Académique Documents
Professionnel Documents
Culture Documents
General Information
General Safety
1-1
1-23
Model Identification
1-3
1-25
Specifications
1-4
1-45
Torque Valves
1-17
Tools
1-21
1-48
General Safety
Carbon Monoxide
If the engine must be funning to do some work, make sure
the area is well ventilated. Never run the engine in an
enclosed area.
lead to death.
Run the engine in an open area or with an exhaust
evacuation system in an enclosed area.
Gasoline
Work in a well ventilated area. Keep cigarettes, flames or
sparks away from the work area or where gasoline is
stored.
OF CHILDREN.
Hot Components
1-1
..
General Information
Coolant
Under some conditions, the ethylene glycol in engine
coolant is combustible and its flame is not visible. If the
ethylene glycol does ignite, you will not see any flame, but
you can be burned.
1-2
keep
sparks, flames and cigarettes away. Provide
adequate ventilation when charging.
The battery contains sulfuric acid (electrolyte).
Contact with skin or eyes may cause severe
burns. Wear protective clothing and a face shild.
- 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.
Electrolyte is poisonous.
- I f swallowed, drink large quantities of water or
milk and follow with milk of magnesia or
vegetable oil and call a physician. KEEP OUT
OF REACH OF CHILDREN.
General Information
Model Identification
'91 (Standard model) Shown:
f/
(2) ENGINE SERIAL NUMBER
The engine serial number is stamped on the rear of the
lower crankcase behind the oil pan.
,,~
\,
---
~"~~
(4) CARBURETOR IDENTIFICATION NUMBER
The carburetor identification number is stamped on each
carburetor body on the intake side.
1-3
General Information
Specifications
Unit: mm (in)
General
Specifications
Item
Dimensions
1-4
Overall length
Overall width ('91-'93)
(After '93)
{'91-'94)
Overall height
(After '94)
Wheelbase
Seat height
Footpeq height
Ground clearance
Dry weight
ABS/TCS or LBS-ABS/TCS model
with saddlebag
('91-'94)
49 state type
California type
Canada type
(After '94)
49 state type
California type
Canada type
Standard model with saddlebag
('91-'94)
49 state type
California type
Canada type
(After '94)
49 state type
California type
Canada type
Curb weight
ABS/TCS or LBS-ABS/TCS model
with saddlebag
('91-'94)
49 state type
California type
Canada type
(After '94)
49 state type
California type
Canada type
Standard model with saddlebag
('91-'94)
49 state type
California type
Canada type
(After '94)
49 state type
California type
Canada type
2,285 (90.0)
835 (32.9) [Saddlebag end]
935 (36.8) [Rear view mirror end]
1,395 (54.9)
1,405 (55,3)
1,555 (61.2)
800 (31.5)
-145 (5.7l
297
298
293
298
299
297
kg
kg
kg
kg
kg
kg
(655
(657
(646
(657
(659
(655
Ib)
Ib)
lb)
Ib)
Ib)
Ib)
284
285
283
288
289
287
kg
kg
kg
kg
kg
kg
(626Ib}
(628 lb}
(624 lb)
(635 Ib)
(637 Ib)
(633 Ib)
326
327
322
327
328
326
kg
kg
kg
kg
kg
kg
(719 Ib)
(721 Ib)
(710 Ib)
(721 Ib)
(723Ib}
(719 Ib}
313
314
312
317
318
316
kg
kg
kg
kg
kg
kg
(690 Ib)
(692 Ib)
(688Ib)
(699Ib)
(701Ib)
(697 Ib)
General Information
Unit: mm (in)
Specifications
Item
Frame
Frame type
Front suspension
Front wheel travel
Rear suspension
Rear wheel travel
Front tire size
{Standard model and '92-'95 ABS/
TCS model}
(After '95 LBS-ABSn-CS model)
Rear tire size
(Standard model and '92-'95 ABS/
TCS model)
(After '95 LBS-ABSn-CS model)
Tire brand FR/RR
{Standard model and '92-'95 ABS/
TCS model}
(After '95 LBS-ABSn-CS model)
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Fuel tank reserve capacity
Engine
Double cradle
Telescopic fork
150 (5.9)
Swingram
120 (4.7)
('91-'93)
('94)
(After '94)
'91-'93 :
Standard California and
U.S.A. ABSn-CS type
After '93 : California type
'91-'93 :
Standard 49 state and
Canada type
After '93 : 49 state and
Canada type
8' BTDC
37" ABDC
33 BBDC
2" ATDC
Firing order
Cylinder arrangement
Cylinder number
Left
Front
1-5
General Information
-
Unit" mm (in)
General (cont'd)
Item
Specifications
Carburetor
Carburetor type
Throttle bore
Drive train
Clutch system
Clutch operation system
Transmission
Primary reduction
Secondary reduction
Third reduction
Final reduction
Gear ratio 1st
Gear ratio 2nd
Gear ratio 3rd
Gear ratio 4th
Gear ratio 5th
Gear ratio 6th
Gear ratio reverse
Gearshift pattern
Multi-plate. wet
Hydraulic operating
5 speeds
1.8292 (75/41)
Electrical
1-6
Ignition system
Starting system
Charging system
Regulator/rectifier type
Lighting system
AC regulator type
--2.8333
2.2666
1.5000
1.1428
0.9166
0.7586
(34/12)
(34/15)
(27/18)
(24/21)
(22/24)
(22/29)
---
General Information
Unit: mm (in)
r-'
Lubrication
Item
Standard
OIL VISCOSITIES
,,
-"
-~
.4U
, ........ ,
--
---
,20
Service Limit
,
""'~
0 1 0 2 0 3 0 ~',
cD
---
--
0~~1I I,~
t
"
i
Fuel System
Carburetor identification number
('91-'93)
(Standard 49 state type}
(Standard California and
U.S.A. ABSjTCS type)
(Canada type)
(Standard 49 state type)
(After '93)
(49 state ABSjTCS or 49
state LBS-ABSjTCS type}
(California type}
(Canada type)
('91-'93}
Main jet
(49 state and Canada type)
(California type)
(After '93)
(Standard 49 state and
Canada type)
(49 state ABSjTCS or49
state LBS-ABSjTCS and
California type}
(All U.S.A. types}
Slow jet
(Canada type}
Pilot screw initial opening
Pilot screw high altitude adjustment
Pilot screw final opening
Float level
Carburetor vacuum difference
Base carburetor (For carburetor synchronization)
Idle speed
(All U.S.A. types)
(Canada type)
Throttle grip free play
Pulse secondary air injection (PAIR) control valve
vacuum pressure
r-'
VD BDA
VD BEA
VD B1A
VD BDA
VD BJA
VD BEA
VD B1A
:j;1: 128
:j;1: 125
:j;1: 128
:j;1:
125
"38
. .0
See page 5-12
See page 5-1 6
See page 5-12
7.0 (0.28)
Within 40 mmHg (1.6 inHg)
NO.4 carburetor
1 ,200 100 rpm
1 ,OOO 100 rpm
2-6 (0.08-0.24)
360 mmHg (14.2 inHg)
1-7
General Information
Unit: mm (in)
r-'
Cylinder Head
Standard
Item
Cylinder compression
Cylinder compression difference
Valve clearance IN
EX
Cylinder head warpage
Cam lobe height CD
IN
IN (Standard California and U.S.A. ABS/TCS or
U.S.A. LBS-ABS/TCStype)
EX
EX{Standard California and U.S.A. ABS/TCS or
U.S.A. LBS-ABS/TCS type}
Camshaft runout
Camshaft oil clearance A
B
B
!If
Service Limit
0.13---0.19 (0.005---Q.007)
0.22---0.28 (0.009--0.011)
0.1010.0041
36.480--36.640 (1.4362-1.4425)
35.680-35.840 (1 .4047-1 .4110)
36.450 (1.4350)
35.650 (1.4035)
35.970--36.130 (1.4161-1.4224)
35.770-35.930 (1.4083-1.4146)
35.940 (1.4150)
35.740(1.4071)
0.020--0.062 (0.0008-0.0024)
0.050--0.092 (0.0020--0.0036)
0.05 (0.002)
0.100 (0.0039)
0.130 (0.0051)
AA
t
Camshaft journal O. D. A
B
A
B
EX
Valve guide 1.0. IN
EX
Stem-to guide clearance IN
EX
Valve guide projection above cylinder head IN (h)
EX {hI
24.959-24.980 (0.9826-0.9835)
24.929-24.950 (0.9815---Q.9823)
25.000--25.021 (0.9843-0.9851)
25.000--25.021 (0.9843---0.9851)
4.475--4.490 (0.1762---O. 1768)
4.465--4.480 (0.1758-0.1764)
4.500--4.512 (0.1772---0.1776)
4.500--4.512 (0.1772---0.1776)
0.010--0.037 (0.0004-0.0015)
0.020--0.047 (0.0008-0.0019)
15.3-15.5 (0.60--0.61)
15.3-15.5 (0.60--0.61)
24.950 (0.9823)
24.920(0.9811)
4.465
4.455
4.562
4.612
1.0 (0.04)
1.0 (0.04)
41.72 (1.643)
41.72 (1.643)
1.5 (0.06)
1.5 (0.06)
39.6 (15.59)
39.6 (15.59)
25.978-25.993 (1.0228-1.0233)
26.010--26.026 (1.0240--1.0246)
25.968 (1.0224)
26.040 11.0252)
(0.1758)
(0.1754)
(0.1796)
(0.1816)
EX
Valve spring free length IN
EX
Inner IN
Inner EX
Outer IN
Outer EX
Rocker arm 1.0. IN
EX
Rocker arm shaft 0.0. IN
EX
Rocker arm-to-rocker arm shaft clearance
Valve lifter 0.0.
Valve lifter bore 1.0.
Hydraulic tappet adjuster assist spring free length
Hydraulic tappet adjuster compression stroke with kerosene
1-8
General Information
Unit: mm (in)
-
Cylinder/Piston
Item
Standard
73.000--73.015 (2.8740--2.8746)
Cylinder I. D.
Cylinder out of round
Cylinder taper
Cylinder warpage
Piston mark direction
Piston O.D. (D)
Piston O. D. measurement point (H)
Piston pin hole I.D. (d)
--<
Service Limit
73.10 (2.878)
0.10 (0.004)
0.10 (0.004)
0.10 (0.004)
----
~IN"
--
72.970--72.990 (2.8728-2.8736)
19 (0.75)
18.002-18.008 (0.7087-0. 7090)
72.850 (2.8681)
-18.020 (0.7094)
r-
TIu
\\
Cylinder-to-piston clearance
Piston pin O. D.
Piston-to-piston pin clearance
Connecting red-to-piston pin clearance
Top ring-to-ring groove clearance
Second ring-to-ring groove clearance
Top ring end gap
Second ring end gap
Oil ring (side rail) end gap
Top ring mark
Second ring mark
r- Crankshaft
Connecting rod small end 1.0.
Connecting rod big end side clearance
radial clearance
Crankshaft runout
0.010--0.045 (0.0004-0.0018)
17.994-18.000 (0.7084-0.7087)
0.002-0.014 (0.0001-0.0006)
0.016-0.040 (0.0006-0.0016)
0.025--0.060 (0.0010--0.0024)
0.015--0.050 (0.0006-0.0020)
0.15--0.30 (0.006-0.012)
0.30--0.45 (0.012-o.018)
0.20--0.70 (0.008-0.028)
~W
mark facing up
mark facing up
-17.98 (0.708)
--
--
0.10 (0.004)
0.10 (0.004)
0.5 (0.02)
0.7 (0.03)
1.0 (0.04)
--
~RN"
--
18.016-18.034 (0.7093-0.7100)
0.10--0.30 (0.004-0.012)
18.050 (0.7106)
0.40 (0.016)
0.05 (0.002)
0-
I-
0.030--0.052 (0.0012-0.0020)
See page 11-6
0.026-0.048 (0.0010-0.0019)
See page 1 1-6
0.080 (0.0031)
0.065 (0.0026}
Kickstarter
Kickstarter pinion gear 1.0.
Kickstarter spindle O. D.
Kickstarter idle gear 1.0.
Countershaft 0.0. at kickstarter idle gear
Klckstarter idle gear bushing 0.0.
I. O.
1-9
General Information
Unit: mm (in)
-
Transmission
Item
Standard
31.000--31.025 (1.2204-1.2215)
31.000--31.025 (1.2204-1.2215)
30.950--30.975 (1.2185-1.2195)
30.950--30.975 (1.2185-1.2195)
28.000--28.021 (1.1024-1.1032)
0.02~.075 (0.0010--0.0030)
0.02~.075 (0.0010--0.0030)
27.967-27.980 (1.1011-1.1016)
C2, C3
Transmission gear bushing 0.0. M4,M5
C2, C3
Transmission gear bushing 1.0. M4
Gear-to-bushing clearance at M4, M5 gear
at C2, C3 gear
Mainshaft 0.0. at M4 gear bushing
servlce Limit
31.040 {1.2220l
31.040 {1.2220)
30.930 {1.2177J
30.930 i1.2177l
28.031 (1.1036)
27.960 (1 .1008l
M'
e:
=C
q
-
R
Shift fork shaft 0.0. at F shift fork
at C shift fork
at R shift fork
0.020--0.054 iO.000B-O.0021)
5.93-6.00 (0.233-0.236)
5.93-6.00 (0.233-0.236)
5.93-6.00 (0.233-0.236)
14.000--14.021 (0.5512-0.5520)
14.000--14.021 (0.5512-0.5520)
14.000--14.021 (0.5512-0.5520)
13.973-13.984 (0.5501-0.5506)
13.973-13.984 (0.5501-0.5506)
13.973-13.984 (0.5501-0.5506)
95.4 (3.76)
93.0 (3.66)
C
R
1-10
5.9 (0.23)
5.9 {0.23)
5.9 (0.23)
14.03 (0.552)
14.03 (0.552)
14.03 (0.552)
13.965 (0.5498)
13.965 (0.54.98)
13.965 (0.5498l
General Information
Unit: mm (in)
Standard
Item
--
--
Service Limit
i
--14.06 (0.553)
13.94 (0.549)
-34.965 (1.3766)
28.016 (1.1030)
--
----40.0 (1.57)
54.2 (2.13)
------
----
r- Cooling System
Coolant capacity (Radiator and engine)
(Reserve tank)
Standard model
ABS/TCS or lBS-ABS/TCS model
Radiator cap relief pressure
Thermostat begins to open
Thermostat fully open
Thermostat valve lift
Drive Train
Recommended final drive oil
Hypoid gear oil SAE #80
150 ern' (5.1 US oa. 5.3 Imp oz)
Final drive gear oil capacity at disassembly
130 ern' (4,4 US OZ, 4.6 Imp oz)
at draining
0.05---0.15 (0.002---0.006)
Final drive gear backlash
Final drive gear backlash difference between measurements
: 0.30-0.60 (0.012---0.024)
Ring gear-to-stop pin clearance (A)
Stop pin shim
See page 12-10
Ring gear spacer
See page 12-10
Pinion spacer
See page 12-11
Final drive gear assembly preload
2-4 kg-cm (1,7-3,5 in-Ib)
Output gear backlash
Output gear I. D.
Output gear bushing 0.0.
1.0.
Output drive shaft 0.0.
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim
r-'
10.3 (0.01)
1-11
General Information
Unit: mm (in)
-
Wheels/Tires
Standard
Item
---
Service Limit
250
290
250
290
1.5 (0.06)
2.0 (0.08)
kPa
kPa
kPa
kPa
(2.50
(2.90
(2.50
(2.90
kg/cm 2,
kg/cm 2,
kg/cm 2,
kg/cm 2,
36
42
36
42
psi)
psi)
psi)
psi)
--
---
--0.2 (0.01)
2.0 (0.08)
2.0 (0.08)
---
-----
--
---------
------
--
Front Suspension
Front spring free length
(L}
415.6 (16.36)
474.2 (18.67)
483.1 (19.02)
Standard model
ABSfTCS model
LBS-ABSiTCS model
190
177
140
187
174
136
model
model
model
model
model
model
Standard model
ABS/TCS model
LBS-ABS/TCS model
(L}
Standard model
ABS/TCS Model
LBS-ABS/TCS model
1-12
407.3 (16.04)
464.7 (18.30)
473.4 (1B.64)
(7.5)
(7.0)
(5.5)
(7.4)
(6.9)
(5.4)
0.08 US oz.
0.08 US ca;
0.08 US oz,
0.08 US oz.
0.08 US oz.
0.08 US oz.
General Information
Unit: mm (in)
r-- Rear Suspension
Item
Standard
ILl
Damper gas pressure
Damper compressed gas
Damper rod compressed force at 10 mm compressed
Damper drilling point
Shock absorber spring installed length (Standard)
(Adjustable range)
Shock absorber spring adjuster standard position
Shock absorber spring direction
Recommended shock absorber oil
Shock absorber oil capacity
air pressure
256.5 (10.10)
258.9 (10.19)
-----
-------
----
Service Limit
251.4 (9.90)
253.7 (9.99)
--
-------
-------
Brakes - - - - - - - - - - - - - - - - , - - - - - - - - - - - - - , - - - - - - - ,
Front brake
Brake fluid
Brake lever free play
Brake pad wear indicator
DOT 4
To the groove
4.8-5.2 (0.19-0.20)
14.000-14.043 (0.5512-0.5529)
12.700-12.743 (0.5000-0.5017)
13.957-13.984 (0.5495-0.5506)
12.657-12.684 (0.4983-0.4994)
27.000-27.050 (1.0630-1.0650)
27.000-27.050 (1.0630-1.0650)
22.650-22.700 (0.8917-0.8937)
25.400-25.450 (1.0000-1.0020)
25.400-25.450 (1.0000-1.0020)
25.400-25.450 (1.0000-1.0020)
22.650-22.700 (0.8917-0.8937)
26.918-26.968 (1.0598-1.0617)
26.935-26.968 (1.0604-1.0617)
22.585-22.618 (0.8892-0.8905)
25.335-25.368 (O.9974-0.9987)
25.335-25.368 (O.9974-0.9987)
25.335-25.368 (0.9974-0.9987)
22.585-22.618 (0.8892-o.8905)
CD
4.0 (0.16)
0.30 (0.012)
14.06 (0.554)
12.76 (0.502)
13.95 (0.549)
12.65 (0.498)
27.06 (1.065)
27.06 (1.065)
22.71 (0.894)
25.46 (1.002)
25.46 (1.002)
25.46 (1.002)
22.71 (0.894)
26.91 (1.059)
26.91 {1.059}
22.56 (O.888}
25.31 (O.996}
25.31 (O.996}
25.31 (O.996}
22.56 (O.888)
1-13
General Information
Unit: mm (in)
r- Brakes (cant'dl
Standard
Item
Rear brake
Brake fluid
Brake pedal height
Brake pedal free play
Brake pad wear indicator
DOT 4
Battery/Charging System
7.3-7.7 {O.29-0.30}
7.3-7.7 (0.29--0.30)
12.700-12.743
17.460-17.503
12.657-12.684
17.417-17.444
27.000-27.050
22.650-22.700
27.000-27.050
22.650-22.700
26.918-26.968
22.585-22.618
26.935-26.968
22.585-22.618
(0.5000-0.5017l
(0.6874-0.6891)
(0.4983-0.4994)
(0.6857-0.6868)
(1.0630-1.0650}
(0.8917--0.8937)
(1.0630-1.0650)
(0.8917-0.8937)
(1.0598-1.0617)
(0.8892--o.8905}
(1.0604-1.0617)
(0.8892-0.8905)
14.000-14.043 (0.5512--0.5529)
13.957-13.984 (0.5495-0.5506)
6.0 (0.24)
6.5 {0.26)
0.30 (0.012}
12.76 (0.502)
17.515 (0.6895)
12.65 (0.498)
17.405 (O.6852}
27.06 (1.065)
22.71 (0.894)
27.06 {1.065)
22.71 (0.894}
26.91 (1.059)
22.56 (0.888)
26.91 (l.059)
22.56 (0.888)
14.06 (0.554)
13.95 (0.549)
-------------r---------------,--------,
1-14
Service Limit
0-1.0 n ('91-'95}
0.22-0.26 n (After '95)
0-4.0 n ('91-'95)
2.6-3.2 n (After '95)
12.6-15.0 V at 5,000 rpm
14.2-14.8 V at 5,000 rpm
12 V-12 AH
(Maintenance free battery: YTX14-BS)
3 mA max.
2 mA max.
1.4Ax5h
6Ax1h
13.1 V
Below 12.3 V
13.7 (Q.54}
14.4 (0.57}
4.7 (O.19)
12(0.5)
General Information
-
Ignition System
Item
Spark plug
(Standard NGK)
(Standard NIPPONDENSO)
(For cold climate/below 5"C/41"F NGK)
(For cold climate/below 5"C/41 'F NIPPONDENSO)
(For extended high speed riding NGK)
(For extended high speed riding NIPPONDENSO)
Spark plug gap
Ignition timing "'F'. mark
Advance starts
stops
Full advance
Alternator exciter coil resistance {At 20'C/68'F}
Ignition coil resistance (Primary; at 20'C/68F)
(Secondary with plug cap)
(Secondary without plug cap)
Ignition pulse generator resistance (At 20"C/68'F)
Standard
CR8EH 9
U24FER9
--CR9EH 9
U27FER9
0.8-0.9 (0.031-0.035)
12~ BTDC at 1,000 rpm
2,000 rpm
5,000 rpm
2T BTDC at 5,000 rpm
-2.16-3.19 Q
22.5-27.5 kQ
13.5-16.5 kQ
405-495 Q
Service Limit
----i--
----------
---
1-15
General Information
Unit: mm (in)
lights/Meters/Switches
Item
Main fuse
Alternator fuse
Fuse ('91-95)
(After '95)
Standard
30A
Standard model
LBS-ABSfTCS model
55A
10Ax 6, 20Ax 1
5A {Accessory}, 10A x 6, 20A x 1
5A (Accessory), lOA x 5, 15A x 2
10Ax3, 20Ax 1
10Ax1,30Ax2
l2V45/45W x 2
12V 60/55W
12V32/3cp x 2
12V32/3cp x 2
12V32cp x 2
12V1.7W x 4
12V3.4W
12V3W
12V3.4W
12V1.7W
12V3.4W
12V3W
12V3.4W
12V3W
12V3.4 x 2
12V3W x 2
12V3.4W
12V1.7W
12V3W x 2
12V3W
LED x 1
LED x 2
10
90
n
n
130-180 n
45-60 n
10-20 n
98-102C (208-216F)
93-9TC (199-20TF)
Starting System
Starter driven gear 0.0.
Starter clutch outer I.D.
Starter motor brush length
1-16
57.749-57.768 (2.2736-2.2743)
74.414-74.440 (2.9297-2.9307)
12.0-13.0 (0.47--0.51)
Service limit
General Information
Torque Values
-
Standard
Torque
Fastener Type
5 (0.5, 3.5)
10 (1.0,7.2)
22 (2.2, 16)
35 (3.5, 25)
55 (5.5, 40)
Torque
Fastener Type
5 mm screw
6 mm screw
6 mm flange bolt (8 mm head)
6 mm flange bolt (10 mm head) and nut
8 mm flange bolt and nut
10 mm flange bolt and nut
410.4, 3)
9 (0.9, 7)
9 (0.9,7)
12 (1.2, 9)
27 (2.7, 20)
40 (4.0, 29)
1.
2.
3.
4.
5.
Engine
Item
Lubrication:
Oil pump driven sprocket bolt
Oil pressure switch
Oil filter
Oil drain bolt
Oil cooler bolt ("91-'95}
Oil filter boss
Oil pan bolt
Timing belt/cylinder head:
Timing belt tensioner bolt
Timing bait idle pulley bolt
Timing belt driven pulley bolt
Timing belt drive pulley bolt
Cylinder head bolt
Camshaft holder bolt
Cylinder head cover bolt
Spark plug
Vacuum joint
Reduction bolt
Clutch/gearshift linkage:
Clutch lock nut
Shift drum center bolt
Shift return spring pin bolt
Slave cylinder bleed valve
Gearshift arm bolt
Crankcaselcrankshaft/transmission :
Connecting rod cap nut
Crankcase bolt 6 mm
Bmm
10 mm
Pulse generator rotor bolt
Neutral switch
32 mm cap
Alternator:
Alternator terminal nut (After '95)
Alternator shaft nut
Alternator drive gear bolt
Q'ty
1
1
1
1
1
1
14
1
1
2
1
12
24
8
4
4
1
1
1
1
1
1
8
6
7
6
1
1
1
1
1
B
Thread
era.
(mm)
6
PT 1/8
20
12
20
20
6
10
12
8
12
10
6
6
10
5
12
22
8
8
8
6
B
6
B
10
12
10
32
6
14
6
Torque
Nom (kg-m, ft-Ib)
15(1.5,11)
12 (1.2, 9)
10 (1.0,7)
38 (3.8, 27)
65 (6.5, 47)
18 (1.8, 20)
12 (1.2, 9)
46 (4.6, 33)
46 (4.6, 33)
27 (2.7, 20)
65 (6.5, 47)
58 (5.8, 42)
12 (1.2, 9)
120.2,9)
11 (1.1,8)
4 (0.4, 2.9)
38 (3.8, 27)
Remarks
Note 1
Note 3
Note 5
Note 1
Note 1
Note 2
110(11.0,80)
23 (2.3, 17)
23 (2.3, 17)
9 (0.9, 6.5)
12 (1.2, 9)
36 (3.6, 26)
12 (1.2, 9)
23 (2.3, 17)
52 (5.2, 38)
100 (10.0,72)
12 (1.2, 9)
12 (1.2, 9)
8 (O.B, 5.8)
58 (5.B, 42)
16(1.6,12)
Note 2
Note 2
Note 2
Note 2
Note 5
Note 1
Note 1
1-17
General Information
r-'
Frame
Item
Frame/body panels:
Center stand pivot bolt
Side stand pivot bolt
Side stand pivot lock nut
Rotary switch attaching bolt
Footpeg holder 8 mm
10 mm
Grab rail
Grab rail center plate bolt
Saddle bag stay bolt 6 mm
8 mm
Center stand grip bolt
Engine guard mounting bolt
Windshield screw
Q'ty
6
4
2
2
2
3
5
1
1-18
1
1
1
1
2
Torque
dia. (mm)
8
10
10
6
8
10
8
8
6
8
6
8
5
8
27 (2.7, 20)
10 (1.0, 7)
27 (2.7, 20)
10 (1.0,7)
27 (2.7, 20)
35 (3.5, 25)
27 (2.7, 20)
35 (3.5, 25)
10 (1.0,7)
8
8
8
6
1
2
12
Thread
6
2
8
2
1
2
10
6
6
6
5
5
16
6
36 13.6, 25)
10 (1.0,7)
27 (2.7, 20)
0.6 (0.06, 0.43)
27 (2.7. 20)
170.7,12)
22 (2.2, 16)
22 (2.2, 16)
27 (2.7, 20)
12 (1.2, 9)
12 (1.2. 9)
10 (1.0, 7)
8 (0.8, 5.8)
0.9 (0.09, 0.65)
0.9 {0.09, 0.65)
12 (1.2, 9)
10 (1.0, 7)
1.2 (0.12, 0.9)
5
1
2
10
12
8
10
10
18
18
55
65
35
40
40
21
28
1
1
18
8
10 (1.0. 7)
27 (2.7, 20)
1
8
4
Remarks
(5.5,
(6.5,
(3.5,
(4.0,
(4.0.
(2.1,
(2.8.
40)
47)
25)
29)
29)
15)
20)
Note 2
Note 1
General Information
Frame
Item
Front suspension:
Handlebar lower cover bolt
Handlebar upper holder bolt
Handlebar weight screw
Ignition switch mounting bolt
Throttle housing screw
Front fender attaching socket bolt
Standard and LBS-ABSfTCS model
ABSfTCS model
Front fender plate bolt (LBS-ABSfTCS model)
Steering bearing adjustment nut
Steering stem nut
Upper fork pinch bolt
Lower fork pinch bolt
Fork cap
Standard and ABS/TCS model
LBS-ABS/TCS model
Fork socket bolt
Fork damper lock nut
Anti-drive case bolt
Front axle bolt
Front axle pinch bolt
Front pulser ring bolt (ABS/TCS or LBS-ABS/TCS model)
Rear suspension:
Shock absorber upper mounting bolt
Shock absorber lower mounting bolt
Swingarm right pivot bolt
Swinqarrn left pivot bolt
Standard and ABSfTCS model
LBS-ABSfTCS model
Swingarm left pivot bolt lock nut
Rear axle nut
Rear axle pinch bolt
Rear wheel damper plate bolt
Rear pulser ring bolt (ABS/TCS or LBS-ABS/TCS model)
Brake/clutch system:
Front wheel speed sensor bracket bolt (LBS-ABS/
TCS model)
Rear caliper stopper pin bolt
Pad pin plug
Pad pin
Caliper assembly bolt (LBS-ABSfTCS model)
Front caliper pin bolt (caliper side)
(bracket side)
Rear caliper pin bolt
(caliper side)
Standard and ABS/TCS model
LBS-ABSfTCS model
(bracket side)
Standard and ABS/TCS model
LBS-ABSfTCS model
Caliper bleed valve
Standard and ABS/TCS model
LBS-ABS/TCS model
Thread
dia. (mm)
5
8
6
8
5
6
8
8
26
8
10
5
14
8
5
12(1.2.9}
22 (2.2, 16)
22 (2.2, 16)
28 (2.8, 20)
105 (10.5, 76)
23 (2.3, 17)
50 (5.0, 36)
20 (2.0, 14)
23 (2.3, 17)
20 (2.0, 14)
23 (2.3, 17)
4 (0.4, 2.9)
90 (9.0, 65)
22 (2.2, 16)
8 (D.B, 5.B)
1
1
1
10
8
30
50 (5.0, 36)
23 (2.3, 17)
105 (10.5, 76)
1
1
1
1
1
5
6
30
30
30
18
8
6
5
18 (1.8, 13)
22 (2.2, 16)
105 (10.5, 76)
110 (11.0, SO)
27 (2.7,20)
20 (2.0, 14)
8 {O.8, 5.B}
1
1
3
3
9
2
2
6
18
10
10
8
8
8
12 (1.2, 9)
70 P.O, 51)
2.5 (D.25, 1.8)
18 (1.8.13)
33 (3.3. 24)
23 (2.3. 17)
13
9}
1
1
1
1
12
12
8
8
3
6
Q'ty
4
4
2
2
2
2
2
2
1
1
2
4
2
2
2
1
4
1
4
Torque
24
8
10
n.s.
28
28
13
23
(2.8,
(2.8,
(1.3,
(2.3,
20)
20)
17)
17)
Remarks
Note 1
Note 1
Note 1
Note 2
Note 1
Note 1
Note 1
Note 1
Note 1
1-19
General Information
r-r- Frame tccnt'dl
Item
Brake/clutch system tccnt'dj:
Right front caliper mounting bolt (Standard and
ABSrrCS model)
Left front caliper pivot bolt (Standard and ABS/
TCS model); upper
lower
Right front caliper pivot bolt (LBS-ABSrrCS
model); upper
lower
Left front caliper pivot bolt (LBS-ABSrrCS model)
Brake disc bolt
Rear master cylinder push rod lock nut
Secondary master cylinder mounting bolt
(LBS-ABSrrCS model)
Secondary master cylinder push rod lock nuts
(lBS-ABSJTCS model)
Secondary master cylinder link plate bolt
(LBS-ABSjTCS model)
Delay valve mounting bolt (LBS-ABSJTCS model)
Brake lever adjuster rod bolt
Master cylinder holder bolt
Master cylinder reservoir cap screw
Clutch lever pivot nut
Clutch lever pivot bolt
Clutch switch mounting screw
Brake lever pivot nut
Front brake lever pivot bolt
Front brake switch mounting screw
Brake hose oil bolt
Standard model
ABSJTCS model
LBS-ABSrrCS model
Clutch hose oil bolt
Brake pipe joint nut (LBS-ABSrrCS model)
Brake hose clamp screw {at fork tube;
Standard model}
Final drive:
Final gear case mounting nut
Final gear case oil filler cap
Pinion bearing retainer
Pinion joint nut
Retainer lock washer bolt
Final gear case bolt 8 mm
10 mm
Final gear case drain bolt
Dust guard plate bolt
Electrical system:
Ignition coil mounting bolt
Meter mounting bolt
1-20
Q'ty
Thread
dia. (mm)
Nm (kg-m, ft-Ib)
27 (2.7, 20)
1
1
8
6
27 (2.7, 20)
12 (1.2, 9)
1
1
2
18
1
8
6
8
8
8
30 (3.0, 22)
12(1.2,9)
30 (3.0, 22)
43 (4.3, 31)
18 (1.8, 13)
12(1.2,9)
18 (1.8, 13)
2
2
1
8
6
5
6
30 (3.0, 22)
12 (1.2, 9)
4 (0.4, 29)
12(1.2,9)
1.5 (Q.15, 1,1)
6 (0,6, 4,3)
1 (0.1,0.7)
1.2 (0.12, 0.9)
6 (0.6, 4.3)
1 (0.1, 0.7)
1,2 (0,12, 0.9)
35 (3.5, 25}
35 (3.5, 25}
35 (3.5, 25)
35 (3.5, 25)
17 (1,7, 12)
1
1
1
1
1
1
5
9
18
2
,.
1
1
1
1
6
2
1
1
6
6
6
6
10
10
10
10
Torque
10
30
70
16
6
8
10
6
65 {6.5, 43}
12(1.2,9)
150 {15.0, 108}
110(11.0,80}
10 (1.0, 7}
26 (2.6, 19)
63 (6.3, 46)
20 (2.0,14)
10 (1.0, 7)
6
6
9 (0,9, 6.5)
9 (0.9, 6.5)
,.
Remarks
Note 1
Note 1
Note 1
Note 1
General Information
Tools
Tool Number
Description
07HAA-PJ70100
Alternate Tool
07506"':30000~:J
07501-4220100
07401-0010000
07KMA-MS60101
07936-3710001
07936-3710100
07936-3710600
07741-0010201
07749-0010000
Equivalent commercially
available in U.S.A.
