

BIIW

Position

Color

BlfIIV

Y /R

Position

FREE
PUSH

FRONT BRA KE SWITCH
INS PECTION
NOT E,
The mhlbltor sWItch
WIre has gl1iY tape
{1}.

.

The lower switch is the brake fight switch and the , - - -- -- u pper switch is the inhibitor switch.

Dis connect the brake light switch connectors (21 and the
inhibilor swi tch connectors (3).
Che ck for continuity between the switch terminals .
There should be continuity with the fron t brake lever
and no continuity with the lever released .

squeszed

22-12

BulBI

LIGHTS/METERS/SWITCHES
REPLACEMENT
Disconnect the brake light swit ch connectors III and the
inhibitor switch connectors [2) from the switches.
Remove the dust cover [3] from the switches.

Squeeze the front brake lever and secure it.
Remove the screw [1 ], brake light switch (2J, inhibitor
switch [3) and spacer [4] from the master cylinder.
Apply locking agent to the screw threads,
Install the switches and spacer by aligning the switch
cutout with the lug of the master cylinder and spacer.
Install and lighten the screw to the specified torque.
TORQUE : 1.2 N'm (0.1 kgfm, O.9Ibf-ft)
Install the dust cover onto the switches properly.
Connect the connectors to the switches.

REAR BRAKE LIGHT SWITCH
LEVER SWITCH INSPECTION
Remove the dust cover [1) from the brake light switch.
Disconnect the rear brake lever switch connectors [2)
and check for continuity between the switch terminals.
There should be continuity with the rear brake lever
squeezed and no continuity with the lever released .

LEVER SWITCH REPLACEMENT
Remove the dust cover [1] from the brake light switch

121·

Disconnect the rear brake lever switch connectors [3].
Remove the screw [4) and switch from the brake lever
bracket.

Apply locking agent to the screw threads.
Install the switch by aligning the switch cutout with the
lug of the brake lever bracket.
Install and tighten the screw to the speCified torque.
TORQUE: 1.2 N'm (0.1 kgf'm , 0.9IbHt)
Connect the connectors to the switch.
Instalilhe dust cover onto the switch proper1y.

22-13

LIGHTS/METERS/SWITCHES
PEDAL SWITCH INSPECTION
Remove the right side cover (page 2-4).
Disconnect the rear brake pedal switch 2P connector

!11 and check for continuity between the switch side
connector terminals.
There should be continuity with the rBar brake pedal
depressed and no continuity with the pedal released.

GEAR POSITION SWITCH
INSPECTION
Remove the right side cover (page 2-4).
Remove the gear position switch BP connector [1] from
the frame and disconnect it.

Check for continuity at the switch side connector
terminals.
gearshift switches, There should be continuity in each gear position as
use the gear follows:
change tool

If the tranSlntsslO/1
wJii not shift with tho

included with the
tool kit (FElFPE
models),

Gear position

Connection

Reverse

Gray - ground

1s t

White/green - ground
White/red - ground
Blue - ground
Yellow - ground
Light bluelwhite - ground

~N"e::""I="~I~~~~~~!~L",I!!c9~hl:,9~,.::.=.fjnjf:.:,::e:.:d",---::9;;'-o:=-~"-:-:n:::d~----1
2nd
3rd
4th
5th

REPLACEMENT
Remove the rear crankcase cover (page 13-6).
Remove the two wire clamp bolts 111.
Remove the wire grommet (21 from the rear crankcase
cover.
Remove the retaining bolt (31 and gear position switch
[4] from the rear crankcase cover.
Apply locking agent to all the bolt threads.
Install a new gear position switch onto the rear
crankcase cover and tighten the retaining bolt.
Apply liquid sealant to the grommet seating surface.
Route the wire as shown and install the grommet into
the crankcase cover groove properly.
Install the two clamp bolts and tighten them to the
specified torque.

111 0 , .
[4)

o

.,(1lW 121

TORQUE : 12 N·m (1.2 kgf·m, 9lbHt)
Install the rear crankcase cover (page 13-9).

22-14

I

I

LIGHTS/METERS/SWITCHES

COOLING FAN
Cooling fan does not start

1. Fuse Inspection
Check the FAN fuse (15 A).

Is the (use blown?
YES

- Replace the FAN fuse.

NO

- GO TO STEP 2.

2. PGM·FI System OTC Inspection
Check the PGM-FI system OTe (page 4-11).

Is OTe 7·1 and/or 7·2 indicated?

YES

-

Perform the DTG 7-1 troubleshooting
(page 4-16).
Perform the DTG 7·2 troubleshooting
(page 4-17),

NO

- GO TO STEP 3.

3. Ground Line Inspection

Remove the rear fender cover.
Disconnect the PCM/ECM 5P (Black) connector [1}.

Check for continuity between the PCM/ECM SP
(Black) connector 11J terminal and ground .

~====

111

Connection : Green - ground
Is there continuity?
YES

- GO TO STEP 4.

NO

- Open circuit in the Green wire.

Green

L-=-

22·15

LIGHTS/METERS/SWITCHES
4. Cooling Fan Operation Inspection

Connect the PCMlECM 5P (Black) connector [1]

111

terminals with jumper wire (2].

Connection: Greenfblack - green

Green/black

Check the cooling fan when connecting the jumper
wire.

121

Does the cooling fan start?
YES

- Replace the PCMlECM with a known good

one, and recheck.
NO

- GO TO STEP 5.
Green

5. Cooling Fan Ground Line Inspection
Remove the fron t fender/carrier (page 2-8).

Remove the cooling fan 2P connector [1] from the
frame and disconnect it.

With the jumper wire connected to the PCM/ECM
5P connector, check for continuity between the fan
motor 2P connector (2] terminal and ground.
Connection : Green/black - ground

Greenlblack

Is there continuity?
YES

- GO TO STEP 6.

NO

- Open circuil in the Green/black wire.

6. Cooling Fan Powe r Input line Inspection
Measure the voltage between the fan motor 2P 111
terminal (+ ) and ground (_).
Is there battery voltage?
YES

- Replace the cooling fan with a new one

(page 8-9).
NO

- Open circuit in the Blue wire between the
cooling fan and fuse box.

22·16

PI

Blue

111

LIGHTS/METERS/SWITCHES

4WD SELECT SWITCH
SYSTEM INSPECTION
Release the wire grommet from the guide of the gear
case and disconnecllhe 4WD select switch connector

11].
Ground the switch connector terminal with a jumper
wire (2].

Turn the ignition switch ON and check the 4WD
indicator.
The indicator should light when the connector terminal
is grounded .
The indicator should not light when the jumper wire is
removed.
FPMlFPE models:

FMlFE models:

If the 4WD indicator 13J operation is abnormal , check
the 8rawnfwhite wire between the 4WD select switch
and EPS ECU, and the Bluelwhite wire between the
EPS ECU and combination meter.
If the 4WD indicator operation is abnormal, check the
Blue/white wire between the 4WD select switch and
combination meier.

FPMfFPE shown:

13]

R N

SWITCH INSPECTION
Disconnect the select switch connector [1].
Check for continuity between the switch terminal [21 and
ground.
There should be continuity when the 2WD/4WD select
lever is 4WD position, and no continuity when the lever
is 2WD position.

REPLACEMENT
Disconnect the select switch connector [1] .
Remove the 4WD select switch [2) and sealing washer

131·
Install the 4WO select switch with a new seating washer
and tighten it.
TORQUE: 12 N·m (1.2 kgfm , 9lbHt)
Connect the switch connector and install its wire
(grommet [4]) in the wire guide.

22-17

LIGHTS/METERS/SWITCHES

FUEL GAUGE/FUEL LEVEL SENSOR
REMOVAL/INSTALLATION
Remove the fuel tank cover (page 2-5).
Disconnect the fuel level sensor 2P (Red) connector [1].

Release the sensor wire [1] out of the sensor cover 12].
Be careful not to
deform the noat

Remove the three bolts (3). fuel level sensor [4] and 0ring [51 from the fuel tank.

,~

Install a new O-ring (1] onto the fuel tank .

Install the fuel level sensor [2] into the fuel lank while
aligning the groove [3] with the boss (4] on the fuel tank .
Install and tighten the bolts to the specified torque.
TORQUE : 9.0 N'm (0.9 kgf'm , 6.6 Ibf-ft)

Install the removed parts in the reverse order of
removal.

22-18

1

LIGHTS/METERS/SWITCH ES
SYSTEM INSPECTION
Check that the speedometer and indicators funct ion
properly.
If they do not function , check the power/ground line
(page 22-7).
If they function, check as follows:
Remove the fuel level sensor 2P (Red) connector
(page 22-18).
Turn the ignition switch ON and check the fuel gauge.
All segments [1] should blink.

(x) (j) (0)

Turn the ignition switch OFF .
Connect the meter side connector terminals with a
jumper wire.
Turn the ignition switch ON and check the fuel gauge.
AI! segments should blink.
If the fuel gauge does not function properly, replace the
combination meter (page 22-6).
Turn the ignition switch OFF.

Remove the fuellevei sensor (page 22-18).

I']

Connect the fuel level sensor 2P (Red) connector.

With the fuel level sensor float [1[ at the top (FULL)
position (2), turn the ignition switch ON and check the
fuel gauge.

All segments up to segment "F" [1[ should come on.
Turn Ihe ignition switch OFF.

P

Move the float to the bottom (RESERVE) pOSition , turn
the ignition swilch ON and check the fuel gauge .

(x) (~/i)

111

/

L
~==~---======~----­

Segment "E" [1] and low fuel indicator [2] should blink.
If the fuel gauge does not function properly, check the
fuel level sensor (page 22-20).
If the fuel level sensor is OK, replace the combination
meter.
Ir all segments blink during inspection, replace the
combination meter.
Turn the ignition switch OFF.
Inslall the fuel level sensor (page 22-18).

1
II
LI

.

*
11]

22-19

LIGHTS/METERS/SWITCHES
FUEL LEVEL SENSOR INSPECTION
Remove the fuel level sensor (page 22-18),
Measure the fuel level sensor resistance with the float
[1] at the lop (FULL) [2) and bollom (RESERVE) [3J
positions.

Connection : Green/yellow - Yellow/white

pF'[L~O~A~T~P~O~S~IT~I02iN"==,R"E,,S",ISS'T~ANCE (20·C/6S0F)
TOP WULl)
11-130
cB"O"TT
-=
O"
M,-,("
R"
ES
",E,"R~V~E~)~_ _ 204 - 210 0

22-20

1')

[2[

23. ELECTRIC SHIFT PROGRAM (ESP: FElFPE models)

ESP COMPONENT LOCATlON·············· ····23 -2

ESP OTC INDEX ······································· 23-13

ESP SYSTEM DIAGRAM ····························23-3

OTC TROUBLESHOOTING ......... ............. 23-14

SERVICE INFORMATION ·············· ············· 23-4

VS SENSOR .............................................. 23 -27

BEFORE TROUBLESHOOTING ·················23-5

SHIFT ANGLE SENSOR ·········· ················· 23-27

SYMPTOM TROUBLESHOOTING ············· 23-5

GEARSHIFT SWITCH ............................... 23-29

ESP CONNECTOR LOCATION ·················· 23-7

SHIFT CONTROL MOTORIREDUCTION
GEARS ...................................................... 23-30

ESP TROUBLESHOOTING
INFORMATION ··········································23-10

23-1

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)

ESP COMPONENT LOCATION

UPSHIFT SWITCH

DOWNSHIFT SWITCH
GEAR POSITION
INDICATOR

FUSE BOX:
- MAIN FUSE 1 (30 A)
- MAIN FUSE 2 (30 A)
- IGN FUSE (10 A)

BATTERY

SENSOR UNIT:
- MAP SENSOR
- TP SENSOR

SHIFT CONTROL MOTOR

VS SENSOR
SHIFT

23-2

GEAR POSITION SWITCH
SENSOR

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)

ESP SYSTEM DIAGRAM

IGNITION
SWITCH

ION FUSE
(lOA)

,- -§-.--B- .. ---,--+------,

ENGIN E STOP SWITCH

",w-B-Il<"