Ref.
Section(sl
4
4
4
Pilot screw wrench
(U.S.A. only)
! Not available in U.S.A.
07746-0010200
07746-0040500
07HMD-ML00100
07757-0010000
Tool Number
07959-KM30101
07HMG-MR70001
07HMH-ML0010l
07LMA-MT8010A or
07MMA-MT3010A
Remover weight
07936-3710200
07HMD-ML0010l
07JMJ-KY20100
07780-0010100
07HMH-ML0010A
5
5
8, 10
8, 10
8, 10
8,10,14
8,9,10,
12,13,14
8, 14
8, 10
8
8
8
8
8
8
8
Equivalent commercially
available in U.S.A.
07780-0010300
07780-001200007780-0012100-
8
8
8
07780-0014000
07781-0010600
07914-3230001
07JMB-MN50300
8
8
9, 15
07LMB-MT30100
07716-0020400, Equivalent commercially
07716-0020500....1 available in U.S.A.
07946-1870100
07746-0040200
07945-3330300
07746-0010300
07746-0040600
07746-0010500
07746-0040700
07746-0041100
07HGB-0010l0B
07MPB-764021A
Holder plate
Clutch center collar "B"
,,
s
s
s
s
s
s
10
10,12,13
10
10, 12
10
10
1-21
General Information
r-'
Cont'd
Description
Tool Number
07910 MA10100
07931-ME40000
07924-ME40000
07924-9690102
07948-4630100
07948-5800101
07946-3710500
07965-MC70100
07746-0010400
07746-0040800
07746-0030100
07746-0030200
07931-4630300
07936-4150000
07908-4690003
07LMF-MT30110,
07LMF-MT30120-l
Alternate Tool
Tool Number
Ref.
Section(s)
12
12
12
12
12
12
12
12
07931-ME4010A
Shaft puller
12, 13
12
12
12
12
12
12
13
07947-KF00100
07947-KA40200
07947-KA50100
07916-3710100
07946-MBOOOOO
07953-MJ10000
07953-MJ10l00
07953-MJ 10200
07946-3710100
07GME-0010000
13
13
13
13
13
13
13
07953-MJ 1OOOB
"
07959-MB 10000
,
KS-HBA-08-469
In
,.,.,.
17,18.20,
21
USA
SP-15D
17,18,20,
TH-5H
17,18,20,
21
Analogue tester (KOWA)
1-22
21
General Information
Engine
Location
Upper and lower crankcase mating surface
Material
Remarks
Uquid sealant
3-4 mm
(0.12-0.16 in)
Semi-circular portion of the cylinder head
Valve stem (valve guide sliding surface)
Crankshaft main journal bearings
Connecting rod bearings
Crankshaft thrust surfaces
Crankshaft thrust bearings
Camshaft journals, cam lobes and thrust surfaces
Camshaft driven gear
Cam reduction gear shaft spline
Valve lifter
Piston pin
Primary drive gear
Clutch outer guide
Transmission gearshift fork grooves
Alternator driven gears
Molybdenum disulfide oil (a mixture of engine oil and molybdenum disulfide grease in a 1
1
ratio)
Engine oil
Multipurpose grease
Locking agent
1-23
General Information
r-
Frame
Material
Location
Center stand pivot
Side stand pivot
Rear brake pedal pivot
Gearshift pedal pivot
Throttle grip pipe flange
Steering head bearings
Steering head bearing dust seal lips
Front caliper pivot collars
Multipurpose grease
Driveshaft
Driveshaft
Driveshaft
Driveshaft
Driveshaft
Molybdenum disulfide
paste
CD
yoke joint cotters <Il
yoke joint thrust washer @
yoke joint oil seal lip
groove @
I'"
._-
~A
-, r
I.
"
Engine oil
Sealant
Fork
Fork oil seal lip
Fork fluid
Silicone grease
Insides of the caliper boots
Brake pad pin stopper rings (LBS-ABS/TCS model)
Front master cylinder push rod ends (LBS-ABS/TCS model)
Front master cylinder piston end (Standard and
ABS/TCS model)
Rear master cylinder push rod upper end and boot
groove
Handlebar weight screw threads
Front fork socket bolt threads
Cooling fan nut threads
Caliper pin bolt threads
Secondary master cylinder push rod lock nut threads
(LBS-ABS/TCS model)
Anti-dive case bolt threads
1-24
@I-m
1+.....1Jl..... +
+
Remarks
Locking agent
General Information
_,;rC'~~~~~~~1~~~il{3)
SPEEDOMETER CABLE
I,
-,I
1-25
General Information
Standard Model
" 1~
(5) WIRE
(7) LEFT HANDLEBAR SWITCH
WIRE HARNESS
B~NDS ~
. \\ i
',
'
\~
,x,
1-26
General Information
Standard Model
(1) HIGH BEAM HEADLIGHT
RELAY
'l
~f
./ 'If '
/.4
.,,, /
>:
---==--J>!;;;~
(9) IGNITION
CONTROL
MODULE - -~7 (---',
(ICM)
(8) HARNESS CLIPS
1-27
General Information
(3) THROTTLE STOP SCREW CABLE
Standard Model
2P CONNECTOR
----
~~~~,
~
(9) TURN SIGNAL RELAY
WIRE 4P CONNECTOR
'91-'95:
n i)
(6) THERMO
SENSOR
(25)
SPARK PLUG
WIRES
,
1-28
,,
' / (20j
\ ALTERNATOR
WIRE
(21) CARBURETOR
DRAIN TUBE
{18) BATTERY
{19} STARTER RELAY
SWITCH
General Information
Standard Model
After '95:
(6) FRAME
GROUND
---~--
(7)
ACCESSORY
(ACC) FUSE
(17) SPARK
WIRES
(16)
1-29
General Information
ABS/TCS Model
rr>
//
'
\
"
,/
\\
SENSOR RELAY
CHECKER
--;r---- LoS8
(13) HIGH BEAM
HEADLIGHT
RELAY
,I
1'1
1'1"1
"
,!~
"
',',y
(6) TCS/IGNITION
CONTROL
MODULE
(ICM)
Iir=
III{--,
",
,
,
,
,
,
,
"~-=I
11'--
,,',--
11,----"~I
"~
',~
'I
1-30
General Information
ABS/TCS Model
1~
1-31
General Information
ABsrrcs
Model
(1} FRONT WHEEL SENSOR
3P CONNECTOR
<;
.~~
(10) FRONT BRAKE HOSES
=-~
7':------ ) \
,0 C::]\?\\
IV'"~ \,~'~'V
'J! ((
'/ ( i
/:
I,
(B} FRONT
MODULATOR
I
\
\(\
'\J
, \ '0 Alt;&:~'0
0t-""--",,,,,"
(19) INDICATOR
LIGHT CHECKER
\.
--------
1-32
General Information
ABS/TCS Model
(4) FUEL
FILTER
(3) REAR MODULATOR PUMP MOTOR!
GROUND 2P CONNECTOR
"-
-------
---
<
(7) HARNESS
CLIPS
1-33
General Information
ABS/TCS Model
(9) FUSE
CASE
;>
---(
0?1~'&_'~~ "
\/1
.
WIRE
(14) CARBURETOR
DRAIN TUBE
(15) CLAMPS:
('91-'95 only)
1-34
(13) ALTERNATOR
~,'llOl
ABS FUSE
CASE
(11)BATIERY
(12) STARTER RELAY
SWITCH
General Information
LBS-ABSfTCS Model
,~
\ \,
---;;"-,
---rr~--
,/
(5) LEFT TURN SIGNAL
WIRE CONNECTOR
Ic\~
4"'~'\
I:' '~c-:>i
,
,
,
,
,
,
I,
----;J
I
i (-)J
~
(9) SERVO-BRAKE HOSE
(Secondary Master
Cylinder-to-PCV)
1-35
General Information
lBS-ABSITCS Model
~-
1-36
General Information
lBS-ABsrrcs Model
/
~
J\\~
\
___====--==.=--=
.
I
Ii / (
/ /
/! )
(20} PINS
(21} STOPPERS
(17} 4P (Blue)
CONNECTOR
(16) 4P (Black}
CONNECTOR
1-37
General Information
LBS-ABSfTCS Model
(1) SERVO-BRAKE HOSE
(Secondary Master Cylinder-to-PCV)
,
,
/
(11) LEVER BRAKE HOSE
(Front Modulator-toLeft Caliper)
--------t'--1!;isltili
1-38
General Information
LBS-ABS/TCS Model
L?~~
'r
10-:(
, //JJ
P
CHECKER
UNIT
, .',
(14) FRAME
DRAIN TUBE
(9) FAN MOTOR 2P
GROUND
(12) FUEL UNIT 2P CONNECTOR
CONNECTOR
(13) BATTERY
(15) ACCESSORY
(ACC) FUSE
<~)~"
1/)
~)~~> --("'>
( 16)
ACCESSORY (ACC)
\ , 1 - ' TERMINALS
(Allowable power
and current
capacity: 60W/SA)
1-39
General Information
lBS-ABS/TCS Model
(3) MODULATOR CRANK ANGLE SENSOR
3P (White) CONNECTOR
---------
'--
///-)-------'~.
, .
-_/
---~
./
1-40
Pcv (Proportional
Control Valve)
General Information
lBS-ABSITCS Model
(2) SERVO-BRAKE HOSE
(Rear Modulator-ta-Rear Caliper)
./
,/;---=0.
,/1
iii'
'1'
HOSE
1- A
(9)
STOPPER
(10) JOINT
NECK
(11) REFERENCE NUMBERS;
Two kinds of the numbers are
stamped on each hose jointrefer to the upper line for the
rear modulator
1-41
General Information
All Models
1-42
General Information
Emission Control Systems'
Model'
49 state
California
Standard
ABS/TCS
LBS ABS
(TCS
94 ......95
49 state
91 ......
California
92 ......95
'96"-
Canada
Canada
(3) TO CARBURETOR
AIR CHAMBER
U.S.A. Only
(2) No. 15 TUBE
(B) CARBURETOR
DRAIN TUBE
(7) EVAPORATIVE
EMISSION (EVAP)
CANISTER
('91-'93: Standard
California and U.S.A.
ABS/TCS type only
After '93: California
type only)
(13)No.15TUBE
(14) PULSE SECONDARY
AIR INJECTION {PAIR}
CONTROL VALVE
(FRONT)
~=~~~:';~=~--r-(15)PULSE
'n-"r+Ff<
SECONDARY
AIR INJECTION (PAIR)
CONTROL VALVE
(REAR)
1-43
General Information
'91-'93:
Standard California Type and U.S.A. ABS/TCS Type
After '93:
California Type
(1) EVAPORATIVE EMISSION
(EVAP) PURGE CONTROL
VALVE
II
111'-
')I\----L.I\;J .'~TUBE\,fL1--.t::::-1,~1
/
~'\jiiC_-(5)
No.7 TUBE
(9) No. 6
TUBE,--J\lh~~~
III
\
J---i-J----!--(7) NO.6 TUBE
(8) No.4 TUBE
1-44
General Information
Source of Emissions
The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide
does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.
'91 :
After '91:
(1) AIR CLEANER
(4) CRANKCASE
BREATHER
SEPARATOR
(4) CRANKCASE
BREATHER
SEPARATOR
~~~~~[]J
~ARBURETOR
<:
11---(31
CRANKCASE
I'J /
(3) CRANKCASE
1-45
General Information
Exhaust Emission Control System (Secondary Air Supply System) [U.S.A. only]
The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in
the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable
amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.
The pulse secondary air injection check valves prevents reverse air flow through the system. The pulse secondary air injection control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system.
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is
recommended.
fr-~2====ZF;!) {3 ) PULSE
SECONDARY
AIR INJECTION
(4) TO
(PAIR) CHECK
EXHAUST
VALVE
PORT
151
~,...
1-46
FRESH AIR
General Information
Evaporative Emission Control System
{'91-'93: Standard California Type and U.S.A. ABS/TCS Typel
(After '93: California Typel
This vehicle complies with the California Air Resources Board requirements for evaporative emission regulations.
Fuel vapor from the fuel tank and carburetors is routed into the evaporative emission canister where it is absorbed and
stored while the engine is stopped. When the engine is running and the evaporative emission purge control diaphragm
valve is open, fuel vapor in the evaporative emission canister is drawn into the engine through the carburetor. At the
same time, the evaporative emission carburetor air vent control valve is open and air is drawn into the carburetor through
the valve.
(1) CARBURETOR
(4) DRAIN
(5) EVAPORATIVE
EMISSION (EVAP)
CANISTER
(6) EVAPORATIVE EMISSION
CARBURETOR AIR VENT (EVAP CAV)
CONTROL VALVE
(ENGINE RUNNING)
,
,
,
t
(9) TO OPEN AIR
(8)
~
FRESH AIR
... FUEL VAPOR
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1.
2.
3.
4.
Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.
Removal of, or puncturing of any part of the intake system.
Lack of proper maintenance.
Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those
specified by the manufacturer.
1-47
General Information
INFORMATION LABEL
(3) VACUUM HOSE ROUTING
DIAGRAM LABEL
ABS/TCS type)
(After '93: California type)
The Vacuum Hose Routing Diagram Label is on the rear
fender as shown. The seat must be removed to read it.
'91-'93:
After '93:
VACUUM HOSE ROUTING DIAGRAM
ENGINE FAMILY
EVAPORATIVE FAMILY
CALIFORNIA VEHICLE
EIlP ,mE
C611iOL
1-48
iILIE~;~~~~~k~j~
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
Seat
Side Cover
Saddlebag
Seat cowling
Saddle Bag Stay
Rear Fender
Lower fairing
Pivot Cover
Maintenance Cover
Top Shelter
2-1
2-2
22
2-2
Instrument Panel
2-6
2-6
2-7
2-7
2-3
2-3
2-4
2-4
Middle Fairing
2-8
28
2-5
2-5
2-5
Fuel Tank
Fairing Pocket
Windshield
Rearview Mirror
Upper Fairing
Front Fender (LBS-ABS/TCS model)
Muffler
Exhaust Pipe
2-9
2-11
2-12
2-13
2-18
Service Information
Gasoline is extremely flammable and explosive under certain conditions.
Serious burns may result if the exhaust system is not allowed to cool before components are removed or
serviced.
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.
This section covers removal and installation of the frame body panels, fuel tank and exhaust system.
Frame body panel installation is in the reverse order of removal, unless noted otherwise.
When removing the covers be careful not to damage any tabs or grooves on the covers.
2-1
..
Seat
Unlock the seat with the ignition key.
Push the front of the seat and remove the seat by pulling
it rearward.
(2) HOLE
(1) TAB
I
h="
Install the seat by aligning the four tabs and one hole as
shown, and lock it by pushing it down securely.
(3) TAB
~:A _
,,;:;:::>,,;;
(4) SEAT
",,>,,::2"
.
/
Side Cover
(2) GROMMET
(1) BOSS
(3) CENTER
STAND GRIP
Remove the attaching screw and trim clip, and release the
three bosses from the grommets, being careful not to
damage the tab. Remove the side cover.
NOTE
On the left side cover, pull the center stand grip outward when removing the cover.
~. ~\\-k~
(7) TRIM'
(4) TAB
CLIP
(6) SCREW
Saddlebag
(1) SADDLEBAG
\
(3) LOCK LEVER
(2) HOOK
2-2
Seat Cowling
Remove the left and right side covers and saddle bags.
Remove the four socket head caps.
Remove the four socket bolts, two 8 mm bolts and the left
and right grab rails.
Remove the two 6 mm bolts, ground terminal {After '95)
and collars, disconnect the tail/brake light connector, and
remove the seat cowling.
Torque:
Grab rail bolts: 27 Nm ( 2.7 kg-m, 20 ft-Ib)
(8) SEAT
COWLl~~/
(5) GRAB
RAil
(6) CONNECTOR
(7) GROUND
TERMINAL
(After '95)
Saddlebag Stay
Remove the seat cowling.
Remove the four 8 mm bolts and the grab rail center plate.
Remove the two 6 mm bolts, one 8 mm bolt and the saddlebag stay.
(1) 8 mm BOLTS
~~
(7) 8 mm NUT
Torque:
Center plate 8 mm bolt: 35 N'm (3.5 kg-m, 25 ft-lb}
Saddlebag stay 6 mm bolt: 10 Nrm (1.0 kg-m, 7 ft-Ib)
8 mm bolt: 35 N'm (3.5 kg-m, 25 ft-Ib)
'-';';l
'\131;~~
\
(5) 6 mm BOLT
2-3
Rear Fender
Remove the battery (page 17-7).
Remove the left and right saddlebag stays (page 2-3).
Remove the four socket bolts, rear fender B and the saddlebag stay stopper.
Remove the starter motor cable from the starter relay
switch, and remove the starter relay switch from the rear
fender A.
Remove the three bolts and the battery holder.
Remove the fuse case (s}.
Remove the two bolts and the center stand grip.
Remove the two mounting bolts and rear fender A.
Torque:
Center stand grip bolt: 10 Nom (1.0 kg-m. 7 ft-Ib)
Lower Fairing
Remove the nine socket bolts and the lower fairing.
2-4
Pivot Cover
Remove the side cover (page 2-2).
Remove the three socket bolts and the pivot cover.
Maintenance Cover
(2) TABS
(3) SCREWS
Top Shelter
(2l SCREWS
\,
\~
.
(3) BOLTS
2-5
Fairing Pocket
(2) SCREWS
(3) SCREW
(4) SCREW
(5) SCREWS
(2) SCREW
NOTE
The TCS OFF indicator turns on when the TCS switch
connector is disconnected and then reconnected with
the ignition switch ON. The TCS can be reactivated
by pushing the TCS switch.
(4) SCREW
(3) CONNECTORS
Windshield
Remove the five screws and the windshield.
Remove the two screws and trim clip attaching the
windshield garnish.
Release the four tabs and remove the windshield garnish
from the upper fairing.
(1)
W'NDSH~:'E~L~D~====l
'91-'95:
~J.~
,
(2) TABS
(4) GARNISH
2-6
~II --@)~
(7) SCREW
(6) PLASTIC
WASHER
Oi
(2) TABS
(5) SElTlNG
RUBBER
(4) GARNISH
Instrument Panel
(1) SCREWS
SCREW
~/,
NOTE
(4) ADJUSTER
KNOB
(7) WASHER
(5) NUT
(6) RUBBER
WASHER
2-7
<:
Middle Fairing
(2) CLIP
Rearview Mirror
Remove the rearview mirror case by carefully releasing the
three bosses from the clips of the upper fairing.
Disconnect the front turn signal connector.
Remove the trim clip and the mirror cover inside spacer.
Remove the two bolts and the rearvtew mirror.
(3) CONNECTOR
(4) MIRROR
(5) MIRROR CASE
2-8
Upper Fairing
Removal/Installation
121
151
131
161
181
Requisite Service
Middle fairing inner cover (page 2-7).
Procedure
Remarks
O'tv
Removal Order
1
2
1
2
4
2
4/2
1
I
At installation, align the holes in the headlight with the
mounting bosses of the fairing stay.
2-9
(7)
(t)
/
,
,
,
,
,
,
,
,
,
,
(4)
(2)
Requisite Service
. Upper fairing removal/installation (page 2-9).
Procedure
(1 )
(2)
(3)
(4)
(5)
(6)
(7)
Disassembly Order
Socket bolt/nut
Bolt
Headlight
Bolt/nut
Upper fairing
Screw
Air duct
2-10
a:ty
Remarks
Assembly is in the reverse order of disassembly.
2/2
2
1
1/1
2
2
1
(2)_=_
===---:!
'_~
i__ ,.j
I.
Tabs
Studs
(4)
-~IIII' / , , '
Setting bosses
NOTE
I On the standard and ABSfTCS model, refer to page 13-6 "Front wheel removal/installation".
Procedure
(3)
Removal Order
Socket bolt
Flange bolt/washer
Upper fender
(4)
Lower fender
(1)
(2)
Q'ty
Remarks
Installation is in the reverse order of removal.
2
2/2
1
1
2-11
FuelTank
'4
....._ - ( 7 )
(2)
(8)
12 (1.2. 9)
Requisite Service
(51
(61
171
(8)
(9)
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
2-12
line
pump connector
level sensor connector
fill cap
tank tray
tank mounting bolt
tank
tank heat protector
Q'ty
,,
,,
1
4
,
1
Remarks
Installation is in the reverse order of removal.
Remove from the fuel fill cap and clamp.
Muffler
Right Muffler: Standard Model
--
11 )
22 (2.2, 16)
141
131
15)
16)
35 (3.5, 25)
-(2)
17)---\il
27 (2.7, 20)
27 (2.7, 20)
Requisite Service
Procedure
111
12)
13)
14)
15)
16)
171
181
Removal Order
Muffler band
Muffler mounting bolt
Right footpeg holder bolt 6 mm
8 mm
10 mm
,,
Remarks
Installation is in the reverse order of removal.
Loosen the band bolts.
Right muffler
Gasket
,,
.
.
2-13
-.
(9)
Requisite Service
Right pivot cover removal/installation (page 2-5)
Procedure
(1)
(2)
(3)
(4}
(5}
(6}
(7)
(8)
Removal Order
Harness band
Connector
Muffler band
Muffler mounting bolt
Right footpeg holder bolt 6 mm
8 mm
10 mm
Right footpeg holder
2-14
Q'ty
Remarks
3
2
1
1
1
2
1
1
(1)
.'~~ tt;~-~
- ,7 ;~ ,/
--,.- ',', ' ,
,
"'10../
'-
tII(S)
cc-. ic~:::;~('"
<:~~
-,"
(7)
(3)
(8)
0 2 7 (2.7, 20)
(2)
""'r
(6)
35 (3.5, 25)
Requisite Service
Right pivot cover removal/installation (page 2-5).
Procedure
Q'ty
(4)
Removal Order
Muffler band
Modulator mounting bolt
Muffler mounting bolt
Right step holder bolt 6 mm
(5)
8mm
1
1
1
10 mm
(1)
(2)
(3)
(6)
Remarks
Installation is in the reverse order of removal.
Loosen the band bolts.
2
3
(7)
(8)
Right muffler
Gasket
1
1
.
(S)
2-15
.,
12)
(9)
(11
(5)
(4)
22 (2.2, 16)
C~,
27 (2.7, 20)
(6)
17)
35 (3.5, 25)
(8)
Requisite Service
Left pivot cover removal/installation (page 2-5)
Battery removal/installation (page 17-12)
Q'ty
Procedure
111
(2)
(3)
(4)
(5)
(6)
(7)
(8)
19)
Removal Order
Muffler band
Battery holder bolt
Muffler mounting bolt
Left footpeg holder bolt 6 mm
8 mm
10 mm
left footpeg holder
left muffler
Gasket
2-16
2
2
Remarks
Installation is in the reverse order of removal.
loosen the band bolts.
1
1
1
2
1
1
1
(11)
erJ
(2)
27 (2,7, 20)
(8)
o /----------
(9)
(10)
35 (3.5, 25)
Requisite Service
Left pivot cover removal/installation (page 2-5).
Battery removal/installation (page 17-12).
Procedure
(1)
(2)
[3)
[4)
[5)
[6)
[7)
[8)
[9)
(10)
(11 )
,
,
!
Removal Order
Alternator fuse cover
Bolt/fuse base plate
Battery holder bolt
Muffler band
Muffler mounting bolt
Left step holder bolt 6 mm
8mm
10 mm
Left step holder
Left muffler
Gasket
Q'ty
,
!
,
,
!
Remarks
Installation is in the reverse order of removal.
1
2/1
2
2
1
1
1
2
1
1
1
,
,
2-17
Exhaust Pipe
Right Exhaust Pipe
f!I
110)
.2, g)
18)
17 (1.7,12)
22 (2.2, 16)
(11)
f!I
161
191
Requisite Service
Right middle fairing removal/installation (page 2-8)
Procedure
Removal Order
131
141
151
161
17)
18)
191
1101
('
2-18
Remarks
1
2
4
5
1
1
4
1
2
o
151
(7)
1121
17 (1.7,12)
(61
141
E): 22 (2.2,16)
IBI
I~
(1)~
55 (5.5, 40)
~111
C
(21
27 (2.7, 20)
Requisite Service
Left middle fairing removal/installation (page 2-8)
Right exhaust muffler removal/installation (page 2-14)
Procedure
11)
(21
13)
141
15)
(6)
171
IBI
191
1101
(11):
(12}1
Removal Order
Bolt
Left engine guard
Bolt
Protector gasket
Left exhaust pipe protector
Muffler band
Exhaust pipe joint nut
8 mm mounting bolt/washer
Left exhaust pipe/,chamber
Exhaust pipe gasket
Muffler gasket
Mounting collar
O'tv
Remarks
Installation is in the reverse order of removal.
2
1
4
5
1
4
'B
2
2
1
2-19
~SJt(JJ-/,~;;--
-!
(3) MOUNTING
COLLAR
2-20
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
MUlti-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
3. Maintenance
3-9
Service Information
3-1
Carburetor Synchronization
3-2
3-11
Maintenance Schedule
3-4
Radiator Coolant
3-11
Air Cleaner
Timing Belt
3-12
Spark Plugs
3-6
3-6
Brake Fluid
3-12
Valve Clearance
3-6
3-13
Engine Oil
3-8
Headlight Aim
3-14
Service Information
Rafer to Common Service Manual for service procedures on items not included in this manual.
Refer to specifications (Section 1) for maintenance service data.
3-1
III
Maintenance
3-2
Maintenance
ABS/TCS model shown
(2) HEADLIGHT
ADJUSTING SCREW
(Aim: page 3-14)
(1) SUSPENSION
(Loose, wear, damage)
3-3
Maintenance
Maintenance Schedule
'91-'94
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and clean, adjust, lubricate, or replace if necessary.
R: Replace C: Clean l: lubricate A: Adjust
The following items require some mechanical knowledge. Certain items (particularly those marked > and U) may require
more technical information and tools. Consult an authorized Honda dealer.
~y
...
Whichever
comes
first
Note
Fuel line
Throttle Operation
xl,OOOmi 0.6
x 100 km
Item
10
Months
.'"
c
0
"Es
ur
..
~
a:
c
0
sn
c,
0
I"
I..
Note 5
36
3 6
3-6
38
R
I
Carburetor Synchronization
Note 6
Note 4
3-11
3-11
Note 5
Note 5
Note 5
Cooling System
Secondary Air Supply System
Timing Belt
3-12
Note 5
Note 5.3-12
I
Note 3
3-8
3-9
Note 3
Note 5
Note 5,3 13
Note 5
Headlight Aim
3-14
Clutch System
Note 3
, Suspension
Nuts, Bolts, Fasteners
Wheels/Tires
Steering Head Bearings
I
I
Side Stand
Clutch Fluid
"E
Engine Oil
Note 5
"-c
Note 5
Valve Clearance
Brake Fluid
"
R
I
Radiator Coolant
Note 2
Spark Plugs
"
"-c
12
16
20 24
8
Refer to
128 192 256 320 384
page
12 , 18
24 30 36
Carburetor Choke
Air Cleaner
4
64
6
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Should be serviced by your authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified.
*" In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.
4. '91-'93: Standard California type and U S.A. ABS/TCS type.
'94: California type.
5. Refer to Common Service Manual.
6. All U.S.A. types.
3-4
Maintenance
After '94
Perlorm the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and clean, adjust, lubricate, or replace if necessary.
R: Replace C: Clean L: Lubricate A: Adjust
The following items require some mechanical knowledge. Certain items (particularly those marked * and "*) may require
more technical information and tools. Consult an authorized Honda dealer.
~y
Fuel Line
"eE
64
6
10
Months
Carburetor Choke
I
Note 5
Note 5
Note 5
R
R
36
3-6
3-6
3-8
R
R
Engine Oil
Carburetor Synchronization
Engine Idle Speed
I
I,
Note 3
Cooling System
Secondary Air Supply System
Note 6
I
I
3-8
3-9
3-11
3-11
Note 5
Note 5
Note 5
Note 4
Timing Belt
Brake Fluid
3-12
I
I
Note 2
Valve Clearance
Radiator Coolant
; Spark Plugs
'"c
Note
12
16 20 24
8
Refer to
128 192 256 320 I 384
page
12
18 I 24
30 36
0.6 I 4
x 1,000 mi
Throttle Operation
Air Cleaner
"-o
.s
x 100 km
Item
..
Whichever
comes
first
I
Note 3
Note 5
Note 5,3-12
Note 5
Note 5,3-13
Note 5
Headlight Aim
3-14
Clutch System
Note 5
"
E
Clutch Fluid
Brake System
"-o
-.
'"
~
c,
0
Note 3
Side Stand
..
..
Suspension
WheelslTires
Steering Head Bearings
: Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Should be serviced by your authorized Honda dealer, unless the owner has propertoofs and service data and is mechanically
qualified .
.. In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replace every 2 years. or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.
4. California type.
5. Refer to Common Service Manual.
6. All U.S.A. types.
3-5
Maintenance
Air Cleaner
Remove the top shelter (page 2-5).
Remove the eight screws and the air cleaner housing
cover.
Remove the air cleaner and discard it.
Install a new air cleaner and the removed parts in the
reverse order of removal.
Torque:Housing cover screw:
0.9 N.m (0.09 kg-m, 0.65 ft-Ib)
"""=7'
Spark Plugs
Remove the maintenance cover (page 2-5).
Disconnect the spark plug caps and clean any dirt from
around the spark plug bases.
Remove the spark plugs.
Visually inspect the spark plug electrodes for wear. The
center electrode should have square edges and the side
electrode should have a constant thickness. Discard the
spark plug if there is apparent wear or if the insulator is
cracked or chipped.
For recommended spark plug, see page 1-15.
Measure the spark plug gaps using a wire-type feeler
gauge.
Spark plug gap: 0.8-0.9 mm (0.031-0.035 in)
0.B-0.9 mm
(0.031-0.035 in)
(1) SIDE
ELECTRODE
1
i
__U-__
Valve Clearance
Inspection
NOTE
Inspect and adjust valve clearance while the engine is
cold (below 35'C/95F)
Remove the cylinder head covers (page 8-2).
Remove the timing hole cover.
3-6
Maintenance
Turn the crankshaft clockwise and align the T1 mark on
the timing belt drive pulley guide plate with the timing
belt cover Index mark.
(2) T1 MARK
Shim Selection
If the valve clearance is not correct:
Remove the camshaft (page 8-4), valve lifter and shim
(page 8-8).
NOTE
Be careful not to allow the shims to fall into the
crankcase. The shim may occasionally stick to the
valve lifter.
Mark the positions of all valve lifters and shims to
ensure correct reassembly.
Remove the shim with tweezers or a magnet.
Clean the valve lifter with compressed air.
3-7
Maintenance
Clean the shim with a clean shop towel.
Measure the shim thickness with a micrometer and record
it.
(1) SHIM
NOTE
Engine Oil
Engine Oil and Filter Change
CAUTION
Used engine oil may cause skin cancer if repeatedly
left in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used
oil on a daily basis, it is still advisable to thoroughly
wash your hands with soap and water as soon as '
possible after handling used oil.
NOTE
Change the engine oil with the engine warm and the
motorcycle on its center stand to assure complete
and rapid draining.
Remove the lower fairing (page 2-4).
Remove the oil filler cap and oil drain bolt. and drain the
engine oil.
Remove the oil filter with the special tool and let the remaining oil drain out. Discard the oil filter.
Is ';""OOL I
Oil filter wrench
3-8
07HAA-PJ70100
'91-'95 shown:
(1) OIL FILTER
Maintenance
Apply a thin coat of engine oil to the O-ring on the new
oil filter.
Install the oil filter and tighten it with an oil filter wrench.
Torque: 10 N"m (1.0 kg-m. 7 tt-tb]
Check that the sealing washer on the drain bolt is in good
condition. Install the drain bolt and tighten it.
Torque: 38 Nom (3.8 kg-m. 27 ft-Ib)
(1) O-RING
......~--/
(2) UPPER
rJ.:J!;;~1 LEVEL
ll),.<;;;;l.iI=L I3 J LOWER
LEVEL
CAP
Carburetor Synchronization
NOTE
Refer to section 2 of Common Service Manual for
carburetor synchronization procedure.
Synchronize the carburetor with the engine at normal
operating temperature. the transmission in neutral and
the motorcycle supported upright.
3-9
Maintenance
(All U.S.A. types)
Disconnect the NO.2 and 4 cylinder vacuum tubes at the
3-way joint, and connect the vacuum gauge adaptors.
U.S.A.TYPE
{Canada type}
Remove the vacuum tube caps from the No. 2 and 4
cylinder vacuum tubes and install the vacuum gauge
adaptor tubes.
'91-'93:
(Standard California type and U.S.A. ABS/TCS type)
After '93:
(California type)
Disconnect the No. 1 cylinder vacuum tube from the
EVAP CAY control valve apply vacuum to the EVAP CAY
control valve and pinch the tube with a clamp.
. '
~
"
r).
:-\ ' , _
_~
fO
"" 'cL
'---~
I
,
"I
,~-./iJl
L~;~Wlli
,
II
I.
'91-'93:
(Standard 49 state and Canada type)
After '93:
(49 state and Canada type}
Remove the vacuum joint tube cap from the No.1 cylinder
vacuum tube and install the vacuum gauge adaptor tube.
.>:
~::Q\'
\.
~~.
" "'~
~~
". a
,--~',
~----
---
-f
~
=--
(2) PLUG
NOTE
I,
~~---
, ,
<,
3-10
Maintenance
NOTE
Inspect and adjust idle speed after all other engine
adjustments are within specifications.
Engine must be warm for accurate adjustment. Ten
minutes of stop-end-go riding is sufficient.
Warm up the engine, shift the transmission into neutral
and place the motorcycle on its center stand.
Open the top shelter lid with the ignition key.
Adjust the idle speed by turning the throttle stop control
knob.
Idle speed:1.200 100 rpm
1,000 100 rpm (Canada typel
./
STANDARD MODEl:
(1) RESERVE TANK
/!)~
~!lJl ~
Radiator Coolant
Check the coolant level in the reserve tank while the
engine is at normal operating temperature.
The level should be between the UPPER and LOWER level
lines.
iJ,4cc;/
/(!:)-'-
, / -' ' /
/ / ~/' :0;-\__
<\
./-
ABS/TCS MODEL:
/~-Aq:.~h
~
L1~4~~~.
/ /.
' - --=-----=-------=---.-----=--
(Standard Model)
If the level is low, remove the right side cover (page 2-2),
remove the filler cap and add the recommended coolant to
the UPPER level line.
NOTE
3-11
Maintenance
(ABS/TCS or LBS-ABS/TCS model)
If the level is low, remove the right maintenance cover
(page 2-5), remove the filler cap and add the recommended
coolant the UPPER level line.
For coolant draining/refilling, see section 6.
Timing Belt
(1) TIMING BELT
Remove the reduction holder covers (page 8-2).
Remove the timing hole cover (page 3-5).
Check the timing belt for cracking, damage or contamination with oil and/or coolant while turning the crankshaft
clockwise.
If the belt is cracked or damaged, replace it with a new
one (page 8-12).
If the belt is contaminated with oil and/or coolant, remove
the timing belt cover (page 8-3). Clean the timing belt
housing and pulleys thoroughly, then replace the belt with
a new one.
Brake Fluid
NOTE
For front brake fluid level checking and fluid
replacement, refer to the Common Service Manual.
For fluid replacement on the LBS-ABS/TCS model,
see page 15-2.
(2) LOWER LEVEL
3-12
Maintenance
(1) SECONDARY
MASTER
CYLINDER
(1) BRAKE
PEDAL
3-13
Maintenance
Headlight Aim
An improperly adjusted headlight may blind
on-coming drivers, or it may fail to light the road
for a safe distance.
Place the motorcycle on a level surface.
Horizontal:
Insert a screwdriver into the hole in the middle fairing inner
cover, and turn the adjusting screw to adjust the headlight
beam.
Vertical:
Adjust the headlight beam to suit riding conditions by
turning the headlight adjusting knob.
~
11
~ \\,
\\
I II
,
:~\\\~
I,
~j
3-14
~(
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
4. Lubrication System
Service Information
4-'
4-4
Troubleshooting
4-'
4-6
4-2
4-8
III
Service Information
;'
If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in
an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness
and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although
this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with
soap and water as soon as possible after handling used oil.
When removing and installing the oil pump use care not to allow dust or dirt to enter the engine.
If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
For oil pressure check, refer to section 4 of the Common Service Manual; for the switch location, see page 21-2 of this
manual.
For oil pressure light inspection, refer to section 25 of the Common Service Manual.
Troubleshooting
Oil level low
Oil consumption.
External oil leak.
Worn piston ring or incorrect piston ring installation.
Worn valve guide or seal.
Oil contamination (White appearance)
Coolant mixing with oil.
-Faulty head gasket.
-Water leak in crankcase
4-1
Lubrication System
'91-'95
~!~iE~!~~~--
(2) CAMSHAFT
b!;;;l[f~-
(5) PISTON
'\,
~.
:'
(7) CRANKSHAFT
(8) ORIFiCE
(19) COUNTERSHAFT
_ =0
{20} MAINSHAFT
t:
4-2
Lubrication System
(1) CAMSHAFT HOLDER
After '95
~!~~!~!~I~~--
(2) CAMSHAFT
(3) ORIFICE
(GASKET} --_.~
~~~~_-(3)
::I::~:RESSURE
(5) PISTON
(GASKET)
,,,
,,
I
(10) OIL GALLERY
(S) ORIFICE
(12) OIL PUMP
(9) ALTERNATOR
(19) MAINSHAFT
(16) CLUTCH
4-3
System
Lubrication
1/InstaIIation
til
(8)
til
(2)
(4)
(5)
(3)
65 (6.5, 47)
. Engln~
.
p
dlil draining
fairing
. remova l/installation
.
(age2
8).
Left mid
Q'ty
Procedure
Removal Order
Oil filter
(2)
a-ring
(3)
Water hose
(4)
Oil cooler bolt
(5) Oil cooler
(6)
a-ring
(7) , Oil orifice
(8)
a-ring
(1)
4-4
Remarks
I
I
!~91-'95
1
1
1
1
onlv
01 I
Lubrication System
MEMO
4-5
Lubrication System
qI
131
(21
\
tIIP
qI
191
.-...
181
liS
1101
141
18)
(11 )
171
015{1.5,11)
(6)
(13)
1121
4-6
J5).IiI
~
tIIP
151
(8)
111
(14)
(15)
(16)"71
Lubrication System
NOTE
The oil pump drive and driven sprockets, and clutch outer guide, can be removed without removing the oil pan.
Requisite Service
Engine oil draining
Exhaust pipe removal/Installation (page 2- 1B)
Clutch disassembly/assembly (page 9-6)
Procedure
(I)
(2)
13)
14)
(5)
(6)
(7)
18)
(9)
lID)
(11)
(12)
('3)
('4)
('5)
(' 6)
{17}
Removal Order
Oil pan bolt
Oil pan
Gasket
Oil strainer
Oil strainer packing
Oil pump driven sprocket bolt
Oil pump driven sprocket
Oil pipe/pump mounting bolt
Oil pipe
a-ring
Oil pump/a-ring
Oil pump drive chain
Oil pump drive sprocket
Washer
Thrust bearing
Clutch outer guide
Oil drain bolt/washer
Q'ty
Remarks
Installation is in the reverse order of removal.
,4
1
,,
,,,
1
2
1/1
1
,,
,,
1/1
4-7
Lubrication System
{b]
Io)
Ill)
qt
(10)
(7)
(4)
111
113)
18)
(9)
(12)
(6)
Punch mark
NOTE
Requisite Service
Oi pump removal/installation (page 4-6)
Procedure
111
121
131
141
15)
(6)
(7)
(8)
(9)
1101
1111
1121
113)
lal
Ib)
101
Id)
Disassembly Order
Bolt
Oil pump cover
Scavenging pump outer rotor
Scavenging pump inner rotor
Drive pin
Scavenging pump body
Oil seal
Dowel pin
Outer rotor
Inner rotor
Ojl pump shaft
Drive pin
Washer
Snap ring
Washer
Relief valve spring
Relief valve piston
4-8
O'tv
Remarks
Assembly is in the reverse order of disassembly.
3
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
5. Fuel System
Service Information
5-1
Troubleshooting
5-2
Carburetor Removal/Installation
5-3
Carburetor Separation/Combination
5-4
Carburetor Disassembly/Assembly
5-8
Carburetor Draining
5-12
onrvl 5-17
5-18
Service Information
Bending or twisting the control cables will impair smooth operation and could cause the cable to stick or bind,
resulting in loss of vehicle control.
Gasoline is extremely flammable and is explosive under certain conditions.
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.
CAUTION
Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms
might be damaged.
Refer to section 2 for fuel tank removal and installation.
Refer to section 21 for fuel pump inspection, removal and installation.
When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
Before disassembling the carburetors, place an approved gasoline container under the carburetor drain tube, then loosen
the drain bolt and drain the carburetor (page 5-18).
After removing the carburetors, wrap the intake port of the engine with a shop towel or cover it with piece of tape to prevent
any foreign material from dropping into the engine.
U.S.A. only:
All hoses used in the secondary air supply system {All U.S.A. types} and evaporative emission control systems {"91'93: Standard California type and U.S.A. ABS/TCS type/After '93: California type are numbered for identification.
When connecting one of these hoses, compare the hose number with the Vacuum Hose Routing Diagram Label, page
1-35, and carburetor tubes. page 5-6.
NOTE
If the vehicle is to be stored for more than one month, drain the float bowls (page 5 18). Fuel left in the float bowls
may cause clogged jets resulting in hard starting or poor dnveability.
5-1
Fuel System
Troubleshooting
Engine won't start
Too much fuel getting to the engine
-Air cleaner clogged
-Flooded carburetor
Intake air leak
Fuel contaminated/deteriorated
-jets clogged
Starting enrichment circuit clogged
No fuel to carburetor
-Fuel filter clogged
-Fuel line clogged
-Fuel level misadjusted
-Fuel tank breather tube clogged
-Fuel pump malfunction
-Auto fuel valve malfunction
Lean mixture
Fuel jets clogged
Float valve faulty
Float level too low
Fuel line restricted
Carburetor air vent tube clogged
Intake air leak
Fuel pump malfunction
Auto fuel valve malfunction
Vacuum piston faulty
Throttle valve faulty
Rich mixture
Starting enrichment valve open
Float valve faulty
Float level too high
Air jets clogged
Air cleaner contaminated
Flooded carburetor
Vacuum piston faulty
Engine stalls, hard to start, rough idling
Fuel line restricted
Ignition malfunction
Fuel mixture too lean/rich
Fuel contaminated/deteriorated
-jets clogged
Intake air leak
Idle speed misadjusted
Float level misadjusted
Fuel tank breather tube clogged
Fuel pump malfunction
Pilot screw misadjusted
Starting enrichment circuit clogged
Auto fuel valve malfunction
EVAP CAV control valve faulty
Hoses of the emission control system faulty
EVAP purge control valve faulty
Afterlire when engine braking is used
Lean mixture in slow circuit
Air cut-off valve malfunction
Secondary air supply system faulty
Hoses of emission control system faulty
Afterlire or misfiring during acceleration
Ignition system malfunction
Fuel mixture too lean
Poor performance (driv8ability) and poor fuel economy
Fuel system clogged
Ignition system malfunction
Faulty EVAP CAV control valve
Damaged/misconnected emission control system hoses
5-2
Fuel System
Carburetor Removal/Installation
131
17)
141
lD~Tl:1--_121
1'1
191
18)
151
Requisite Service
Fairing pocket removal/installation (page 2-6)
Air cleaner housing removal/installation (page 5-10)
Procedure
111
12)
13)
141
Removal Order
Choke cable
Fuel tube
Throttle stop screw cable
NO.6 tube
15)
161
171
181
O'tv
,,
Remarks
Installation is in the reverse order of removal.
4
2
,,
1
1
5-3
Fuel System
Carburetor Separation/Combination
(2)
(4)
1'81
l
0'
8 (0.8, 5.8)
1111
191
11 )
;;
(81
til :
. , : O-rings
5-4
Fuel System
Requisite Service
Carburetor removal/installation (page 5-3)
EVAP purge control valve and tube removal/installation
('91-'93 : Standard California type and U.S.A. ABS;TCS type/After '93 : California type: page 5-17)
Procedure
111
12)
(3)
14)
15)
IB)
(7)
IB)
19)
(10)
111)
112)
(13)
(14)
(15)
(1B)
117)
11 B)
119)
120)
Disassembly Order
Carburetor drain tube/joint assembly
Screw
Lock plate
Air duct holder
Screw/lock plate
Air chamber/duct assembly
Dowel pin
Air vent tube/joint assembly
Fuel tube/joint assembly
Carburetor joint bracket
Carburetor connecting screw
Starting enrichment valve link
Throttle link
Starting enrichment valve arm shaft/spring
Starting enrichment valve arm
Thrust spring
Synchronization spring
Sub air cleaner tube/joint
Air joint pipe/O-ring
Fuel joint pipe/O-ring
Reassembly Order
Fuel joint pipe/O-ring
Air joint pipe/O-ring
Sub air cleaner tube/joint
Starting enrichment valve arm
Starting enrichment valve rod/spring
Carburetor connecting screw
Carburetor joint bracket
Throttle link
(12) Starting enrichment valve link
IB) Air chamber/duct assembly
120)
119)
I' 8)
I' 5)
114)
111)
110)
I' 3)
15)
117)
(1B)
19)
(8)
(7)
(4)
13)
12)
111
Screw/lock plate
Synchronization spring
Thrust spring
Fuel tube/joint assembly
Air vent tube/joint assembly
Dowel pin
Air duct holder
Lock plate
Screw
Carburetor drain tube/joint assembly
Q'ty
Remarks
,
4
2
1
8/4
1
8
2
,
,,
1
2
2/2
2
2
3
2
2/4
2/4
2/4
2/4
2
2
2/2
2
1
1
1
8/4
3
2
2
8
1
2
4
5-5
Fuel System
Carburetor Tube Routing ('91-'93: Standard California type and U.S.A. ABSrrCS type)
(After '93 : California type)
5-6
Fuel System
MEMO
5-7
Fuel System
Carburetor D'isassemblv/Assembly
Canada type
(32)
151
(34)
1311
(31
~
1141
1131~
(21 )
1201
{1 O} - - - - - - - - - - -
5-8
Fuel System
NOTE
The vacuum chamber and float chamber can be serviced with the carburetors assembled .
The pilot screws are factory pre-set and should not be removed unless the carburetors are overhauled.
Requisite Service
Procedure
(11
(2)
(3)
(4)
15)
(6)
(7)
(8)
Disassembly Order
. Vacuum chamber
Screw
Vacuum chamber cover
Compression spring
Diaphragm/piston
Needle holder
Spring
Jet needle
Washer (Canada type only)
{10)
(11 )
(12)
( l3)
(14)
(15)
( l6)
(17)'
(18)1
(19)
Float chamber
Screw
Float chamber
O-ring
Float-pin
Float
Float valve
Float valve seat
Sealing washer
Main jet
Needle jet holder
Slow jet
(20)
(21 )
122)
123)
(24)
(25)
(26)
(27)
(28)
Pilot screw
Pilot screw
O-ring
Washer
Spring
(9)
Remarks
! Assembly is in the reverse order of disassembly .
4
I
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
I 1/1
1
~=t
1
1
1
5-9
Fuel System
0:
(11
(2)
,}-----c, (3)
4)
~
(5)
u,...-__ 17)
61-_-- 18 )
(10)
(9)
(13)
f!1
/.-_--1 6)
5-10
Fuel System
Requisite Service
(' )
(2)
(3)
Removal Order
Air cleaner housing cover screw
Air cleaner housing cover
a-rings
(4)
(5)
Air cleaner
Air cleaner gasket
(6)
(7)
(6)
(9)
(10)
(11)
(12)
(13)
Q'ty
Remarks
Installation is in the reverse order of removal.
,,
,
1
6
2
,,
,
5-11
Fuel System
W" .\>
07KMA-MS60101or
07LMA-MT8010A or
07MMA-MT3010A
(U.S.A. only)
Insert the pilot screw wrench from the direction
shown to turn each pilot screw. Use a flashlight to
help locate the pilot screw.
1. Turn each pilot screw clockwise until it seats lightly and
back it out to the specification given.
This is an initial setting prior to the final pilot screw
adjustment.
Initial opening:
2-1/4 turns out (Standard 49 state typel
2-5/8 turns out (Standard California type and U.S.A.
ABSi TCS typel
1 7/8 turns out (Canada type)
I I
WRENCH
~ (2) NO 3
, ,;.
..
CARBURETOR
"'"T
~'" .~ -..1
)''-:;;''~I'-<.."","
;-.
.
I,,':', <'~"~.k:.,i.
'<. /"
-""'
_Y"
W..
(2} NO.3
~~;~~~~W-'"
~~;~t
~" " P "
\j
/
'C,\c'C:":----=,",-)~/'
~~~~~~REW1" I,'~~~:~~ ;~:~::',~_
', '(',;lYC-'(
I -'" '-'-'-
"'.
1
.1'1"
(5)
~.~-
'"''-'''
,
-~
'/c"=5)~~:o
~:JR:)
T''--{
A \
,'N.I
CAUTION
Damage to the pilot screw seat will occur if the
pilot screw is tightened against the seat.
2 Warm up the engine to operating temperature.
Stop-and-go riding for 10 minutes is sufficient.
3. Attach the tachometer according to the tachometer
manufacturer's instructions.
4. Adjust the idle speed with the throttle stop control
knob.
(1) PILOT
SCREW
5. Turn each pilot screw 1/2 turn out from the initial
setting.
6. If the engine speed increases by 50 rpm or more, turn
each pilot screw out by successive 1/2 turn increments
until engine speed does not increase.
7. Adjust the idle speed with the throttle stop control
k.nob.
8. Tum the No.1 carburetor pilot screw in until the engine
speed drops 50 rpm.
9. Turn the No.1 carburetor pilot screw out 7/8 turn
from the position obtained in step 8.
10. Adjust the idle speed with the throttle stop control
knob.
11. Perform steps 8, 9 and 10 for the No.2, 3 and 4
carburetor pilot screws.
5-12
Canada Type
(1) PILOT
SCREW
Fuel System
Pilot Screw Access
No. 1 Carburetor
Remove the right side Maintenance Cover. Remove the
plastic timing belt cover on the front of the cylinder
head. Using a 12-inch or longer #1 screwdriver and a
flashlight to guide you, push the rubber carburetor heat
insulator away from the carburetor body.
Insert the Pilot Screw Wrench into the pilot screw hole
by using the lug on the carburetor body as a guide.
Align the socket with the pilot screw head by turning the
wrench slowly while pushing it lightly onto the pilot
screw head.
Return the carburetor heat insulator to its
position after making the adjustment.
(2) LUG
original
07LMA-MTB010A or
07MMA-MT3010A
No. 2 Carburetor
Insert the Pilot Screw Wrench from the rear upper side
of the cylinder head between the frame and the fairing
as shown.
~~~(3) LUG
(2) SOCKET
5-13
Fuel System
No.3 Carburetor
Insert the pilot screw wrench from the lower side of the
auto fuel valve between the frame and the fuel filter as
shown.
Align the socket of the wrench to engage with the pilot
screw head in the same manner as for No. 1 carburetor.
)~~
(2) FRONT
:?'H--f--131 LUG
(6) FUEL
FILTER (5) FRAME TUBE
(1) SOCKET
- ." :'[",--=-.
\
(1) #4 TUBE
5-14
Fuel System
Position the socket end of the wrench against the lug on
the carburetor.
(1) SOCKET
Push the tool against the lug to bend the flexible portion
of the tool under the throttle bell crank as shown.
(1) THROTILE
BELL CRANK
{2) PILOT
SCREW
WRENCH
NOTE
Do not operate the throttle when the Special Tool is
on the pilot screw.
5-15
Fuel System
(1) NO, 1
,r-"...-[
CARBU---1_C
l+i~2il;~~~
RETOR
(2) NO.3
CARBURETOR
(4) NO.
NOTE
(1) NO
1'~
~
CARBURETOR
Is~()~1
07KMA-MS60101 or
07LMA-MT8010A or
07MMA-MT3010A
(U.S.A. only)
Insert the pilot screw wrench from the direction
shown for each pilot screw. Use a flashlight to help
locate the pilot screw.
""
rx-r121 NO.3
(L ")''.::,:1
I.
".y.>.'
~,,;~-,<'-J'~
~,=zJ/_ =->:(\~ r
j-
CARBURETOR
~I~-_
I.,:
100 rpm
NOTE
These adjustments must be made at high altitude to
ensure proper high altitude operation.
---!
Attach the Vehicle Emission Control Information Update
label on the left side of the frame as shown. See Service
Letter No. 132 for information on obtaining the label.
NOTE
5-16
(1) UPDATE
LABEL
Fuel System
SUC~TlaN
PORT
, I
U
'
Ix
NOTE
The pulse secondary air injection (PAIR) control valve
and the pulse secondary air injection (PAIR) check
valve are combined in one assembly.
rfTUBE
,,'
..
r.E09
, ( 3 ) PAIR
:
CONTROL
L-
/~{;..,:c~=~.
l
VALVE
:", . "'J~I
[!Ot'y! ,<,
i~
'
Remove the air cleaner housing cover and put your finger
on the air suction port of the air chamber.
Perform the secondary air supply system inspection (refer
to section 7 of the Common Service Manual).
(1) NO.15TUBE
\
"
",,,",
ABS/TCS type}
(1) N} 11 TUBE
~'~:}~;,~7r:;!:'~',~:~",~
'''''''' ' ",,,,, I, '"",. 1J
' :~i?l;f$~ , V;."",,'
(J;
~'", ,"
f? "~,-", '",""':'
U . 1i~/
,~
<,
(2)EVAP
PURGE
(3} No.5 TUBE CONTROL
VALVE
5-17
Fuel System
Carburetor Draining
~2
CARBURETOR:
(2) ACCESS HOLE
(3)
14 in.
SCREWDRIVER
--
(1} FRONT
~4
CARBURETOR:
:"""-.
...
----
(1) FRONT
5-18
(3) NOTCH
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
6. Cooling System
Service Information
6-1
Radiator Disassembly/Assembly
6-6
Troubleshooting
6-1
6-7
6-2
Coolant Draining
6-4
Installation
6-8
Radiator Removal/Installation
6-5
Thermostat Removal/Installation
6-10
Service Information
Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot
and the coolant is under pressure may causa serious scalding.
Radiator coolant is toxic. Keep it away from eyes. mouth, skin and clothes.
-If any coolant gets in your eyes. rinse them with water and consult a doctor immediately.
-If any coolant is swallowed, induce vomiting. gargle and consult a physician immediately.
-If any coolant gets on your skin or clothes. rinse thoroughly with plenty of water.
KEEP OUT OF REACH OF CHILDREN.
Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system service can be made with the engine in the frame.
Avoid spilling coolant on painted surfaces.
After servicing the system, check for leaks with a cooling system tester.
Refer to section 25 of the Common Service Manual for fan motor switch and thermo sensor inspections.
Troubleshooting
Engine temperature too high
Faulty radiator cap.
Insufficient coolant.
Passages blocked in radiator, hoses, oil cooler, or water jacket.
Air in system.
Faulty water pump.
Thermostat stuck closed.
Faulty cooling fan motor.
Faulty cooling fan motor switch.
Coolant leaks
Faulty pump mechanical seal.
Deteriorated O-rings.
Faulty radiator cap.
Damaged or deteriorated cylinder head gasket.
Loose hose connection or clamp.
Damaged or deteriorated hoses.
6-1
Cooling System
(3) RADIATDR
OVERFLOW TUBE
(2) THERMOSTAT
(1) RADIATOR CAP
(4) BYPASS TUBE
(8) RADIATOR
6-2
Lubrication System
After '95
(3) RADIATOR
OVERFLOW TUBE
(5) RESERVE TANK
LBS-ABSjTCS model shown:
(2) THERMOSTAT
(1) RADIATOR CAP
(4) BYPASS TUBE
(7) RADIATOR
6-3
Cooling System
Coolant Draining
NOTE
For coolant replacement, refer to section 5 of the
Common Service Manual.
Remove the left and right middle fairings (page 2-8).
Remove the radiator cap.
Remove the radiator drain plug and gasket, and drain the
coolant from the radiator.
Remove the drain bolts and sealing washers from the left
and right cylinders, and drain the coolant from the engine.
STANDARD MODEL:
ABS!TCS or lBS-ABSI
TCS MODEL:
.. ~
~.\
~"t!J~>:-~1
.. ~
6-4
---_/1
Cooling System
Radiator Removal/Installation
151
111
.2 (0.12, 0.9)
141
"
~;o,~--131
Requisite Service
Upper fairing removal/installation (page 2-9)
Coolant draining {page 6-4}
Coolant refill (Section 5 of the Common Service Manual)
Procedure
111
121
131
141
151
Removal Order
Radiator hose
Fan motor switch connector
Horn
Radiator mounting bolt/collar
Radiator
Q'ty
,,
Remarks
Installation is in the reverse order of removal.
2
1
1
2/2
1
6-5
Cooling System
Radiator Disassembly/Assembly
(1) '91-'95 shown
ew
(51
181
(41
(101------!~-
et
c:
(91
12 (1.2, 9)
(31
Requisite Service
Radiator removal/installation (page 6-5)
Q'ty
Procedure
( 11
(21
(31
(41
(51
(61
(71
(81
(91
(101
Disassembly Order
Radiator grille
Fan motor switch wire connector
Shroud mounting bolt/ground wire
Shroud
Fan mounting nut
Cooling fan
Fan motor mounting nut
Fan motor
Fan motor switch
O-ring
6-6
Remarks
Assembly is in the reverse order of disassembly,
I,
I
1
1
3/1
1
1
1
3
1
1
1
Cooling System
After '91:
iIiIliI
(3)
,.,
(6)
'91-'95 only:
Requisite Service
Timing belt idle pulley removal/installation (page 8-10)
Procedure
(11
(2)
(3)
(4)
(5)
(6)
Removal Order
Oil cooler water hose/breather hose
Timing belt tensloner spring hook bolt
Bolt
Water pump
I Dowel pin
'I O-ring
my
Remarks
Installation is in the reverse order of removal.
1/1
1
7
,
Be careful not to damage the reduction holder gasket.
2
2
6-7
Cooling System
P) --f+--f-~'ir'
-'IV"
~(j
(2)~_ _
(3)
(4)
Requisite Service
{11
(2)
(3)
(4)
Removal Order
Rear brake reservoir mounting bolt
Reserve tank mounting bolt/clamp
Radiator overflow tube
Reserve tank
6-8
O"ty
,
,,
2/1
Remarks
Installation is in the reverse order of removal.
Cooling System
I I '-
Requisite Service
Right middle fairing removal/installation (page 2-8).
Q'ty
Procedure
(' I
(21
(31
141
Removal Order
Reseve tank mounting bolt
Radiator overflow tube
Breather tube
Reserve tank
,,
Remarks
Installation is in the reverse order of removal.
6-9
Cooling System
Thermostat Removal/Installation
161
~10 (1.0, 7)
..... 18)
111
121
.2 (0.12, 0.9}
110)
191
13)
"'14)
{11}
~151
Requisite Service
Upper fairing removal/installation (page 2-9)
Coolant draining (page 6-4)
Coolant refill (Section 5 of the Common Service Manual)
Procedure
Removal Order
Mounting bolt
Radiator overflow tube
Bypass tube
Thermo sensor
Thermo sensor wire connector
Radiator hose
Water hose
Thermostat case bolt
Thermostat case
Thermostat
(11 ) O-ring
111
12)
13)
14)
15)
16)
17)
18)
19)
110)
6-10
a'ty
Remarks
Installation is in the reverse order of removal.
1
1
1
1
1
1
2
2
1
1
1
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
7-1
Engine Removal/Installation
7-2
Service Information
A floor jack or other adjustable support is required to support and maneuver the engine.
CAUTION
Do not support the engine using the oil filter.
The following components can be serviced with the engine installed in the frame.
- Oil pump (Section 4)
-Carburetor (Section 5)
-
7-1
Engine Removal/Installation
Engine Removal/Installation
'91-'95
(1 1 )
131
(16)
111
40 (4.0, 29)
(19)
35 (3.5, 25)
0 4 0 (4.0, 29)
65 (6.5, 47)
1151
1151
--rr----=~~~
40 (4.0, 29)
~~o
35 (3.5, 25)
141
(14)
(20)
(13)
1171
(18)
(16)
171
40 (4.0, 29)
7-2
.,
55 (5.5, 40)
Engine Removal/Installation
Requisite Service
Muffler removal/installation (page 2- 13)
Exhaust pipe removal/installation (page 2-1 B)
Carburetor removal/installation (page 5-3)
Radiator removal/installation (page 6-5)
Procedure
Q'ty
11}
12}
13}
14}
15}
16}
17}
18}
19}
110}
111}
112}
113}
114}
115}
Removal Order
Engine ground cable
Starter motor cable
Gearshift pedal tie rod bolt
Spark plug cap
Altemator wire connector
Heat guard plate
Front head cover
Ignition pulse generator wire connector
Carburetor heat insulator rubber
Water outlet hose
Water bypass hose
Auto fuel valve vacuum tube
Clutch slave cylinder
Breather hose
Engine mounting bracket
1
1
1
4
2
1
2
1
1
2
1
1
1
1
4
116}
117}
118}
(19)
120}
Remarks
Installation is in the reverse order of removal.
44/1
1
1/2
1
Loosen the lock nuts and remove the bolt by turning it.
7-3
Engine Removal/Installation
After '95
Ii) 55 (5.5,40)
(11)
(12)
(10}
(17)
(4)
(1 )
(16)
(19)
Ii)
I
27 (2.7, 20)
Ii)
65 (6.5, 47)
40 (4.0, 29}
(15}it!-_--;:
(5)
A~~
(14}
(17)
{18)
{16)
Ii)
40 {4.0, 29)
7-4
Ii)
55 (5.5, 40)
Engine Removal/Installation
Requisite Service
Muffler removal/installation (page 2-13).
Exhaust pipe removal/installation (page 2-1S).
Carburetor removal/installation (page 5-3).
Radiator removal/installation (page 6-5).
Procedure
Removal Order
Engine ground cable
(2) Starter motor cable
(3)
Alternator cable/connector
(4) Gearshift pedal tie rod bolt
(5) Spark plug cap
(6) Hear guard plate
(7)
Front head cover
(B)
Ignition pulse generator wire connector
(9) Carburetor heat insulator rubber
(10) Water outlet hose
(1 1) i Water bypass hose
(12) Auto fuel valve vacuum tube
(13) Clutch slave cylinder
(14} Breather hose
(15} Engine mounting bracket
,
Q'ty
(1)
(16)
(17)
us:
(19)
(20)
Remarks
1
1
1
1
Loosen the lock nuts and remove the bolt by turning it.
4
1
2
1
1
,
1
1
1
1
1:,J
1
7-5
Engine Removal/Installation
Engine Mounting Bolt Tightening Procedure
(1) ADJUSTING
COLLAR
.-
~-
L-o--
(j)-~-@-@-@
CD
and (J).
(2} ADJUSTING
COLLAR
(After '95)
.:
After '95:
Lengthen the lower adjusting collar on the 12 mm engine
mounting bolt@untilthecollarcontactswiththeengine
and frame by turning the adjusting nut of the collar.
Tighten the adjusting nut of the lower adjusting collar.
Torque: 10 Nom (1.0 kg-m, 7 ft-Ib)
Tighten the lO mm engine mounting bolts
and
~'.
'91
95 Shown:
(1) ADJUSTING COLLAR
~
~
7-6
(2) FRAME
~
-,
(5) ADJUSTING
BOLT
'\
(4) LOCK
NUT
(3) ADJUSTING
NUT
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
8. Cylinder Head
Service Information
8-1
8-4
Troubleshooting
8-1
8-8
8-2
8-10
8-3
Service Information
Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the
cylinder head.
Clean all disassembled parts with clean solvent and dry them by blowing them off compressed air before inspection.
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their proper locations.
Take care not to damage the cylinder walls and pistons.
~
If valve seat cutting is required. a commercially available cutting set is recommended.
-=-
Troubleshooting
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down
test, or by tracing noises to the top-end with a sounding rod or stethoscope.
If performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smokey,
check for a seized piston ring.
Compression too low, hard starting or poor performance
at low speed
Valves
-e-Incorrect valve clearance
- Burned or bent valves
-Incorrect valve timing
- Broken valve spring
- Uneven valve seating
- Sticking valve
Cylinder head
- Leaking or damaged head gasket
- Warped or cracked cylinder head
Excessive noise
Incorrect valve clearance
Sticking or broken valve spring
Damaged or worn camshaft
Loose or damaged timing belt
Weak or damaged belt tensioner
Damaged timing belt pulleys
Rough idle
Low cylinder compression
8-1
Cylinder Head
~'6lm!
181~
19)--
E/''''----151
~16)
171
11)
141~\ ,\\>--..I~
12)
~
Requisite Service
Upper fairing removal/installation (page 2-9)
Procedure
111
12)
13)
14)
151
161
171
181
191
Removal Order
Bolt
Front head cover
Bolt/collar
Reduction holder cover
Spark plug cap
Cylinder head cover bolt
Washer
Cylinder head cover
Gasket
8-2
a'ty
Remarks
Installation is in the reverse order of removal.
2
1
3/3
1
2
4
4
1
1
Cylinder Head
III
12}
Requisite Service
Radiator removal/installation (page 6-5)
Reduction holder cover removal/installation (page 8-2)
Clutch cover removal/installation (page 9-6)
Procedure
(1)
(2)
Removal Order
Bolt
Timing belt cover
Q'ty
Remarks
Installation is in the reverse order of removal.
8-3
Cylinder Head
if): 12 (1.2, 9)
(2)
11 }
if):71
58 (5.8, 42)
(e)
(b)
6 x 40 mm
"""~~_J
(3)
(k)
L:W
(h)
(i!
~
(g)
~
(f)
(,)
8-4
,/
Cylinder Head
NOTE
The camshaft can be removed with the timing belt driven pulley installed and without removing the carburetors and
exhaust pipe. The timing belt driven pulley, carburetors and exhaust pipe must be removed to remove the cylinder
head.
Before removing the right cylinder camshaft, align the index line on the driven pulley with the index mark on the
reduction holder. Before removing the left cylinder camshaft, align the punch mark on the driven pulley with the index
mark on the reduction holder.
For camshaft installation, see page 8-6.
Requisite Service
Cylinder head cover removal/installation (page 8-2)
Timing belt driven pulley removal/installation (page 8-10)
Carburetor removal/installation (page 5-3)
Exhaust pipe removal/installation (page 2-18)
Procedure
(11
Removal Order
Camshaft holder bolt
5 x 40 mm
5 x 45 mm
(,I
[b}
101
(dl
(el
(fl
(91
(hi
(i)
01
Ikl
Q'ty
4
8
Remarks
Installation is in the reverse order of removal.
Install in the positions shown on page 8-4
6
6
,,
,
3
1
,, .
.
III
The shaft for the right cylinder has a single bearing and
the one for the left cylinder has a double bearing.
Align the wide tooth with the wide groove (punch mark)
of the reduction gear.
8-5
Cylinder Head
Camshaft Installation
(2) T1 MARK
Make sure that the Index Line on the driven pulley aligns with
the Index Mark on the reduction holder. If not, turn the
crankshaft clockwise one full turn and realign the T1 Mark
with the Index Mark.
8-6
Cylinder Head
Install the intake and exhaust camshafts so that the Index
Lineson the end of the shafts are facing outward and that
they align with the top of the cylinder head as shown.
II
I'
./
"--< _
---'-'t-(2) TAB
NOTE
If the right camshaft has been removed. install it first,
then turn the crankshaft clockwise 1-1/4 turns (450
degrees) and align the T4 Mark with Index Mark.
(2) T4 MARK
Make sure that the Punch Mark on the driven pulley aligns
with the Index Mark on the reduction holder. If not, turn the
crankshaft clockwise one full turn and realign the T4 Mark
with the Index Mark.