~~ .w _ - - - - - l
~N

Bl

~

______________________________

_!

~~~ONTROl
E=~::::~'l'~~~= : =====rrf.1\
~ Ei'IW

PC~

c·,

"'-\
A-l,

"'·Zl

"'_II

5 -1

8-11
11-12

B·n

Ge&r~""''''''oc

BI: Black

Sl'IIuo
O~~
~

R. R!!d

W:WMo

Lg Wtllf'H'" y. y..."..

I>P(BlKt.I CONNECTOR

331' (SI»)CONNECTOR

J3f'

(Gr~YI

CONNECTOR

23-3

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)

SERVICE INFORMATION
GENERAL
Refer to "Before Troubleshooting" first and begin the troubleshooting (page 23-5).

When performing the DlC troubleshooting, read "ESP Troubleshooting Information" carefully , and Inspect and troubleshoot
according to the DTG. Observe each step of the procedures one by one. Note the DIG and probable faulty part before starting
diagnosis and troubleshooting.
The PCM may be damaged jf dropped. Also, if Ihe connector is disconnected when current is flowing. the excessive voltage may
damage the PCM . Always turn off the ignition switch before disconnecting or connecting the connectors.
Use a digital lester for ESP system inspection.

For ESP Troubleshooting
The PCM con trols the PGM-Ft and ESP systems. Therefore some detection items are shared by the PGM-FI and ESP and they
may affect the operation of both systems.
Before starling any troubleshooting . check the items as follows and refer to the appropriate troubleshooting .
1. MIL blinks or DTC forthe PGM-FI system (page 4-10).
2. Gear position indicator blinks or DTC for the ESP (page 23-10).
3. Symptom of the ESP opera tion (page 23-5).
Refer to PGM-FI System section for "General Troubleshooting" information (page 4-10),

TORQUE VALUE
ITEM
Shift angle sensor bolt

~Q-'T-y--Ti
THREAO

_ +_.,----+- "
OIA.
' (mm)

2

5

TORQUE

REMARKS

N'm (kgf·m. IbHt

6.0 (0.6. 4 .4)

Apply locking agent to
the threads.

TOOLS
SCS service connector
070PZ-ZY30100

23-4

Test probe
07ZAJ-RDJA 11 0

------wHirD"'S~pocket lester

TDS 3557-0112-01 (U .S.A. Only)

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)

BEFORE TROUBLESHOOTING
NOTE:
If the ATV has any ESP trouble, the gear position indicator brinks to indicate Ihe DTC (Diagnostic Trouble Code) (page 23-10).
Check the DTC and refer to the OTG index and begin the appropriate troubleshooting procedure (page 23-13),
If there are no DTG stored in the PCM memory, do the troubleshooting as "Symptom Troubleshooting" (page 23-5).

VERIFY THE COMPLAINT
Check the accuracy of the customer complaint by lest riding the A TV.
Note the symptoms.
Do not begin disassembly or testing untll you have determined if the problem is electrical or mechanical by shifting the gear
manually (page 23-6).
Temporarily failures can occur. Under certain conditions, the ESP system can "miss a shift." When this happens, the PCM may
record a DTC. Be sure to note and erase any stored OTC(s) when verifying the customer's complaint. If the customer's
complaint is duplicated during the test-ride , and the blinking gear position indicator displays a OTC. proceed with
troubleshooting.

PRELIMINARY ESP SYSTEM INSPECTION
Inspect the following before diagnosing the system .
-

Make sure the battery is fully charged and in good condition (page 21-8)
Make sure the clutch is adjusted properly (page 3-24)
Check the main fuse 1 (30A), main fuse 2 (30A) and IGN fuse (10A) for blown

SYMPTOM TROUBLESHOOTING
Diag nosis
Toroubleshoot the "Electric
Shift Does Not Operate"
(page 23-6)
Gear position indicator blinks
Inspect the serial
~";-~
" _c~o~n~s~ta~n~tI~Y~(N~O~D~T~C~se~tL
) -+~communication line (page 22-7)
Gear position indicator is no
Inspect the OLC circuit
(page 4-29)
indication and MIL stays on .
but no OIC is set
Sympto m
Shift control failure but no
OlC set

Also check for
clutch adjustment (page 3-24 )

Short circuit in the OlC rela ted wire

23-5

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
ELECTRIC SHIFT DOES NOT
OPERATE
1. Shifting Operation Check
OTe 23·1 will
be Ind,ca fed
with /he igmtlOfl
SWitch lumed

ON.

Remove the left side cover (page 2-4).
Turn the ignition swi tch OFF.

Manually shift the transmission by ro tating the
gearshift spindle [11 with the emergency gear
change 100112].
Can the gears be changed manually?
YES

- GO TO STEP 2.

NO

- Check the gearshift linkage (page 12·19)

Dow"

and the transmission (page 14-8).

2. Gearshift Switch Inspection at PCM Connector
Disconnect the PCM 33P (Black.) connector [1\.
Check for continuity between the wire harness side
PCM 33P (Black) connector terminals while pushing

the gearshift sWitch.
TOOL:
Test probe

[1[

A5

07ZAJ·RDJA 110

Connection :
With the upshift switch pushed :
A3 - A6
With the downshift s witch pushed :

A3 - A5

A6

Is there c ontinuity?
YES

- Loose or poor contact of the PCM 33P ' - - - - - - - - - (Black) connector.

NO

- GO TO STEP 3.

3. Gearshift Switch Inspection
Check the gearshift switch (page 23-29).
Is the gearshift switch normal?

23-6

YES

_ . Open circuit in the following wire
between the handlebar switch 14P
(Green) connector and PCM 33P
(Black) connector.
- While/red or WhiteJblue
- White/red or White/yellow

NO

- Faulty gearshift switch.

A3

ELECTRIC SHIFT PROGRAM (ESP: FEIFPE models)

ESP CONNECTOR LOCATION
NOTE 1: Remove the front fender/carrier (page 2-8).

I:[:D~ (Switch side connector)

HANDLEBAR SWITCH 14P (Green)

CONNECTOR (NOTE 1)
NOTE 2: Remove the right mudguard (page 2-6).

SHIFT CONTROL MOTOR 2P (Black) CONNECTOR
(NOTE 2)

23-7

ELECTRIC SHIFT PROGRAM (ESP: FElFPE models)
NOTE 1: Remove the right side cover (page 24).
ENGINE SUB-WIRE HARNESS 6P (Black) CONNECTOR
(NOTE 1)

(Switch side connector)

GEAR POSITION SWITCH 8P (Grav) CONNECTOR
(NOTE 1)
NOTE 2: Remove the left side cover (page 24).
NOTE 3: Remove the left mudguard (page 2-6).

{D }

VS SENSOR 3P (Black) CONNECTOR
(NOTE 2)

23·8

SHIFT ANGLE SENSOR 3P (Gray) CONNECTOR
(NOTE 3)

,I

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
NOTE 1: Remove the rear fender cover (page 2·9).

B33

B23

PCM 33P (Gray) CONNECTOR
(NOTE 1)

A33

A23

PCM 33P (Black) CONNECTOR
(NOTE 1)

C3

C1

C5

C4

P9:

PCM 5P (Black) CONNECTOR
(NOTE 1)

l
NOTE 2: Remove the seal (page 2-4).

DLC (NOTE 2)

23-9

ELECTRIC SHIFT PROGRAM (ES-:P_:F-:E;..'::FP-:E-::::-m:-,O-:d-:el::S,-:):-:-:_ _ _ _ _ _ _ _ _ _ __

ESP TROUBLESHOOTING INFORMATION
• Refer to PGM-FI System section for "General Troubleshooting" information (page 4-10).

SYSTEM DESCRIPTION
SELF·DIAGNOSIS SYSTEM

The PCM controls the PGM-Ft and ESP systems. Therefore some detection
items are shared by the PGM-FI and ESP and they may affect the operation
of both systems.

[11

\

The ESP system is equipped with the self·diagnostic system. If the PCM
detects an ESP failure. it stops the sys tem function and turns on the gear
position indicator (1] blinking In failed gear position to indicate the DlG, and
stores a DTG in ils erasable memory for the relevant system failure .
To reset the ESP system, turn the ignition switch from ON to OFF and back
to ON again. However, if the PCM still detects a problem, It will continue to
stop the ESP system function When this occurs, the gear position indicator
will blink a certain number of times to indicate the oTC.
To indicate the oTC , the gear position indicator blinks
kind of trouble

~-~;

depending on the

DTC (Diagnostic Trouble Code)

,\R) (N)

,-,'-, --,
(~

(I) (J',) ~

-

1...... 1

I'"J
000

- il
I!!!I

101.

"

WltE

=-u

\U /

\

I

Refer to PGM-fl System section for oTe information (page 4-10).
INDICATOR BUNKING PATIERN
The number of indicator blinks IS the equivalent of the main code of the OTC (the sub code cannot be displayed by the indicator
blinking).
The indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for
0.3 seconds. One long blink is the equivalent of ten short blinks. For example, when two long blinks are followed by Ihree short
blinks, Ihe OTG is 23 (two long blink = 20 blinks, plus three short blinks).

GEAR

',,\

ON

0.5 sec.

0.3 sec.

-

POSITION
INDICATOR OFF _ _..J
One Blink

-

0 _ _ __

Pattern
repeated

_

Long Blinking

Short Blinking

2 limes

3 times
OTC 23

When the PCM stores more than one o TC, the indicator displays in the order from the lowest number to highest number.
CURRENT DTCf$TORED DTe
The OTC is indicated in two ways according 10 the failure status.
If the PCM detects the problem at present, the gear position Indicator will blink at all times. It is possible to readout th e indicator
blink pattern as the curre nt OTC.
If the PCM does not detect any problem at present but has a problem stored in its memory. the indicator will not blink. If it is
necessary to retrieve the past problem , readout the stored OTC by following the OTC readout procedure.

I

j
23-10

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
HDS POCKET TESTER INFORMATION
• The HOS can readout the OTe , stored data, current data and other peM condition.

How to connect the HDS Pocket Tester
Turn the Ignition sWitch OFF .
Remove the seat (page 2-4).
Remove the OLe 111 from the dummy connector 12].
Connect the HOS pocket tester to the Ole .
Turn the ignition switch ON and engine stop sWitch ·0", check the OlG and
stored data.
NOTE '
• Stored data indicates the engine and ESP conditions when the first
malfunction was detected.
PCM reset
The HOS can reset the peM data including the OTG. stored data and some L -_ _ _ _ _---'[1[
learning memory.

DTC READOUT
NOTE
If the MIL blinks, refer to "PGM-FI Troubleshooting Information" and troubleshoot the PGM-FI system first. Then recheck the
ESP after erasing the PGM-FI OTC.
After performing diagnostic troubleshooting, erase the problem OTC(s) (page 23-12) and test -ride the vehicl e to be sure that the
problem(s) have been removed.
Connect the HOS pocket tester to the OLC (page 23-11 ).
Read the DTC , stored data and follow the troubleshooting index (page 23-13).
To read the OTC without the HOS pocket tester, refer to the following procedure.
Reading DTe with the gear position indicator
Turn the ignition switch ON and engine stop switch ·0·, read and note the rl-:[1~[---------­
gear poSition indicator {II blinks "- ".
The number of blinks Indicates the current OTC.
Refer to the troubleshooting Index (page 23-13).

['(R) (N)

1"'-- J
000

When retrieving the stored OTC , refer to the following procedures

1. Remove the OLC from the dummy connector (page 23-11 ).

[11

(ps) (X)

(41~)

1--1

rl -=F
il

LI,=,

I!!!I

2 . .·

LE

[2[

1

2. Short the OLC [1) terminals using the special tool.
TOOL:
[2] SCS service connector

070PZ-ZY30100

Connection : Brown/red - Green
3. Turn the ignition switch ON and engine slop SWitch "0". read and note
the gear position indicator blinks.
The number of blinks indicates the stored OTG.
Refer to the troubleshooting index (page 23-13).

23-11

ELECTRIC SHIFT PROGRAM (ESP : FE/FPE models)
ERASING DTC
NOTE '
• When erasIng the ESP OTe as follows, the PGM-FI oTe would also be erased at the same time, check the MIL blinks and
troubleshoot the PGM-Ft system before readout/erasing the ESP oTC.
Connect the HOS pockellester to Ihe OLe (page 23-11).
Erase the OTC with the HOS while the engine is stopped.

To erase the OTC without HOS, refer to Ihe following procedure.

How to erase the oTC without HOS
1. Remove Ihe OLe from the dummy connector (page 23-11).

(1(

(2J

2. Short the OLe [1] terminals using the special tool.

TOOL:
[2) SCS service connector

070PZ·ZY30100

Connection: Brown/red - Green
3. Tum the ignition switch ON and engine stop switch "0 ".
4. Remove the special tool from Ihe OLe.
5. The indicator will light for approximately 5 seconds. While the indicator
tights, short the OLC terminals again with the special tool. The self·
diagnostic memory is erased if the malfunction indicator goes off and
starts blinking.
NOTE:
The OLC must be shorted while the indicator lights. If not, the indicator will not start blinkIng .
• Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the indicator starts blinking.