8-7
Cylinder Head
~121
131~
1,~oocI141
~
~"f:)
.~V
151
161
A_
...
191~(fjji)
~
~~
I,~ooq 1101--===-~ ~
181
111
171---/1
/)
8-8
Cylinder Head
NOTE
The valve lifter and valve adjusting shim can be removed with the cylinder head installed. Refer topage 3-5 for the shim
replacement.
Mark all parts during disassembly so they can be placed back in their original position.
Requisite Service
Remarks
Q'ty
111
Disassembly Order
Carburetor insulator
12)
Valve lifter
8
16
8
8
8
8
8
8
mm mm
I
TOP VIEW
/ /
,,'
I,
r: . .
I]
\\
-..'
'~~~
,\
\\
. \\
II
'r
,Ii
/,..1
\ .:::-
25 mm 0.0.
[when compressed)
8-9
Cylinder Head
46 (4.6, 33)
(4)
(2)
----------------------~
C
46 (4.6, 33)
(1 1)
8-10
(8)
(101
(6)
27 (2.7, 20)
;
(9)
65 (6 5, 47)
Cylinder Head
NOTE
Requisite Service
Timing belt cover removal/installation (page 8-3)
Spark plug removal/installation
Procedure
Q'ty
Remarks
Removal Order
Drive pulley bolt/washer
2/2
(51
(61
(71
(81
1
1
2/2
1/1
1/1
1/1
1/1
(91
Guide plate A
1
1
(11
(21
(31
(4)
8-11
Cylinder Head
(1) GUIDE
(2) WASHER
NOTE
CAUTION
( 3) BOLT
CAUTION
When align the T1 Mark with the Index Mark, be
sure that the Punch Mark on the drive pulley guide
plate aligns with the Projection on the crankcase,
too.
Remove the timing belt from the pulleys.
CAUTION
Do not turn the camshafts after removing the
timing belt or you may damage the valves and
piston domes.
Installation
NOTE
When the camshafts are removed, install the camshaft I
first (page 8-6). then install the timing belt.
Before installing the timing belt, move the tenaioner
pulley to the fully released position and temporarily
tighten the teC"'='CoC"CeC'CbCoCIt,.
8-12
Cylinder Head
Align the T1 Mark on the drive pulley guide plate with the
Index Mark on the crankcase.
CAUTION
When align the T1 Mark with the Index Mark, be
sure that the Punch Mark on the drive pulley guide
plate aligns with the Projection on the crankcase,
too.
Align the Index Lines on the driven pulley with the Index
Marks of the reduction holders.
NOTE
When the Index Line is aligned with the Index Mark:
-on right cylinder head, the Index lines on the
camshaft end are facing outward and align with the
top of the cylinder head.
-on left cylinder, the Punch Marks on the camshaft
end are facing outward and align with the top of the
cylinder head.
Install the timing belt on the drive pulley, next on the left
driven pulley, then on the right driven pulley.
~
~
..
-'",
1-'././,
/Q-o
, ,-
-', "~
,i
(8) Tl MARK
(10) PROJECTION
Install the left driven pulley guide, washer and bolt, and
tighten the bolt while holding the crankshaft.
Torque: 27 Nom (2.7 kg-m, 20 ft-Ib)
Loosen the timing belt tensioner bolt to apply the tension
to the belt. Then turn the crankshaft 2 to 4 full turns to
stabilize the belt run, and tighten the bolt.
Torque: 46 Nom (4,6 kg-m, 33 ft-lb)
When installing a new belt, apply initial tension to the belt
as follows:
8-13
Cylinder Head
Loosen the tensioner bolt.
Turn the crankshaft clockwise 2 to 4 full turns, and align the
T1 Mark with the Index Mark. (The Index Lines on the driven
pulleys must align with the Index Marks.)
CAUTION
When align the T1 Mark with the Index Marit, be
sure that the Punch Mark on the drive pulley guide
plate aligns with the Projection on the crankcase,
too,
Then turn the crankshaft ckockwise 3 teeth further and
tighten the tensioner bolt.
8-14
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
9. Clutch
Service Information
9-1
Troubleshooting
9-1
9-4
Clutch Disassembly/Assembly
9-6
9-2
Service Information
DOT 4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in this section. Do not use other
types of fluid as they are not compatible.
Engine oil viscosity and level and the use of oil additives have an effect on dutch disengagement. Oil additives of any
kind are specifically not recommended. When the clutch does not disengage or the vehicle creeps with clutch disengaged, inspect the engine oil for proper level and the presence of additives before servicinq the clutch system.
Clutch maintenance can be done with the engine in the frame.
Troubleshooting
Clutch lever soft or spongy
Air in hydraulic system
Low fluid level
Leaking hydraulic system
Clutch slips
Sticking hydraulic system
Worn discs
Weak clutch springs
Hydraulic system clogged
Oil additive used
"..d
Air in hydraulic system
low fluid level
leaking or sticking hydraulic system
9-1
Clutch
X: IB)
19)
\
)10)
-1--'/
15)
X:
12 (1.2, 9)
f!~J!-----(6)
Boot:
'91-'94
(19)
(2)
X:
35 (3.5, 25)
(12)
X:
1 {0.1, 0.7)
(1)
(7)
X:
(17)
(11 )
ISTOO~I
6 (0.6, 4.3)
(14)
(13)
9-2
Clutch
CAUTION
Avoid spilling hydraulic clutch fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the
system is serviced.
When removing the oil bolt. cover the end of the clutch hose to prevent contamination. Do not allow the foreign
material to enter the system.
Handle the master piston. spring, primary cup and secondary cup as a set.
Do not allow the lips of the master cylinder cups to tum inside out and be certain the snap ring is firmly seated
in the groove.
NOTE
Requisite Service
(II
(21
(31
(41
(51
(61
(71
(81
(91
(101
(' 11
(12)
('31
('41
(151
('61
('71
('81
('91
(201
(211
Removal
Clutch switch wire
Oil bolt
Sealing washer
Clutch hose
Master cylinder holder bolt
Master cylinder holder
Clutch switch
Reservoir cap screw
Reservoir cap
Set plate/diaphragm
Clutch lever pivot nut
Clutch lever pivot screw
Clutch lever
Push rod end piece
Push rod
Boot
Snap ring
Washer
Master piston
Primary cup
Spring
Q'ty
,
,,
,,
Remarks
Installation is in the reverse order of removal.
2
2
2
I
1/'
I
I
,,
,,
,,
1
I
I
9-3
Clutch
(4)
(7)
131
12)
CAUTION
Avoid spilling hydraulic clutch fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the
system is serviced.
When removing the oil bolt. cover the end of the clutch hose to prevent contamination. Do not allow the foreign
material to enter the system.
NOTE
Use only DOT 4 brake fluid from a sealed container.
Requisite Service
lower fairing removal/installation (page 2-4)
Clutch fluid draining
Procedure
Removal Order
Oil bolt
Sealing washer
Clutch hose
Mounting bolt
151 Slave cylinder assembly
161 Gasket
17) Dowel pin
(8) Slave cylinder piston
(' )
(2)
(3)
(4)
9-4
Q'ty
,
,
Remarks
Installation is in the reverse order of removal.
2
3
1
1
2
1
1
1
Clutch
MEMO
9-5
Clutch
Clutch Disassembly/Assembly
14)
/(12)
'A"'J'"\
(131
Clutch
NOTE
It is not necessary to disconnect the clutch hydraulic system for clutch disassembly/assembly.
Requisite Service
Engine oil draining
Clutch slave cylinder removal/installation (page 9-4)
Right exhaust pipe removal/installation (page 2-18)
Q'ty
Procedure
111
(21
(31
(41
(51
(61
(71
(81
(91
(101
(111
(121
(131
Disassembly Order
Clutch cover bolt
Clutch cover
Gasket
Dowel pin
Litter rod
utter plate bolt
9
1
1
2
1
5
Lifter plate
Lifter rod guide
Clutch spring
Lock nut
Lock washer
Clutch assembly
- pressure plate
1
1
5
1
1
1
1
Remarks
10
9
1
1
1
1
1
NOTE:
, After tightening the belts, check that the lifter rod guide
rotates smoothly.
Remove from the lifter plate.
Removal/installation (page 9-8)
Install with the "OUr wark facing out.
At installation, align the ~ ... ~ marks on the pressure plate
and clutch center as shown.
9-7
Clutch
Clutch Lock Nut Removal/Installation
Removal
Unstake the clutch lock nut with a drill or grinder. Using
the special tools, place a collar in each of the slots marked
with a "5 on the tool.
Install the clutch center holder by aligning the collars in
the slots so they fit over the bosses in the clutch center.
Using a 17 mm wrench, tighten the collar nuts in position.
Secure the holder to the clutch center using the clutch
spring bolts.
Hold the clutch center with the clutch center holder and
remove the lock nut.
>""1
(4)
<""~
Nd~~
HOLDER-:c~~~~~
COLLAR
07JMB-MN50300 or
07HGB-001010B
(U.S.A. only)
Clutch holder collar (3 pieces) 07LMB-MT30100 or
07MPB-764021A
Clutch center collars "B"
(U .S.A. only)
Lock nut wrench, 30 x 32 mm 07710-0020400 l
07716-0020500 l
Extension bar
Equivalent commercially
available in U.S.A.
Clutch center holder
Installation
Hold the clutch center with the clutch center holder as
described above.
07JMB-MN50300 or
07HGB-001010B
(U.S.A. only)
07LMB-MT301oo or
Clutch holder collar (3 pieces)
07MPB-764021A
Clutch center collars "B"
(U.S.A. only)
Lock nut wrench, 30 x 32 mm 07716-0020400 l
07716-0020500 l
Extension bar
Equivalent commercially
available in U.S.A.
Install a new lock nut and tighten it.
Clutch center holder
9-8
Clutch
Turn the oil pump driven sprocket with a screwdriver as
shown while pushing the clutch outer in until you feel a click.
At this time. the holes in the clutch outer are aligned with
the pins on the oil pump drive sprocket. Push in the clutch
outer further to insert the pins into the holes.
9-9
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
10-1
Troubleshooting
10-1
10-2
10-5
Transmission Removal/Installation
10-6
Transmission Disassembly/Assembly
10-8
Shaft Removal/Installation
10-4
Service Information
The gearshift linkage can be serviced with the engine installed in the frame.
The transmission can be removed as a unit without separating the crankcases.
Troubleshooting
Hard to shift
Improper clutch operation
10-1
Gearshift LinkagelTransmission
(6)
(12)
(17)
(16)
(14)
r<f:r-----{B)
(10)
(2)
17)
(1)
12{1.2,9)
jet
(4)
10-2
23 (2.3,17)
Gearshift Linkage/Transmission
Requisite Service
(11
(21
Removal Order
Gearshift arm bolt
Gearshift arm
Q'ty
(10)
(11)
1
1
1
4
1
(12)
(13)
(14)
(15)
(16)
(17)
Dowel pin
Stopper arm bolt
Collar
Return spring
Stopper arm
Washer
1
1
1
1
1
1
(5)
(5)
(7)
(8)
(9)
Bolt
Gearshift linkage cover
Gasket
Dowel pin
Gearshift spindle assembly
Shift drum center bolt
Shift drum center plate
Dowel pin
Shift drum center
(3)
(4)
Remarks
1
1
2
Pull out the spindle while pushing the shift pawl in.
10-3
Gearshift Linkage/Transmission
141
NOTE
The transmission can be removed from the engine as an unit.
The transmission unit can be removed with the clutch installed.
The clutch and oil pump drive sprocket must be removed to remove the primary damper shaft.
Requisite Service
Engine removal/installation (page 7-2)
Clutch disassembly/assembly (page 9-6)
ow
Procedure
(I)
(2)
(3)
(4)
1'1
Removal Order
Transmission unit mounting bolt
Transmission unit
Gasket
Dowel pin
Primary damper shaft
10-4
,,
8
,
2
Remarks
Installation is in the reverse order of removal.
Gearshift LinkagelTransmission
(2)
L-o
t
(8)
(5)
(6)
(1)
(1)-----~
Requisite Service
Primary damper shaft removal/installation (page 10-4)
Procedure
, I Disassembly Order
(1) , Primary spring cotter
O'tv
Remarks
Assembly is in the reverse order of disassembly.
Set the damper shaft assembly in a hydraulic press
with the washer {3l supported. Compress the spring
approx. 5 mm (0.2 inl, slide the retainer (2) up and
remove the cotters as shown.
CAUTION
Do not compress the spring more than 7 mm
(0.28 in).
(2)
(3)
(4)
(51
(61
(71
(8)
(9)
,,
1
,
,,
I Install with the small coil end facing away from the
pimary damper lifter as shown.
10-5
Gearshift LinkagelTransmission
Transmission Removal/Installation
121
141
191
,
,
151
11.o-~_171
131
161
181
o
111
10-6
Gearshift Linkage/Transmission
Requisite Service
Gearshift linkage removal/instaliation (page 10-2)
Transmission unit removal/installlation (page 10-4)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Disassembly Order
Transmission case cover bolt
Transmission case
Dowel pin
Shift fork shaft
Aear shift fork
Center shift fork
Gearshift drum
Front shift fork
Mainshaft/countershaft assembly
Q'ty
Remarks
Assembly is in the reverse order of disassembly.
2
1
1
1
1
,,
10-7
Gearshift Linkage/Transmission
Transmission Disassembly/Assembly
After '91
Mainshaft
: SHIFTER GEAR
GROOVE
: GEAR SLIDING
SURFACE
24T
(9)
(9)
(2)
(11 )
(4)
16)
16/21T
(4)
18)
(8)
(5)
NOTE
Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from the thrust load.
After installing a snap ring, slightly open the ring and rotate it in its groove to be sure it is fully seated.
Do not use worn snap rings which could easily spin in the groove. They may be too loose to properly seat in the
groove. Align the gap in the snap ring with the groove in the spline.
Align all oil holes in the bushings with the shaft oil holes.
Requisite Service
Transmission removal/installation (page 10-61
Procedure
0)
(2)
(3)
(4)
(5)
(6)
(7)
(B)
(9)
(10)
(11)
Disassembly Order
Washer
M5 gear (29T)
M5 gear bushing
Spline washer
Snap ring
M2IM3 gear (18121
Snap ring
Spline washer
M4 gear (24T)
M4 gear bushing
Mainshaft/M1 gear (15n
10-8
Remarks
Q'ty
1
1
1
1
,,
1
~ I
Gearshift Linkage/Transmission
Countershaft
22T
(16)
: SHIFTER GEAR
GROOVE
(' 5)
: GEAR SLIDING
SURFACE
(10)
T
+
(17)
+
(3)
(5)
(15)
(7)
(3)
(4)
(5)
(6)
(7)
(6)
(9) I
(10)
(11 )
('2)
(13)
(14)
(15)
(16)
(17)
22T
(14)
Procedure
(I)
(2)
(6)
Disassembly Order
Washer
Cl gear (34T)
Cl gear needle bearing
Washer
C4 gear (22T)
Snap ring
Spline washer
C3 gear (24n
C3 gear bushing
Lock washer
Spline washer
C2 gear (27T)
C2 gear bushing
Spline washer
Snap ring
C5 gear (22T)
Countershah
, O'ty
Remarks
Assembly is in the reverse order of disassembly.
1
1
1
1
,,
,,
!
i
1
1
1
1
1
1
1
1
10-9
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
11. Crankcase/Piston/Crankshaft
Service Information
11 -1
Troubleshooting
11-1
Crankcase Separation/Assembly
11-2
Crankshaft/Connecting Rod
Removal/Installation
11-4
Piston Removal/Installation
11-8
11-10
Service Information
CAUTION
Improper installation of bearing inserts may block the oil holes, causing insufficient lubrication and eventual
engine seizure.
Remove the engine and separate the crankcases to inspect the crankshaft, connecting rod and starter clutch.
Mark and store the connecting rod and crankshaft bearing inserts so they can be installed in their original locations for
reassembly.
Prior to assembling the crankcase halves, apply a sealant to their mating surfaces. Wipe off excess sealant thoroughly.
Mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
Troubleshooting
III
Excessive noise
Worn connecting rod bearings
Bent connecting rod
Worn crankshaft main journal bearing
11-1
Crankcase/Piston/Crankshaft
Crankcase Separation/Assembly
(12)
'91-'95
-:71
52 (5 2, 38)
161
~171
12 (1.2, 9)
1,1--__ (5)
1131
I~/
...-/'
13 1 _
~---121
I
191
o
11-2
23 (2.3, 17)
4-
1~
lll
Crankcase/Piston/Crankshaft
CAUTION
Improper installation of bearing inserts may block the oil holes causing insufficient lubrication and eventual
engine seizure.
NOTE
Mark all parts during disassembly so they can be replaced in their original position.
All bearing inserts are select fitted and are identified by color code. Select replacement bearings from the selection
tables (pages 11-6 and 11-7).
Requisite Service
Engine removal/installation (page 7-2)
Cylinder head removal/installation (page 8-2)
Oil cooler removal/installation (page 4-4)
Alternator removal/installation (page 17-18)
Starter motor removal/installation {page 20-B}
Procedure
(2)
(3)
(4)
(5)
(6)
(7)
(B)
(9)
(10)
(11)
(12)
(13)
(14)
Separation Order
Bolt
Water cover/pipe
O-ring
Bolt/cooler hose guard
Clutch cover base"
Gasket
Dowel pin
Upper crankcase bolt 6 mm
Bmm
Lower crankcase bolt 6 mm/stay
B mm
10 mm/washer
Dowel pin
Crankshaft main journal bearing
i O'rv
I
,
3
1
1
7/1
1
1
2
2
1
4/1
6
6/6
3
3
11-3
Crankcase/Piston/Crankshaft
36 (3.6, 26)
(1)
(2)
(4)
(5)
(6)
(7J
(4)
(3)
11-4
Crankcase/Piston/Crankshaft
CAUTION
Improper installation of bearing inserts may block the oil holes causing insufficient lubrication and eventual
engine seizure.
NOTE
Mark all parts during disassembly so they can be replaced in their original position.
All bearing inserts are select fitted and are identified by color code. Select replacement bearings from the selection
~_ _
tables (pages 11-6 and 11-7).
Requisite Service
Crankcase separation/assembly (page 11-2)
Procedure
(I)
(2)
(3)
(4)
(5)
(6)
(7)
Removal Order
Connecting rod bearing cap nut
Connecting rod bearing cap
Connecting rod/piston assembly
Connecting rod bearing
Crankshaft
Crankshaft thrust bearing
O'ty
Remarks
Installation is in the reverse order of removal.
4
4
B
1
2
11-5
Crankcase/Piston/Crankshaft
Main Journal Bearing Selection
Record the crankcase 1.0. code letters on the front side of
the upper crankcase.
NOTE
Letter A, B or C is the code for the main jounal 1.0.
The numerals 1, 2 and 3 stand for the crankshaft
main journals, as viewed from the front.
, ,
2
~'
I.D.code 43.000-
Main journal
0.0. code
39.994--40.000 mm
(1.5746-1.5748 in)
Yellow
Green
Brown
39.988-39.994 mm
(1.5743-1.5746 in)
Green
Brown
Black
3 39.982-39.988
(1.5741-1.5743 in)
Brown
Black
Blue
See section 14 of the Common Service Manual for crankshaft main bearing oil clearance inspection.
11-6
Crankcase/Piston/Crankshaft
Record the crankpin 0.0. code letters on the crank weights.
NOTE
[
~
I.D. code
Crank pin
O.D. code
A 39.994-40.000 mm
(1.5746-1.5748 in)
Yellow
Green
Brown
B 39.988-39.994 mm
(1.5743-1.5746 in)
Green
Brown
Black
C 39.982-39.988
(1.5741-1.5743 in)
Brown
81ack
Blue
11-7
Crankcase/Piston/Crankshaft
Piston Removal/Installation
(4)
(5)
171
Oil hole
(21
(11
/~
"IN" mark
Oil hole
11-8
<<::
Crankcase/Piston/Crankshaft
Requisite Service
Connecting rod removal/installation (page 11-4)
Procedure
Q'ty
. I Removal Order
Piston pin clip
Piston pin
Piston
1
1
0)
(2)
(3)
(4)
(5)
Remarks
Installation is in the reverse order of removal.
1
1
2-
1-
11-9
Crankcase/Piston/Crankshaft
(12}
(111
iIiIII
16(1.6,12)
(10}
{BI
\J/
~ ..
t?
t?
~~~~~
{5}
(13)
{1}
{21
{3}
i\)~
{7}
{6}
"'I
After '91:
o
{.}
11-10
..,
Crankcase/Piston/Crankshaft
NOTE
The starter idle gear can be removed without removing the crankshaft.
Requisite Service
Procedure
(' )
(2)
(3)
(41
(51
(6)
(7)
(6)
(9)
(10)
(11 )
(12)
(13)
(,)
(b)
(el
(d} !
Removal Order
Collar
O.ring
Stopper circlip
Primary drive gear
Starter clutch assembly
- Starter driven gear
- Needle bearing
- Snap ring
- Starter clutch
- Bolt
- Alternator drive gear
- Starter clutch outer
Washer
Bolt/washer
Starter idle gear shaft
Starter idle gear
Oil separate plate After '91
Remarks
Installation is in the reverse order of removal.
,,
,
,
1
1
1
1
8
1
1
1
,,
1
11-11
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
12-1
Troubleshooting
12-1
12-4
Driveshaft Disassembly/Assembly
12-2
12-6
Service Information
Replace all oil seals and O-rings whenever the final drive gear assembly is disassembled.
Check the tooth contact pattern and gear backlash when the bearing, gear set and/or gear case is replaced.
(Section 15 of the Common Service Manual)
Troubleshooting
Excessive noise in final drive
Worn or damaged ring gear and driven flange
Damaged driven flange or wheel hub
Worn or damaged pinion gear and/or pinion joint splines
Excessive backlash between pinion and ring gears.
Low oil level
Excessive rear wheel backlash
Worn driveshaft splines
Excessive backlash between ring gear and pinion gear
Worn driven flange and ring gear splines
Excessive play in final drive case bearings
Worn driveshah and or pinion joint splines
Oil leaks at final gear case
Clogged breather hole
Oil level too high
Faulty oil seans)
12-1
Final Drive
Driveshaft Disassembly/Assembly
Attachment
(')
(2)
(4)
Base
Requisite Service
Swingarm removal/installation (page 14-8)
O'ty
Procedure
I
(11
(2)
(3)
(4)
(5)
(6)
(7)
Disassembly Order
Snap ring
Spring stopper
Driveshaft spring
Universal joint cotter
,,
1
Thrust washer
Damper case
,,
12-2
,
1
I Universal joint
Remarks
Assembly is in the reverse order of disassembly.
1
1
,,
I
Remove from the damper case.
If necessary, remove using the bearing race remover
{07946-371 0500).
Install using the driver (07749----001 CXXlO) and attachment,
52 x 55 mm (07746-0010400).
Final Drive
r;;;;;;,.
til
110}
23 (2.3, 17)
151
65 (6.5, 43)
17}
19}
NOTE
ABS/TCS or LBS-ABS/TCS model: After installing the rear wheel, perform the wheel sensor air gap inspection
(page 16-A-51 or 16-B-34).
Requisite Service
Rear wheel removal/installation (page 14-2)
Final gear oil draining
Procedure
(1)
(2)
(3)
(4)
(5)
Removal Order
Wheel sensor mounting bolt
Wheel sensor
Sensor shim
Shock absorber lower mounting bolt
Final gear case mounting nut
(6)
(7)
Driveshaft joint
Q'ty
2
1
Remarks
Instllation is in the reverse order of removal.
ABS/TCS or LBS-ABS/TCS model
Remove from wire clamp.
11}
1
4
12-3
Final Drive
(6)
(4)
(5)
(26)
(27)
(9)
(3)
(25)
(2)
120}
(19)
(23)
(22)
Is TOOL)
(18)
( 1)
(8)
( 17)
{16}
(14)
Is~ooLI
12-4
(7)
(12)
(11)
(10)
Final Drive
----
Always wear insulated gloves when handling a heated gear case to prevent burning your handso
CAUTION
Do-n-o-.-u-s-.-.-o-,cCh-.o--:h-.-atthe
e
final gear case; it may cause warpingo
NOT"E=--
Requisite Service
(I I
(2)
13)
14)
15)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
113)
(14)
115)
116)
(17)
(18)
(19)
(20)
(21 )
(22)
123)
124
125)
126)
127)
128)
Disassembly Order
Distance collar
Standard model
Bolt
ASS/TeS or LBS-ABS/TCS model
Dust guard plate
8 mm gear cover bolt
10 mm gear case cover bolt
Gear case cover
Ring gear
Wave washer
Oil seal
Ring gear bearing
Ring gear shim
O-ring guide
O-ring
Pinion joint nut
Pinion joint
Bolt
Pinion retainer lock washer
Pinion retainer
O-ring
Oil seal
Pinion gear assembly
Pinion bearing/inner race
Pinion gear shim
Final gear case bearing
Oil seal
Breather cap
Ring gear stop pin
Stop pin shim
)1
Remarks
Oty .
1
1
3
1
6
2
I
I
NOTE
If the ring gear stays in the cover, press the ring
gear out of the cover.
,,
1
1
I
I
I
I
I
1
1
1
1
I
1/2
I
2
I
I
I
I
12-5
Final Drive
Iilii
26 (2.6, 19)
(241
63 (6.3, 46)
(25)
.m:iiIt
~
(3)
~[STOOLI
(2)
(201
(23)
"'=....
010
(4)
(1.0,7)
(271
~
fiijii"
I S ;COOL I
-Aoo
(6)
SO'
(7)
(10)
(14)
(28)
.,
(26)
(5)
(16)
(17)
(101
0 1 0 fl.0,7)
(15)
CUa
0
110(11.0.80)
12-6
(11 )
Is ;;;OL I
0150 (15.0,108)
(21 )
.....
(18)
Final Drive
NOTE
Keep dust and dirt out of the gear case.
Be careful not to damage the case and cover mating surfaces.
Refer to section 15 of the Common Service Manual for the backlash inspection, the gear tooth contact pattern check
and the ring gear-to-stop pin clearance check.
If the gear set, pinion gear bearing, ring gear bearing, gear case bearing and/or gear case are replaced, install a
1.50 mm pinion gear shim and a 2.00 mm ring gear shim.
The ring gear and pinion gear must be replaced as a set.
Requisite Service
Procedure
(I)
(2)
(31
(41
Disassembly Order
Stop pin shim
Ring gear stop pin
Breather cap
Oil seal
1
1
1
1
(51
(61
(7)
(6)
1
112
Oil seal
(12)
O-ring
Pinion retainer
Pinion retainer lock washer
1
1
1
(13)
(14)
(15)
(16)
117)
(18)
(19)
Bolt
Pinion joint
Pinion joint nut
Ring gear shim
Ring gear bearing
O-ring
O-ring guide
1
1
1
1
1
1
1
(20)
121)
122)
123)
Oil seal
Ring gear
Wave washer
Gear case cover
1
1
1
1
(24)
(25)
(26).
(27) I
2
6
(9)
Remarks
Selection (page 12-10)
Clean the breather hole and install.
Use the driver (07749--OO10CXXl) and attachment. 52
x 55 mm (07746-0010400).
Use the driver (07749--0010000), attachment, 62 x
I 68 mm (07746--0010500) and pilot, 35 mm (07746. 00408001.
Selection (page 12-10)
Drive onto the pinion gear, using the driver, 40 mm
I.D. (07746-0030100) and attachment, 25mm 1.0.
(07746-0030200).
Drive into the gear case until enough threads are
visible to engage the pinion retainer, using the bearing
race insert attaccnment (07931-4630300).
Install into the pinion retainer, using the driver (077490010000) and attachment, 52 x 55 mm (07746-
(010400).
(10)
(11)
(28)
1
1
3
[Install with the polished side toward the final gear case.
12-7
Final Drive
Pinion Joint Nut Removal/Installation
Removal
Install the pinion joint holder and remove the pinion joint
nut.
07924-M E40000
07924-9690102
rf ::::,:/ ;~;
~'
Installation
Install the pinion joint and pinion joint nut.
Install the pinion joint holder and tighten the pinion joint nut.
r{,
~~",\
;,J";9',~C',"
07924-ME40000
07924-9690102
Removal
Remove the pinion retainer with the pinion retainer wrench.
Is-;=001.1
Pinion retainer wrench
07910-MA10100
Installation
Coat the O-ring on the pinion retainer with grease or gear
oil. Screw the pinion retainer in, pressing the pinion bearing
in place, then tighten it with the pinion retainer wrench.
Torque: 150 N'm (15.0 kg-m. 108 ftlbJ
(S ';'"001.1
Pinion retainer w:'8f1ch
12-8
07910-MA10100
Final Drive
Pinion Gear Assembly Removal
Shaft puller
(2) PINION
JOINT
/HOLDER
07931-ME40000 or
07931-ME4010A
(U.S.A. only)
07924-ME40000
07924-9690102
~"
131 PINION
JOINT
HOLDER
AITACHMENT
A,
:::1J
~~~~
CAUTION
Install the oil seal remover into the gear case bearing.
is ~oLI
Oil seal remover
07948-4630100
Turn the gear case over and drive the gear case bearing out.
NOTE
Place a new ring gear bearing on the ring gear and drive it
on with the oil seal driver.
[s ;"OOL I
07965-MC70100
(2) BEARING
12-9
Final Drive
If the ring gear stayed in the cover:
Press the ring gear bearing into the case cover.
(2) AITACHMENT
(1) DRIVER
[s -;=-oo~l
Driver
Oil seal driver attachment
07749-0010000
07948-8800101
Support the bearing inner race with the oil seal driver
attachment, and press the ring gear into the bearing with a
suitable tool.
Is Too~1
Oil seal driver
07965-MC70100
/.'1i!:==
(1) OIL SEAL DRIVER
A: 0.10 mm
A: 0.15 mm
(3) STOP PIN
(3) STOP PIN
(2l SHIM
12-10
Final Drive
Pinion Gear Shim Selection
Check the gear backlash (Section 5 of the Common Service
Manual).
Backlash: 0.05-0.15 mm (0.002-0.006 in)
If the backlash is not within the specifications, remove and
change the ring gear shim.
The backlash is changed by about 0.06-0.07 mm (0.0020.003 in) when the thickness of the shim is changed by
0.10 mm (0.004 in).
NOTE
12-11
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
13-1
Fork Removal/Installation
13-11
Troubleshooting
13-1
13-14
13-18
Handlebar Removal/Installation
13-22
13-26
13-30
13-4
13-6
Service Information
When servicing the front wheel, support the motorcycle securely with a jack or other support under the engine.
Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service
Manual. When remounting the tire, note the normal rotating direction.
Refer to the section 15 for brake system information.
Refer to the section 21 for light, meter and switch information.
Troubleshooting
Hard steering
Steering head bearing adjustment nut too tight
Faulty steering head bearings
Damaged steering head bearings
Low tire pressure
Faulty tire
Steers to one side or does not track straight
Bent fork
Bent front axle: wheel installed incorrectly
faulty steering head bearings
Bent frame
Worn wheel bearings
Worn swingarm pivot bearings
Soft suspension
Weak fork springs
Low fluid level in fork
Faulty anti-dive system
III
Hard suspension
Incorrect fluid viscosity
Bent fork tubes
Clogged fluid passage
Front suspension noise
Low fluid level in fork
Loose fork fasteners
Lack of grease in speedometer gearbox
13-1
Front Wheel/Suspension/Steering
'91-'94
(31
Holes
(41--~~;$'
T'b
Procedure
O'tv
Remarks
-
(1)
(2)
(3)
(4)
Removal Order
Screws
Handlebar upper cover
Bolt
Handlebar lower cover
13-2
Front Wheel/Suspension/Steering
After '94
(5)
(2)
/~~
/<vp
(1)
1:----(6)
(4)
Procedure
(11
(2)
(3)
(4)
(5)
(6)
Removal Order
Trim clip
Screw
Handlebar rear cover
Screw
Handlebar front cover
Handlebar cover stay
Q'ty
Remarks
Installation is in the reverse order of removal.
4
4
1
1
1
13-3
Front Wheel/Suspension/Steering
Handlebar Removal/Installation
(15)
(1)
(3)
(16)
(9)
(5)
-(7)
C
4.2 (0.42, 3.0)
12(1.2,9)
(13)
27 (2.7, 20)
(14)
Requisite Service
I Disassembly Order
(1) Clutch switch wire
(2) Clutch master cylinder holder
(3) I Clutch master cylinder
(4)
(5)
(6)
(7)
(8) i
(9) I
(10)
(11)
(12)
(13)
(14)
13-4
Q'ty
Remarks
Assembly is in the reverse order of disassembly.
2
1
1
CAUTION
Keep master cylinder upright, to prevent air
from entering the system.
1
2
1
1
CAUTION
Keep master cylinder upright, to prevent air
from entering the system.
1
2
2
2
4
2
1
2
1
Front Wheel/Suspension/Steering
(9)
(8)
(7)
(6)
(3)
(2)
(11
o
1IIIIiI (5)
4 (0.4. 2.9)
The anti-dive case is under spring pressure. Use care when removing the case to keep it from becoming a
projectile.
Requisite Service
Left fork oil draining (Standard and ABS/TCS model)
Right fork oil draining (LBS-ABS/TCS model)
Procedure
-
Disassembly Order
Pivot collar
Bushing
Rubber boot
Socket bolt
Case cover
O-ring
Piston seal
Oil seal
Anti-dive piston
Spring
O'tv
-
,,
,
Remarks
,
,,
,,,
,
4
13-5
Front Wheel/Suspension/Steering
Wheel sensor
~(101
C
(5)
(121
90 (9.0, 65)
(61~
(11 )
:X:
22 (2.2,16)
(141
(91
(151
(13)
13-6
(BI
Front Wheel/Suspension/Steering
..
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality braka degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Never use an air hose or dry brush to clean brake assembly. Use an OSHA-approved vacuum cleaner or an alternate
method epprovedbv OSHA, designed to minimize the hazard caused by airborne asbestos fibers.