CIRCUIT INSPECTION
INSPECTION AT PCM CONNECTOR
Always dean around and keep any foreign material away from the PCM
connector before disconnecting it.
A faulty ESP system is often related to poorly connected or corroded
connections. Check those connections before proceeding .
Do not pull the wire harness while disconnecting the PCM connectors.
In testing at PCM connector (wire harness side) terminal, always use the
test probe. Insert the test probe into the connector terminal, then attach
the digital multimeter probe to the test probe.
TOOL:
[1] Test probe

23-12

07ZAJ·ROJA 110

(1J

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)

ESP DTe INDEX
NOTE
When the gear position indicator"-" is blinking constanlly (and the Mil and coolant temperature indicator lights are dark). but no
DTG is indicated or retrievable, check the serial communication line (page 22-7).
There are some OTCs (21-1 Ihru 23-1) related to the shift angle sensor circuit that have different conditions of malfunction
detection. In case of the low voltage (about 0 V) or high voltage (about 5 V) in the shift angle sensor circuil, DIG 22-2 will be
Indicated when the control motor does not operate.

Ole

Function Failure

("-" blinks)

Refer

Symptom/Fail-safe function

to

--'---:--'Poor engine acceleration
Fail·safe value: O~
8-' (8)
4·18
ESP does not work
TP sensor circuil High voltage (more than 4.93 V)
Poor engine acceleration
8-2 (8)
• Loose or poor contact of the TP sensor connector
Fail-safe value: O·
4·19
• TP sensor or its circuil malfunction
_ __ _ _t--:-,;ESP does not work
VS sensor no Signal
Engine operates normally
ESP does not work
• loose or poor contact of the Rear VS sensor
23-14
11·1 (11 )
connector
• Rear VS sensor or its circuit malfunction
Shift angle sensor circuit low vol tage (less than T
ESP does not work
21·1 (21)
0.37 V)
23-15
• Shift angle sensor or its circuit malfunction
- -- - -- Shift angle sensor circuit High voltage (more than 4.62 V)
• ESP does not work
21.2 (21)
• loose or poor contact of the Sub-gearshift spindle
23-17
angle sensor connector
• Shift angle sensor or its circuil malfunction _cc-----:-,
----Shift angle sensor response (Control motor lock)
• ESP does not work
PCM activates the motor but the angle sensor voltage
22-1 (22)
23-18
does not change in middle position
Control motor or its circui t malfunction
Shift angle sensor or its circui t malfun~c~tio~nic;",_ _
----~--.Shift angle sensor response (Control motor stuck)
• ESP does not work
PCM does not activate the motor but angle sensor
22·2 (22)
23-18
voltage stays out of middle position (195 - 3.05 V)
• Control motor or its circuit malfunction
• Shift angle sensor or its cirCUit malfunction
Shift angle sensor response (VOltage variation)
- ESP does not work
• PCM does not activate the motor but angle sensor
voltage varies constantly
23·1 (23)
• Shift angle sensor installation problem
I 23-'9
Shift angle sensor or its circuit malfunction
• Control motor or its circuit malfunction
Shift control motor drive circuit
+ E SP does not wo,k
23-20
24-1 (24)
• Control motor or its circuit malfunction
• Control motor drive circuit malfunction
ESP does not work
Fail·safe relay circuit
23-21
32-' (32)
• Fail·safe relay circuit malfunction
4-25
33-2 ( )
_ _ _ __ _--j_,- Engine operates normally
EEPROM malfunction
Gear posiliOn switch circuit
Engine does not start
41 ·1 (41)
• Gear position switch cirCUit malfunction (Short)
ESP does not work
23·22
_ __ _--!_ :-iGear position indicator bhnks
" -"-_"--!_ _ _--1
Gear position switch circuit
ESP does not work
23-23
41·2 (41)
• Gear position switch circuit malfunction (Op~e~n~)_ ___l-"G~e~a~'_!:_o::sition indicator blinks "-"
Gearshift (UP/DOWN) switch circuil
ESP does not work
23-25
42·1 (42)
Gearshift (UP/DOWN) switch circuit malfunction
_ _ _ - '("'5....
hort)_ __ _ __
TP sensor circuit low voltage (less than 0.22 V)
• TP sensor or its circuit malfunction

r

t

---h

-r_

.
:-+

;;;;;.____-+_

j

t

23-13

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)

DTC TROUBLESHOOTING
NOTE :
Refer to "ESP Connector Location" for the connector

location and the necessary parts to disconnect the
connector (page 23-7),

After troubleshooting , erase the oTC and test-ride
the vehicle to be sure that the system is normal.

VERIFY PROPER CONNECTOR
CONTACT
Many ESP shifting problems and subsequent olCs are
caused by poor connector contacts. The first step in
troubleshooting any OTG is to inspect the affected

connectors.
CONNECTOR INSPECTION
Check for moisture in the affected connector
Check for corrosion

Check for folded pins on the male side of the
connector
Check for loose pins and/or pins pushed out of the
connector

DTC 11-1 (VS SENSOR NO SIGNAL)
NOTE '
Before starting the troubleshooting , check for loose or

poor contact of the following connectors, and recheck
the OTC (page 23-14 )
- VS sensor 3P (Black)
- engine sub-wire harness 6P (Black)
- PCM 33P (Black and Gray)
Make sure the battery is fuUy charged.
1. VS Sensor System Inspection
Erase the OTC (page 23- 12).
Test-ride the vehicle and check the VS sensor
signal with the HOS pocket tester.

Is the VS sensor signal indicated normally?
YES

-

' Intermittent failure.
• Loose or poor contact of the connector.

NO

- GO TO STEP 2.

2. VS Sensor Input Voltage Inspection
Tum the ignition switch OFF.
~isconnect the VS sensor 3P (Black) connector (11 .
Turn the ignition sWitch ON and engine stop switch

111

Blacklwhite

Green

~O" .

Measure the voltage between the wire harness side
VS sensor 3P (Black) connector terminals.
Connection : Blacklwhlte (+) - Green

H

Is the voltage more than 10 V?

23-14

YES

- GO TO STEP 3.

NO

- ' Open or short circui t In the Black/white
or Black/pink wire.
Open circuit in the Green wire.

,

1
I

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
3. VS Sensor Signal line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnecllhe peM 33P (Gray) connector [1).
Check for continuity between the wire harness side
VS sensor 3P (Black) connector [2J and peM 33P
(Gray) connector terminals .

121

Pink

816

PI

Connection : 816 - Pink

TOOL:

Test probe

07ZAJ·RDJA110

Is there continuity'?

YES

- GO TO STEP 4.

NO

- Open circuit in the Pink or Pink./green wire .

4. VS Sensor Signal line Short Circuit Inspection
Check for continuity between the wire harness side
VS sensor 3P (Black) connector [1] and ground.
Connection : Pink - Ground

PI

Pink

Is there continuity?
YES

- Short circuit in the pink or Pink/green wire .

NO

- GO TO STEP 5.

5. VS Sensor Inspection
Turn the ignition switch OF F.
Replace the VS sensor wi th a new one (page 23-27).
Erase the DTC (page 23-12).
Test-ride the vehicle and recheck the DTC .

Is the ore 11-1 indicated ?
YES

- Replace the PCM with a known good one
(page 4-34), and recheck.

NO

- Faulty original VS sensor.

DTC 21·1 (SHIFT ANGLE SENSOR
LOW VOLTAGE)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the DTC (page 23-14).
- shift angle sensor 3P (Gray)
- engine sub-wire harness 6P (Black)
- PCM 33P (Black)
1. Shift Angle Sensor System Inspection
Turn the ignition switch ON and engine stop switch

·0·.
Check the shift angle sensor with the HDS pocket
tester.

Is about 0 V (low voltage) indicated?
YES
NO

- GO TO STEP 2.
Intermittent failure.
• Loose or poor contact of the connector.

23-15

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
2. Shift Angle Sensor Resistance Inspection
Turn the ignition switch OFF.
Disconnect the shift angle sensor 3P (Gray)
connector.
Measure the resistance at the shift angle sensor
side connector [11 terminals.
Connection:
Standard :
Connection:
Standard:

A4A2-

111
B

C
6 kG (20°C/68°F)
B
3 kG (20°C/68°F)

Is the resistance within specification?
YES

- GO TO STEP 3.

NO

- Faulty shift angle sensor.

c

A

3. Shift Angle Sensor Input Voltage Inspection
Turn the ignition switch ON and engine stop switch , - - - - -- - - - - - -- -- - --

"0".

11)

Measure the voltage between the wire harness side
shift angle sensor 3P (Gray) connector (1) terminals.

Brown/white

Green/red

Connection : Brownfwhite (+) - Green/red (-)
Is the voltage within 4.75 - 5.25 V?
YES

- GO TO STEP 4.

NO

- Open circuit in Brown/whi te or Green/red
wire. If the wire is normal, faulty PCM.

ffiV

e

4. Shift Angle Sensor Output Line Open/short
Circuit Inspection
Turn the ignition switch OFF .
Disconnect the PCM 33P (Black) connector [1 ).
Check for continuity between the wire harness side

shift angle sensor 3P (Gray) connector [2] and peM

33P (Black) connector terminals.

Green/yellow

A14

IIf~:::;"i'~~~~~~?:;=;l

Connection: A14 - Green/yellow
TOOL:
Test probe

07ZAJ·RDJA110

There should be continuity.
Check for continuity between the wire harness side
shift angle sensor 3P (Gray) connector terminal and
ground.
Connection: Green/yellow - Ground
There should be no continuity.

Is there normal condition ?

23-16

YES

- Replace the peM wi th a known good one
(page 4-34). and recheck.

NO

- Open or short circuit in Green/yellow or
Green/blue wire.

[11

[21
[2)

Green/yellow

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
OTC 21·2 (SHIFT ANGLE SENSOR
HIGH VOLTAGE)
1. Shift Angle Sensor System In spection

Turn the ignition switch ON and engine slop switch
~O".

Check the shift angle sensor with the HDS pocket
tester.
Is about S V indicated?

YES

- GO TO STEP 2.

NO

- ' Intermittent failure.
• Loose or poor contact of Ihe connector.

2. Sh ift Angle Sensor Resistance Inspection

Turn the ignillon switch OFF .
Disconnect the shift angle sensor 3P (Gray)
connector (1).
Measure the resistance at the shift angle sensor
side connector (1) terminals.

Connection: A - C
Standard : 4 - 6 kO (20"e /68"F)
Connection : A - B

Standard : 2 - 3 kO (20°C/58"F)
Is the resis tance within specification ?
YES

- GO TO STEP 3.

NO

- Faulty shift angle sensor.

3. Shift Angle Sensor Input Voltage Inspection

L

Turn the ignition switch ON and engine stop switch I [lJ
"C)",

Measure the voltage between the wire harness side
shift angle sensor 3P (Gray) connector [1) terminals.
Connection : Brown/white (+)- Green/red (-)
/s

Brown/While

Green/red

the voltage within 4.75 - 5.25 V?

YES

- Replace the PCM with a known good one
(page 4-34). and recheck .

NO

- Open circuit in Brown/white or Greenlred
wire.

ffiV

e

23·17

ELECTRIC SHIFT PROGRAM (ESP: FEIFPE models)
OTC 22·1/22·2 (SHIFT ANGLE SENSOR
RESPONSE: CONTROL MOTOR LOCK!
STUCK)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and reelleck
the OTe (page 23-14).
- shift angle sensor 3P (Gray)
- engine sub-wire harness 6P (Black)
- peM 33P (Black)

1. Shift Angle Sensor System Inspection
Tum the ignition switch ON and engine slop switch
~O~.

Check the shift angle sensor with the HOS pocket
tester.

Is about Low voltage (about 0 V) or High voltag e
(about 5 V) Indicated?
YES

_. 0 V : Refer to OTe 21·1 (page 23- 15),
• 5 V: Refer to OTe 21-2 (page 23-17),

NO

- GO TO STEP 2 .

2. Sh ifting Operation Check
OTe 23·' will

be IndICated
with the ignition
sWitch turned

ON.

Remove the left side cover (page 2-4).
Tum the tgnltion switch OFF.

(2)

Manually shift the transmission by rotating the
gearshift spindle [lJ with the emergency gear
change tool [21.
Can the gears be changed manually?
YES

- GO TO STEP 3.

NO

- Check the gearshift linkage (page 12-19)
and the transmission (page 14-8).

3. Shift Angle
Inspection

Sensor

Operation

Dow"

Resistance

Disconnect the shift angle sensor 3P (Gray)
connector.
Measure the resistance at the shift angle sensor
side connector [1] terminals varies while shifting the
gear manually (page 23-27).
Connection: A - B

(1)

B

When shifti ng up :
Resistance increase
When shifti ng down: Resistance decreases
Does the resistance vary properly?
YES

- GO T O STEP 4 .

NO

- Faulty shift angle sensor.

A

4. Shift Angle Sensor Condition Check
Check. Ihe shift angle sensor for installation