CAUTION
After installing the front wheel. apply the front brake and check the brake operation.
NOTE
Do not depress the brake lever when the caliper is removed, or it will be difficult to refit the disc between the brake
pads.
Requisite Service
Raise the wheel off the ground by placing a jack or other support under the engine .
O'tv
Procedure
111
(21
(31
(41
(51
(61
(71
Removal Order
Wheel sensor wire grommet (ABSjTCS
model only)
Bolt
Front brake hose stay
Socket bolt
Front fender
Front fender plate
Right front brake caliper mounting bolt
,
(81
(91
(101
(11)
(12)
(131
(141
(15)
2
2
2
2
1
1
2
I
Speedometer cable set screw
Speedometer cable
Front axle bolt
Front axle pinch bolt
Front axle
Front wheel assembly
Right side collar
Speedometer gear box
Remarks
CAUTION
ABSiTCS model only: Be careful not to damage the tip
of the wheel sensor.
Do not heng the caliper from the brake hose. Air
may enter the brake system.
1
1
,
4
1
1
1
1
13-7
Front Wheel/Suspension/Steering
LBS-ABS/TCS Model
14)
0 1 2 (1.2, 9)
0 3 0 (3.0, 22)
_~
(1)
12)
(7)
~"..I
'
(9)
li
\,
(8)
(11)
(6)
(5)
(12)
13-8
Front Wheel/Suspension/Steering
A contaminated brake disc or pad reduces stopping power, discard contaminated pads and clean contaminated disc
with a high quality degreasing agent.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush
to clean brake assemblies.
CAUTION
I. After installing the front wheel. operate the brake lever and pedal and check the brake operation {page 313).
NOTE
Do not depress the brake lever or pedal when the front caliper is removed, or it will be difficult to refit the disc
between the brake pads.
Requisite Service
Raise the wheel off the ground by placing a jack or other support under the engine.
Frant fender removal/installation (page 2-11).
Procedure
Removal Order
Sensor bracket bolt
(3)
(4)
(1)
(2)
(5)
(6)
(7)
(8)
(9)
(10)
nn
{12}
Remarks
Q'ty
1/1
1
1
1
1
1
1
1
13-9
Front Wheel/Suspension/Steering
151
fit
B (0.8, 5 8)
....
IBI
(21
III
NOTE
The left brake disc has "L" mark and the right brake disc has' "R" mark. Install them on the correct sides.
For wheel bearing replacement, refer to the section 1 of the Common Service Manual.
Requisite Service
-
111
121
131
141
151
151
III
Q'ty
Disassembly Order
Dust seal
Speedometer gear retainer
Brake disc bolt
Brake disc
Gasket
Torx bolt (T25) (ABS;TCS or LBS-ABS/TCS
model)
Pulsar ring (ABS;TCS or LBS-ABSjTCS
model)
2
1
12
2
At installaion, align the tabs with the slots in the wheel hub
Install the disc with the" L mark on the left side, and the
disc with the .. R mark on the right side.
12
5
1
1
1
1
(1 1) Front tire
13-10
Remarks
Install the pulser ring with the concave portion of bolt hole
facing out.
CAUTION
Be careful not to deform, distort. or damage the pulser
ring.
Front Wheel/Suspension/Steering
Fork Removal/Installation
/
4.3 (0.43, 3.1)
23 (2.3, 17)
(51
//
\
(61
'---J"'" -
(I I
c_"'"- .
~.,.'-
.-.,.-.-".-.-.-:0-
-/
~~\
~\
/
(II
~
P
j~\
"
(2)
27 (2.7, 20)
12 (1.2, 9)
NOTE~_ _
When the fork is to be disassembled, loosen the fork bolt but do not remove it.
I . After assembling the fork, tighten the fork cap temporarily before tightening the upper fork pinch bolt.
Requisite Service
Handlebar cover removal/installation (page 13-2)
Front wheel removal/installation (page 13-6)
Procedure
(I )
(2)
Removal Order
Left brake caliper pivot bolt (upper)/collar
Left brake caliper pivot bolt (lower)
Q'ty
Remarks
Installation is in the reverse order of removal.
III
I
CAUTION
(31
(41
(51
(61
Fork asssembly
13-11
Front Wheel/Suspension/Steering
LBS-ABS/TCS Model
(6) E:t 22 (2.2, 16)
/
E:t 12 (1.2. 9)
(51
, ,0
~'~~
(11
Short
I
(21
(4)
""'--'(J
30 (3.0, 22)
E:t12 (1.2, 9)
(31
/
Tube end
(10)
(8)
13-12
Front Wheel/Suspension/Steering
CAUTION
When performing this service, provide the calipers with a support (sl. Do not hang the calipers from the brake hose
and pipe.
NOTE
When the fork is to be disassembled, loosen the fork cap but do not remove it yet.
After assembling the fork, tighten the fork cap which is temporarily tightened before tightening the upper fork pinch
bolt.
Requisite Service
Handlebar cover removal/installation (page 13-2).
Front wheel removal/installation (page 13-6).
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Removal Order
Oil pipe and wire stay fixing bolt
Delay valve mounting bolt
Left brake caliper pivot bolt (lowen/couar
Secondary master cylinder link plate bolt
{lower; slider-to-link born/cottar
Secondary master cylinder mounting bolt
Fender plate mounting bolt
Front fender plate
Lower fork pinch bolt
Upper fork pinch bolt
Q'ty
Remarks
Installation is in the reverse order of removal.
1
2
1(1
1(1
2
2
1
4
Only loosen.
Only loosen.
NOTE
Be careful not to let the fork drop when loosening the
bolt.
At installation, align the end of the fork tube with the upper
surface of the top bridge.
.
(10)
Fork assembly
13-13
Front Wheel/Suspension/Steering
(151
116)
1181
(191
/
/
~(21
/
(3)
(41
(5)
(21)
(61
13-14
(91
(81
Front Wheel/Suspension/Steering
DIIII__
The fork cap is under spring pressure. Use care when removing it.
Requisite Service
Fork removal (page 13-11)
Procedure
I--~------''-''-'
Disassembly Order
(1)
Fork tube protector
Remarks
Q'ty
NOTE
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Fork cap/O-ring
Spring collar
Spring seat
Fork spring
Socket bolt/washer
Fork piston assembly
Stopper ring
Oil lock valve
Oil lock valve spring
Spring seat
Stopper ring
Rebound spring
Piston rings
1/1
1
1
1
1/1
1
1
1
1
1
1
2
NOTE
Do not remove the piston rings unless they are to
be replaced.
(15)
(16)
(17)
(18)
(19)
Dust seal
Stopper ring
Fork tube
Oil seal
Back-up ring
(20~ i Slider bushing
(21) I Fork tube bushing
CAUTION
Be careful not to damage the fork tube sliding
surface.
1
1
1
1
1
I NOTE
13-15
Front Wheel/Suspension/Steering
LBS-ABS/TCS Model
(5)~
'-----l
(14)
12)
1'1
Lock nut
13-16
Front Wheel/Suspension/Steering
Requisite Service
Fork removal (page 13-12).
Procedure
Q'ty
Remarks
1/1
Remove the cap form the fork tube, then remove it from
the fork damper rod while holding the lock nut as shown.
Remove the stopper while compressing the fork spring as
shown.
11 }
Disassembly Order
Fork cap/O-ring
12}
13}
18}
19}
Spring seat
Fork spring
Socket bolt/washer
Fork damper
Oil lock piece
Dust seal
Stopper ring
1
1
1/1
1
1
1
1
(10)
(11)
(12)
(13)
(14)
Fork tube
Oil seal
Back-up ring
Slider bushing
Fork tube bushing
I'}
15}
16}
17}
1
1
1
1
1
CAUTION
Be careful not to damage the fork tube sliding surface .
NOTE
Do not remove the bushing unless it is to be replaced .
13-17
Front Wheel/Suspension/Steering
~~
S'"
(14)
(15)
if) 20 (2.0,14)
(20)
(19(
(1 B)
(111
/
..
\ -
17)
18)
(9)
(11
13-18
Uii
(21 J
Front Wheel/Suspension/Steering
Q'ty
Procedure
(I)
(2)
(3)
(4)
(5)
(6)
(7)
(B)
(9)
(10)
(11 )
(12)
(13)
(14)
Assembly Order
Fork tube bushing
Fork tube
Piston rings
Rebound spring
Stopper ring
Spring seat
Oil lock valve spring
Oil lock valve
Stopper ring
Fork piston assembly
Socket bolt/washer
Slider bushing
Back-up ring
Oil seal
(15)
Stopper ring
(16)
Dust seal
,
,
(' 7)
Fork spring
Remarks
1
1
2
1
1
1
1
1
1
1
11'
;
,
1
,,
11'
NOTE
Wrap vinyl tape around the fork tube top end to
avoid damaging the oil seal lip during installation.
Drive the slider bushing and oil seal into the slider
using the fork seal driver body (07947-KA501 DO}
and attachment (07947-KFOOl 00).
CAUTION
Be careful not to damage the fork tube sliding
surface.
Pour in the fork fluid to the specified level with the fork
fully compressed before installing the fork spring.
Wipe fluid off the spring thoroughly using a clean lint
free cloth and install with the tightly wound coil end
facing down.
After completing fork assembly, refer to fork installation procedures (page 13-11}.
13-19
Front Wheel/Suspension/Steering
lBS-ABS/TCS Model
I,;;ocl"
(B)~
0 2 3 (2.3,17)
,
/
,/
,/
//
,!
/
''
'------~!
(4)
(' )
(3)
(13)
mm (O.41
>-c--~ 10.5
minimum
in)
~=
13-20
=~::~~~;=:::t~
lock nut
0 2 0 (2.0, 14)
Front Wheel/Suspension/Steering
Procedure
111
121
131
141
151
161
171
181
Assembly Order
Fork tube bushing
Fork tube
Oil lock piece
Fork damper
Socket bolt/washer
Slider bushing
Back-up ring
Oil seal
191
Q'ty
1
1
1
1
1/1
1
1
1
Stopper ring
,
(10) : Dust seal
{ll}
Fork spring
(12)
Spring seat
Spring seat stopper
1
1
(13)
Remarks
NOTE
Wrap vinyl tape around the fork tube top end to avoid
damaging the oil seal lip during installation.
Drive the slider bushing and oil seal into the slider using
the fork seal driver body (07947-KA50100) and attachment (07947-KA40200l.
CAUTION
Be careful not to damage the fork tube sliding surface.
Pour in the fork fluid to the specified level before installing
the fork spring.
Wipe fluid off the spring thoroughly using a clean lintfree cloth and install with the tightly wound coil eod
facing
down.
,
Install the stopper between the spring seat and lock nut
while compressing the fork spring as shown.
NOTE
Before installing the stopper, measure the distance
between the lock nut and the top of the damper rod, it
should be at least 10.5 mm (0.41 mm)
Instatl the fork cap onto the damper rod and tighten the
lock nut as shown, then screw it into the fork tube, but do
not tighten yet.
CAUTION
Be careful not to cross-thread the fork cap.
(14)
Fork cap/a-ring
1/1
After completing fork assembly, refer to fork installation procedure (page 13-13).
13-21
Front Wheel/Suspension/Steering
(13)
(15)
(2)
~ ~7
(16)~~
(17)~~
~~
(14)~ ~
(1)
/1
~\
(5)
(6)
(7)
(9)
(8)
(18)
(11)
(4)
=
(2)
13-22
Front Wheel/Suspension/Steering
Requisite Service
O'ty
(1)
I Fork
Disassembly Order
tube protector
(2)
I Fork cap
(3)
(4)
a-ring
Spring seat stopper
(5)
(5)
(7)
(8)
(9)
(10)
Spring seat
Spring collar
Spring seat
Fork. spring
Socket bolt/washer
Fork damper
(11) Oil lock piece
(12) Dust seal
(13) Stopper ring
(14)
(15)
(16)
(17)
(18)
Fork tube
Oil seal
Back-up ring
Slider bushing
Fork tube bushing
Remarks
NOTE
Do not remove unless necessary.
Remove the fork cap from the fork tube, then remove it
from the fork damper rod while holding the lock nut as
shown.
1
1
1
1
1
1
1/1
1
1
1
1
1
1
1
1
1
CAUTION
Be careful not to damage the fork tube sliding
surface.
I NOTE
13-23
Front Wheel/Suspension/Steering
LBS-ABS/TCS Model
(14)
(15)
(17)
(18)
(19)
(20)
(1)
(21)
(16}
(2(
(22}
(8)
(5)
13-24
(7)
Front Wheel/Suspension/Steering
The fork cap is under spring pressure. Use care when removing it.
Requisite Service
Fork removal (page 13-12).
Q'ty
Procedure
Disassembl Order
Fork cap/a-ring
Spring collar
Spring seat
I'} Fork spring
15} Socket bolt/washer
16} Fork piston assembly
17} Stopper ring
18} Oil lock valve
19} Oil lock valve spring
(10) Spring seat
(1 1} Stopper ring
(12} Rebound spring
(13} Piston ring
11}
12}
13}
(14)
Dust seal
1/1
1
1
1
1/1
1
1
1
1
1
1
1
2
1
1
Fork tube
(17) Oil seal
(18) Back-up ring (upper)
(19) Packing
(20) Back-up ring (lower)
(21 ) Slider bushing
(22) Fork tube bushing
1
1
1
1
1
1
1
(16)
Remarks
i
NOTE
Do not remove the piston rings unless they are to be
replaced.
CAUTION
Be careful not to damage the fork tube sliding surface.
NOTE
Do not remove bushing unless it is to be replaced.
13-25
_
8'"
(10)
tf!:tt. 20 (2.0,
~(18)
(15)
s-.
$I
R':::"
(19)
es
(14)
(13)
(12)
(11)
~ 23 (2.3,17)
~ (15)
(16)
UP
13-26
14)
(lB)~
Lock nut
Front Wheel/Suspension/Steering
t(11
(2)
(3)
(4)
(5)
(5)
(7)
(8)
a'ty
Procedure
Assembly Order
Fork tube bushing
Fork tube
Oil lock piece
Fork damper
Socket bolt/washer
Slider bushing
Back-up ring
Oil seal
1
1
1
1
1;1
1
1
1
(9)
(10)
Stopper ring
Dust seal
1
1
(12)
(13)
(14)
(15)
Spring seat
Spring collar
Spring seat
Lock nut
( 17) O-ring
(18) Fork cap
(19)
Remarks
1
1
1
1
1
1
1;1
NOTE
Wrap vinyl tape around the fork tube top end to
avoid damaging the oil seal lip during installation.
Drive the slider bushing and oil seal into the slider
using the fork seal driver body (07947-KA501 00)
and attachment (07947-KFOO100).
CAUTION
Be careful not to damage the fork tube sliding
surface,
Pour in the fork fluid to the specified level with the fork
fully compressed before installing the fork spring.
Wipe fluid off the spring thoroughly using a clean lint
free cloth and install with the tightly wound coil end
facing down.
After completing fork assembly, refer to fork installation procedures (page 13-11).
13-27
Front Wheel/Suspension/Steering
LBS-ABS/TCS Model
..
(15)
UP
(18)
1,';""ooLI . ,
,t::rl====
1
. . 1141-----+i~O~~\~ ~~~
1
I
(1S}
IIii;'ijiIII
(,3)~'j
(17}
I I
(22)
~\
(20)
/$/
20 (2.0, 14)
1ta
13-28
111
181
121)
Front Wheel/Suspension/Steering
Procedure
Assembly Order
11 } Fork tube bushing
12} fork tube
13} Piston ring
14} Rebound spring
15} Stopper ring
16} Spring seat
17} Oil lock valve spring
IS} Oil lock valve
19} Stopper ring
(10) Fork piston assembly
(11) Socket bolt/washer
(12) Slider bushing
(13) Back-up ring (lower}
(14) Packing
(15) Back-up ring {upper)
(16) Oil seal
Q'ty
Remarks
1
1
2
1
1
1
1
1
1
1
1/1
1
1
1
1
1
(17)
Snap ring
(18)
Dust seal
(19)
Fork spring
{20}
{21}
(22)
Spring seat
Spring collar
Fork cap/O-ring
1
1
1/1
CAUTION
Be careful not to damage the fork tube sliding surface.
Pour in the fork fluid to the specified level before
installing the fork spring.
Wipe fluid off the spring thoroughly using a clean lint
free cloth and install with the tightly wound coil end
facing down.
I CAUTION
After completing fork assembly, refer to fork installation procedures (page 13-13l.
13-29
Front Wheel/Suspension/Steering
e1I
151
161
171
28 (2.8, 20)
,,
-,
(4)
-,
,,
,,
131
13-30
Front Wheel/Suspension/Steering
NOTE
The steering head bearings and races should always replaced as a set .
When loosening and tightening the steering stem nut, temporarily install the fork legs.
Requisite Service
my
Procedure
(I)
(2)
(3)
Removal Order
Steering stem nut
Washer
Ignition switch wire
(4)
(5)
(6)
(7)
(8)
(9)
('D)
(11)
(' 2)
(' 3)
(14)
(15)
(16)
Remarks
Installation is in the reverse order of removal.
1
1
,,
,,
,
I
,,
,
,,
,
,
i
I Disconnect at the connector holder. At installation,
13-31
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
14-1
Troubleshooting
14-1
14-2
14-4
Installation
14-6
14-7
14-8
Service Information
Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service
Manual. When remounting the tire, note the normal rotating direction indicated by the arrow.
Refer to the section 15 for brake system information.
Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points.
Troubleshooting
Rear wheel wobbling
Bent rim
Hard suspension
Damaged shock absorber mount bushing
Incorrect suspension adjustment
Bent damper rod
Damaged swingarm pivot bearing(s)
Lack of lubrication in swing arm pivot bearings or
suspension pivot points
III
Soft suspension
Weak shock absorber spring
Oil leakage from damper unit
Incorrect suspension adjustment
14-1
Rear Wheel/Suspension
151
70 (7.0, 5 1)
111
I
II,
"",
Wheel sensor
12)
,
14)
131
27 (2.7, 20)
Driven flange
Dust guard plate
Ring gear
161
Handle of pliers
14-2
Rear Wheel/Suspension
~
. A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
NOTE
.
0
0
ABS/TCS or LBS-ABS/TCS model: Do not remove the wheel sensor to remove and install the rear wheel.
Do not depress the brake pedal when the caliper is removed, or it will be difficult refit the disc between the brake pad.
Support the removed caliper with a piece of wire so that it does not hang from the brake hose. Do not twist the brake
hose.
Apply multipurpose NLGI NO.2 grease (molybdenum disulfide additive) to the driven flange and the ring gear
engagement splines.
Requisite Service
0
Removal Order
caliper stopper pin bolt
axle nut
axle pinch bolt
axle
caliper assembly
wheel assembly
,
,
Q'ty
01 Rear
121 Rear
131 Rear
141 Rear
151 , Rear
151 i Rear
1
1
1
1
1
1
Remarks
Loosen the bolt.
1 4-3
Rear Wheel/Suspension
~
/
J >I
//
//
...
l ir e;;
/ ://r ~,
l{~~ . '
"f'~;;
)/)\, <:
'
'\'v~
~~
20 (2.0, 14)
111
(51
(15)
(81
(21
.,
_ fiiiiiiH
(21
(51
191
(111
(41
(101
43 (4.3,31)
"
~
171
( 13)
(12)
Arrow([)
Arrow4;'
00
@ ---~
Arrow
14-4
//
Rear Wheel/Suspension
NOTE
Replace the rear wheel damper rubbers as a set.
Replace the wheel bearings as a set.
For wheel bearing replacement, refer to the section 1 of the Common Service Manual.
ABS(TCS or LBS-ABS(TCS model: When the pulser ring is replaced, perform the wheel sensor air gap inspection
{page 16-A-51 or 16-B-34} after installing the rear wheel.
Requisite Service
Rear wheel removal/installation {page 14-2}.
Procedure
(1 )
(2)
Disassembly Order
Torx bolt (T25) (ABS(TCS or LBS-ABS(TCS
model)
Pulser ring (ABS(TCS or LBS-ABS(TCS model)
G'ty
Remarks
Assembly is in the reverse order of disassembly.
Install the pulser ring with the concave of bolt hole facing
out.
CAUTION
Be careful not to deform, distort, or damage the pulser
ring.
At assembly, apply 3 g {D.1 1 oz} of molybdenum disulfide
paste to the driven flange mating surface of the hub, to
the inside diameter of the driven flange and to the
splines of the driven flange as shown.
(3)
(4)
Thrust washer
O-ring
Socket bolt
Damper holder plate
1
1
5
1
(14)
5
1
6
1
1
1
1
(15)
Rear tire
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
I
I
14-5
Rear Wheel/Suspension
/
~121
~ 23 (2.3,17)
NOTE
Use a floor jack or other adjustable support under the final drive to relieve stress for ease of left shock absorber lower
mounting bolt removal/installation.
Note the position of the spring preload adjuster for future reference. Adjust the spring preload adjuster to the softest
position for disassembly. Return the adjuster to the position noted before disassembly.
Requisite Service
Place the motorcycle on its center stand
Right side cover (page 2-2)
(1)
(2)
(3)
Removal Order
Upper mounting bolt
Lower mounting bolt
Shock absorber assembly
14-6
Rear Wheel/Suspension
(2)
NOTE
Adjust the spring preload adjuster to the softest position before disassembly.
---'----
Requisite Service
Procedure
(1)
Disassembly Order
Stopper ring
1
1
1
,
(2)
(3)
(4)
Remarks
Assembly is in the reverse order of disassembly.
Compress the shock absorber spring using the spring
I compressor (07GME-0010000) and attachment
(07959-MB10000) and remove the stopper ring.
Install with the tightly wound coil end facing up.
14-7
Rear Wheel/Suspension
Swingarm Removal/Installation
LBS-ABS/TCS model shown:
0:
:'.TOOLI
105 (10.5, 76)
13)
18)
I')
e;:,. Standard
~
0:
model"
18 (1.8,13)
ABS/TCS or
LBS-ABS/TCS model:
22 (2.2, 16)
I' )
\ v/
(6)
"UP" mark
14-8
Rear Wheel/Suspension
NOTE
,.
,
Requisite Service
O'ty
Remarks
Installation is in the reverse order of removal.
Remove the wire harness from the swingarm.
2
1
1
1
1
2
1
1
19)
181
17)
151
161
Installation Order
Rubber boot
Driveshaft assembly
Pivot bearing
Right pivot bolt
Swingarm
1
1
1
1
1
14)
13)
12)
111
4
1
,
Pivot bearing outer race replacement (page 14-10)
Disassembly/Assembly (page 12-2)
14-9
Rear Wheel/Suspension
Pivot Bearing Outer Race Replacement
Punch or drill a 13 mm (1/2 in) hole into each grease retain-
07936-4150000
07741-0010201
(3) ATTACHMENT
"-------"
Driver
Attachment, 37 x 40 mm
07749-0010000
07746-0010200
(1) DRIVER
' '_"
(~
'"
.---/
~-:-:~_
,,~
1'"",;;/,'0"',
_--_-~""':>,J./~-
-_,,/'
\i , \
----;
14-10
"
(2) ATTACHMENT,
37 x 40 mm
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
15-'
15-1
15-8
15-10
15-12
15-16
15-20
15-24
15-28
15-29
Service Information
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
Brake dust may contain asbestos. inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate
method approved by OSHA. designed to minimize the hazard of airborne asbestos fibers.
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber
parts. Be very careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
Once the hydraulic system has been opened, or if the brakes feel spongy, the system must be bled.
The brake fluid air bleeding procedure on the ABS/TCS ('92-95) model must be performed in the same manner as in
the ordinal air bleeding procedure. Note that replacement and bleeding air from the brake fluid in the modulator is
not necessary, as it is sealed in the modulator. On the LBS-ABSfTCS model (After '95), refer to page 15-2.
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 motorcycle.
~
~
Troubleshooting
Brake lever/pedal soft or spongy
Air in the hydraulic system
Leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake pad/disc
Contaminated caliper
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warped/deformed brake disc
Sticking/worn caliper piston
Sticking/worn master cylinder piston
Contaminated master cylinder
Bent brake lever/pedal
15-1
Brake System
(1) SCREWS
NOTE
On the LBS-ABSiTCS model, note that there is no brake
fluid in the modulator (except in the modulator head),
because the modulator is the motor-driven hydraulic
pressure type. Therefore, brake fluid replacement and
bleeding air from the modulator body is not necessary.
Once the hydraulic system has been opened, or if the
brake feels spongy, the system must be bled.
When using a commercially available brake bleeder,
follow the manufacturer's operating instructions.
CAUTION
Use only DOT 4 brake fluid from a sealed container.
Do not mix different types of fluid. They are not
compatible.
Operate the brake lever several times to bleed air from the
master cylinder.
15-2
(2) CAP
(1) LEFT
(2) RIGHT
Brake System
1. Pump the brake bleeder and loosen the bleed valve.
Add brake fluid when the fluid level in the reservoir is low.
NOTE
Check the fluid level often while bleeding the brake to
prevent air from being pumped into the system.
Repeat the above procedure until sufficient amount of the
fluid flows out from the bleed valve.
Close the bleed valve.
NOTE
It is not a problem if the fluid flowing out from the bleed
valve contains air bubbles because the lines will be bled
in later steps.
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
2. Perform step 1 for the other side bleed valve.
Next, periorm the air bleeding from the system (page 15-4).
(2) BLEEDER
(1)
15-3
Brake System
AIR BLEEDING
1. Connect a transparent bleed hose to the bleed valve.
Pump the brake lever several (5-10) times quickly. then
squeeze the brake lever all the way and loosen the bleed
valve 1/4 turn. Wait several seconds and close the bleed
valve.
-@"
~/
NOTE
Do not release the brake lever until the bleed valve has
been closed.
Release the brake lever slowly and wait several seconds
after it reaches the end of its travel.
/~/ ...../1,"I,
(1) LEVER
air bubbles
disappear
~
,
--
I
I
~ntil
-
I
I
:;-:{j'
Ii! -,",',~; {"f)/1'
"
"'"
'I f
v
'.,'
(1) SCREWS
15-4
,1,.0"
---
Brake System
FLUID FEEDING
Support the motorcycle on its center stand.
Remove the right side cover (page 2-2}.
~(1)CAP
--'<',
~"",
~ ~7~~----
(2) RESERVOIR
Operate the brake pedal several times until brake fluid level in
the reservoir goes down.
."'-: ,- "E:3'
w~
(1) FILLING
(2) PEDAL
15-5
Brake System
NOTE
15-6
@~~mc__~_
f~~
{SJ:'' '.
~~
Brake System
AIR BLEEDING
1. Connect a transparent bleed hose to the left front caliper
lower-side bleed valve.
CD
(l!;J
...
~C)j.
/~':J
Fill the reservoir to the upper level line with DOT 4 brake fluid
from a sealed container.
Install the diaphragm, set plate and reservoir cap.
Check the pedal line brake operation (page 3-13).
15-7
Brake System
LBS-ABS/TCS Model
Front
Front
r.
,i"
(3)
\i-
..""l
:~\
..
..\.\\
\~
,
I',
(2)
E): 18 (1.8,13)
",',
/>
-';',
(3)
" "
1
C
Rear
Rear
(2)
E): 18 (1.8,13)
...-
Stopper ring
mO
(1 )
Stopper ring
(2)
(11
(31
18 (1.8,13)
91
I
:' I
1,1
r-
_~
15-8
(5) Tabs
Brake System
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
After replacement, operate the brake lever or pedal to seat the caliper pistons against the pads and check the brake
operation [For front brake pad of the LBS-ABS/TCS model, operate the lever and pedal (page 3-13) 1.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
NOTE
The brake pads can be replaced without disconnecting the hydraulic system.
Replace the brake pads as a set.
Apply a thin coat of grease onto the pad pin and pad pin plug threads to prevent rust.
Standard and ABS/TCS model:
Procedure
111
121
13}
Removal Order
Pad pin plug
Pad pin
Remarks
D'tv
P,d
NOTE
Push the pistons all the way in to provide clearance for
the new pads.
Before installing the pads, make sure that the pad
spring is positioned properly as shown.
LB5-ABS/TCS model'
Procedure
11}
12}
13}
Removal Order
Pad pin plug
Pad pin
P,d
Q'ty
Remarks
Installation is in the reverse order of removal.
1
1
2
NOTE
Push the piston all the way in to provide clearance for
the new pads.
On the rear pad, be careful not to scratch the rear wheel
hub.
When installing the inside pad, insert between the tabs
(retainers) of the pad spring and caliper body.
15-9
Brake System
012
(10)
(1.2, 9)
(5)
o
et
(6)_~-;--t:~
35 (3.5, 25)
(2)
(3)
(12)
: Lever pivot
1 (0.1,0.7)
~MIIl---Boot:
e:w
(7)
'91-94
(I)
(14)
0 4 (0.4, 2.9)
(11 )
------....,
1'3)
(19)
{20)
-4'
15-10
lBS-ABS/TCS model:
Brake System
Check the brake system by applying the lever brake after air bleeding.
CAUTION
Avoid spilling fluid on painted, plastic. or rubber parts. Place a rag over these parts whenever the system is serviced.
When removing the oil bolt, COverthe end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the master cylinder piston cups to be turned inside out and be certain the snap ring is firmly
seated in the groove.
NOTE
Use only DOT 4 brake fluid from a sealed container.
After assembly, align the index mark on the adjuster with the arrow mark on the joint pin.
Requisite Service
Handlever cover removal/installation (page 13-2}
Front brake fluid draining/air bleeding (Standard and ABSJTCS model: section 17 in Common Service Manual)
Lever brake line fluil draining/air bleeding (LBS-ABS,rrCS model: page 15-2)
Procedure
G'ty
Disassembly Order
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
{14}
(15)
(16)
(17)
(18)
{19}
{20)
(21)
(22)
(23)
(24)
(25)
Remarks
Assembly is in the reverse order of disassembly.
At assembly, check the brake system by applying the brake
after bleeding air from the system.
2
1
2
1
2
1
1
2
1
1/1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
LBS-ABSJTCS model
Use snap ring pliers (07914-3230001),
On the LBS-ABS,rrCS model, it is installed onto the piston.
15-11
Brake System
Right side:
(1)
'<\~
-------\
(5)
(9)
Wheel sensor
ew
0 2 3 (2.3, 17)
(14)
(17)
(11 )
(15)
110}
(13)
...-'iiSiII
15-12
Brake System
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Check the brake system by applying the brake after air bleeding.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
CAUTION
Spilled brake fluid will damage painted, plastic. or rubber parts.
NOTE
Requisite Service
Procedure
Q'tv
Disassembly Order
(' )
(2)
(3)
(4)
(5)
P,d
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Pad spring
Caliper bracket
Pad retainer
Caliper pin bolt boot
Caliper pin bolt
Caliper piston
Dust seal
Piston seal
(6)
Remarks
Assembly is in the reverse order of disassembly.
At assembly, check the brake system by applying the brake
after bleeding air from the system.
,
,
,,
,
,, .
,
2
2
2
CAUTION
Be careful not to damage the wheel sensor.
Install as shown.
2
2
2
;T .
CAUTION
Be careful not to damage the piston sliding surface.
15-13
Brake System
LBS-ABS/TCS Model
Right side:
left side:
(5)
30 (3.0, 22)
0 3 0 (3.0, 22)
~/7----c ~i'/(
/-.
--~ -'U'
{;
r- " / ; '
0/ ':.0. el
.'-.j,c,,,-~~
.z
0
./
/
",
I Q
'~',
:''.,,,
c 'I"~
I'
, C
(,i y.
nrr
"\ o"\\J
.",:0'\
:::;\0' 'I',.,
...-umtt,
,
-:
{51
0 3 0 (3.0, 22)
{6J
{7J
iV
{81
,'(::
..
33 (3.3, 24)
;<"/>"
(10)
13 (1 .3_,9_J_-Hc'ii
(11)
RIGHT:
LEFT:
..-'iiSiIi
Stopper
ring
{9J
{41
, ~-J- __ ~
(11)
15-14
1 8 (1 8 , 13 )
Brake System
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Check the brake system by applying the lever and pedal brake after air bleeding (page 3-13).
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method
approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
CAUTION
Spilled brake fluid will damage painted, plastic, or rubber parts.
NOTE
Do not remove the bleed valve unless it is replaced.
Reinstall the removed pistons and seals in the original position securely.
After installing the right caliper, check the wheel speed sensor air gap (page 16-B-34).
Requisite Service
Lever and pedal brake lines fluid draining/air bleeding (page 15-2)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Disassembly Order
Brake oil bolt
Sealing washer
Brake hose
Pad
Caliper mounting bolt
no:
Q'ty
Remarks
Assembly is in the reverse order of disassembly.
2
4
2
2
2
1
1
1
1
3/1
3
Install as shown.
;I .
CAUTION
Be careful not to damage the piston sliding surface.
15-15
Brake System
E:t
(ZIe/
35 (3.5, 25)
(4)
(1)----.,
----
>
(3)
(,OI------:t:::jrilJ
(10)
(7)
.-
IS"
131
(6)
(8)---(51
fit
191
(181
1161
IABS/TCSM"';-d-el:1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
.....
"
(12)
(17)
.J
@--------j(11)
E:t
/LJ
1141
(15)
I s ';"OO~ I
15-16
(13)
18(1.8, 13)
Brake System
Check the brake system by applying the brake after bleeding air from the system.
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the master cylinder piston cups to be turned inside out and be certain the snap ring is firmly
seated in the groove.
NOTE
Use only DOT 4 brake fluid from a sealed container.
Loosen and tighten the oil bolt and master cylinder mounting bolts with the step holder installed.
The master piston, piston cups and spring must be replaced as a set.
Requisite Service
my
Procedure
(1)
(2)
(3)
(41
(5)
(6)
(7)
(8)
(91
(10)
(111
(12)
(13)
(14)
(15)
(16)
(17)
(18) I
Disassembly Order
Oil bolt
Sealing washer
Brake hose
Mounting bolt
Reservoir hose joint screw
Reservoir hose joint
O-ring
Cotter pin
Joint pin
Master cylinder assembly
Lock nut
Spring pin
Push rod joint
Boot
Snap ring
Push rod
Master piston/piston cup
Spring
Remarks
Assembly is in the reverse order of disassembly.