condition or any damage (page 23-28).
Is the shift angle sensor installed properly and
in normal condition ?

23-18

YES

- GO TO STEP 5.

NO

- Inslall properly or replace
sensor.

the angle

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
5. Reduction Gear Condition Check
Check the reduction gears and control motor for
installation condition or any damage (page 23-30).

Are the reduction gears and control motor
ins talled properly and in normal condition?
YES

- Replace the PCM with a known good one
(page 4-34), and recheck.

NO

- Install properly or replace faulty part.

OTC 23-1 (SHIFT ANGLE SENSOR
RESPONSE: VOLTAGE VARIATION)
NOTE :
Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the DTe (page 23- 14 ).
- shift angle sensor 3P (Gray)
- engine sub-wire harness 6P (Black)
- PCM 33P (Black)
This code will be indicated when shifting the gear
manually while the ignition switch is turned ON.

1. Shift Angle Sensor System Inspection
Turn the ignition switch ON and engine stop switch
·0 ".
Check the shift angle sensor with the HDS pocket
tester.
Is about Low voltage (about 0 V) or High voltage
(about 5 V) indicated?

YES

_ . OV:RefertoDTC21-1 (page 23-15) .
• 5 V: Refer to OTC 21-2 (page 23-17)

NO

- GO TO STEP 2.

2. Shift Angle Sensor Condition Check
Check the shift angle sensor for looseness (page
23-28).
Is the shift angle sensor installed properly?

YES

- GO TO STEP 3.

NO

- Install properly or replace the shift angle
sensor.

3. Shift Angle
Inspection

Sensor

Operation

Resistance

Turn the ignition switch OFF.
Disconnect the shift angle sensor 3P (Gray)
connector.
Measure the resistance at the shift angle sensor
side connector [1) terminals varies while shifting the
gear manua lly (page 23-27).

When shifting up:
Resistance increase
When shifting down : Resistance decreases

YES

- Replace the PCM with a known good one
(page 4-34), and recheck.

NO

- Faulty shift angle sensor.

B

tV,

Connection : A - B

Does the resistance vary properly?

(11

Q

A

23-19

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
DTC 24-1 (SHIFT CONTROL MOTOR
DRIVE CIRCUIT)
NOTE
Before starting the troubleshooting, check for loose
or poor contact of the control motor 2P (Black) and
PCM 5P (Black) connectors, and recheck the DTe
(page 23-14).
1. PCM Motor Power Input Line Inspection
Turn the ignition switch OFF.
Disconnect the PCM 5P (Black) connector (1).
Measure the voltage between the wire harness side
peM 5P (Btack) connector terminal and ground.

I\,
[1]

-r""y-,
t~~~:J-1

Connection: C4 (+) - Ground (- )

Is there battery voltage '?
YES

- GO TO STEP 2.

NO

- ' Blown main fuse 2 (30 A).
Open circuit in the Redlwhite or Red
wire .

C4

2. PCM Motor Power Ground Line Inspection
Check for continuity between the wire harness side , - -- -- - - - - - - - - - - - - - - ,
PCM 5P (Black) connector [lJ terminal and ground.
[1]
Connection : C5 - Ground

Is there continuity'?
YES

- GO TO STEP 3.

NO

- Open circuit In the Green wire.

C5

3. Control Motor Line Open Circuit Inspection
Disconnect the control motor 2P (Black) connector

~~

Check for continuity between the wire harness side
control motor 2P (Black) connector and PCM 5P
(Black) connector 12jterminats.
Connection: C1 - Red
C2 - Green

r

~
C2

Is there continuity'?

YES
NO

23-20

- GO TO STEP 4.
Open circuit in the Red wire .
• Open circuit in the Green wire.

C1

111

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
4. Control Motor line Short Circuit Inspection
Check for continuity between the wire harness side
PCM 5P (Black) connector [1J terminals and ground.

[11

C2

C1

Connection : C1 - Ground
C2 - Ground
Is there continuity?
YES

_. Short circuit in the Green wire.
• Short circuit in the Red w ire .

NO

- GO TO STEP 5.

Q

5. Control Motor Inspection
Connect a fully charged 12 V battery [1] to the
control molor side 2P connector [2] terminals.

r-----------------~

Does the motor turn ?
YES

- GO TO STEP 6.

NO

- Faulty control moior.

[2[

111

6. Electric Shift Failure Checking
Connect the PCM SP (Black) and control moior 2P
(Black) connectors.
Erase the DTG (page 23-12),
Turn the ignition switch OFF.
Turn the ignition switch ON and engine stop switch

·0",
Recheck the gear shifting operation and oTC.

Is the DTC 24·1 indicated?
YES

- Replace the PCM with a known good one
(page 4-34), and rechec k. If the DTC
indicated again, replace the control motor
(page 23-30).

NO

- Intermittent failure.

OTC 32·1 (FAIL·SAFE RELAY CIRCUIT)
1. Recheck OTe
Erase the OTC (page 23-12) .
Turn the ignition switch OFF.
Turn the ignition switch ON and engine stop switch
~O~.

Recheck the DTC.

Is the DTC 32·1 indicated?
YES

- Replace the PCM with a known good one
(page 4-34), and recheck.

NO

- Intermittent failure.

23-21

ELECTRIC SHIFT PROG RAM (ESP: FE/FPE models)
DTC 41-1 (G EAR POSITION SWITCH
CIRCUIT: SH ORT)
NOTE :

. Before starting the troubleshooting, check for loose or
poor contact of the following connectors, and recheck
the DTe (page 23-14).
- gear position switch 8P (Gray)
- peM 5P (Bla ok)

1. Gear Positio n Switch Inspection with HOS
Check the gear position switch status with the HDS
data list menu

Is the gear p ositfon s tatus normal?
YES

- Intermitten! failure.

NO

o

GO TO STEP 2.

2. Gear Positio n Switch Inspection
Turn the igniti on switch OFF.

Disconnect th e gear position switch 8P (Gray)

connector.

pnt~~~:~) ~~~~~O/~~l fe~~in~~sSi~~~ ~~i~~

Check for co
switch side 8

ground.
There should be continuity in each gear position,
and should be NO continuity in the other position.

G~,~a~
o~~~i"I~~":V1~~~htl:'leenl

blue/,__

~ ~

.

Gear positi
Reverse

Neutral
Blue

1st
2nd
3,d
4th
5th

White/red

Is the gear p osition switch normal?
GO TO STEP 3.

YES

o

NO

- Fault y gear position switch.

,

I

1
23-22

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
3. Gear

Position

Switch

Inspection

at

PCM

Connector
Connect the gear position switch BP (Gray)
connector and disconnect the peM 33P (Black)
connector {1].
Cneck for continuity between the wire harness side
peM 33P (Black) connector terminals and ground.
There should be continuity in each gear position,
and should be NO continuity in the other position.
TOOL:
Test probe
07ZAJ·RDJA110

Gear position
Reverse
Neutral

Connection

A2

A17

[1 [

A12

••
A27

A26

A25

A24

A25 - Ground
A 17 - Ground

1st.-______-+~A2~4--~G~'o~u~n~dc_----------~

12nd

A27 - Ground

r'3~'~d,---______~~
A~2~6_- Ground
14th

~

A2 - Ground

____-LA
~12~-~G~m~U~n~d,:_~~~~~~~~~~~

Is the continuity normal condition?
YES

- GO TO STEP 4.

NO

- Open or short circuit in the wire harness
between Ihe peM and gear position
switch.

4. Recheck oTe
Connect the PCM 33P (Black) connector.
Erase the OTC (page 23~ 12).
Turn the ignition switch OFF .
Turn the ignition switch ON and engine stop switch
"0".
Shift the transmission into each gear and check the
DTC.

Is the OTC 41-1 indicated?
YES

- Replace the PCM with a known good one
(page 4-34). and recheck.

NO

- Intermittent failure.

DTC 41 -2 (GEAR POSITION SWITCH
CIRCUIT: OPEN)
NOTE :
Before starting the troubleshooting. check for loose or
poor contact of the following connectors, and recheck
Ihe DTC (page 23-14).
- gear position switch 8P (Gray)
- PCM 5P (Black)

1. Gear Position Switch Inspection with HDS
Check the gear position switch status with the HOS
data list menu.

Is the gear position s tatus normal?
YES

- Intermittent failure.

NO

- GO TO STEP 2.

23-23

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
2. Gear Position Switch Inspection
Turn the ignition swit ch OFF .
Disconnect the gear position switch 8P (Gray)
connector.
Check for continuit y between the gear position
switch side 8P (Gra y) connector [1] terminals and
ground .
There should be con tinuity in each gear position.

Light bluel
white

Connection

Gear position
Reverse

Gray - Ground

Neutral

light green/red - Ground

1st
2nd
3rd
14th

White/green - Ground

L

White/red - Ground
Blue - Ground
Yellow - Ground

Yellow

-

Blue

White/red

-------'

ILight blue/white - Ground

5th

Is there continuity ?

YES - GO TO STEP 3.
NO

- Faulty gear position switch.

3. Gear

Position
Connector

Switch

Inspection

at

PCM

Connect 'he gear position switch BP (Gray)
connector and disconnect the PCM 33P (Black)
connector (1).
Check for continuity between the wire harness side
peM 33P (Black) co nnector terminals and ground.
There should be con tinuily in each gear position .

TOOL:
Test probe

Neutral

.

-

Connection

A17 - Ground
2"5c--->Gc:cro,,u=
nd: ;-_ _ _
A24 - Ground
A27 - Ground
A26 - Ground

---!~
1

A2 - Ground

A12 - Ground

Is there continuity

,

YES

- GOTOST EP4 .

NO

- Open circu it in the wire harness between
the peM a nd gear position switch.

4. Recheck DTC
Connect the peM 33P (Black) connector.
Erase the DTC (pag e 23-12).
Test-ride the vehicle and check the OTC .

Is the DTe 41-2 indicated?

23-24

A12

•

07ZAJ-ROJA110

Gear position
Reverse
A

1st
2nd
3rd
4th
5th

A17

!1]

YES

- Replace Ihe PCM with a known good one
(page 4-34 ). and recheck.

NO

- Intermittent failure .

L

A27

A26

A25

A24

ELECTRIC SHIFT PROGRAM (ESP : FE/FPE models)
DTC 42 -1 (GEARSHIFT SWITCH
CIRCUIT)
NOTE
Before starting the troubleshooting , check for loose or
poor con tact of the following connectors , and recheck
the DTC (page 23-14).
- handlebar switch 14P (Green)
- PCM SP (Black)

1. Gearshift Switch Inspection
Check the gearshift switch status with Ihe HOS data

list menu .

UP

- - DOWN !

"Up" ON
" Down" ON
Both ON

3.64 - 4.08 V
, 1.76 - 2.09 V
' 4.0 4.99 V

Both OFF

I O_D .99V

I

~

1.76 - 2.09 V
--3.64 -4.08 V

4.0 - 4.99 1
O-O.g9V

Is the gearshift switch status normal?

YES

- Intermittent failure

NO

- GO TO STEP 2.

2. Gearshift Switch Inspection at Handlebar Switch
Connector
Turn the ignition switch OFF .

Disconnect Ihe handlebar switch 14P (Green)
connector [1].
Check for continuity between the handlebar switch
side 14P (Green) connector terminals while pushing
the gearshift switch.
Connection :
With the upshift switch pushed :
White/red - White/blue
With the downshift switch pushed :
White/red - White/yellow

Whltelblue
White/yellow

Is there continuity?
YES

- GO TO STEP 3.

NO

- Faulty handlebar switch .

111

White/red

3. Gearshift Switch Inspection at PCM Connector
Connect the handlebar switch 14P (Green)
conneclor and disconnect the PCM 33P (Black)
connector [11.
Check for continuity between the wire harness side
PCM 33P (Black) connector terminals while pushing
the gearshift switch.
TOOL:
07ZAJ-ROJA110
Test probe
Connection :
With the upshift switch pushed:
A3 (White/red) - A6 (White/blue)
With the downshift switch pushed :
A3 (White/red) - AS (White/yellow)

111

A5

A6

Q

A3

/s there continuity?
YES

- GO TO STEP 4.

NO

- Open circuit in the Whitelred, White/blue or
White/yellow wire between the sWitch and
PCM .

23-25

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
4. Recheck OTe
Connect the handlebar switch 14P (Green) and
PCM 33P (Black) connectors.
Erase the OlC (page 23-12).
Tum the ignition switch OFF.
Tum the ignition switch ON and engine stop switch
-O~ .

Check the shift operation and the Ole.

23-26

Is the

ore 42-1 Indicated?

YES

- Replace the PCM with a known good one
(page 4-34). and recheck.

NO

- Intermittent failure.

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)

VS SENSOR
REMOVAUINSTALLA TION
Remove the left side cover (page 2-4).
Disconnect the VS sensor 3P (Black) connector [1].
Remove the bolt (2] and VS sensor [31 from the rear
crankcase cover.

J

p

Coal a new O-ring [1] with engine oil and install it onto
the VS sensor [2] .

L

~:;:....::.=~=;;_r==i;:;:;:====:;:';

Install the VS sensor to the rear crankcase cover and
tighten the bolt securely.
Connect the VS sensor 3P (Black) connector.
Install the left side cover (page 2-4),

SHIFT ANGLE SENSOR
INSPECTION
Remove the left mudguard (page 2-6),