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1;2
15-17
Brake System
c:
LBS-ABS/TCS Model
35 (3 5, 25)
121
161
131t!1
,,~
14I
1151~
11 I
(19}
(1O}
027
(2. 7, 20)
(11)
35 (3.5, 25)
(18}
i.~
(12)
(22)
-'I' i
rl~
162 m m
1 lJ
15-18
J?J
1201' LI__i-
I
18(1.8,13}
Brake System
Check the brake system by applying the brake after air bleeding (page 313).
CAUTION
Avoid spilling fluid on painted. plastic, or rubber parts. Place a rag over these parts whenever the system serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the cups to be turned inside out and be certain the snap ring is firmly seated in the groove.
NOTE
The master piston, piston cups and spring must be replaced as a set.
Use only DOT 4 brake fluid from a sealed container.
Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2).
Right pivot cover removal/installation (page 2-5).
Procedure
Disassembly Order
111
121
13}
14}
{5}
16}
(7)
(8)
19}
(10)
(11)
{12}
{13)
(14)
(15)
(16)
(17)
{1S}
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Remarks
Q'tv
1
1
1
1
1
1/2
1
1
1
1
15-19
Brake System
90 (9.0, 65)
(7)
\\!/I---~~
(91
(I)
35 (3.5, 25)
.,
,,
(2)
(3)
(5):---~.elJ
70 (7.0, 51)
(8)--~.J
ew
0 2 8 (2.8, 20)
(14)
f!!J
18(1.8,13)
(6)
27 (2.7, 20)
5 .5 (0 .55, 4.0)
(15).
.--'iSitI
(131
(121
(131
~
(10)
(4)
(14)
0 1 3 (1.3, 9)
15-20
iI!ili
(11)
Brake System
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
Check the brake system by applying the brake after air bleeding.
Brake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer.
Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate
method approved by OSHA, designed to minimize the hazard of airborne asbestos fibers.
CAUTION
NOTE
Do not remove the bleed valve unless it is replaced.
Requisite Service
Procedure
(I)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Disassembly Order
Brake oil bolt
Sealing washer
Brake hose
Pad
Caliper stopper pin bolt
Rear axle pinch bolt
Rear axle nut
Rear axle
Brake caliper assembly
Pad spring
Caliper bracket
Pad retainer
Caliper pin bolt boot
Caliper pin bolt
Caliper piston
Dust seat
Piston seal
Remarks
Assembly is in the reverse order of disassembly.
1
2
1
2
1
1
1
1
1
1
2
2
2
2
2
15-21
Brake System
lBS-ABSfTCS model
(8)
(6)
0 2 7 (2 7, 20)
5 (0 25
2.
1.B)
28
(2.8. 20)
~,."'~~"'~
'. t"~/"
(12)
"~'"~
/
".
(13)
. (2)'.
/!!: .,'10:>.
.
"I
,,
\------------------------------.
(4)?-~--'-'.;
(14)
UP
(16)
~.
Same 0.0.
15-22
I
t1t
(15)
(11)
(14)
c:
23 (2 3. 17)
"
'U1!ti
(10)
Brake System
Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
Check the brake system by applying the pedal brake after air bleeding (page 3-131.
CAUTION
NOTE
Requisite Service
II)
)2)
)3)
14)
15)
16)
17)
18)
19)
Disassembly Order
Brake oil bolt
Sealing washer
Brake hose
Pad
Caliper stopper pin bolt
Rear axle pinch bolt
Rear axle nut
Rear axle
Brake caliper assembly
(10}
(11}
(12)
(13)
(14)
(15)
(16}
Caliper bracket
Pad retainer
Pad spring
Assembly bolt I caliper body
Caliper piston
Dust seal
Pistson seal
Q'tv
Remarks
Assembly is in the reverse order of disassembly.
2
4
2
2
1
1
1
1
1
1
1
3/1
3
3~
3~
Install as shown.
CAUTION
Be careful not to damage the piston sliding surface.
15-23
Brake System
(8)
(7)
~~---13)
16)
.,
12)
(4)
Requisite Service
Right step holder removal/installation {page 2-13)
Q'ty
Procedure
Remarks
Installation is in the reverse order of removal.
Removal Order
11)
12)
13)
14)
15)
16)
(7)
(8)
(9)
15-24
1
1
1
1
1
1
1
1
1
Brake System
MEMO
15-25
Brake System
til
(2)
(9)
Rubber
.u> til
(4)
{10)
0~~~--(3)
(1)
0 3 5 {3.5, 25}
(7)
0 3 0 (3.0. 22)
~~
(3)
.1(161
""~'"
'if
(19)
tw:I
(15}
@
(21)
.~
if)1B{1.8,13}
(20)
c:w
(13)'
(17)
(14)
15-26
.I
Brake System
Check the brake system by applying the brake after air bleeding (page 3-13J.
CAUTION
Avoid spilling fluid on painted. plastic. or rubber parts. Place a rag over these parts whenever the system is serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
Do not allow the lips of the cups to be turned inside out and be certain the snap rings is firmly seated in the groove.
NOTE
The master piston, piston cups and spring must be replaced as a set.
Use only DOT 4 brake fluid from a sealed container.
Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2)
Front fender removal/installation (page 2- 11)
Procedure
111
12}
13}
14}
15}
15}
17}
IB}
19}
(10)
(11)
(12)
(13}
(14)
(15)
(16)
(17)
{18}
(19)
(20)
(21)
Disassembly Order
Oil bolt
Sealing washer
Brake hose
Oil pipe stay bolt
Link plate bolt
Link plate
Upper caliper pivot bolt
Master cylinder mounting bolt
Secondary master cylinder & link arm assembly
Cotter pin
Joint pin
Link arm
Boot
Snap ring
Push rod
Master piston
Primary cup
Spring
Lock nut
Push rod nut
Push rod joint
Remarks
Q'ty
4
2
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
15-27
Brake System
C:
17 (1.7,12)
{3)
Check the brake system by applying the pedal brake after air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced.
When removing the oil bolt or pipe, cover the end of the brake hose and pipe to prevent contamination. Do not allow
foreign material to enter the system.
Requisite Service
Pedal brake nne fluid drainmq/air bleeding (page 15-2)
Front fender removal/installation (page 2-11)
Procedure
(1)
{2)
{3)
{4)
{51
{51
Removal Order
Oil bolt
Sealing washer
Oil pipe joint nut
Wire stay & hose joint bolt
Mounting bolt
Delay valve
15-28
Q'ty
Remarks
Installation is in the reverse order of removal.
2
4
1
1
2
1
Brake System
I \,
-:
\ \,
~~~~~~~~~~?~~~.;.~:=~~
cj
/
II
/1
I
i/
,'''
{21
{ll
{31
17 (1.7,12)
Check the brake system by applying the pedal brake after air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced.
When disconnecting the oil pipe, cover the end of the oil pipe to prevent contamination. Do not allow foreign material
to enter the system.
Requisite Service
Pedal brake nne fluid draining/air bleeding (page 15-2)
Right side cover removal/installation (page 2-2)
Procedure
{11
{21
{31
Removal Order
Oil pipe joint nut
Mounting bolt
Proportional control valve
my
2
2
1
Remarks
Installation is in the reverse order of removal.
Be careful not to deform the oil pipe.
15-29
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
16-A-1
Troubleshooting
16-A-5
System location
16-A-2
16-A-51
16-A-3
16-A-52
Circuit Diagram
16-A-4
16-A-54
Service Information
CAUTION
Use a fully charged battery for troubleshooting. Do not diagnose the ABS with a charger connected to the battery.
On removal and installation of the wheels and wheel sensors, be careful not to damage the wheel sensors and'
pulser rings.
NOTE
Check the following before performing any ASS troubleshooting.
- Pre-start self-diagnosis of ABS
- ABS indicator light
If an abnormality is found during the above checks, perform the ASS troubleshooting following the Symptom-toSystem Chart (page 16-A-8). The ASS is normal if no trouble is found. Go to the checks on the other basic systems (e.q.,
brake system).
Troubles not resulting from a faulty ASS, i.e. brake disc squeak, unevenly worn brake pad, etc., cannot be recognized by
the ASS diagnosis system. (See the Common Service Manual.)
Record the symptom ofthe problem and the problem code in MEMO before troubleshooting.
When the ASS is faulty, the ASS indicator light blinks or it comes on. The ASS does not function at this time; take care
during the test ride.
Do not disassemble the modulator assembly. If it is faulty, replace it as an assembly.
After replacing the modulator, bleed air from the brake fluid according to the standard air bleeding procedure. Note that
replacement and bleeding air from the brake fluid is not possible, as it is sealed in the modulator.
When the rear wheel sensor or rear pulsar ring is replaced, perform the air gap inspection (page 16-A-51).
The ASS indicator light might blink in the following cases. If the indicator light blinks, clear the problem code and
perform the pre-start self-diagnosis of the ASS (page 16-A-5). The ASS is normal if the ASS indicator light goes oft.
- The motorcycle has continuously run on the bumpy road.
- The ASS control unit (ECU) was disrupted by extremely powerful radio wave (Electromagnetic Interference).
- After riding {i.e. after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for more
than 30 seconds) with the motorcycle on the center stand.
The ASS indicator light might blink in the following cases. If the indicator light blinks, service the faulty parts, clear the
problem code, and perform the pre-start self-diagnosis of the ASS (page 16-A-5). The ASS is normal if the ASS indicator
light goes off.
- Incorrect tire pressure
- Tires not recommended for the motorcycle were installed.
- Deformation of the wheel
After troubleshooting, clear the problem code and perform the pre-start self-diagnosis again to be sure that the ASS
indicator light is operating normally.
16-A-1
l'1:li.
u:.
System Location
(3) BATTERY
SENSOR
(20)
16-A-2
For example:
LIGHT SWITCH
-Top shelter
(page 2-5)
-Inner
MJ
,
(~)
ABS/TCS INDICATOR
LIGHT SWITCH
e-Maintenance part
S(
(page 2-
___-~_2-21
@GROUND TERMINAL
-R. side cover (page 2-2)
/
,j]) FRONT PUMP
-Upper fairing
(page 2-9)
t4J REAR
PUMP MOTOR
-R. side cover (page 2-2)
Bl
BLACK
Y YELLOW
Bll BLUE
G GREEN
R RED
W WHn:E
Br
0
Lb
Lg
P
,~-_
BROWN
ORANGE
UGHTBLUE
UGHTGREEN
PINK
Or GRAY
PI iW, o~
W
IP
BI
(~) ~
J2: REAR WHEEL SENSOR
-R. side cover (page 2-2)
{~,
FRDr
-uoo
(page
llCATOR LIGHT 2
Teen
7}
ABS ('92-'95)
:1::
(page 2-7)
I~I
(~)
L~B1
Y;Gr
GfSI
o: INDICATOR (WHITE)
-Inner screen (page 2-7)
s,
,-,
B7y
Rlsr %u
t]) REAR PUMP MOTOR RELAY
r-r-r
B~p B~L9
R/ R/
Sr Su
@ECU {BLACK}
-Upper fairing (page 2-9)
{~GROUND
(f" ECU
(WHITE)
-Upper fairing (page 2-9}
TERMINAL
-Upper fairing
(page 2~-..:9..:)_ _-,-
~ [~)
IT WHEEL SENSOR
er fairing
2-9)
INDICATOR (BLACK)
-Inner screen (page 2-7)
~
:J.: FRONT SOLENOID VALVE
-Upper fairing
(page 2-9}
-,
($I$J
16-A-3
ABS ('92-'95)
Circuit Diagram
PUMP MOTOR RELAY
(FRONT) (REAR)
ABS
MAIN~~~rm~
ASS FUSE
BOX
1 2 3
1:
2:
3:
4:
~TTIT%:rr=rr%:
RELAY
!1::
sea:;
;::(:J,,
m"
c,il..5'<i5
.--.-"-"
~~~.ii
0>"-
a1Cl:c3O::
III
a: III c::
Ci
"(,'J
:::0 ~ :::0
m"m
1QA
2QA
10A
lOA
REAR SOLENOID
PUMP MOTOR
FRONT SOLENOID
ASS MAIN
a:E'2. !!?
""
BlfGr~
BI/Gr_
O!G_
P/BI..-04
BI/G----4
BlfGoooo4
alBI_
PN/Bu/P_
Br/Lg_
Bu/Lg_
BrlY_
Bu/Gr ...
ASS CONTRe
G/_
Gr/R-
I~
l
(:J
PUMPMOTOR
>
m
I""
iiim~
,@,
~
sss
os:li:
c..
Q tD
~~~~
e,
E!:
9~
l~ ~C
16-A-4
iiic..~
LIMIT
SWITCH
CONNECT(
. - 81
o-w
SOLENOID
VALVE
REAR MODULATO R
61
BLACIt
YELLOW
; S,
0
BROWN
ORANGE
Su ~(Lb' LIGHT6LUE
G ~REEN
Lg LIGHT GREEN
RED
PIN It
WHITE
cr
GRAY
(!)
BATTERY
4P
STARTER{" SYSTEM
_-----I
---+I "
=====+:t-_
==
----LJ$'p
-w
'I
==eRJJ[R..l:J ,GN'T'ON
1
t"
R/BI1lfR/BIt.:..J SWITCH
;>--R/Br-
G/SI I'ND'CATOR
~Gr/.~"==l~;;~~~;~~~!~~~~~~~~~~;;:~BI
L...-R/BI~BI/B,
Bl/Br
CONTROL
UNIT
2P_BI
I l - - L g / O . - - - - - ...... TCS
4P-BI
2P-R
:0
l UNIT {ECU)
:J [
~g::I~
ABS INDICATOR
4P-W
2P-BI
~lIGHT 2
"':l
:J L G: IBu
~G/O
9P-W
ABS INDICATOR
LIGHT 1
~G/Gr
~BI/O
>-Bu/G
~G/O
~BI/P
~G,/YJ..-E3-1
INDICATOR LIGHT
SWITCH
WHEEL SENSOR
ABS 1'92-'95}
Troubleshooting
Before Beginning Troubleshooting:
Summary of ABS pre-start self-diagnosis system
The ASS pre-start self-diagnosis system diagnoses the electrical system as well as the hydraulic system operation in the
modulator. When there is any abnormality, the problem and the problem part can be detected by outputting the problem
code.
After starting the engine, the ASS pre-start self-diagnosis system operates the pump motor and solenoid valve inside the
modulator, checks the limit switch ON/OFF condition with the ECU and detects whether the hydraulic operation is normal.
Then, the diagnosis system enters the stand-by phase for receiving the signal from the wheel sensor, and it completes the
pre-start self-diagnosis when the wheel sensor signal is input in the ECU at approximately 10 km/h (6 mile/h) or more of
the vehicle speed.
If the ASS is normal, the ASS indicator light goes off just after starting the engine and the motorcycle is in motion indicating
that the dignosis is completed.
If a problem is detected, the ASS indicator light blinks or comes on and stays on to notify the rider of the problem.The
self-diagnosis is also made while the motorcycle is running, and the indicator light blinks when a problem is detected.
When the indicator light blinks, the cause of the problem can be identified by retrieving the problem code following the
specified retrieval procedure. (page 16-A-6)
~F~::Jr---------------
IGNITION SWITCH
ENGINE RUN:~~~
m- m
mu----
n----
START
o
VEHICLE SPEED
ON -----------.-------------
PUMP MOTOR
OFF ---------'
O~~
SOLENOID VALVE
-nnumummnmm-muJU1JlL-
~~F-~
ABS INDICATOR
LIGHT 1, 2
L
L
Pre-start self-diagnosis completes
Tee
I[
,
A
iii s
110lL
II
16-A-5
ASS 1'92-'95)
ABS/TCS INDICATOR LIGHT SWITCH
-,
code. However, output cannot be restarted by turning the ignition switch ON. Restart the output following the problem code retrieval procedure.
shooting.
res
ON/OFF SWITCH
Retrieval:
1. Turn the ignition switch OFF.
2. Turn the ignition switch ON while pressing the ASS/
res indicator light switch. The ASS indicator light 1
and 2 should come ON.
3. Hold the ABS/TCS indicator light switch pressed (for
approximately 5 seconds). The ABS indicator light 1
and 2 should go OFF.
4. Release the ABS/TCS indicator light switch immdiately
(within 1 second) after the ABS indicator light go OFF.
~> Output of the problem code starts and the ABS indicator light 1 blinks. (The ASS indicator light 2 is OFF
this time.)
Clearing:
5. Press the ASS/TCS indicator light switch during
output of the problem code (while the ASS indicator
lignt is blinking).
=? The Problem code is cleared and the ASS indicator
light 1 and 2 comes ON and stay ON.
I~
Problem code
clearing signal
,,
ABS/TCS
INDICATOR
LIGHT SWITCH
IGNITION SWITCH
:~~::sej
ON
==J-----+----------ON---+OFF
OFF
Blinking
ON
ASS INDICATOR
LIGHT 1
OFF
ASS INDICATOR
LIGHT 2
ON
OFF
16-A-6
---.JrL
L.-
:::::::::J
,,
,
i
=.=:o+--+-+-+-H--+--+--+i-.------.J
Previous time
problem code
ABS ("92-'95)
Problem code indication pattern
Example:
When the problem code is stored;
Latest problem
Problem code start signal
code
~pmbl",m code:
ASS indicator light 1 ON------------------
r--
Previous time
problem code
Problem code:
Problem code:
r--.r--z:-~'r--~r---
Pattern repeated
-----=-1
/>--t-tt---
,"0 .
0.3 sec.
~--0.2 sec.
OPe
ASS indicator light 1 OFF
.>
ttern repeated
~ 3 sec.
NOTE
The ECU can store up to two problem codes. The latest problem code is output first, then the previous one is output,
When the two problem codes are output, diagnose on the latest problem code (i.e. code output first).
After troubleshooting, perform the pre-start self-diagnosis again to be sure that there is no problem in the ASS indicator
lights and the problem code is cleared.
See page 16-A-46 for the problems that are not represented with the problem codes.
Check the following before performing ASS troubleshooting:
- Pre-start self-diagnosis of ASS
- ASS indicator light
If an abnormality is found during the above checks, perform the ASS toubleshooting following the Symptom-toSystem Chart (see the following page). The ASS is normal if no trouble is found. Go on to the check the other basic
systems (e.g., brake system).
16-A-7
Problem
Fuse
Modulator
-c
0
sr
0
Item
"'3
-c
0
c,
ro 3
0
0
,
~
-c
"
"'0,
-c
J>
,"'0
-c
,-e
0
0
0;
-n
-n
, ,o , , , ,
$:
sensor system
$:
0:
,-n
0
0
-n
" "
<e-
".
0 0
16-A-9
0 0
16-A-16
0 0
16-A-23
0 0
0 0
16-A-30
0 0
16-A-37
0 0
16-A-4{)
0 01
16-A-43
0
,
0
0
0 0
,
,
,
c,
0
0
, , , ,
"3 , , ,
"'
,n0;
-n
e,
o0 J>
, ro a
3' 0,
,Q. s n
" 3 -m". , ,Q.
0
.c, -c:o ". ,
<
0
0
..
s-c
". "'3 ,
,
"o 0; ,
s
"z
,<1
.- ,e. ,s
;;
0
-u
"-
ro
J>
,-
-c
:;;
16-A-45
16-A-45
0 0 0 0 0
16-A-46
NOTE
Check the following before periorming ASS troubleshooting.
- Pre-start self-diagnosis of ASS (page 16-A-5)
- ABS indicator light (page 16-A-5)
If an abnormality is found during the above checks, perform the ABS troubleshooting following the Symptom-toSystem Chart. The ABS is normal if no trouble is found. If no trouble is found, continue on to the other basic system
checks (e.g .. brake system).
After troubleshooting, clear the problem code (page 16-A-6} and perform the pre-start self-diagnosis again (page
16-A-6) to be sure that the ABS indicator light is operating properly.
16-A-8
ABS ('92-'95)
Flowcharts
NOTE
Normal
(Temporary problem: Fine foreign matter in the
modulator or the ECU has been disrupted by an
extremely powerful radio wave.)
NOTE
No
I
No motor sound in either
modulator
I
I
No motor sound in
the front modulator
IL
Burned out.
Normal
Disconnect the pump motor relay connectors Q) I
I and @.
16-A-9
ABS 1'92-'95)
View from terminal side.
t!f~
No battery
<
voltage
Repair open in the RED or RED/BLUE harnesses between the battery and pump motor relay.
Battery voltage
Check the harnesses and connectors for secure
connection (page 16-A-3).
(From the previous page: No motor sound in the
front modulator)
Interchanged.
Faulty pump motor relay
~8)
(jJ;
I I
-
co
j
(Continue to the following page)
16-A-10
I I
->
BLUE/LIGHT GREEN
BLUE/LIGHT GREEN
ABS ('92-'95)
(From the previous pagel
I
Is there continuity?
No continuity
Repair open in the BLUE/LIGHT GREEN harness between the pump motor relay and ECU.
Continuity
cE
,:/y"
EB
I'--~
<
BROW N/YELLOW
Is there continuity?
;*i~~",t"'J~
\'1'
'I 1,/;1 If;.
No continuity
Continuity
BRQWN/yELLOW
1--------"
of the ECU.
I point.
<
Sound
Faulty modulator
No sound
Faulty ECU
16-A-11
ABS 1'92-'951
(From page 16-A-9: Motor sound in both modulators]
Front motor
sound does not
stop.
j
(Go to page
16-A-14.)
I
j
j
Interchange the front
j
Interchanged.
<
Poor connection
Is it connected securely?
Secure connection
I
I
GRAY/RED
GREEN/PINK
No continuity
Continuity
16-A-12
ABS ('92-'951
(From the previous page)
j
Turn the ignition switch OFF.
wire.
WIRE
<
I@
GRAY/R~EEN/PINK
While connecting the main harness side terminate of the limit switch ccnnectcr -J with a
jumper wire, check for continuity between the
WHITE connector eft' terminals cif the ECU.
<
No continuity
Is there continuity?
Continuity
Faulty ECU
16-A-13
ABS ('92-'95)
(From page 16-A-12: Front motor sound does
not stop.)
,nd
Interchanged.
I
BLUE/LIGHT
_BROWN/YELLOW
GREEN
respectively.
<
Continuity
Is there continuity?
No continuity
Faulty ECU
16-A-14
<
~2"?
Problem code
~ 1"
':E'
<
No continuity
Repair open in the BROWN!YELLOW harness
between the pump motor relay and ECU.
Is there continuity?
Continuity
rs':
~~OWN/YELLOW
<
Continuity
Is there continuity?
No continuity
Faulty ECU
16-A-15
ABS ('92-'95)
Problem code 2: Faulty rear hydraulic pressure circuit system
NOTE
There are two types of the modulator prestart self-diagnosis sounds; one is the intermittent clattering sound of the solenoid valve
operation sound, and the other is the continuous beep of the pump motor operation
sound.
starts.
No
I
Turn the ignition switch OFF.
O~
10=
-'
Normal
and ~!Jl;.
16-A-16
I
I
ABS ('92-'95)
View from terminal side
and
Eq
@l,)
RED/BL~
No battery voltage
Battery voltage
Repair open in the RED or RED/BLUE harnesses between the battery and pump motor relay.
I
Turn the ignition switch OFF.
'nd
rear pump
motor
Interchanged.
Faulty pump motor relay
~E8
QJ;
BLUE/~E/PINK
16-A-17
ABS ('92-'95)
(From the previous page)
No continuity
Is there coutinuity?
Repair open in the BLUE/LIGHT GREEN harness between the pump motor relay and ECU.
Continuity
@c,. --';______
side
_~_
connector terminal.
B ROWN/L1GHT GREEN
I
No continuity
Continuity
ee
of the ECU.
j
Start the engine and check the front pump motor
relay for a clicking sound at the relay contact
point.
Sound
Is there a clicking sound in the relay?
No Sound
Faulty ECU
16-A-18
BROWN/LIGHT GREEN
Is there continuity?
<
."'?~~
,,_ ""
9~'@f~~T
<::::S~~;'!!!Jlf0~"-
Faulty modulator
ABS {'92-'951
(From page 16-A- 16. Motor sound in both modulators. )
I
Rear motor sounds for
approximately
5
seconds, then it stops. (Normally, it should sound for
approximately
3
seconds.)
I
(Go to page 16-A-21).
I
Turn the ignition switch OFF.
j
: Interchange the front eod rear pump motor
with each other.
i relays
Interchanged.
<
Poor connection
Is it connected securely?
Secure connection
View from terminal side
I
I
CD.
GRA Y/ORANGE
No continuity
(Is there continuity during pump motor rotation?
Continuity
GREEN/BROWN
16-A-19
ABS 1'92-'951
(From the previous page)
I
View from terminal side
CD
Connect the main harness side terminals of the
limit switch connector CD with a piece of jumper
wire.
Problem code
~4"
G RAY/ORANGE GREEN/BROWN
While connecting the main harness side terminals of the limit switch connector CD with a
jumper wire, check for continuity between the
WHITE connector@terminalsofthe ECU.
<
JUMPER WIRE
l@J
No continuity
Is there continuity?
Continuity
Faulty ECU
16-A-20
,nd rear
pump motor
Interchanged.
Faulty motor relay
B
Disconnect the pump motor relay connector
and BLACK connector 'CD: of ECU.
<
Continuity
Is there continuity?
No continuity
Faulty ECU
16-A-21
ABS ('92-'95)
(From page 16-A-19: Motor sound is normal.)
<
{g,
~t]
BROWN/LIGHT GREEN
BROWN/LIGHT G R L @ - - J
the ECU.
<
No continuity
Is there continuity?
Continuity
<
I
Is there continuity?
No continuity
Faulty ECU
16-A-22
Continuity
Repair short in the BROWN/LIGHT GREEN
harness between the pump motor relay and
ECU.
ABS ('92-'95)
Problem code 3: Faulty front hydraulic control system
Turn the ignition switch ON {but do not start the
enginel and check the ASS indicator light 1 and
2.
Light blinks.
Light stays
00.
Light blinks.
1<
1
Light goes
OFF.
Light blinks
(Appears repeatedly).
problem code.
I
Check the harness and connector for secure
connection (page 16-A-3 I
(Go to page 16-A-2B.)
<
Burned out.
Normal
<
Sound
[nc:=:J
Lj
0
1
No sound
(Continue the following page)
16-A-23
ABS 1'92-'95)
HEADLIGHT RELAY
j
Disconnect the ASS main relay connector@land
connect the headlight relay instead.
Light blinks.
View from terminal side
,---1E
RED/BROWN
<
No battery voltage
Battery voltage
I
View from terminal side
(iJ)
~BLUE/GRAY
ASS main relay and disconnect the BLACK connector @ of the ECU.
Check for voltage between the BLACK connectcrqe terminal of the ECU and body ground.
<
Battery vclteqe
Faulty ECU
16-A-24
No battery voltage
ABS ('92-'95)
(From page 16-A-23: Operation sound in the
ASS main relay.)
tom
WH'TE/P~'TE/P'NK
No continuity
Is there continuity?
Continuity
OJ.GREEN
rIl
No continuity
Is there continuity?
Continuity
I
Retrieve the problem code. Check whether the
valve operation sound (i.e., clattering sound] can
be heard for approximately 3 seconds before the
problem code appears.
Operation sound
Go to page 16-A-27
No operation sound
16-A-25
ABS ('92-'95)
{From the previous page}
J]"_,_F::;:=:;==j_,",,
rE
ORANGE! GREEN
<
I
No continuity
Is there continuity?
ORANGE/GREEN
-----1@1
Repair open in the ORANGE/GREEN harness
between the modulator (solenoid valve) connector and ECU.
Continuity
BLAC
No battery voltage
Battery voltage
Repair open in the BLACK/GRAY or RED harness between the ECU and battery.
View from terminal side
WHITE/PINK
! Connect the valve side terminals of the solenoid
valve connector ':11; to the battery terminals.
I ORANGE/GREEN: Positive (+)
WHITE/PINK: Negative(-)
ORANCllCREEN ,j,
(J
When connecting, is there the valve operation sound (i.e., clattering sound)?
/
Operation sound
Faulty ECU
OJ
m
W
BAITERY
ND operation sound
CAUTION
Connect to the battery terminals securely.
Be sure not to connect to the battery terminals for more than 5 seconds continuously.
16-A-26
ABS 1'92-'951
(From page 16-A-25: Valve operation sound.)
flrr=Tli
~N/PINK
GRAYl@J
Check for continuity between the switch side
terminals of the limit switch connector@.
Is there continuity?
Continuity
Faulty modulator
No continuity
GRAY/RED~
Is there continuity?
No continuity
Continuity
Faulty ECU
16-A-27
ABS ('92-'95)
(From page 16-A-23: ASS indicator light stays
on.)
j
Start the motorcycle. Raise the vehicle speed to
10 km/h (6 mile/h) and check the ABS indicator
light. (After checking, the motorcycle can be
parked.)
motorcycle starts to
move.
I
Turn the ignition switch OFF.
Go to page 16-A-29
I
View from terminal side
E8
PINK/BLACK
Check for continuity between the main harness
side terminal of the solenoid valve connector @
and BLACK connector 'J!) terminal of the ECU.
<
No continuity
Is there continuity?
Continuity
PINK/BLACK
Q _ _I
With the BLACK connector of the ECU disconnected, check for continuity between the main
harness side terminal of the solenoid valve connector@and body ground.
<
PINK/BLACK
Continuity
Is there continuity?
No continuity
16-A-28
ABS ('92
'95)
GRAY/RED
Connect the valve side terminals of the solenoid
valve connector 8 to the battery terminals, and
check for continuity between the switch side
terminals of the limit switch connector @.
Connect the PINK/BLACK (Inlet valve side)
WH
G REENjPINK
n
@ORANG
ITE/PIN~
"
PIL/SLAC K
.J,
E/GREEN
!J
8
BATTERY
Faulty modulator
Continuity
Faulty ECU
"3~?
No problem code
Faulty ECU
16-A-29
ABS ('92-'95)
Problem code 4: Faluty rear hydraulic control system
Turn the ignition switch ON {but do not start the
engine} and check the ASS indicator light 1 and
2.
Light blinks. I Retrieve the problem code and record it. Clear
the problem code.
<
Light stays
on.
1<
Light go
OFF.
Light blinks
(Appears repeatedly}.
I
Turn the ignition switch OFF.
.
I Check the solenoid fuse in the ASS fuse case.
Is the fuse normal?
Normal
Start the engine. Check the ASS main relay for a
clicking sound at the relay contact point immediately after starting the engine.
16-A-30
\
Check the harness and connector for secure
connection (page 16-A-3).
(Go to page 16-A-35).
Burned out.
Sound
ABS ('92-'951
HEADLIGHT RELAY
l
Disconnect the ASS main relay connector
and connect the headlight relay instead.
(I~
Light blinks.
View from terminal side
Disconnect the ASS main relay connector
from the headlight relay.
<
No battery voltage
Battery voltage
Tr
~GRAY
@)
Check for voltage between the BLACK connector {fl terminal of the ECU and body ground.
No battery voltage
Faulty ECU
16-A-31
ABS ('92-'95)
(From page 16-A-30: Operation sound in the
ASS main relay.)
I
Turn the ignition switch OFF.
B3cw
WHITE/PINK
<
WHITE/PINK
No continuty
Is there continuity?
Continuity
i>ril
~-
<
ITJ.GREEN
No continuity
Is there continuity?
Continuity
<
Operation sound
16-A-32
Go to page 16-A-34.
ABS {'92-'951
{From the previous page}
View from terminal side
ORAN
Check for continuity between the main harness
side terminal of the solenoid valve connector @
and BLACK connector @ of the ECU.
No continuity
Is there continuity?
Continuity
lID
Turn the ignition switch ON .
I
B
Check for voltage between the BLACK connector (jJ) terminals of the ECU and body ground
respectively.
<
BLACK/GREEN
No battery voltage
Battery voltage
ORANGE/ WHITE/PINK
BLA,\;K
;!,
CJ
BATTERY
<
Faulty ECU
No operation sound
CAUTION
Connect to the battery terminals securely.
Be sure not to connect to the battery terminals for more than 5 seconds continuously.
16-A-33
ABS ('92-'95)
(From page 16-A-32: Valve operation sound.)
1TIL
I ~N~BROWN
GRAY/ORA~
Check for continuity between the switch side
terminals of the limit switch connector CD.
Is there continuity?
Continuity
Faulty modulator
No continuity
-GRAY/ORANGE
Check for continuity between the main harness
side terminal of the limit switch connector CD and
body ground.
Is there continuity?
No continuity
Faulty ECU
16-A-34
Continuity
ABS ('92-'95)
(From page 16-A-30: ASS indicator light stays
on.]
j
Start the motorcycle. Raise the vehicle speed to
10 km/h (6 mile/h) and check the ASS indicator
light. (After checking, the motorcycle can be
parked.)
I
The ASS indicator light
1 and 2 go off once as
motorcycle
move.
start
to
-tt
and
1];
PINK/i H1TE
Check for continuity between the main harness
side terminal of the solenoid valve ccnnectorqt
and BLACK cormector Jr of the ECU.
Is there continuity?
No continuity
Continuity
~
PINK/WHITE
With the BLACK connector of the ECU disconnected, check for continuity between the main
harness side terminal of the solenoid valve connector {to and body ground.
Is there continuity]
No continuity
Q~PINK/WHITE
Continuity
16-A-35
ABS ('92-'95)
(From the previous page)
CD
GRAY/ORANGE
GREEN
ORANGE/BLACK
l@JROWN
.II
II
WHITEI
/p INK
PINK/
W HIT E
ri,
BATTERY
CAU TION
,
Connect to
B e sure not to connect to the battery termin als for more than 5 seconds continuously.
Continuity stops.
Faulty modulator
Continuity
Faulty ECU
<
16-A-36
No problem code
~4"?
Problem code
Faulty ECU
~4 y
ABS 1'92-'95)
Problem code 5: Faulty front wheel speed sensor system
CAUTION
When removing/installing the wheel sensor and wheel. take care not to damage the tip of the sensor.