Disconnecllhe shift angle sensor 3P (Gray) connector

111.
SENSOR RESISTANCE

Measure the resistance at the shift angle sensor side
connector [21 terminals.
Connection : A - C
Standard : 4 - 6 kO (20°CJ68°F)
Measure the resistance at the shift angle sensor side
connector 111 terminals varies while shifting Ihe gear
manually with the emergency gear change 1001 (page
23-6).

Connection: A - 8
When shifting up :
Resistance Increase
When s hifting down: Resista nce decreases

23·27

ELECTRIC SHIFT PROGRAM (ESP : FE/FPE models)
INPUT VOLTAGE
Turn the ignition switch ON and engine stop switch ·0·,

111

Measure the voltage between the wire harness side
shift angle sensor 3P (Gray) connector 111 terminals.

Connection : Brown/white (+) - Green/red

Brownlwhite

Green/red

H

Standard: 4.75 - 5.25 V
If the input voltage is out of specification , check for
open or short circuit in the Brown/white or Green/red
wires between the shift angle sensor and PCM.

L ffi V _
8 _
REMOVAL
Remove the left mudguard (page 2-6) .
Disconnect the shift angle sensor 3P (Gray) connector

(11Remove the two socket bolts [2) and shift angle sensor

131_

Remove the O-ring [4J from the shift angle sensor.
Check the shift angle sensor for wear or damage.

INSTALLATION

I

Coat a new O-ring 111 with engine oil and install it into r - - : - - - - - - - - - - - - - - - - - - - - - ,

the shift angle sensor [21 groove.
Apply locking agent to the threads of the shift angle
sensor socket bolts PI.

~

--"'1 111

[2]

Carefully install the shift angle sensor by aligning the

nat surtaces of the sensor shaft hole and gearshift
spindle end.

Install and lighten the two socket bolts to the specified
torque.

TORQUE : 6.0 N-m (0.6 kgf'm, 4.4IbHt)
Connect the shift angle sensor 3P (Gray) connector [41.

Install the mudguard (page 2-6).

23·28

Alig~

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)

GEARSHIFT SWITCH
SYSTEM INSPECTION
Remove the front fender/carrier (page 2-8).

Remove the handlebar switch 14P (Green) connector
11] from the frame and disconnect it.

Check for continuity between the switch side connector
terminals with each switch pUShed.

[1]

Continuity should exisl between the color coded wires
as follows:

UPSHIFT SWITCH [II /DOWNSHIFT SWITCH [2J

Color
Position

White! White! Whitel
red
blue yellow

Upshift pushed
Free
Downshift pushed

...)

[2]

INPUT VOLTAGE
Remove the handlebar switch 14P (Green) connector , - - - - - - - - - - - - - - - - -,
White/red
[1[
from the frame and disconnect it (page 23-29),

Turn the ignition switch ON and engine stop switch "0",
Measure the input voltage between the wire harness
side handlebar switch 14P (Green) connector [I]
terminal and ground .

Connection : White/red (+) - Ground (-)

Standard : 4.75 - 5.25 V
If the input vol tage is out of specification , or if there is
no input voltage, check for open or short circuit in the
White/red wire, or loose or poor contact of the PCM 33P
(Black) connector.

8

v

23-29

ELECTRIC SHIFT PROGRAM (ESP: FElFPE models)

SHIFT CONTROL MOTOR/REDUCTION
GEARS
REMOVAL
CONTROL MOTOR
Remove the following:

-

left side cover (page 2-4)

-

right mudguard (page 2-6)
right frontwtleet (page 16-13)

Disconnect the con trol motor 2P (Black) connector [1).
Remove the three bolts (2J and Ihe control motor (3).

REDUCTION GEARS

Remove the three bolls (1J and the gear cover (2J.

Remove the following:
-

reduction gear PI
spindle gear [2]
two dowel pins [3]

Check the gear teeth and splines for wear or damage.

23·30

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
INSTALLATION
SPINDLE GEAR

GEAR COVER

S",

G-RING

REDUCTION GEAR

DUST SEAL
CONTROL MOTOR

Remove any grease from the gears, gear cover and , - - - - - - - - - - - - - - - - -,
crankcase cover.

UNIREX N3 GREASE

Clean the mating surfaces of the covers thoroughly,
being careful not to damage them.
Install the spindle gear 11] by aligning with the reference
marks on the crankcase cover.
Apply 2 - 4 9 (0.07 - 0. 14 oz) of specified grease to the

gear journals (both sides of the reduction gear) and
gears teeth as shown .
Install the reduction gear [2).
SPECIFIED GREASE : UN1REX N3

grease

(EXXON)

Install the dowel pins [31 into the crankcase cover.

23-31

ELECTRIC SHIFT PROGRAM (ESP: FE/FPE models)
Apply engine oil to the seal lips of a new dust seal [1[.
Install the dust seal into the gear cover {2] with the flat
side facing out until it is fully seated.
Apply liquid sealant (ThreeBond 1215 or equivalent) to
the mating surface of the gear cover as shown.
Tighten the bolts
after installing the
control motor.

Install the gear cover with the three bolts [3J.

Coat a new O·ring [11 with engine oil and install it into
the control motor (2] groove.

Install the con trol motor [lJ with the three bolts [2].
Tighten the sil( bolts in a crisscross pattern in several
steps.
Connect the control motor 2P (Black) connector [31.
Install the following:
-

23-32

right front wheel (page 16·13)
tight mudguard (page 2·6)
left side cover (page 2-4)

24. ELECTRIC POWER STEERING (EPS: FPM/FPE models)

EPS COMPONENT LOCATION·· ················24-2

EPS TROUBLESHOOTING
INFORMATION ··········································· 24-9

EPS SYSTEM DIAGRAM ····························24-3
EPS DTC INDEX ········· ······························ 24-16
SERVICE INFORMATION ···························24-4
DTC TROUBLESHOOTING ······················ 24-18
SYMPTOM TROUBLESHOOTING ············· 24-4
EPS CONNECTOR LOCATION ··················24-5

EPS INDICATOR CIRCUIT
INSPECTION ..................... ........................ 24-32
EPS ECU ..................................... .............. 24-35

24·1

ELECTRIC POWER STEERING (EPS : FPM/FPE models)

EPS COMPONENT LOCATION

EPS INDICATOR

4WD INDICATOR

EPS UNIT (Including EPS
MOlor and Torque Sensor)

EPS FUSE BOX (40A)
FUSE BOX:
- FPM: MAINFUSE (30 A)
- FPE: MAIN FUSE 1 (30 A)
- IGN
A)

EPS ECU

PCMlECM
CKP SENSOR
VS SENSOR

24-2

4WD SELECT
SWITCH

ELECTRIC POWER STEERING (EPS: FPM/FPE models)

EPS SYSTEM DIAGRAM
BAnERY

FPM MAIN fUSE 13OA)
FPE. MAlNFUSE 1130A) ; - - - ---u-S-A. ~- - - ,

R- "'.. BI-- - -t"L."''8I

_ " .
4-- --_ canada
rypo; -

i-'~

i rtl
,

~

RECTIFIER

IGNITKlN
SWITCH

J

IGN FUSE
(IDA)

. ---------1~ -~~~

. -,

.~ ~
!
R

I'

"

I
,
I

,-t'oo'l-t~-------'' -

•• ------I

•

••
A'

·R

..." e,."

COMBINATION
MEIER

VSSENSOR~
_. :. ;_j£;";::;<~;;::==
.

81 11 )124 1 ~c.-.

EP$ ECU

811 3)(161
(17)118)
(33)(35)

L_+-__

~

r;~::::w:-L_"_
•••
>eM

w.

.. ---"----,
n,

SCS SERVICE CONNECTOR

~

e1l

""p

-,

.,

[==;;cLJet...

B2

'~ ~~~OFl
R

0

(131114)
(181(21)

ghl blue

c,

EPS EeU

0: Orange
P' P,nk
R R""
W While

'( VallO>\'

@( ) EPS i,,(hcator bhnk
Shon terminals lor
readmg OTC

C-21
2P (Brown) CONNECTOR

2P (Gray) CONNECTOR

C·15

21P (Gray) CONNECTOR

24·3

ELECTRIC POWER STEERING (EPS: FPM/FPE models)

SERVICE INFORMATION
GENERAL
This section covers electrical system service of the EPS (FPMIFPE models). For other service of the steering system , see Front
WheelfSuspension/Steering section (page 16-32).
When performing the DIG troubleshooting, read "EPS Troubleshooting Informalion" carefully (page 24-9), and inspect and

troubleshoot according to the OTe. Observe each slep of the procedures one by one. Note the DTC and probable faulty part
before starting diagnosis and troubleshooting.
The EPS ECU may be damaged if dropped. Also. if the connector is disconnected when current is flowing, the excessive voltage
may damage the EPS ECU . Always turn off the ignition switch before disconnecting or connecting the connectors.

TOOLS
SCS service connector
070PZ-ZY30100

•

HOS pocket tester
TOS 3557-0112-01 (U.S.A. Only)

Test probe
07ZAJ-RDJA110

SYMPTOM TROUBLESHOOTING
Symptom
EPS indicator does not come

o;,~.g~n~o~S~iS;:;:::::::::=,=+=

00

Inspect the EPS indicator circuit
(page 24-32)

EPS indicator does not go
off, and no DTCs are stored

Inspect the EPS indicator circuit
(page 24-33)

L

24-4

Also check for
Short circuit between the com~bi:"
na~t~io~o~m~e~te-r and
ECU
combination meter and

Short circuit in
Open circuit in
Open circuit in
Open circuit in

the OLC related wire
the EPS ECU line
the motor power input line
the power ground line

I

I

ELECTRIC POWER STEERING (EPS: FPM/FPE models)

EPS CONNECTOR LOCATION
NOTE 1: Remove the assist headlight cover (page 22-4)

COMBINATION METER 21P (Black) CONNECTOR
(NOTE 1)

NOTE 2: Remove the right side cover (page 2-4).

Cl

=

I'

CB

r

,X X

CIS

'X
X

C7

IX

/

...J

C14

IX IX

EPS MOTOR 2P (Gray) CONNECTOR

C21

(NOTE 2)

EPS ECU 21P (Gray) CONNECTOR
(NOTE 2)

EPS EeU 2P (Gray) CONNECTOR
(NOTE 2)

EPS ECU 2P (Brown) CONNECTOR
(NOTE 2)

24-5

ELECTRIC POWER STEERING (EPS: FPM/FPE models)
NOTE 1: Remove the right side cover (page 2-4).

(Motoe "de co""ectoe)
TORQUE SENSOR 3P (Gray) CONNECTOR
(NOTE 1)

(n;n)

EPS MOTOR 2P (Gray) CONNECTOR
(NOTE 1)

NOTE 2: Remove the right side cover (page 2-4).

FPM: ENGINE SUB-WIRE HARNESS 3P (Black) CONNECTOR (NOTE 2)
FPE: ENGINE SUB-WIRE HARNESS 6P (Black) CONNECTOR (NOTE 2)

I

I

I

24-6

ELECTRIC POWER STEERING (EPS: FPM/FPE models)
NOTE 1: Remove the left side cover (page 2-4).

\I \\
\

~

:

-- 1--'--

{n ~

v s SENSOR 3P (Black) CONNECTOR
(NOTE 1)

NOTE 2: Remove the seat (page 2-4).

OLe (NOTE 2)

24-7

ELECTRIC POWER STEERING (EPS : FPM/FPE models)
NOTE 1: Remove the rear fender cover (page 2·9).

~:Mtt 8lifE g'

A12

~

~

A33
PCM/ECM 33P (Gray) CONNECTOR
(NOTE 1)

A23

PCMfECM 33P (Black) CONNECTOR
(NOTE 1)

l

24·8

ELECTRIC POWER STEERING (EPS: FPM/FPE models)

EPS TROUBLESHOOTING INFORMATION
SYSTEM DESCRIPTION
SELF·DlAG NOSIS SYSTEM
The EPS system is equIpped with the self-diagnostic system. If the EPS
ECU detects a system failure. it functions as follows:

111

/

1. Turns on the EP$ indicator 11110 notify the rider of the problem.
2. Stores a DTG (Diagnostic Trouble Code) in Its erasable memory.
3. Slops power assist (manual steering operation begins or reduces the
assist power),

I (R)

-[\I

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 mitial diagnosIs until the
igmtion switch is turned OFF .
Revest: The EPS indicator turns on when the OlG is set. The EPS
indicator will turn off after the vehicle has recovered from the fall-safe
condition , but the OTC will be stored in the EPS ECU. There was a
temporary problem, but the system is now fully operational.

/
(N)

000

I

\c5' /

-,
--

( I ) (4) (a)

(~

1..... 1

rl

LI

2 '~

- il

I ll'

I!!!I

\

J

DTC (Diagnost ic Trouble Code)
The OTC(s) is memorized in the EEPROM (nonvolatile memory) therefore the memorized OTC(s) cannot be erased by
disconnecting the battery. Perform the specified procedures to erase the OTC(s) (page 24.11) ,
EPS IN DICATOR
Under normal condItions, the EPS indicator comes on when the ignitIon switch Is turned ON , then goes off after startIng the engIne .
This indicates thai the LED and tts circuit are operating correctly
If there is any trouble in the system after the engine IS started, the EPS indicator will stay on and the EPS ECU memorizes the OTC.
(When the oTC 22 is stored; No initializing the torque sensor neutral position. the EPS indicator will blink .)
When a problem is detected and the EPS indicator comes on. there are cases that the indicator stays on until the ignition switch is
turned OFF, and the indicator goes off automatically when the system returns to normal.
If a problem is continuing after restartIng the engIne . the EPS indIcator stays on and the EPS ECU stops the EPS function.
When the oTC 23 (torque sensor problem) is slored in the EPS ECU , the EPS indicator win slay on until the OTC is erased .

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 motor. The increase of electric current causes the motor to heat up. Because thIS heat
adversely affects the system, the EPS ECU monitors the electric current of the motor. When the EPS ECU detects heat build-up in
the motor. it reduces the electric current to the motor graduany to protect the system (motor and EPS ECU) , 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 EPS ECU wilt gradually restore the power assist.

TORQUE SENSOR NEUTRAL POSITION (Torque Sensor Inilializalion)
The EPS ECU stores the torque sensor neutral poSItion in the EEPROM. The torque sensor must be initialized whenever the EPS
unit. the EPS ECU , etc is serviced (page 24-1 3).
Perform the Torque Sensor InitializatIon when you service the follOWIng components.

--------r
---+-

MAINTENANCE L OCATI ON._

Cables and harness around handlebar
Handlebar
SteerlllgShaft and steering shaft bushing
Steenng arm and end nut
EPS unit
EPS ECU

REPLACEMENT

INITIALIZE
INITIALIZE
INITIALIZE
- +IN ITIALIZE
INIT IALIZE
INITIALIZE

RE"M" O""V"'
A'U'---IN STALLATION
INITtALIZE
INITIALIZE
INITIA~L~IZ~Ec--INITIALIZE

1 INITIAlIZ~
: - NO

NEED~

NOTE
• The torque sensor neutral poslilon is not effected when erasing the OTC.

24-9

ELECTRIC POWER STEERING (EPS : FPM/FPE models)
HOW TO TROUBLESHOOT EPS DTC
1, Questton the customer about the conditions when the problem occurred. and try to reproduce the same conditions lor
troubleshooting . Find out when the EPS indicator came on, such as during EPS control , after EP$ control, when the vehicle was
al a certain speed, etc.
2. When the EPS indicator does not come on during the lest-ride, but troubleshooting is done based on the DTC, check for loose
connectors, poor terminal contact, etc., in the affected circuil before you start troubleshooting.
3. After troubleshooting, erase the DlC(s) and test-ride the vehicle to be sure that the EPS indicator does not come on.

HDS POCKET TESTER INFORMATION
• The HDS can readout and erase the DIG (without the torque sensor neutral position).

How to connect the HOS Pocket Tester
Turn the ignition switch OFF,

121

Remove the seat (page 2-4 ),
Remove the OLC [1) from the dummy conneclor [2),
Connect Ihe HDS pockel tesler 10 the OLC,
Turn Ihe ignilion switch ON and engine slop swilch ·0 ", check the DTC and
stored data.

DTC READOUT
NOTE
If Ihe HoS pocket tester is not available, oTC can be read from the EPS ECU memory by the EPS indicator blinking pattern
(page 24-10).
After pettorn-ling diagnostJc troubleshooting, erase the OTC(s) (page 24-11) and test-ride the vehicle to be sure Ihal the
problem(s) have been removed ,
Start Ihe engine and check the EPS indicator (1),

NOTE
Under normal conditions, the EPS indicalor stays on with the ignition
switch is turned ON until the engine slans, and it goes off after starting
the engine.
If the EPS indicator stays on or blinks wi th the engine running, connect the
HDS pocket tester to the OLC (page 24-10).
Read the OTC, stored data and follow the troubleshooting index
(page 24-16).
To read the OTC without the HoS pocket tester, refer to the following
procedure.

~I
R

NI

-1\1

,n

,-, --,
IPS) I

,1,) '"

1...... 1

LI I:- e ilII!!!I
2 ",lE

u

\

Read ing DTC wi th the EPS indicator
1 Remove the OLC from the dummy connector (page 24-10),

2. Short the OLe [1) terminals using the special tool.
TOOL:
(2] SCS service co nnecto r

070PZ-ZY30100

Connection : Brown/red - Green
3, Turn the ignition switch ON and engine stop switch "0 ", read , note the
EPS Indicator blinks and refer to the troubleshooting index (page 24-16).

24-10

11 I

121

~

ELECTRIC POWER STEERING (EPS: FPM/FPE models)
EP$ Indicator Blinking Pattern
The number of EPS indicator blinks is the equivalent to the main code of the ore (the sub-code cannot be displayed by the
indicator blinking).
The indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for
0.3 seconds . One long blink is the equivalent of len short blinks. For example, when two long blinks are followed by one short
blink, the DIG is 21 (two long blink = 20 blinks, plus one short blink).
When the EPS ECU stores more than one DIG, the indicator blinks in the order from Ihe lowest number to highest number.
0.3 sec

0.5 ,ec \
1.3 sec

1.3 sec

\

0.3 sec

04 " ; / , '

I... ~sec

_

0.4

... ------ f- --10

sec

/

'--l

I

@OFF ....

0.3 sec

2.6,ec

Pattern

--------- - --------- - -

Repealed

2
OTCI2

OTC21

ERASING DTC
NOTE-

• Perform this procedure using fully charged battery. The EPS indicator will stay Iii and the EPS ECU will abort the process If you
use a low or dead battery.
How to erase the OTC with HOS
Connect the HOS pocket tester to the OLC (page 24-10).
Erase the OTC with Ihe HOS while the engine IS stopped.
To erase the OTe without HOS. refer to the following procedure.
How to erase the OTC without HOS
I . Raise the fronl wheets off the ground and support the vehicle securely.

[11

2. Remove the OLe from the dummy connector (page 24-10).

121

,

3. Short the OLC (II terminals using the special 1001.
TOOL:
[2] SCS service connector

1£

070PZ-ZY30100

Connection: Brown/red - Green

4. Place a 6 mm width screwdriver [1] between the right side of the steering
stopper [2] and steering arm [31 as shown.

[2]

131
[11

24-11

ELECTRIC POWER STEERING (EPS: FPM/FPE models)
5. Make sure the engine stop switch is turned ·0-,

131

Fully lum the handlebar [1) to the left to apply a toad and hold it firmly.

• • •
.."@"
..
: 1\

6. Turn the ignition switch [2] ON .
The EPS indicator [3[ comes on and it goes off after 4 seconds.

.. ~

• 6

~

~
4 seconds

11 I
7. Within 4 seconds after the EPS indicator [1J goes off, turn the handlebar
(2] in the straight ahead position and release it immediately.
The EPS indicator comes on again 4 seconds .

I

121
Straight

- 'wi~"

111

I

,

~
~
• 1 •

::~.:.

.6.· : .".

4 seconds

121
8. Within 4 seconds after the EP$ indicator (1) comes on, fully turn the
handlebar [2J to the left and hold it immediately.

111

The EPS Indicator goes off after 4 seconds.

•••

-"@".."

,

.':\

~
4 seconds

121
9. Within 4 seconds after the EPS indicator [1] goes off, lurn the handlebar

Straight

[2] in the straight ahead position and release it immediately .

11 I

I

The EPS indicator blinks twice.

,

~

Turn the ignition switch (3J OFF within 5 seconds after the EPS indicator
blinks twice (o Te erasure is completed at this time).
NOTE·
The ignition switch must be turned OFF at this time .
If it is not, the system will be changed to the torque sensor initialization
(page 24-14).
If the EPS indicator does nol blink twice, an error was made in the
procedure and the o Te was not erased. Turn the ignition switch OFF,
and repeal the operation from step 4.

10.Remove Ihe special tool from the Ol e and inslallthe Ole to the dummy
connector.
Remove the screwdriver inserted in Step 4 .
1Unstailihe seat (page 2-4).

24·12

•• ••
• •

::~-:.
~/ ......
:

.

121

131

Blinks

ELECTRIC POWER STEERING (EPS : FPM/FPE models)
TORQUE SENSOR INITIALIZATION
NOTE :
Perform this procedure using a fully charged battery. The EP$ indicator will stay lit and the EPS EeU will abort the process if

you use a low or dead battery.
The DTC will be erased when Initializing the torque sensor.

How to Initialize the Torque Sensor with HOS
1. Raise the front wheels off the ground and support the vehicle securely.

Straight

2 . Connect the HOS Pocket Teslarto the OLe (page 24-10).

I

3. Turn the ignition switch ON and engine slop switch ·0 · ,
Tum the handlebar (1) straight ahead.
Initialize the torque sensor With the HOS while the engine is stopped .

Follow the Instructions on the HOS display.

(11

How to Initialize the Torque Sensor without HOS
1. Raise the front wheels off the ground and support the vehicle securely.
2. Remove Ihe OLe from the dummy connector (page 24-10).

(11

(21

3. Short the OLe [ 1jterminals using the special tool.
TOOL:
(2) SCS service connector

l

070PZ-ZY30100

Connection: Brownfred - Green

4. Place a 6 mm width screwdriver (1 ) between Ihe fight side of the steenng
stopper (21 and steering arm (31 as shown.

(11

24·13

ELECTRIC POWER STEERING (EPS: FPM/FPE models)
5. Make sure the engine stop switch is turned ·0·.

,

131

Fully turn the handlebar [1J to the left to apply a load and hold it firmly.

·: .

6. Tum the ignition switch (2) ON .

::~.:.

,

·•· I ...••

The EPS indicator 13] comes on and it goes off after 4 seconds.

~

®
4 seconds

121

111
7. Within 4 seconds after the EPS indicator (1 J goes off, tum the handlebar

Straight

12] in the straight ahead position and release it immediately.

.

1'1

I

The EPS indicator comes on again 4 seconds.

,

®

.:...®:..
·"
•

•r•

4 seconds

[2[

8. Within 4 seconds after the EPS indicator [1J comes on , fully turn the
handlebar [2]10 the left and hold it immediately.

I

['I

The EPS indicator goes off after 4 seconds.

..."@"
..
·•· : ..•.
• •I
~

,

®
4 seconds

[21
9. Tum the handlebar I1J in the straight ahead position (fully tum-tostraight ahead lime: within 1 second) and release it immediately after the
EPS indicator [2] goes oft
The EPS indicator blinks twice. Wait for 5 seconds and the EPS indicator
blinks 3 times.

Straight

[21

I

,

®

r

NOTE

Do not touch the handlebar after releasing the handlebar.

1/
..®.,
.
.~

Tum the ignition switch [31 OFF after the EPS indicator blinks 3 times
(torque sensor initialization Is completed at this time).
NOTE
If the EPS indicator does nol blink 3 times, an error was made in the
procedure and the torque sensor was not Initialized. Tum the ignition
switch OFF, and repeat the operation from slep 4.
10.Remove the special tool from the OlC and install the DlC to the dummy connector.
Remove the screwdriver inserted in Step 4.
11 .lnslall the seat (page 2-4).

24-14

~"
~

[' [

[3[

•t

~

~

• ..

• I .

B
: :J

ELECTRIC POWER STEERING (EPS: FPM/FPE models)
CIRCUIT INSPECTION
INSPECTION AT EPS ECU AND PCM/ECM CONNECTOR
Always clean around and keep any foreign material away from the EPS ,----------------~,
ECU and PCM/ECM connector before disconnecting it.
A faulty EPS system is often related to poorly connected or corroded
connections. Check Ihose connections before proceeding.
Do not pull the wire harness while disconnecting the EPS ECU and
PCMfECM connector.
In lesting al EPS ECU 21 P (Gray) and PCMIECM connector (wire
harness side) terminal, always use the test probe. Insert the test probe
into the connector terminal, then attach the digital multimeter probe to
the test prObe.

TOOL :

{1] Test pro be

07ZAJ-RDJA 110

24-15

ELECTRIC POWER STEERING (EPS : FPM/FPE models)

EPS DTC INDEX
DEFINITIONS
Latch : The EPS indicator turns on and stays on whenever the ignition switch is in the ON position, or until the DTG is erased.
Reset: The EPS indicator turns on when the DIG is set The EPS indicator will not turn on after the ignition switch is cycled from
ON to OFF, but the OTG will be stored in the EPS ECU.
Revest: The EPS indicator turns on when the DTG is sel. The EPS indicator will turn off after vehicle has recovered from the failsafe condition, but the DTC will be stored in the EPS ECU. There was a temporary problem. but the system is now fully operational.
Initial diagnosis: Performed right after the engine starts and untillhe EPS indicator goes off.
Regular diagnosis: Performed right after the initial diagnosis until the ignition switch is turned OFF.

r--oTC
(EPS
indicator
blinks)

- ----,----- - , ----,
Symptom/Fail-safe
function

Function Failure

Detection
timing

Type

Refer

to

Excessive change of vehicle speed
Indicator ON/Substitution
24-18
Revest
Regular
signal
control of the engine rpm
Comparison between vehicle speed
Indicator ON/Substitution
Regular
Revest
24-19
11-02 (11)
control of the engine ~,p~m"-_~_ _ _ _-+ ____ _ _ _-j
and en.gine speed signal
13-01 (13)
EPS EGU internal circuit
Indicator ON/Disables
24-19
Reset
Initial
'--_ _ __ +_ (Lower FET stuck ON)
_ __ _ _~'~te~e~'~i"~g_":assist immediately
I 13-02 (13)
EPS EGU internal circuit
Indicator ON/Disables
Initial
24-20
Reset
+--a*~FDE~T;;;;:~ ON)