NOTE
Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
periorm the pre-start self-diagnosis. The ASS is normal if the warning light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when he brings his motorcycle to your dealership for
inspection.
The motorcycle has continuously run on bumpy road.
After riding on the roadlatter the pre-start self diagnosis), the engine was kept running and the rear wheel turning (for
more than 30 seconds) with the motorcycle placed on the center stand.
Periorm the inspection of the wheel sensor.
Check the area around the wheel sensor as
well
<
Incorrect
Correct
Defomed and/or
Is the pulser ring defonned or damaged (e.q. ~ damaged
chipped teeth, etc.] ?
Deposits
NOTE
No deposits
Loosely installed.
Securely installed.
16-A-37
ABS ('92-'951
(From the previous page)
NOTE
res
Turn the front wheel [Vehicle speed: approximately 4 km/h (2.5 mile/h) or above, t.e.as fast
as when the wheel rs turned with all your
INDICATOR LIGHT
strength by hand.]
TIVE)
I
ABS
l~
res
<
,
,
>
I
View from terminal side
I
Disconnect the wheel sensor connector @.
I
Turn the ignition switch ON.
I
Check for voltage between the main harness side
terminals of the wheel sensor connector @.
<
IBattery voltage
16-A-38
GREEN/ORANGE
BLA CK/PIN~
No battery voltage
I
View from terminal side
~EEN~
@
Check for continuity between the WH ITE connectar @ terminal of the ECU and the main
harness side terminal of the wheel sensor connector@.
Is there continuity?
Continuity
BLUE/
WLJE/GREEN
No continuity
16-A-39
ABS ('92-'951
Problem code 6: Faulty rear wheel speed sensor system
CAUTON
When removing/installing the wheel sensor and wheel, take care not to damage the tip of the sensor.
NOTE
Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
perform the pre-start self-diagnosis. The ABS is normal if the warning light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when he brings his motorcycle to your dealership for
inspection. (Was the motorcycle has continuously run on bumpy road?)
When the rear wheel sensor or rear pulser ring is replaced, perform the air gap inspection (page 16-A-51).
\
Place the motorcycle on its center stand ood
measure the air gap between the pulser ring
and wheel sensor.
Standard: 0.8 ~g1 mm
(0.031 ;- g:86~ in)
<
Incorrect
Check each part for deformation and looseness and correct accordingly. Recheck the air
gap.
Deformed and/or
Is the pulser ring deformed or damaged (e.g.
chipped teeth, etc.I?
\damaged
Not deformed
and damaged
Deposits
Remove the deposits and recheck.
NOTE
No deposits
<
16-A-40
Loosely installed.
ABS 1'92-'951
(From the previous page)
NOTE
j
Retrieve the problem code and record it. Clear
the problem code.
TIVEj
81
ABS
I
Light blinks.
<
Turn the rear wheel [Vehicle speed: approximately 4 km/h (2.5 mile/h) or above, i.e. as fast
as when the wheel is turned with ,II your
strength by hand.]
(Sensor
res
cator light.
<
;DlJ
I
Turn the ignition switch ON.
BLA CK/ORANGE
GREEN/GRAY
l@
<
No battery voltage
16-A-41
ABS 1'92-'951
(From the previous page}
J
Turn the ignition switch OFF.
Check for continuity between the WH ITE connector (@ terminal of the ECU and the main
harness side terminal of the wheel sensor con-
nector
<
J:$
BLUE/ BROW~UE/BROWN
::[~:.
Is there continuity?
continuity
16-A-42
No continuity
ABS 1'92-'95)
Problem code 7: Faulty ABS main relay system
Disconnect the ASS main relay connector @ .
HEADLIGHT RELAY
Light blinks.
I
Is there a clattering sound?
No clattering sound
Clattering sound
Faulty ECU
16-A-43
ABS ('92-'95)
{From the previous page: problem code
~r}
modulator
I
I
Disconnect
the
front
and
rear
I
Problem code
I
Problem code "3"
~7"
IL
I
8 FRONT:
Is there continuity?
No continuity
Faulty ECU
16-A-44
Tv REAR:
PINK/~E/BLACK
"ifF O@"""' @ @
Continuity
ABS 1'92-'951
Problem code 8: Faulty power circuit
NOTE
Before starting the troubleshooting, check to see whether the idle speed.conforms to the specified speed. If the idle
speed is below specification, adjust idle speed.
Ask the rider about the following when the motorcycle is brought in for inspection.
- Ask whether the motorcycle has been run with electrical accessories.
- Ask whether the motorcycle has been left for a long time with the ignition switch in the ON position. This problem
code will light up to indicate battery discharge.
Low or no battery
voltage
Is it normal?
Normal
repeatedly.
,>-_-,-====
Appears repeatedly.
Faulty ECU
16-A-45
ABS ('92-'95)
Trouble not represented by a problem code
Abnormal sound from the modulator
(Difference in sound level is twice or more between the front and rear modulators during the pre-start
self-diagnosis.) :
Connect the pump motor terminal to the battery securely. Avoid loose terminal connections and do not allow the
battery terminals to contact the frame and other parts.
The modulator motor becomes very hot when it is turned ON repeatedly to check for the motor sound. Take care
not to burn your hands. etc.
CAUTION
Do not turn the motor continuously for more than 30 seconds. If you have to turn the motor repeatedly to check
for the sound. be sure to stop the motor within 30 seconds and wait at least one minute before starting it again.
Otherwise. the motor can be damaged.
NOTE
There are two types of the modulator sounds; the solenoid valve clattering sound and the pump motor beep sound.
Front modulator:
Remove the instrument panel (page 2-7). Check
the modulator for interference with the upper
fairing and/or other parts.
Not
interfering.
Is it interfering?
Interfering.
ILoose bolt or
. damaged rubber
16-A-46
{To
Deformed.
ABS ('92-'95)
(From the previous page)
)
I
FRONT MO DULATOR
\/f:,
"
.,!!
REAR MODULATOR
r~>
'1~ ~~!
','7(
()
BAn ERY
12 V
~,
BATIERY
12V
l
-.-L
NOTE
After checking the motor sound. connect
the front and rear pump motor connectors,
retrieve the problem code and erase it (page
16-A-6) .
16-A-47
ABS ('92-'95)
Rear modulator:
Remove the right side cover (page 2-2). Check
Is it interfering?
Not
intertering.
Interiering.
Normal
Loose bolt or
damaged rubber
. Tighten
Deformed.
(To
,~)
j
(Continue to the touowtnc page)
16-A-48
stay.
1Normal
!
I
!
ABS ('92-'95)
(From the previous page)
REAR MODULATOR
FRONT MODULATOR
Connect the front and rear pump motor terminals to the battery respectively, and check the
motor sound between the front and rear modulators.
NOTE
After checking the motor sound, connect
the front and rear pump motor connectors,
retrieve the problem code and erase it (page
16-A-6) .
16-A-49
ABS ('92
'95)
-,
,.
tn
U>
,c,
a
0
"
'"
5
0
<is.
~
"
0
~
ON
Blink
OFF
Normal
A. B. F. E
-.
~ ~
D. G.I. K
D. G.!. K
-n
While riding
"" -. -.
-. ~ -.
ON
,.
Blink
tn
OFF
U>
S
c,
o
a ,
~
"
<is.
~
"
D. E. F. G. I
-n
-n
A. C.I
Normal
When there is no motor sound in the modulator after starting the engine and the indicator light is faulty (i.e. pre-start
self-diagnosis does not start):
-
- Before riding (with the engine started and the motorcycle par'r<ed)
r.
,.
~
Blink
OFF
H.I. J. M
U>
,c,
o
" ,_.
Q
<is.
~
~
0
-n
-n
ON
-.
While riding
,.
~
-.
K. L
ON
I. J. M
Blink
OFF
K. L
U>
,c,
0
,_.
~
~
~
0
-n
-n
LIGHT
16-A-50
>.
jHT 2
ABS 1'92-'951
16-A-51
ABS ('92-'95)
<
(1)
c:
35 (3.5, 25)
(3)
(2)
,
)6)
(4)
~\-1 ~
,
,
\
"
"
c:
16-A-52
(3)
35 (3. 5, 25)
ABS ('92-'95)
Check the brake system by applying the brake after the bleeding air from the system.
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign ma-
Requisite Service
Front brake fluid draining/air bleeding
Upper fairing removal/installation {page 2-9}.
Procedure
Removal Order
(1 ( Conector
(21 Ground terminal bolt
(31 Oil bolt
(41 Sealing washer
(51 Modulator mounting bolt/collar
(61 Washer
(71 Modulator
Q'ty
Remarks
Installation in the reverse order of removal.
3
1
2
4
3/3
3
1
CAUTION
, Do not disassemble the modulator.
16-A-53
ABS ('92-'9 5)
III
31
12 1
121
121
151 ~
191
'~
0, 35 (3. 5,25)
181
(12)
16-A-54
27 f2.7, 20)
111}
ABS ('92-'95)
Check the brake system by applying the brake after the bleeding air from the system.
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign ma-
NOTE
After replacement of the moduator, bleed the brake system according to the standard air bleeding procedure.
Note that replacement and bleeding air from the brake fluid in the modulator is not possible, as it is sealed in the
modulator.
Requisite Service
Rear brake fluid draining/air bleeding
Right pivot cover removal/installation (page 2-5)
Procedure
11)
12)
13)
14)
15)
161
171
181
191
1101
Q'ty
Removal Order
Harness band
Connector
Ground terminal bolt
Oil bolt
Sealing washer
Reservoir bolt
Muffler mounting bolt
Right footpeg holder bolt 6 mm
8 mm
10 mm
(11 ) Modulator mounting bolt/collar
[121 Washer
(13) Modulator
Remarks
Installation is in the reverse order of removal.
1
4
1
2
4
1
1
1
1
2
3/3
3
1
CAUTION
Do not disassemble the modulator .
16-A-55
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
168-1
Troubleshooting
16-8-5
System Location
16-6-2
16-B-34
16-6-3
16-B-36
Circuit Diagram
16-6-4
16-B-38
Service Information
CAUTION
Use a fully charged battery for troubleshooting. Do not diagnose the ABS with a charger connected to the battery.
On removal and installation of the wheels and wheel speed sensors, be careful not to damage the wheel speed sensors
and pulser rings.
NOTE
16-8-1
System Location
(3) BATIERY
(2) ASS FUSE CASE
(1) REAR WHEEL
SENSOR
16-B-2
Ci:
ct' ABS/TCS
REAR MODULATOR
CRANK ANGLE SENSOR
-R. side cover (page 2-2)
INDICATOR
LIGHT SWITCH
-Tap shelter
UNIT
-L. fairing pocket
(page 2-6)
(page 2-5)
BI/Sr GISI
GriBu LgiBI
~~
"i
?oS
FRONT MODULATOR
CONTROL MOTOR
!SJ
(lOA)
REAR MODULATOR
CONTROL MOTOR
(10A)
ASS FUSE CASE
-L. side cover (page 2-2)
,ec..
",.
"
BLACK
YELLOW
BLUE
GREEN
RED
WHITE
Br ..
0
,C,'"
BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK
G,--
GRAY
/
G
e.v
BI/G
SliR
Cftj
MOTOR DRIVE
(4P Blue)
-Upper fairing
(page 2-9)
~'ASS
INDICATOR
LIGHT 1
-Inner screen
(page 2-7)
@INDICATOR (Black)
-Inner screen
(page 2-7)
ASS
INDICATOR
LIGHT 2
-tnner screen
(page 2-7)
J)
INDICATOR (White)
-Inner screen (page 2-7)
~
LgiBI
Lg..'B1rx
G/81 ViG,
v:(;, GI81
(;..0
WiO
W.ID
GiO
G'iSe
fl.: 0
RiO
Gr:'Bu
(]~,
Y.'O
RiG
RiBr
Br'Y
::E' REAR
MODULATOR CONTROL
MOTOR RELAY -Upper fairing
(page 2-9)
ViO
W:'Bu
RiB,
V..W
,:[~~
.>
~
-
~2!
==
'W
BIlG
BliR
@, MOTOR DRIVER
(4P Black)
-Upper fairing
(page 2-9)
H' FRONT
16-B-3
Circuit Diagram
MODULATOR
(REAR)
~~~
ASSFUSE
,OX
3 ,
~~~~ ~~~~
,--~--""---------,
12P-BI
~RiBr
~RJBr
I-R/Br-
f--Grlal---+
\I---O/G--"
r1--- Lg/O--"
1---- G'/'I--<>
1--- R/'I'----;
f-- BuIGr---+
MOTOR DRIVER
f--BuIG--"
1--- Bu/Lg,--"
1--- '"/p---
I---R/'"'---+
I
ABSCONT
CONNECTOR: 4P
BI
0- Bu
...L
2P-BI
2P-BI~
r-
CONTROL
MOTOR
CONNECTOR
BI
O-W
REAR MODULATOR
FRONT MODULATOR
CRANK ANGLE
SENSOR
16-B-4
Be
BI
y
G
R
W
BLACK
YELLOW
BLUE
GREEN
RED
WHITE
MOTOR
Be.
Ge
Lb
L9 .
BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK
~Ie
GRAY
WTOR
STARTER
SYSTEM
{f
<O---..
.JI
Ell
0:
);
BATIERY
4'
II
"
$3PW
'I
I~
-==:;R~R'~
RIBlllrRlBIU
IGNITION
SWITCH
4P-BI
>--Gr!BB:=J~~~~~~;;i~~~~~~~~~~~~~j~~1
,
;--,
lOA
GISI
L-R/al~BI/Br
BllSr
INDICATOR
CONTROL UNIT
2P-BI
4P-BI
.
IOLUNIT(ECUI
2P-R
[ ] )[
LglBI----+N+.,
GIBI~
lOS
~
coa, .......fDi+,
ASS INDICATOR
LIGHT 2
GlO~
ABS INDICATOR
>-B"!B:~~~
~BI/O
>-aufG
G10 1
r-
~BI/P
2P-BI
,,"""GelY"'--fl~
~C-GIR:::1
16P
_____
~G/BI---,
J 1,
I ~
G
,V
---'>--G/BI----+---G!B'--/-~,
ABSfTCS INDICATOR LIGHT
SWITCH
LIGHT1
Troubleshooting
Before Beginning Troubleshooting
Summary of ABS pre-start self-diagnosis system
The ASS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator.
When there is any abnormality, the problem and the problem part can be detected by outputting the problem code.
When the vehiclespeed is approximately 10 km/h (6 mile/h) or more, thewheel speed sensor signal is inputto the ASS control
unit (ECU), then the ASS pre-start self-diagnosis system operates the control motor inside the modulator, checks the crank
angle condition with ASS control unit (ECU) and thereby it detects whether the modulator operation is normal, and it
completes the pre-start self-diagnosis.
When the ASS is normal, the ASS indicator light goes off just after starting up indicating that the diagnosis is completed.
If a problem is detected, the ASS indicator light blinks or comes on and stays on to notify the rider of the problem. The selfdiagnosis is also made while the motorcycle is running, and the indicator light blinks when a problem is detected.
When the indicator light blinks, the cause of the problem can be identified by retrieving the problem code following the
specified retrieval procedure. {page 16-S-6}
O~~ =.J
IGNITION SWITCH
O~~
ENGINE RUNNING
STOP
VEHICLE SPEED
ON
CONTROL MOTOR
=:J
-------------------r= START
__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
nn__m__ mmm n
~ 10
km h (6 mile/h) or above
nnmm_m_1 1 -
OFF
ASS INDICATOR
ON::J
OFF
LIGHT 1 and 2
~[
ASS
I~
-"----~
ABS INDICATOR LIGHT 2
16-8-5
Retrieval:
1. Turn the ignition switch OFF.
2. Turn the ignition switch ON while pressing the ASS/
TCS indicator light switch. The ASS indicator light 1
and 2 should come ON. (The ASS indicator light 2 is
OFF this ttrne.)
3. Hold the ASS/TCS indicator light switch pressed (for
approximately 5 seconds). The ASS indicator light 1
should go OFF.
4. Release the ASS/TCS indicator light switch
immediately (within 1 second) after the ASS indicator
light go OFF.
~. Output of the problem code starts and the ASS
indicator light 1 blinks.
Clearing:
5. Press the ABS/TCS indicator light switch during output
of the problem code (while the ASS indicator light is
blinking).
<::. The Problem code is cleared and the ASS indicator
light 1 and 2 comes ON and stay ON.
ASS INDICATOR
LIGHT 2
\
TCS ON/OFF SWITCH
Problem code
Clearing signal
:~!
ON
rL
::::::Ji-i- - - - - + - - - - - - - - - ON--->OFF
Blinking
ON
OFF
i;
~~F ==nL..----------+---+--+-+---+-f---i--+_
,!
--'
Problem code
start signal
Latest
problem
code
16-8-6
~i
:~~::se =J~'-+-------+-L
OFF
ASS INDICATOR
LIGHT 1
:
!
:
:
,!
Previous time
problem code
code
'"
n m __ n
__
ProbleZm code:
Previous time
problem code
Problem code:
Problem code:
2
mm~~r----'~-~~-~'-~ -
(>
ABS indicator light 1 OFF
Pattern repeated
-----.,1
/1---1*--
3 sec.
- ' * - - 0 . 3 sec
-1-1---0.2 sec.
No output of code
(>
ASS indicator light 1 OFF
/'
I--- 3
p attern repeated
sec.
NOTE
The ECU can store up to two problem codes. The latest problem code is output first, then the previous one is output.
When the two problem codes are output, diagnose on the latest problem code (i.e. code output first).
After troubleshooting, perform the pre-start self-diagnosis again to be sure that there is no problem in the ABS indicator
lights and the problem code is cleared.
See page 16-B-33 for the problems that are not represented with the problem codes.
Check the following before performing ABS troubleshooting:
- Pre-start self-diagnosis of ABS
- ASS indicator light
If an abnormality is found during the above checks, perform the ABS troubleshooting following the Symptom-toSystem Chart (see the following paqe). The ABS is normal if no trouble is found. Go on to the check the other basic
systems (e.g., LBS or basic brake system).
16-B-7
Affected
Fuse
Item
Modulator
"
CD
<n
cQ.
3
a
!-:;;--=+=cr::1 ~
"
o o
o o
~.
00
16-8-15
00
16-8-19
00
16-8-23
00
16-B-26
000
16-8-29
00
16-8-31
c
o
16-8-12
00
"
00
o o
o o
(ECU)
c
n
16-8-9
cO
00
0000016-8-33
NOTE
Check the following before performing ASS troubleshooting.
- Pre-start self-diagnosis of ASS (page 16-B-5)
- ASS indicator light (page 16-8-5)
If an abnormality is found during the above checks, perform the ABS troubleshooting following the Symptom-toSystem Chart. The ABS is normal if no trouble is found. If no trouble is found, continue on to the other system checks
(e.g., LBS or basic brake system).
After troubleshooting, clear the problem code (page 16-B-6) and perform the pre-start self-diagnosis again (page16B-5) to be sure that the ABS indicator light is operation properly.
16-8-8
Flowcharts
CAUTION
Use a fully charged battery. Do not diagnose with a charger connected to the battery.
NOTE
Turn the ignition switch OFF unless otherwise specified.
When the ASS control unit (ECUl. motor driver or modulator is detected to be faulty, recheck the wire harnesses and
connectors connections closely before replacing the control unit, motor driver or modulator.
After troubleshooting, perform the pre-start self-diagnosis again and be sure that the ASS indicator light is normal.
The encircled numbers in the texts and connector diagrams indicate the connectors (see page 16-8-3). All connectors
diagrams in the text are view from the terminal side.
Light stays
on_. . 1. Retrieve the problem code and record it. Clear the
")__-"_
_'--_
problem code.
/
2. Perform the pre-start self-diagnosis (including riding motorcycle I and check the ASS indicator light.
I Light blinks
Light goes
'------
--"O"-FF
Turn the ignition switch ON and check for the prestart self-diagnosis sound (Le. click sound) from the
front modulator.
fight blinks
---,------
~---~--
/1
(Go to page 16-B-11)
,,
Click
sound
NormallTemporary problem)
- Fine foreign matter in the modulator or the ECU
has been disrupted by an extremely powerful radio
wave.
- Check the harness and connector for secure connection (page 15-B-3)
j~
Green. Brown
Black Blue
'------@-J
16-8-9
__L
Out of specification ~
Normal
f~;
_ _ _L
~CmJ
ve;w;ught Green
l
I
"
No continuity
/>_:C:C'::::,"::,"='-_.~~
15 there continuity?
Continuity
~'"0W
_ Liqht Green
--'--'--'--'----.~~
Continuity
Is there continuity?
- - - -
(,
-------'
~""ity
I
1. Retrieve the problem code and record it.
Clear the problem code.
2. Interchange the front and rear modulator with each
other (page 16-B-36 and 16-B-38).
3. Perform the pre-start self-diagnosis (including riding motorcycle) and retrieve the problem code.
16-B-10
..
HEADLIGHT RELAY
IL indicator light.
-'
--,
Light stays on
Light blinks
Yellow
Continuity
Is there continuity?
No continuity
16-8-11
Light stays on
Light goes
~
.
<,
OFF
Light blinks
Click
sound
,
Normal (Temporary problem)
No sound
(Go to page 16-8-14)
Normal
16-8-12
Brown Green
Black 'Gray
~
Out of specification
~~
- ~ No continuity
_/
...
Continuity
-----
No continuity
--------.
.
>
Continuity
Is there continuity?
Blue Brown
Is there continuity?
Blue Brown
CD.
..
1. Retrieve the problem code and record it.
Clear the problem code.
2. Interchange the front and rear modulator with each
other (page 16-B-36and 16-B-38).
3. Perform the pre-start self-diagnosis (including rid
ing motorcycle) and retrieve the problem code.
"
Is the problem code "1" ?
16-8-13
rF.01;...-~-HEADLIGHTRELAY
"-----~
.r.,
Does the ASS indicator light blink or come
on and stay on?
Ugh< blinks
ig ht stays on
.-===.-c-'C'--_
Yellow
,n,
No continuity
16-8-14
Continuity
I
Light blinks
Light stays on
Other
___--'
,code
__i
In
the I
Burned out
-)>--=--
Normal
------,----~
<
I.:~
l~: :~
L,g" bliok,
Light blinks
16-8-15
..
1. Disconnect the front modulator control motor relay
connector (8) with the ignition switch OFF.
2. Check for voltage between the relay connector (~)
terminal and body ground.
No voltage
Does battery voltage register?
Vo"ogo
connecto~
...
---
No continuity
Is there continuity?
Continuity
--
Rod
Voltage
No voltage
~ c~
,n
Yellow Orange
4:----J
No continuity
Is there continuity?
)-~
Continuity
16-B-16
Yellow/Oranqe
----'------
'--------~----).-----==~
No continuity
Is there continuity?
Continuity
n~:,
GJG,eec
IS
,
the~e continui~
~--
~r-"""""~'"'---"
Continuity
No continuity
RedY,~,ow
II
Orange iRed i
'~,'1.2:: ?reen
Orange. Green
Yell\w
/Gray,pra
nge
:J[
I I
,
harness colors.
- - --------"
/
Light Green
Gray.'
Orange
Orange
I
Light Green
Orange
~
e
Gravvellcw
<
=">P
GraYi'(ellow
,
No continuity
Is there continuity?
Continuity
16-B-17
J---c-------;c _
Green/Black
No continuity
Is there continuity?
body ground.
Continuity
2. Connect the@,Qt',,'!t'and,:n'connectors.
3. Perform the pre-start self-diagnosis (including
riding motorcycle) and check the ASS indicator
light.
__J
~--="""'c::-=~--1~~
Light goes off
-c.
11.
i
Ught blinks
_ _ "3"?
_ _ _ _ _
Is the problem code
_
TCObl,m
cod, "3"
16-8-18
Light blinks
Other
Code
2. Perform the pre-start self-diagnosis (including riding motorcycle) and check the ASS indicator light.
Light blinks
11--1
L"i,~i'---
-~'-------
Burned out
Normal
~ghtblinks
>
16-B-19
Blue
No voltage
---.
- - ~ Volt,g,
I',
I
tE
E@
Yellow/White
Yellow/White
--I(Q))-----"
,---I
No continuity
Is there continuity?
Continuity
<ID
Red Brown
I-t~tj
J
Does battery voltage register?
>-
No vOCC'''c9,'=--_--<..
Voltage
____t _
~ ~~
veuow/Oranoe
_
L
c=_
Is there continuity?
Continuity
J
(Continue to the following page)
16-8-20
Yellow 'Orange
4Q}----J
No continuity
--
,
No continuity
Continuity
,
I
Continuity
Is there continuity?
No continuity
Blue/
Blue/Green
Red/Blue
Red/
Light Green
'\
n:,
Blue
I I I
, I
I
Bluei
Bluei
Light Green
Gray
""
'>"
/
Blue/
Bluei
Green
Gray
Blue/Pink
No continuity
Is there continuity?
,
I
Continuity
16-B-21
Green/Black
,
No continuity
,
I
<
0r-~~~"''-C--.
Light goes off
~bl;"k'
,-------
- -
,I
16-8-22
CAUTION
When removing/installing the wheel speed sensor and wheel. take care not to damage the sensor and pulser
ring.
NOTE
Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
perform the pre-start self-diagnosis. The ABS is normal if the indicator light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when the brings his motorcycle to your dealership for
inspection.
- The motorcycle has conttnouslv run on bumpy road.
-After riding on the road (after the pre-start self-diagnosis), the engine was kept running and the rear wheel turning (for
more than 30 seconds) with the motorcycle placed on the center stand.
Place the motorcycle on its center stand and measure the air gap between the pulser ring and wheel
speed sensor (page 16-8-34).
Standard: 0.4-0.5 mm (0.016-0.020 in)
<
-----c-------='
-----,
Incorrect
Deformed andl
or damaged
Is there iron or other magnetic deposits between the pulser ring and wheel speed sensor?
,
,
I
Deposits
No deposits
Loosely installed
Correct deformation. Install securely
and recheck.
Securely installed
NOTE
r-:-check the wheel speed sensor tip for damage. If it is damaged, replace with a new
,
one and recheck the air gap.
16-8-23
Light stays on
Black/Pink
Green-Oranqe
L-w---J
No voltage
Repair open in the Black/Pink or Green/
Orange harness between the wheel speed
sensor and ABS control unit (ECU).
:::j'
<
--
_i__
IS the_,_e_"O_"_'_!"_"_!_"_'_'
Continuity
16-8-24
No continuity
--./
,
!
res INDICATOR
Does the
~~I AB=M[~
LIGHT
~~rOblem
~/
code "5"
..
16-8-25
CAUTION
When removing/installing the wheel speed sensor and wheel. take care not to damage the sensor and pulser ring.
NOTE
Check the tire size and air pressure and check the tire for deformation before troubleshooting.
The ASS indicator light might come on while riding under the following conditions. Turn the ignition switch OFF and
perform the pre-start self-diagnosis. The ASS is normal if the indicator light goes off. However, the problem code is
stored in the ECU. Ask the rider for the riding conditions in detail when he brings his motorcycle to your dealership for
inspection (Was the motorcycle continuously run on bumpy road?}.
t'----_
Place the motorcycle on its center stand and measure the air gap between the pulser ring and wheel
speed sensor (page 16-B-34).
Standard: 0.8 ~:t mm (0.031 ~:8J~ in)
Incorrect
Correct
Deformed and!
or damaged
-----.
- -
---.
Deposits
No deposits
--.
Loosely installed
Are the pulser ring and sensor loosely installed?
,
!
Securely installed
NOTE
Check the wheel speed sensor tip for damage. If it is damaged, replace with a new
one and recheck the air gap.
16-B-26
Light blinks
(Sensor signal is
input in the EeU)
Light stays on
~--J
__
Black Orange
~voltage
--+-- ::J
--
Green Gray
LwJ
Cnf~
BI"e~Bcown
at'
-----,----- ----)
.
Is there continuity?
NocontinuH;'~Y
_ _
-..
I Continuity
16-8-27
res INDICATOR
res
problem code.
16-8-28
ABb~
LIGHT
Low or no battery
voltage
Is it normal?
Normal
---~/
Light stays on
I
I
j~G~
I
"',00'
Black
0j)
Red Brown
Red/Brown
0j)1--_ _
___t
(~
Abnormal
(Less than 11 Vor
More than 18 V)
Is it normal?
Normal{11V-18VJ
16-8-29
__
:oc"-=::C"-=__~~.,
Light blinks
Faulty battery
16-B-30
The ASS indicator light blinks or comes on and stays on when the ECU has been disrupted by an extremely powerful
radio wave (Electromagnetic interference}, This is just a temporary symptom. Clear the problem code and the ECU is
normal unless the symptom recurs. Ask the ride whether he used a radio apparatus or a security unit of a radio system
when he brings his motorcycle to your dealership for inspection.
<
Light blinks
Does the ABS indicator light blink or come on ~~_~~
a stay on?
/
-j....
J------
Light stays on
i Problem
code "8"
..
Light blinks
1. Perform the pre-start self-diagnosis (include riding motorcycle) and retrieve the
problem code.
2. Repeat above procedure several times.
-)l
,
1. Disconnect the motor driver 12P connector :,16',
and ECU Black connector ,tt with the ignition
switch OFF.
2. Check for continuity between the motor driver
W' connector terminals and body ground.
<
Is there continuity?
Temporary problem
(Electromagnetic interference)
~
/
Appears repeatedly
No continuity
16-8-31
'--------
,--
-- ,
-,
I Light blinks
16-8-32
When the clicking sound in the modulator control motor relay can be heard after turning the ignition switch ON, and where
the ASS operates normally while riding:
-
- While riding
I~
,. 0
co z
ON
Blink
OFF
Normal
A.S.f.E
,.ro
'"
"'f.-l-,---------+,--------+,---------1
o
c,
(i"
0
Z
o co
_.
:3'
"
, H-----'--+-------''------I----'---i
D.G.I.J
D.G.I.J
- "
to
,
D. E. F. G.I
0
~
-n
ON
Blink
OFF
-, -,
-, -, -,
-,
I
A.C.I
Normal
When there is no clicking sound in the modulator control motor relay after turning the ignition switch ON and the indicator
light is faulty Ii.e. pre-start self-diagnosis does not start).
-
- While riding
r,
,. 0
'" Z
en
ON
Blink
OFF
H. I. L
-,
A:
S:
C:
0:
E:
F:
G:
H:
I:
,.
rn
'"_.
0
Z
ON
Blink
OFF
I.L
<,
J.K
0
c,
o ro
0,
'"
J. K
""
0
-n
-n
~L
ASS INDICATOR
LIGHT 2
ABS~I'e?l
16-B-33
Front
,'>,
Rear
(2) SENSOR
(1) FEELER
GAUGE
O.5mm
/
~
16-B-34
(3) SHIM
MEMO
16-B-35
(4) 3P Blue
(81
(31
(5) 2P Black
(2(
(10)
(1)
16-B-36
Check the brake system applying the lever and pedal brake after the air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on a painted, plastic. or rubber parts. Place a rag over these parts whenever system is serviced.
When removing the oil bolts, cover the end of the brake hose to prevent contamination. Do not allow foreign material
Requisite Service
Lever and pedal brake line fluid draining/air bleeding (page 15-2)
Upper fairing removal/installation (page 2-9)
Procedure
(1)
{21
(31
(')
(5)
(6)
{71
{81
Removal Order
Motor driver connector
Motor driver mounting bolt
Motor driver
Modulator crank angle sensor connector
Modulator control motor connector
Oil bolt
Sealing washer
Brake hose
(9)
Modulator mounting bolt
(10) Front modulator
Remarks
O'tv
3
2
2
1
1
,
,
8
3
1
NOTE
The reference nu-mbers are stamped on each brake hose
end and the modulator head. When installing, align each
numbers (page 1-37)
CAUTION
Do not disassemble the modulator.
16-B-37
(After '95 J
ABS
Rear
Modulator Remova 1/lnstaliatlOn
~
(3)~
35 (3.5, 25)
15)
17)
(1) 3P White
(2) 2P Black
16)
16-B-38
Check the brake system by applying the pedal brake after the air bleeding (page 3-13).
CAUTION
Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever system is serviced.
When removing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow foreign material to
enter the system.
When removing and installing the modulator, take care not to drop or strike the modulator.
NOTE
Note that there is no brake fluid in the modulator (except in the modulator head), because the modulator is the motordriven hydraulic pressure type. Therefore, brake fluid replacement and bleeding air from the modulator body is not
necessary.
Use only DOT 4 brake fluid from a sealed container.
Requisite Service
Pedal brake line fluid draining/air bleeding (page 15-2)
Right side cover removal/installation (page 2-2)
Procedure
(1)
(2)
(3)
(4)
(5)
Removal Order
Modulator crank angle sensor connector
Modulator control motor connector
Oil bolt
Sealing washer
Brake hose
Q'ty
1
1
4
Remarks
Installation is in the reverse order of removal.
Remove the sensor wire from the clamp and clip.
8
4
.NOTE
The reference numbers are stamped on each brake hose
end and the modulator head. When installing, align each
numbers (page 1-41),
(6)
(7)
CAUTION
Do not disassemble the modulator.
16-8-39
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
Battery Removal/Installation
System Location
17-2
Troubleshooting
17-4
Alternator Removal/Installation
Service Information
17-12
('91-'95) 17-13
Alternator Disassembly/Assembly
Regulator/Rectifier ('91'95)
17-7
17-8
17-10
Service Information
The battery gives off explosive gases; keep sparks. flames, and cigarettes away_ Provide adequate ventilation
when charging or using the battery in an enclosed space.
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 follow with milk of magnesia or vegetable oil and call a physician.
KEEP OUT OF REACH OF CHILDREN.
-------
Always turn off the ignition switch before disconnecting any electrical component.
I.
CAUTION
So~e 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 place.
For battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
NOTE
The maintenance free battery must be replaced when it reaches the end of its service life.
~~~~------
CAUTION
The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.
Battery can be damaged if overcharged or undercharged, or if left to discharge for long periods.These same conditions
contribute to shortening the "lite span" of the battery. Even under normal use, the performance of a battery deteriorates
after 2-3 years.