steering assist ..im,,",m~e~d~;a~te~ty,--+_ _ __
I 13-03 (13)
i
circuit
Indicator ON/DTSables
Reset
24-20
Regular
) _':--=-"'''-+~fJ:~~,~k;ON 000)

07ZAJ -RDJA 110

Is there continuity?

24·32

111

YES

- Short circuit in the Yellow/green wire.

NO

- Recheck for loose or poor contact on the

Yellow/green

combination meier 21 P (Black) connector ' - - - - - - - - - - - - - -- - -- - - '
and EPS ECU 21P (Gray) connector. If
they are OK. replace the combination
meter with a known good one (page 22-6).

ELECTRIC POWER STEERING (EPS: FPM/FPE models)
EPS INDICATOR DOES NOT GO OFF ,
AND NO DTCs ARE STORED
NOTE
Under normal conditions, Ihe EPS Indicator comes
on when the ignition switch is turned ON. then goes
off after starting the engine .
Before starting the troubleshOO!lng check the
following ilems:
- check for loose or poor contact of the following
connectors, and recheck Ihe EPS indicator.
- EPS EeU 21P (Gray)
- EPS ECU 2P (Brown)
- combination meter 21 P (Black)
- check for blown EPS fuse (40A) and IGN fuse
( lOA)
- battery condition (must use a fully charged
battery) (page 21-8)

1. Fus e Inspection
Check the EPS fuse (40A) and IGN fuse (10A).

Is the fuse OK?
YES

- GO TO STEP 2.

NO

- Replace Ihe fuse and recheck If the fuse
is blown, check for short to ground in this

fuse circuit.
2. Rec hec k OTC

Check the DTG (page 24-10).
Are th ere any DTCs ?
YES

- Perform the troubleshooting
indicated DTC (page 24.16).

NO

- GO TO STEP 3.

3. Indica tor Operation
Inspection)

Check

(Open

for

the

Circuit

Turn the ignition switch OFF .
Disconnect the EPS ECU 21 P (Gray) connector 11J.
Ground the wire harness side EPS ECU 21P (Gray)
connector terminal with a jumper wire.

Connection : C5 - Ground
TOOL:
Test pro be

I

[11

C5

""?r==r=r=ffi~

07ZAJ·ROJA110

Turn the ignition switch ON and engine stop SWitch

"0 ",
Check the EPS indicator.

Does the indicator go off?
YES

- Recheck for loose or poor contact on the
EPS ECU 21 P (Gray) connector. If they
are OK, replace the EPS ECU with a
known good one (page 24·35), and
recheck.

NO

- GO TO STEP 4.

L

24·33

ELECTRIC POWER STEERING (EPS : FPM/FPE models)
4. Indicator Line Open Ci rcu it Inspection
Tum the ignition switch OFF.
Disconnect the combination meier 21P (Black)
connector [1].
Check for continuity between the wire harness side
combination meter 21 P (Black) connector and EPS
ECU 21P (Gray) connector 121 terminals.

Yellow/green

C5

""

~
00' 000§

oc )0000
o r)OOOG 9

Connection : C5 - Yellow/green

TOOL:
Test probe

07ZAJ·RDJA110

Is there continuity?

111

[21

YES

- GO TO STEP 5.

NO

- Open circuil in the Yellow/green wire.

5. SCS Line Short Circuit Inspection
Disconnect the PCMfECM 33P (Gray) connector.
Check for continuity between the wire harness side
EPS ECU 21P (Gray) connector [1] terminal and
ground .

111

C9

Connection: C9 - Ground
TOOL:
Test probe

07ZAJ·ROJA110

Is there continu ity?
YES

- Short circui t in the Brown/red wire between
the EPS ECU and DLC,

NO

- GO TO STEP 6.

6. IG1 Line Open Circuit Inspection
Tum the ignition switch ON and engine stop sWitch

·0 · ,
Measure the voltage between the wire harness side
EP$ EeU 21P (Gray) connector 111 terminal and
ground .
Connection: C7 - Ground H
TOOL:
Test probe

r-I-'I- - -- - - - - - - - - - - - - '
C7

07ZAJ ·RDJA110

Is there battery voltage ?
YES

- GO TO STEP 7 .

NO

- Open circuit in the Black/red wire.

7. EPS ECU +8 Line Open Circuit Inspection
Tum the ignition switch OFF.
Disconnect the EPS ECU 2P (Brown) connector \11.
Measure the voltage between the wire harness side
EPS ECU 2P (Brown) connector terminal and
ground .
Connection: Red (+) - Ground (-)

Is there battery voltage?

24-34

YES

- GO TO STEP 8.

NO

- Open circuit in the Red wire.

Red

ELECTRIC POWER STEERING (EPS: FPM/FPE models)
8. EPS Eeu PG Line Open Circuit Inspection
Check for continuity between the wire harness side , - - - - - - - - - - - - - - - - - - - ,
EPS ECU 2P (Brown) connector [1] terminal and
]1J
Green
ground.
Connection : Green - Ground

Is there continuity?
YES

- GO TO STEP 9.

NO

- Open circuit in the Green wire.

9. Battery Inspection
Perform
the
Battery/Charging
troubleshooting (page 21 ·6 ).

System

Is the battery and charging system In good
condition ?
YES

- Recheck for loose or poor contact on the
combination meter 21 P (Black) connector,
EPS ECU 21 P (Gray) connector and EPS

ECU 2P (Brown). If they are OK. replace
the EPS EeU with a known good one
(page 24-35), and recheck.
NO

- Repair the bal1eryfcharging system
(page 21-8).

EPS ECU
REMOVALIINSTALLATION
Remove the right mudguard (page 2-6).
Disconnect the following connectors :
-

EPS ECU 21P (Gray) (1)
EPS ECU 2P (Gray) [2)
EPS ECU 2P (Brown) (3)

Remove the EPS ECU [4) from the stays on the EC U
holder [5).
Installation is in the reverse order of remova1.
Perform the torque sensor initialization if the EPS ECU
replaced (page 24-13).

24-35

MEMO

25. WIRING DIAGRAMS

FM model .. ···· ·············································· 25-2

FPM model ·················································· 25-4

FE model ····················································· 25-3

FPE model ·················································· 25-5

25-1

MEMO

MEMO

MEMO

INDEX
2WD/4WD SELECT SYSTEM ·· ............................ ····· 3-19
4WD SELECT SWITCH ············ .............
·······22-17
............... "' 22-10
ACCESSORY SOCKET ··· ........

AIR CLEANER ...................... -.- ···································· 3-5
AIR CLEANER HOUSING ................................. ········· 7-19
AIR CLEANER HOUSING DRAIN TUBE· ·······················3-7
ALTERNATOR CHARGING COIL ······························21-10
ALTERNATQRSTATOR ...................................... 13-6
ASSIST HEADLIGHT ······ .. · .. ·· .... ····· .. ··· ...... ··· .. ·.. ·.... ·· ,,, 22.-4
BANK ANGLE SENSOR ···· .. ············· .. ············ .. ·········· .. 4-33
BATIERy ············· ...................................................... '· 21-8
BODY PANEl LOCATIONS ...................................... "' 2-3
BRAKE FLUiD· ····· ... ..... .......................... ................ ···· 3-20
BRAKE FLUID REPLACEMENT/AIR BLEEDING .... "' 18-7
BRAKE LIGHT SWITCH ···············································3-21
BRAKE PAD/DISC ,... ..........................
·· ·· ······ ,8-8
BRAKE PADS WEAR ······················,····························3-21
BRAKE SHOES WEAR ··' ........... - .. ········ ··_-_············· 3-21
BRAKE SYSTEM ........................ ································ 3-22
BRAKEIT AILLlGHT · .... ... .... -........................................ 22-6
CABLE & HARNESS ROUTING ··································· 1-23
CAMSHAFT INSTALLATION ······································ 10-23
. ........ 10-20
CAMSHAFT REMOVAL .. .. ...............
CENTRIFUGAL CLUTCH ············································· ,2-8
CHANGE CLUTCH ············································.. ··· ···· 12· 13
CHARGING SYSTEM INSPECTION ····························21-9
··· ··· ···3-24
CLUTCH SySTEM ····· ···· ············ ·· ·············
COMBINATION METER ...
······22-6
COMPONENT LOCATION
BATTERY/CHARGING SYSTEM " ................... ······ 21-2
ELECTRIC POWER STEERING (EPS) ··················· 24-2
ELECTRIC SHIFT PROGRAM (ESP) ······················23-2
ELECTRIC STARTER .......... ,......................... "'6-2
IGNITION SySTEM ········ ....................... ··················· 5-2
LIGHTS/METERS/SWITCHES ................................. 22-2
PGM-FI SYSTEM ...................................................... '4-2
CONDENSER (Canada type) ········································· 5-8
CONNECTOR LOCATION
ElECTRIC POWER STEERING (EPS)
··········· 24-5
ELECTRIC SHIFT PROGRAM (ESP)······················23-7
PGM-FI SYSTEM ,,, ..................................... ············· 4-7
COOLANT REPLACEMENT ............................... ··-········ 8-6
COOLING FAN · .... ........... ........
. .......... ········ 22-15
COOLING SySTEM ·······················
·········· 3-16
COOLING SYSTEM FLOW PATTERN .. ························· 8-2
COOLING SYSTEM TESTING ·······································8-5
CRANKCASE ASSEMBLY ···············-························· 14·21
CRANKCASE BEARING ······· .................. ··················14-18
CRANKCASE SEPARATION ···················
········,· 14-7
......... 14·15
CRANKSHAFTIBALANCER ....................
CYLINDER COMPRESSiON ···· ·· ·············
..... ........ 10-7
CYLINDER HEAD ASSEMBL Y··································· ,0-14
CYLINDER HEAD COVER ASSEMBL YI
INSTALLATION ··· ............................................... ········ ,0-17
CYLINDER HEAD COVER REMOVAU
DISASSEMBLY .......................................................... , 10-7
CYLINDER HEAD DiSASSEMBLy ···· ························ 10-10
CYLINDER HEAD INSTALLATION .......................... ' 10-16
CYLINDER HEAD REMOVAL .............. ····················10-9
CYLINDER/PISTON INSTALLATION .... .... ................. " 11-6
CYLINDER/PISTON REMOVAL ························· .. ········ 11-4
.............................
······ 6-10
DIODE· ··························
............... ········3-17
DRIVE TRAIN BOOTS ....... . ...... .
DTCINDEX
ELECTRIC POWER STEERING (EPS) ......... ·······24 -16
ELECTRIC SHIFT PROGRAM (ESP) ····················23-13
PGM-FI SYSTEM .........
················ 4-13
DTC TROUBLESHOOTING
ELECTRIC POWER STEERING (EPS) ' .... ·········· 24· 16

ELECTRIC SHIFT PROGRAM (ESP)····· .. ············· 23-14
PGM-FI···································· .............. ················· 4-14
ECT SENSOR .......................................... ················· 4-32
EMISSION CONTROL SYSTEMS ............. ················ 1-44
ENGINE GUARD ···········-···························· .. ·················· 2-7
ENGINE IDLE SPEED ······ ··············· ··· ·· ························ 3-15
ENGINE INSTALLATION · .................................. ····· ··,5-9
ENGINE OIL '" ....................
····························3-12
ENGINE OIL FILTER ··············· ................................... 3-14
ENGINE REMOVAL ......... .... ..................................... 15-4
EPS ECU ................................................................... 24-35
EPS INDICATOR CIRCUIT INSPECTION ................. 24-32
ESP BEFORE TROUBLESHOOTING· ······
... 23-5
EXHAUST SySTEM ·········································· .. ········· 2-14
FL YWHEEUSTARTER CLUTCH .......................... -.... 13-11
FRONT BRAKE CALiPER ·········································· 18-12
FRONT BRAKE SWiTCH ·······································,··· 22-12
FRONT CRANKCASE COVER INSTALLATION··· .. ··· 12-23
FRONT CRANKCASE COVER REMOVAL········ ...... 12-6
FRONT DRIVE SHAFT··············· .. ································ 19· 7
FRONT FENDER/CARRIER ··········································2-8
FRONT FINAL CLUTCH .. ····································· ···· 19-16
FRONT FINAL DRIVE INSTALLATION '" .................. 19-37
FRONT FINAL DRIVE REMOVAL·· .. ·························· 19-12
FRONT FINAL GEAR ASSEMBLY························-··· 19-33
FRONT FINAL GEAR CASE BEARING
REPLACEMENT ... .. .................................................... 19-30
FRONT FINAL GEAR DISASSEMBL YI
INSPECTION ......... ......... ··································· 19-22
FRONT GRILLE······························································ 2-7
FRONT MASTER CYLINDER ···································· 16-10
FRONT PROPELLER SHAFT ········_······· ··_··············· 19-14
FRONT SHOCK ABSORBER
................ ··············16-26
FRONT WHEEL································ ·························· ,6-13
FUEL GAGEiFUEL LEVEL SENSOR .. ·········· .. ··········· 22-16
FUEL INJECTOR································ ........................ 7-25
FUEL LINE .................... ··········, ········ ························ ·· ·· 3-4
FUEL LINE INSPECTION ···· ................................... ···· · 7-6
FUEL PUMP RELAY ......................................... ·········· 4-29
FUEL TANK ·································································· 7-18
FUEL TANK COVER ······················································ 2-5
FUEL TANK SIDE COVER ············································· 2-5
GEAR POSITION SWITCH ..................................... 22-14
GEARSHIFT LINKAGE ···· .................. .. ..................... 12-19
GEARSHIFT SWITCH ............... ,.......................... ···· 23-29
GUARDS .................................................................... 3-24
HANDLEBAR ············· .............. •............. .. .................. 16-8
HANDLEBAR SWiTCH ······ ··
................... ······· 22-11
HEADLIGHT ................................ ............. ··················22-5
IACV .................................................................... ····· 7-24
IGNITION COIL .............................. -........................... 5-7
IGNITION SWiTCH·····················,·······························22-11
IGNITION SYSTEM INSPECTION .............................. 5-5
IGNITION TIMING .......................................................... 5--8
LUBRICATION & SEAL POINTS .. ······"""""""""""""1-19
LUBRICATION SYSTEM DIAGRAM .............................. 9-2
MAINTENANCE SCHEDULE ...... ·································3-3
Mil CIRCUIT INSPECTION ................... ····················· 4-29
MODEL IDENTIFICATION ............................................. 1-3
MUDGUARD··································································· 2-6
MUDGUARD BRACKET .......... .................................... 2-13
NUTS, BOLTS . FASTENERS" ................................ ··· 3-25
Oil PUMP ' ..................................................................... 9-4
PCMlECM ·········· .. ·· .. ···· .. ························•··· •.......... ······· 4-34
POWER RELAY (Canada type)············ ·· ···················· 21-11
RADIATOR COOLANT ····· ············ ··· ········ ......... -... ······3- 15
RADIATOR RESERVE TANK ...................................... 8-1 1
RADIATORlCOOUNG FAN ... ....................................... 8-9
REAR AXLE INSTALLATION ........... ····················· .. ·· 20-24

INDEX
REAR
REAR
REAR
REAR

AXLE REMOVAL ··············································· 20·7
BRAKE DRUMfSHOES ........... .. ............ .. ... ... 18·16
BRAKE LIGHT SWiTCH·· ··· .... ··· .... ··· .. ···· ...... · .. 22-13
BRAKE PEDAL···· .. · .... ··· .. ··· .. ·.. ·· .. ················ . 18-20

REAR FENDER COVER ········ .. · .. ······· .. ····, .... ......... ···· 2-9
REAR FENDER/CARRIER ··· ··· ········ ···· ··· ····· .. ··· ···· ····· .. · 2-11
REAR FINAL DRIVE INSTALLATION ·· ··········· .......... 20-22
REAR FINAL DRIVE REMOVAL ·············· .. ··· .......... '" 20-9

REAR FINAL GEAR ASSEMBLy ····················· ·········· 20-19
REAR FINAL GEAR CASE BEARING
REPLACEMENT························ ................ ······ ····· ···· 20-17
REAR FINAL GEAR CASE OIL AND
DIFFERENTIAL OIL ········ .. ·· ··· .. ··········· ·· .. .. ···· .. ·· ·· ·· ·.... ·· 3·17
REAR FINAL GEAR DISASSEMBL Yf
INSPECTION ·.... ···· .... ···· .. ·· .. ·· .. ·· .... ··· .. ··· .. · .. ·· .. ·· ··· .. ·., .. 20-12
REAR SHOCK ABSORBER .. ·· .................... .......... 17-6
REAR WHEEL ""'"''''''''''''' '' ''''''''''''''' ......... .... .. ..... 17·6
RECOIL STARTER (Canada type) ...... ....... ................. 13-6
RECTIFIER (Canada type) ..... .. ....................... -............ 5-10
REGULATOR/RECTIFIER ·,······ ····· .. ··· .... ····,· ,·· .. ········ 21-10
RELIEF VALVE ........................................................... 9-6
REV ERSE LOCK SySTEM .. ·.............. ·.. · .................. 3·23
SEAT ........... , ........ ,......... .. .............. ...................... ,... 2-4
SENSOR UNIT (MAPfTP SENSOR) .. ...... .................... 4·30
SERVICE INFORMATION
ALTERNATOR/STARTER CLUTCH .... ,...... ,.... ... 13-4
BATIERYfCHARGING SYSTEM ................ ............ 21-4
BRAKE SYSTEM ............. .. ............................. ......... 18-4
CLUTCH/GEARSHIFT LINKAGE .......................... 12-3
COOLING SySTEM ···· .. ··· .... ··· .... ··· .. ··· ···,··· .. ···· .. ·····," 8-3
CRANKCASElTRANSMISSIONfCRANKSHAFTI
BALANCER ·............................................................ 14·3
CYLINDER HEADNALVE .. .... · .... ·........ · ................ 10-4
CYLINDER/PISTON ...... ... .......... ................... .......... 11·3
ELECTRIC POWER STEERING (EPS)·· .. ···· .. ········· 24-4
ELECTRIC SHIFT PROGRAM (ESP)··· .... ·· .. · .. ·.... ··· 23-4
elECTRIC STARTER .... ,................... ............... ,...... 6-3
ENGINE REMOVAUINSTALLATlON ...... ·...... ·........ 15-3
FRAME/BODY PANElSfEXHAUST SYSTEM .......... 2·2
FRONT DRIVING MECHANiSM .... ·.... ·................ ·.. 19-3
FRONT WHEEUSUSPENSIONISTEERING ,.. ... ,.... 16-4
FUEL SYSTEM ....... .................................................. 7-3
IGNITION SYSTEM ............. ,............................... -..... 5-3
LlGHTSfMETERS/SWITCHES .... ............................ 22-3
LUBRICATION SySTEM ··· ···.. ···· ····· .. ··· .... ·· ·.... ·· .. ··· .. · 9·3
MAINTENANCE ......
.................. .......... . 3-2
PGM·FI SySTEM ·· .. ···· .... ·.. ·.. ··· ...... ·.... ·· .... ·•·.. ··.... ,·· .. 4-4
REAR DRIVING MECHANISM ......
.. .. ........ 20·3
REAR WHEEUSUSPENStON ·········· .. ·· .... ··· .. ····· .. ··· 17-3
TROUBLESHOOTING .... ··· .................................... 19-6
SERVICE RULES .. ·.................................................. 1-2
SHIFT ANGLE SENSOR ·.... ··· .. ····· .. ···· .. ··· ·.. ·· ········ .... · 23-27
SHIFT CONTROL MOTOR/REDUCTION GEARS .... 23-30
SIDE COVER ............... ...... .........
.. .............. 2-4
SPARK ARRESTER .. ·............ ·.. ·........................ · ........ · 3-25
SPARK PLUG ...... ·.... .. .. ·· .............. .. .......................... 3-8
SPECiFiCATIONS ·.. ·· ··· .. · .............................................. 1-6
STARTER MOTOR ............................................... ' ,···· ··6-6
STARTER RELAY SWITCH ..........
.. .. .... ........... 6-8
STEERING SHAFT (FMfFE models) ...... ·.. ·............ .... 16-27
STEERING SHAFT HOLDER BEARING .................... 3-26
STEERING SHAFTfEPS UNIT (FPMJFPE models) '" 16-32
STEERING SYSTEM .... ,..... .. ........... .. ........... ..... ... ....... 3-26
SUB-FUEL TANK/FUEL PUMp .. · ........................ ·...... 7-13
SUSPENSION ..... ,..... ,............................ ,..................... 3-25
SUSPENSION ARM" """""" "" """"""" ,,,,,,, ,,,,, ,,, ,,,, 16-23
SWINGARM .... . ....... . ........................................ 17-8
SYMPTOM TROUBLESHOOTING

ELECTRIC POWER STEERING (EPS) ..... ·.. ·.. ·.... -24-4
ELECTRIC SHIFT PROGRAM (ESP) .. .. .. ........... .. ... 23-5
PGM-FI SYSTEM ...... ..... .......... ..... ·.. ···· ··· .. ······ .. ······ 4·5
SYSTEM COMPONENTS
ALTERNATOR/STARTER CLUTCH ······· ············· .. ,· 13-2
BRAKE SYSTEM .. ··· .. ,······· .. ·····,····,· ·.. ··· ·· ········· .... ··· 18-2
CLUTCHfGEARSHIFT LINKAGE .... ·.................. ·.. ·.. 12-2
CRANKCASEfTRANSMISSIONfCRANKSHAFTf
BALANCER ... ........... ... .. ........... ... ........... .. ........... .... 14-2
CYLINDER HEADNALVE ........ ·.. ·........ ·.. ·.. ·.. ·........ ' 10-2
CyLINDER/PiSTON .. ······ .... ·.... ·.. ···....
11-2
ENGINE REMOVAUINSTALLATION · .. .............. ' 15-2
FRONT DRIVING MECHANISM .. · ........ .... .......... .. .. 19·2
FRONT WHEEUSUSPENSIONfSTEERING ,.. ·.... 16·2
FUEL SYSTEM ..................................................... .. 7-2
REAR DRIVING MECHANiSM ·.. ···· .. ,···· ··.. ·········· .. ·· 20-2
REAR WHEEUSUSPENSION ...................... ·.. .. .... 17-2
SYSTEM DIAGRAM
BATIERYfCHARGING SySTEM .............. ·.... · ........ 21-2
ELECTRIC POWER STEERING (EPS) ··.. ·· ·.. ,··,····· ·24-3
ELECTRIC SHIFT PROGRAM (ESP) ................ ,-... , 23-3
ELECTRIC STARTER .. ·...... · ............................ ·.. · 6-2
IGNITION SYSTEM ......................... .... .... · .... .. .. .. ·.. · 5-2
PGM-FI SySTEM ·,···· ·· ·········· ·.. ················ .... ··· .. ··· .. ··" 4-3
THERMOSTAT ....
......................... ·.... ·.... ·........ ·.... · 8·8
THROTILE BODy .. ·· .... ·.. ··· .. ··· .. ··· .. ··, ..... .......... ,.. ····· 7-20
THROTILE HOUSING .... .. ...... · .. .. ·.... · ...... · .. ·, .. ·.... ·.. .. 16- 11
THROTILE OPERATION .. ' .................................... 3-4
TIE·ROD .... ·· .. ·· .... ·· .. ,·· .. ··· .. ···· ...... ·· .... ·· .. ···· .. ·· .. ······· ·.. · 16-40
TIE·ROD AND JOINT BOOTS .. ·.. .. .... ·.... ·.... ·........ ·.... ·.. 3·26
TIRES ... .... ,..... ............... ... ........... .. ..................... ,· .. ···· 16·13
TOOL BOX LID ........
.. ............................... ....... · 2· 10
TORQUE VALUES ............... ,................................. 1·13
TRANSMiSSiON·· ··,·· .. ··· .. ,····,··· .. ··· .. ···· .. ······ .. ··· .. ·· .. ·· ·· .. 14-8
TROUBLESHOOTING
ALTERNATOR/STARTER CLUTCH .............. .. ..... 13·5
BATIERYfCHARGING SySTEM ········ .. ··· ··.. ······ ··· .. 21 -6
BRAKE SYSTEM ··· .. ·.... ·····,· .... ······ .. ···· .. ····· ······ .. ··· ·· 18·6
CLUTCH/GEARSHIFT LINKAGE ·.. ··· .. ··· .... ·· .. ··· .. ·· .. 12-5
COOLING SYSTEM ·· .. ··· .. ··· .. ··· .. ········ .... ·· .. ·· .. ··· .. ····· .. 8-4
CRANKCASElTRANSMISSIONfCRANKSHAFTf
BALANCER ............. .. .. . ......... ... ......... ........ ·...... · 14·6
CYLINDER HEADN ALVE .............................. ·.. ··· .. ·10-6
CYLINDER/PISTON ··· ··· ··,·· .. ·········· .. ······ .. ··········,·,· .. 11· 3
ELECTRIC STARTER ······· .. ········· .... ······ ·.. ······· .. ········ 6-4
FRAME/BODY PANELSfEXHAUST SYSTEM .......... 2-2
FRONT WHEEUSUSPENSIONfSTEERING .. ···· ··.. · 16-7
FUEL LINE ... ............ ...... ,... ................ ···· ····· ···· ··· .. ···· 7-5
IGNITION SySTEM· ·· .... ·· .. ·, .... ·· .. ··· .. ···· ·· · .. ··· ···· .. ·.. ·· 5-4
LUBRICATION SYSTEM ............. ,
···· .. · .. · 9·3
REAR DRIVING MECHANiSM···..
··········· .... ·· ·20·6
REAR WHEEUSUSPENSION .. .. ........... ,............... , 17-5
TROUBLESHOOTING INFORMATION
ELECTRIC POWER STEERING (EPS) ..... .. .......... 24-9
ELECTRIC SHIFT PROGRAM (ESP) ..... .. ............. 23-10
PGM·Fl SYSTEM ............................................... ·.... 4-10
VALVE CLEARANCE ..........................................· .. ·.. · 3-9
VALVE GUIDE REPLACEMENT .... ·.. ·...... ·.. .. .. · ........ · 10-12
VALVE SEAT lNSPECTlONfREFACING .. ·.. .. .. · .. · .. ·.. · 10· 13
VS SENSOR ......................... -.............. ,...................... 23-27
WATER PUMp .. ·.. ··· .. ···· .. ·· .... ····· ·.. ···· ···· .. ·· .. ···, ·.. ·· ·.. ··.. 8-11
WHEEL HUB AND KNUCKlE ·· ·· .. ··· ·.. ···· .. ····· ·.. ··· .. ·· .. ·16-16
WHEElSfT1RES ......................................................... 3-25
WIRING DIAGRAMS
FE model ··· .. ··· .. ····,··· .. ··· .. ·········· .. ······ .. ··· .. ····, ····· ···· 25-3
FM model .............. ,.... ,................... ,................ ·· .. ···25·2
FPE model ·.... ·· .. ·· .... ·· .. ··.. ··· .. ·· .. ····••••·· .. ··· .. ••·
"' 25-5
FPM model .. · .. ,.. ··· .. ·· .. ··.. ···· ·• •·.. ···• .. ··•·· .... ··· .. · ·· .. ·· ·· 25-4
Source Exif Data: 
File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.3
Linearized                      : No
Page Count                      : 564
Title                           : Honda Foreman 500 service manual 2012
Creator                         : Image2PDF Command Line Software
Producer                        : Mac OS X 10.5.8 Quartz PDFContext
Create Date                     : 2012:06:28 15:12:35Z
Modify Date                     : 2012:06:28 15:12:35Z
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