Battery voltage may recover after battery charging, but under heavy load. battery voltage will drop quickly and
eventually die out. For this reason, the charging system is often suspected to be the problem. Battery overcharge often
results from problems in the battery itself, which may appear to be an overcharge 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
motorcycle.
The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks
to prevent sulfation from forming.
Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance,
always charge the battery. Also, the battery life is lengthened when it is initial-charged.
When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-4).
For battery testing/charging, refer to section 22 of the Common Service Manual.
For charging system location. see page 17-2.
17-1
Charging System/Alternator
System Location
'91-'95
Standard model shown:
(1) IGNITION
SWITCH
(2) REGULATOR
RECTIFIER
(3) BATIERY
(5) ALTERNATOR
(4) MAIN FUSE
30A
----- - -
{1} IGNITION
SWITCH
BI~R/BI~
,
(3) BATTERY
lZV lZA
8
(Z) REGULATOR
RECTIFIER
(5) ALTERNATOR
17-2
Charging System/Alternator
After '95
LBS-ABS/TCS model shown:
--~l
(1) IGNITION SWITCH
/tarjl ,
(2) BATTERY
(6) ALTERNATOR
(4)
ALTERNATOR
FUSE 55A
(6) ALTERNATOR
~-,--.----~
,
(5)
~,
~
~
.i
'0"-
"
00
'n
"
f-SY
~
~
(2) BATTERY
MAIN
FUSE
30A
~ j
0
"
"
-m-
.Q: "
RECTIFIER
(1) IGNITION
SWITCH
L-
_ ri)
:.=:J
,/,,--0
R--- --Red
BI Black
17-3
Charging System/Alternator
Troubleshooting
'91-'95
Battery Overcharging
Faulty regulator/rectifier
Battery Undercharging
NOTE
In order to obtain accurate test readings when checking the charging system, the battery must be fully charged and
in good condition. See Common Service Manual section 22 for checking the battery condition.
Incorrect
Incorrect
L:
Correct
Correct
Correct
Not Charging
~-----:--L
:="""':-:c__
Normal
Check the alternator (charging and field coils)
resistance at the regulator/rectifier connector
(page 17-7}
Abnormal
1-
Normal
1_ _
,--~.-.
Abnormal
17-4
Normal
Faulty alternator
Faulty regulator/rectifier
Charging System/Alternator
After '95
Inspect the following before diagnosis the system.
- discharged battery
- loose or corroded terminals of the connectors
NOTE
In order to obtain accurate test readings when charging system, the battery must be fully charged and in good condition.
See Common Service Manual section 22 for checking the battery condition.
a~pere leakage
Incorrect
!'-_'-='-::C'
---.1
---
I
Correct
Incorrect
Correct
_t,--------',
14.2-14.8 V
Lessthan 14.2 V
Abnormal
Normal
Abnormal
If--'-=='-='-_
Normal
L'~~~~
Disassemble the alternator
and inspect the
following:
stator coil (page 17-11)
rotor coil (page 17-11)
brush length (page 17-11)
regulator/rectifier (page 17-10)
Faulty regulator/rectifier
Faulty battery
Abnormal
17-5
Charging System/Alternator
(2) BATTERY
NEGATIVE
TERMINAL
NOTE
I.
-,-----
17-6
Charging SystemlAlternator
Disconnect the starter relay switch connector and remove
the main fuse.
Reconnect the connector secoretv.
Connect the ammeter as shown.
~n
~l
~ ~
"
CAUTION
0
(2) CONNECTOR
NOTE
Before making this test. all the lights and the other
electrical equipment should be OFF.
Use fully charged battery to make this test for correct
measurement.
."
'~~
Ir: +eo
liLt'!! e
~,~f~
~~~~--~~--(~2~1
:B1ATIERY NEGATIVE(-)
TERMINAL
Regulator/Rectifier ('91-'95)
.-------
(1) CONNECTOR
Specification
Battery charging
line
Red/White (+)
and ground
Battery voltage
should register.
White and
Black
Item
0-4_0n.
1120'C/68'FI
17-7
Charging System/Alternator
Unit Inspection
Unit' kg
Provided the circuits on the wire harness side are normal and
there are no loose connections at the connector, inspect the
regulator!rectifier unit by measuring the resistance between
the terminals.
NOTE
Specified Multimeter :
-SP-15D
-TH-5H
\ + Probe
"
Red/
White
~lWhite
<,
- Probe
co
ca
co
Yellow 1
7.5
<,
co
ca
co
~low2
7.5
<,
oo
co
7.5
co
co
<,
cc
60
28
28
28
<,
Yellow
White
SANWA; kO
KOWA; Xl00
'-
(2) BLACK
._\
White
(1)YELLOW~
An old battery stored in the multimeter could cause inaccurate readings. Check the battery if the multi meter
resistance is incorrect.
(3) WHITE
(4) YELLOW
~"'
Remove the left side cover (page 2-2) and disconnect the
alternator 3P (Red) and 2p (Black) connectors.
Measure the resistance between the yellow wire terminals
and check for no continuity between each terminal and
ground.
17-8
(5) YELLOW
(1) 3P CONNECTOR
---,
,4
!~
~__
..u=:.
__ -"S:y
/.~_!,n,
,
c
I'",
-
V.------
I,
(2) 2P CONNECTOR
-'p
'
, _'
Charging System/Alternator
NEGATIVE
TERMINAL
Connect the ammeter {+} probe to the ground cable and the
ammeter (-) probe to the battery (-) terminal.
i.
---------
CAUTION
17-9
Charging System/Alternator
Wire Harness Inspection
::==J
I-~
drL
i/""
I.'~
- -
V,:1
$>,
Ij~ooo<~-_-:'-:'~~~j;:;0/-
'-
r~
ITEM
TERMINALS
SPECIFICATION
Alternator cable
BalTery voltage
ground H
should register.
BalTery voltage
White connector
input line
(1) E (ground)
Rectifier
P,
"'-e
'"
17-10
Charging System/Alternator
Stator
(1) TERMINALS
Rotor Coil
Check the slip rings for stepped wear.
Measure the 0.0. of each slip ring.
Brushes
Measure each brush length.
(l) BRUSHES
17-11
Charging System/Alternator
Battery Removal/Installation
{11
(4)
(3)
~(2)
Requisite Service
f-(1)
(2)
(3)
14)
Procedure
Removal Order
Battery negative (-) cable
Battery holder nut
Battery positive (+) cable
Battery
17-12
Q'ty
Remarks
Installation is in the reverse order of removal.
1
1
1
1
,
After removing, open the battery holder.
Charging SystemlAlternator
(5)
{11
(4)
------~
(3)
(2)
~l~-~
{7)=!t"7J
{6)~-~ ~
Requisite Service
(1)
(2)
(3)
[4)
(5)
(6)
[7)
Removal Order
Lock nut
Gearshift pedal connecting rod
Tube holder
Gearshift pedal
Alternator connector
Stator assembly
O-ring
Q'ty
2
1
1
1
Remarks
2
1
1
17-13
Charging System/Alternator
~1t:=~{41
Alternator base
~T
i
Mounting bosses
Alternator base
(6)
-,
17-14
...
Charging System/Alternator
servicing, disconnect the batlery negative cable from the batlery to prevent sparking when disconnecting the
alternator cable.
Requisite Service
Left pivot cover removal/installation (page 2-5}
Q'ty
Removal Order
(4)
Remarks
1
1
, Alternator cable
Mounting bolt
(5)
Alternator
(6)
O-ring
NOTE
Before removing the alternator, turn the alternator
clockwise and temporarily secure the alternator base
with a 8 mm bolt as shown.
If the alternator base is not secured, it will cause the
alternator shaft to come out with the alternator. If this
occurs, oil pan removal will be necessary when
reinstalling (page 17-18}.
Pry the mounting bosses of the alternator using a
screwdriver.
Disassembly/assembly (page 17-16)
17-15
Charging System/Alternator
(10)
cu )
---------
1131qJ.
141
------------
(5)
..,
{3j
151
(9)
17(
12(
17-16
Charging SystemlAlternator
Requisite Service
11 }
12}
131
141
151
161
171
18}
19}
(10)
(11)
(12)
(13)
(14),
(15}i
(16}
(H}
Disassembly or der
End cover screw
Nutfterminal insulator
Rear end cover
Terminal screw (pan-head)
Terminal screw (flange)
Regulator
Brush assembly/holder insulator
Terminal screw (flange)
Rectifier
Housing nut
Rear housing
Rotor
Oil seal
Retainer screw
Bearing retainer
Front bearing (6202)/washer
Spacer ring/rear bearing (6002}
, Q'ty
Remarks
Assembly is in the reverse order of disassembly.
3
1/1
1
2
3
1
1/1
4
1
2
1
1
1
4
1
1/1
1/1
,
,
17-17
Charging System/Alternator
131et,
.{J/~Y
(t I
5 8 (5.8, 42)
121
6 mm bolt
Requisite Service
Engine removal/installation (page 7-2)
Oil pan removal/installation (page 4-6)
Stator coil removal/installation {page 17-13)
Procedure
Q'ty
(t)
Removal Order
Alternator shaft bolt
121
(31
O-ring
17-18
Remarks
Installation is in the reverse order of removal.
NOTE
Before removing, insert a 6 mm bolt in the holes in the
alternator shaft driven gears for easy alternator shaft
assembly installation. After installing, do not forget to
remove the bolt.
NOTE
Before installing, apply molybdenum disulfide grease to the
alternator shaft driven gears. Disassembly/assembly {page
17-20}
Charging System/Alternator
After '95
et'l
121
I' 1
6mm bolt
Requisite Service
Oil pan removal/installation (page 4-6)
Alternator removal/installation {page 17-14}
Procedure
Q'ty
Remarks
Removal Order
.NOTE
Before removing, insert a 6 mm bolt into the holes in
(2) la-ring
17-19
Charging System/Alternator
IS}
IS}
141
131
15}
17}
Requisite Service
. Alternator shaft removal/installation (page 17-18).
Procedure
11 }
12}
13}
14}
15}
Disassemlby Order
Alternator shaft nut
Washer
Bearing
Shaft collar
Cone washer
Remarks
Q'ty
1
1
1
1
1
19:}1
110}
Alternator shaft assembly
17-20
5
12
1
1
Charging System/Alternator
After '95
(9(
~I
I
I
I
(51
(41
(31
(11)
Requisite Service
Q'ty
Disassembly Order
(1) , Alternator shaft nut
(2(
(31
141
151
161
171
181
(91
Washer
Bearing (6003)
Shaft collar
Cone washer
Remarks
Assembly is in the reverse order of disassembly.
1
1
1
1
1
Install the washer with the tapered side facing to the shaft
nut.
4
8
1
3
1
1
1
17-21
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
18-1
Ignition Coil
18-8
System Location
18-2
18-9
Troubleshooting
18-4
18-10
18-6
18-11
Service Information
When checking the ignition system, always follow the steps in the troubleshooting flow chart (page 18-4).
The digital transistorized ignition system uses an electrically controlled ignition timing system. No adjustments can be
made to the ignition timing.
A rough diagnosis can be made by identifying the cylinder whose spark timing is incorrect.
The ignition control module (leM) may be damaged if dropped. Also, if the connector is disconnected when current is
flowing, the excessive voltage may damage the unit. Always turn off the ignition switch bercre servicing.
A faulty ignition system is often related to poorly connected connectors. 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 plugs.
Use spark plugs of the correct heat range. Using spark plugs with an incorrect heat range can damage the engine.
Refer to section 2 of the Common Service Manual.
For neutral switch inspection, refer to section 25 of the Common Service Manual; for switch location, see page 18-2 or
18-3 of this manual (System Location).
For the ignition switch and engine stop switch inspection, check for continuity on the continuity chart of the Wiring
Diagram (section 22). Refer to page 21-4 for side stand switch inspection.
18-1
Ignition System
System Location
Standard Model
SENSOR
y;"
/\
GENERATOR
(13) IGNITION
CONTROL
MODULE
{ICM}
(12) NEUTRAL
SWITCH
30A
(9) BATIERY
SENSOR RELAY
(5) BANK ANGLE
SENSOR
S~TCH
-0
IGNITION COIL
/>-J
W I G RIW
-;[
(13) ICM
RjW
W/Y
...L
,--'--
lOA
L--BI'-----I
..."..,
R _
R/BI
FUSE
30A
_L'----
-=-
(9) BATTERY
SWITCH
FUSE
lOA
(11)SIDESTAND
SWITCH
(12) NEUTRAL
SWITCH
TO TACHOMETER
TO STARTER
CIRCUIT
18-2
Ignition System
ABS/TCS model shown:
INDICATOR LIGHT
~-~
(1) TCS/ignition
control module
(lCM)
C~\
GENERATOR
'---~
(12) NEUTRAL
SWITCH
(11) SIDE STAND
SWITCH
(10) MAIN
FUSE
30A
(9) BATTERY
SENSOR
(1) TCS/ICM
BI/Y
W/Y
'-
L--BI----.J
R _
R/BI
_BI/BR
--=-
(9) BATTERY
LG
~~o
-~,
(11)SIDESTAND
(12) NEUTRAL
SWITCH
SWITCH
TO TACHOMETER
(8) IGNITION PULSE
TO STARTER
GENERATOR
CIRCUIT
18-3
Ignition System
Troubleshooting
No spark at all plugs (Faulty input system)
If there is no spark at all plugs, the problem could be at the input of the ignition system (ignition pulse generator. power input circuit of the ignition control module (ICM), neutral switch, side stand switch or ICM).
Check for loose or poorly connected ICM con-I
nector.
I
Normal
~ Normal
I Check for battery voltage between the power
input line (Black/White: standard model, Black/
'Yellow: ABSTCS model) and ground (Green) at
the 'CM connector with the engine stop switch
at RUN (except ABSTCS model) and the ignition
, switch ON (page 1B-6).
Abnormal
I Normal
j
Measure the ignition pulse generator resistance I
at the lCM connector (page 18-6).
Normal
Normal
!Normal
Faulty ICM
Abnormal
Abnormal
Faulty neutral
switch
Abnormal
Faulty side stand
switch
18-4
Ignition System
No spark at either ignition group
If there is no spark at either group, the problem is suspected in the primary coil side of the ignition system (ignition
coil, or ignition control module (ICM) and ignition coil circuit).
..I
Switch the ignition coil primary terminal con! nection between the faulty pair and good pair.
Try spark test again
"No Spark"
condition
remains with
faulty pair
No Spark" condition
shifts to other pair
U
~.
.. "
I,
Abnormal
Normal
Faulty ICM
No spark at one plug (Trouble in secondary coil side)
" Faulty spark plug is most likely.
Replace (suspected bad spark plug) with known I
good spark plug and conduct spark test.
i
Abnormal
Put the spark plug wire on and measure resistance
of ignition secondary coil (page 18-7).
Normal
Abnormal
Remove the spark plug wire, and measure the
_"
resistance of the ignition secondary coil (page f - Abnormal
18-7) .
Normal
Normal
Abnormal
Normal
Abnormal
Faulty side stand switch
18-5
Ignition System
STANDARD MODEL:
(1) ICM
NOTE
Check the system components and lines step-by-step
according to the troubleshootinq chart on pages 1B-4
and 18-5.
Standard model:
Remove the left fairing pocket (page 2-6).
Remove the ignition control module (ICM} from the stay,
disconnect the ICM connector and check it for loose or
corroded terminals.
Item
Terminals
Standards (20"C/6B"F)
405-495 Q
Ignition primary
coil line
No. , ,3
No. 2,4
2.16-3.19
Continuity in neutral
No continuity in any gear
Ground line
Continuity
Tachometer line
18-6
Continuity
Ignition System
Ignition Coil
(1) 3P CONNECTOR
Inspection
Remove the upper fairing (page 2-9).
Disconnect the ignition primary coil 3P connector (white)
and measure the primary coil resistance between each ignition
coil.
Primary coil resistance:
Standard: 2.16-3.19Q (20'C/6So F)
Disconnect the spark plug caps from the plugs and measure
the secondary coil resistance with the spark plug caps in
place,
(1lIGNITION COIL
OJl\-~
(OJ
;,=
(iiiiiii
.~t:r
iiiiiii
f
I
18-7
Ignition System
STANDARD MODEL:
NOTE
It is not necessary to remove the ignition pulse generator to make this inspection.
Standard model:
Remove the right side cover (page 2-2).
ABS/TCS or LBS-ABS/TCS model:
Remove the top shelter (page 2-5).
w
@
~---
~~~~~~
-~~~cccc~_D
(G';"'-------------::;)~~q
:----J
-;:-------r--
18-8
Ignition System
"
(11
0'12 (1.2, 9)
.,('G1l!
(61
(31
(~,
Clamp
0'12 (1.2, 9)
(21
Requisite Service
111
(21
Removal Order
Oil pressure switch terminal
Neutral switch connector
(3}
my
1
1
(6}
2
2
(7}
(81
14} Bolt
151 Gasket
Dowel pin
Bolt
Ignition pulse generator
Remarks
18-9
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
19. les
Service Information
19-1
Circuit Diagram
19-4
System location
19-2
Troubleshooting
19-5
Service Information
CAUTION
Use the fully charged battery for troubleshooting. Do not diagnose the TeS with a charger connected to the
battery .
On removal and installation of the wheel sensors/wheels. be careful not to damage the wheel sensors and pulser
rings.
NOTE
res
res
19-1
TCS
System Location
ASS/les model shown:
(6)
res INDICATOR
LIGHT
(7)
(4)
res ON/OFF
res
ACTIVATION LIGHTS
SWITCH
(8)
res
OFF INDICATOR
(2) BATTERY
(1) FUSE CASE
(19)
REAR
WHEEL SENSOR
(17)
IGNITION
PULSE GENERATOR
19-2
res
ON/OFF SWITCH
-Top shelter
(page 2-5)
For
example::~
_---_
INDICATOR FUSE
("METER TAIL POSIT1QW)
IGNITION FUSE
nGN ACG STARTER")
FUSE CASE
-L. side cover
(page 2-2)
~~~'"~~C
------------------------
--------
..
G
R
GREEN
RE.
0 ORANGE
Lb UGHTBLUE
L. UGHTGREEN
P PINK
WHITE
G. GRAY
0' BLACK
Y YELLOW
BLUE
O.
BROWN
t.':: FRQN
-Upp
(page
TCS
F SWITCH
:~:
INDICATOR (WHITE)
-trmer screen (page 2-7)
=
G/O
G~
ts u
V\jo
RJ
0
Vj
Ala G!B
(~)
yv
61 B
AIw 61
(~l
dJ FRONT WHEEL SENSOR
-Upper fairing
(page 2-9)
19-3
TCS
Circuit Diagram
B,
81
BLACK
YELLOW ,0
BROWN
ORANGE
GREEN
REO
Lb LIGHT BLUE
Lg LIGHT GREEN
P PINK
WHITE
Gr GRAY
~BLUE
SIDE STAND SW
NEUTRAL SW
SWITCH
....... - - - . ,
.... - -
{:lllJ~I~~~~~G;':,.
y-
* 6-::=====+.
rBl-r--- g
res
-Z
-Z
-n
-n
G,IY
WI
"o
-i
-i
IGNITION
r-
"o
m
Q
~
o
e
"
"
-Z
-Z
2P- 81
rB r-'i{~~'::::Y====l:H
INDICATOR LIGHT
SWITCH
01y.
-i
-i
Bul G
BIIO
Bul 8'
-n
"
o
m
Q
~
n
e-
TRACTION
CONTROL
f-
o
e
"
-i
19-4
REAR WHEEL
SENSOR
Q
~
FRONT WHEEL
SENSOR
"
o
m
//~
: ~ ~fl
D5 0 fe. ~ a:l{.9 ~
~~ iii): ~;: ~
TACHO
METER
~R~AITERP
Q.
II:
~W/O
~R/O
t- Su/Y
lOA
I-Y/Bu
~BIIY
~LglO_
IGNITION SWITCH
lrl-I-F~B~~
R/W-=t..a
BANK ANGLE
SENSOR RELAY
3P-G
-+-----t=;~:::1J1::=~~
rRIW~/~
BANK ANGLE
9~-R
-Y/G<-+....,H--..1
,.....-+-BIIW-BIIY-
SENSOR
_BIIW:===r~BIIW~
-BIIY
-BIIY-h::::U
ENGINE STOP
SWITCH
~G,--t-----~
_L.
.L.
TCS
Troubleshooting
Before Beginning Troubleshooting:
ON
OFF
o
ON
OFF
ON
OFF
ON
OFF
_ _ _ _ _ _/
.J
.J
I"
=:J------
I completes.
.JC'
Approx, 2 seconds
(Check for blown out bulb)
TCSACTIVE
NOTE
Check the following before performing TCS troubleshooting:
- Pre-start self-diagnosis of TCS
- Check all lights and indicators of TCS
If an abnormality is found during the above checks, perform the TCS troubleshooting following the Symptom-toSystem Chart (see the following page). The TCS is normal if no trouble is found. Go on to the check the other basic:
systems (e.g., fuel system, ignition system).
I
19-5
TCS
Symptom-to-System Chart
Affected
Fuse
-0
Symptom
c,
o
0
."
--< - l>
tn
;:i: Ul
0
~o
'"a:
0
_z
;:i:
U)
0_
~-<
-"
~- ~~
~O
O~
3~
3~
Wheel
sensor
system
0"
-n
<3
0
-= ;::j:
3-<
~U>
0-~
"
0
0'
"0
0
0
0
'"
Lights and indicator of leS (except les indicator light) do
not go off 2 seconds after the ignition switch is ON.
rcs
ON/OFF switch.
When leS indicator light blinks while riding, it does not
go off by operating the indicator light switch.
-< Reference
"
U>
c,
-n
5
c,
o
0
0
0
g.
page
<
"'. "
Q
~
~
(J (J
"
o-<
U>
-<
U>
Indicator system
t:::::'
e-
"
(J (J (J
19-7
(J (J (J
19-10
(J
19-11
'0
(J
C)
r'.
,~
(J
19-13
(J
19-15
19-17
"
'J
(J
NOTE
Check the following before performing TCS troubleshooting.
- Pre-start self-diagnosis of TCS (page 19-5)
- Check all lights and indicators of TCS (page 19-5)
If an abnormality is found during the above checks, perform the TCS troubleshooting following the Symptom-toSystem Chart. The TCS is normal if no trouble is found. Go on to the check the other basic systems (e.g. fuel system,
ignition system, etc.}.
After troubleshooting, perform the pre-start self-diagnosis again (page 19-5) to be sure that the indicator lights of the
TCS are operating properly.
Tes
TCS OFF
INDICATOR
ABS/TCS INDICATOR
LIGHT SWITCH
ACTIVATION
LIGHT
TC.
0 ..
ABB~
\
TCS ON/OFF SWITCH
19-6
TCS
Flowcharts
NOTE
Turn the ignition switch OFF unless otherwise specified.
When the reS/ignition control module oeM) is found to be faulty, recheck the connectors before replacing the res;
ICM.
Atter troubleshooting, perform the pre-start self-diagnosis again and be sure that the indicator light of the
are
normal.
The encircled numbers in the text and connector diagrams indicate the connectors (see page 19-3).
res
Lights and indicators of the leS do not turn on when the ignition switch is ON.
NOTE
res
TeS
Tes
..
//------f-=
~
~= - - -, - '
TCSACTIVa
T""
A ....
/:=- -=:_-~
-
res
~~:---:..~
"
lights)
Lights go off.
<
Is it normal?
Burned out.
Normal
<
Is it normal?
JNormal
Burned out.
<
-'
Poor connection
Secure connection
I
(Continue to the following page)
-',r(
r :-='1
L
INDIC':-'TOR FUSE
"METER TAIL POSITION)
I11_
LI ~
IGNITION FUSE
r'IGN ACG STARTER")
~~
FUSE CASE
19-7
TCS
(From the previous page)
GREffi
Check for continuity between the GREEN terminal of the TCS/ICM 4P ccnnectcr rg and body
ground.
<
No continuity
Is there continuity?
Continuity
Disconnect the 16P connector <7) and 4P con-
nector
(~)
of the TCS/ICM.
'L'
8LACK/YEL
I
No battery voltage
Battery voltage
leM
I
TCS activation light and
OFF indicator do not
come on (See page 19-
.~
7)
I
YELLOW/GRAY
1-
j
Connect the WHITE/ORANGE terminal (TCS
OFF indicator) and the YELLOW/GRAY terminal
(TCS activation light} of the TCS/ICM 16 P connector (lJ to the body to ground.
WHITE/ORANGE
I
Does the light come on or go off?
Light comes on.
Faulty TCS/ICM
19-8
.L
Light goes off.
TCS
(From the previous page)
I
Disconnect the BLACK/BROWN connector
the TCS indicator light.
C1; of
I
Turn the ignition switch ON.
I
! Check for voltage between the BLACK/BROWN
connector@ofthereS indicator light and body
i
i ground.
No battery voltage
<
Battery voltage
,~
I I I I
I I I
I
Check for continuity between the RED/ORANGE
terminal
of the
RED/O
res
iconnector Ct,.
Is there continuity?
No continuity
Continuity
Connect the TCS/ICM 16P connector ,j)and connect the BLACK/BROWN and WHITE/ORANGE
connectors of the TCS indicator light.
Replace the LED of the TCS indicator light.
Turn the ignition switch ON and check the TCS
indicator light.
Does the light come on?
..
19-9
TCS
Indicator lights of the TCS (except TCS indicator light) do not go off 2 seconds after the ignition switch is ON.
NOTE
res
res
res
res
mand
4P con-
res
Lights come on
Lights go off.
Faulty TCS/ICM
TCS OFF INDICATOR
TCS ACTIVE
19-10
1 Tce
I~
TCS
TCS indicator light does not go off after the motorcycle starts to move.
NOTE
If the
res
to move.
res
INDICATOR LIGHT
Poor connection
Secure connection
i
Disconnect the 4P connector () of theTCS/ICM,1
j
Check for continuity between the GREEN terminal of the TCS/ICM 4P connector (f{;: and body
ground
j
<
Is there continuity?
No continuity
Continuity
<
Poor connection
Secure connection
(-t terminals of the TCS/ICM and the main harness side terminal of the wheel sensor cormectors eft: for front and CD for rear)
(Continue to th
following page)
ill)FRONT,
BLUE/GREE~EEN
L-@-J
~ cfb
'J) REAR:
BLUE/BROWN
BLUE/BROWN
C@--J
19-11
TCS
(From the previous page)
<
No continuity
Is there continuity?
Continuity
<
I, the wheel
,~n,o, no,m,I'
>
Abnormal
Faulty TCSjlCM
19-12
TCS
TCS indicator light blinks and TCS OFF indicator comes on after the ignition switch is turned ON or while
riding.
NOTE
I . res indicator light should go off after the motorcycle starts to move.
Turn the ignition switch OFF.
D"
Poor connection
Secure connection
LIGHT
/~~
res INDICATOR
TC.
-"T'"''
TC.
of the TCS/ICM.
Check for continuity between the GREEN terminal of the TCS/ICM 4P connector ::E' and body
, ground.
Is there continuity?
No continuity
Continuity
<
Poor connection
I Secure connection
l
Disconnect the 16P connector CD of the TCS/
ICM and the wheel sensor connectors (CI9' for
front and (j) for rear).
19-13
TCS
(From the previous page)
I
Check for continuity between the l6P connector
terminal of the TCS/I~M and the main
harness side terminals of the wheel sensor con-
.t:
nector
(rLO
CD
:[ilFRONT"
BLUE/GREE~REEN
%
~~
(t
BLUE/B~ROWN
~T
:T REAR:
I I I I
q:tJ
Is there continuity?
No continuity
No continuity
INormal
j
Faulty TCSIICM
19-14
Abnormal
trouble-
TCS
TCS does not turn ON or OFF by operating the TCS ON/OFF switch.
NOTE
The
res
should automatically turn ON when the ignition switch is ON. The TCS can then be turned ON/OFF by
j
Check the res ON/OFF switch connector ':tJ for
secure connection.
<
Poor connection
Is it connected securely?
\
Connect securely and recheck.
Secure connection
Discormest the
(2).
Abnormal
Is it normal?
Normal
Check the 16P connector U) and 4P connector
':a:, of the TCS/ICM for secure connection.
Poor connection
Are they connected securely?
c===~;:tI~~~~*~~~~~:===>-~~~"":"'~"-_
Connect securely and recheck.
Secure connection
ground.
Is there continuity?
Continuity
No continuity
..
GREEN
n
19-15
TCS
(From the previous page)
j
Disconnect the 16P connector
nector
res
ill
and 4P con-
iJ)
-,
ORANGE
jYElLOW
<
No continuity
Is there continuity?
Continuity
tj)
~tB
ORANGE/YELL~EEN
<
Is there continuity
No continuity
Faulty TCS/ICM
19-16
Continuity
TCS
TCS indicator light blinks while riding and does not go off by operating ABS/TCS indicator light switch.
NOTE
res
res
I
Check the ABS!TCS indicator light switch connector (J) for secure connection.
-- -
~=U=:4 ~".
=--
->
(
Is it connected securely?
- - -
--
Poor connection
--------
Secure connection
connector (J).
I
Check for continuity between the switch side
connector Q) terminals of the indicator light
switch.
Push: No continuity
Release: continuity
Is it normal?
Abnormal
Normal
Poor connection
I Secure connection
wtE
Check for continuity between the GREEN terminal of the rCS/ICM 4P connector :Je and body
: ground.
~
Is there continuity?
Continuity
No continuity
19-17
TCS
(From the previous page)
m~
GR~EN
Cit terminal of the TCS/ICM and the main harness side connector :,3) terminal of the ABS/leS
indicator light switch, ,nd between the 16P
connector oj) terminal of the TCS/ICM and the
main harness side connector CJ" terminal of the
ASS/leS indicator light switch.
.tp
(])
GRAY/yELLQW
I
<
Is there continuity?
No continuity
Continuity
I
With the ABS/leS indicator light switch connector C~: disconnected, check for continuity
between the 16P connector CD terminal and 4P
connector ;~!L terminal of the TCSjICM.
<
Is there continuity?
No continuity
19-18
GRAY/YELLOW
~tp
GR AY/YELLQW
Continuity
GREEN
TCS
(From the previous page)
View from terminal side
(~
GRAY/YELJ
EN
No
Yes
Faulty TCS/ICM
19-19
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
20-1
System Location
20-2
Troubleshooting
20-4
20-6
Service Information
~tion
switch OFF before servicing the starter motor. The motor could suddenly start. causing
serious injury.
A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
For the following component inspections, refer to the following pages; for the parts locations, see page 20-2 of this
manual (System Location).
Starter motor
Clutch switch
Neutral switch
Ignition switch
Check for continuity on the continuity chart of the Wiring Diagram, section 22.
20-1
Electric Starter
System Location
Standard Model
112)IGNITION--,If7~~+~~~~~~~~-;--:--;;
:j
SWITCH
- -
'91-'9 4
I---
--':-
SENSOR RELAY
(4) BANK
ANGLE
SENSOR
--
VIR
G/R
R
MOTOR
1M
(7) BATIERY
TO REGULATOR/RECTIFIER
~O)STARTER
R/W
BIIY
FUSE lOA
co R/BI
BI
-'
I
-'-
GIW
Lo'11) CLUTCH SWifCH
FUSE lOA
(1) SIDE STAND
r;;
BIIBr ~
_____ -
~lg/R
32
INDICATOR LIGHT
(2) NEUTRAL
LIGHT
01000
Lg
(6) NEUTRAL
SWITCH
20-2
~
.......
YIBI
)
G/R
-J
L
G;;)
(9) SIDE STAND
SWITCH
Electric Starter
111 NEUTRAL
L1GHTJ~~. _~
~\,
1121 IGNITION
__
SWITCH -~y.d.
(11) CLUTCH
SWITCH
:::
~:::::~~:~:::~:RE~Y
:-V:',
;:::=lJ2,.--(5)
SWITCH
(8) STARTER RELAY SWITCH
After -94
, - - - - - - , (1 0) STARTER
MOTOR
(7) BATTERY
---e-
Y-+--t-J
G/R
IL-_-T~-G/R
BI
Y/R
G/R
(5) STARTER
t-BIIl
BIBI
R/W-
SWITCH
2Y-6-
CLUTCH
DIODE
sl/w
L9
BI/Y
R:+=~=t1 (13)
~
(4) BANK
ANGLE
SENSOR
( 1 1) CLUTCH
SWITCH
G/W
ENGINE STOP
SWITCH
(6) NEUTRAL
SWITCH
20-3
Electric Starter
Troubleshooting
Starter motor will not tum
Check for a blown out main or sub fuses before servicing.
Make sure the battery is fully charged and in good condition.
Abnormal
Normal
Check for loose or poorly connected starter relay
switch terminals and 4P connector.
Abnormal
Normal
Abnormal
Normal
Turn the ignition switch ON and the engine stop
switch to "RUN" position. Push the starter switch
and check for a "click" sound from the starter
relay switch.
Clicks
St~rter
motor
turns
No click
No continuity
Starte1r motor
does not turn
Continuity
No voltage
20-4
..
Normal
Electric Starter
The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position
except neutral, with the side stand up and the clutch lever pulled in.
Abnormal
Normal
Abnormal
Normal
Check the side stand switch (page 21 4).
Abnormal
Normal
20-5
Electric Starter
(7)
(B)qJ-,
. ""0)~---=:='(2)
(4)
(5)
Requisite Service
Middle fairing removal/installation (page 2-8)
With the ignition switch "OFF", remove the negative cable at the battery before servicing the starter motor.
Procedure
(11
(21
(3)
(4)
(5)
(6)
(71
(BI
Removal Order
Heat guard mounting nut
Starter motor mounting bolt
Starter motor heat guard
Starter motor terminal cover
Terminal nut
Starter motor cable
Starter motor assembly
O-ring
20-6
O'ty
Remarks
-
1
2
1
1
1
1
1
1
Electric Starter
(3)f1I
(6)
I' )
..'"
cs
III
"
"
/
~~
~\
<
(2)
I
I
l/
")~(
(6)
(8)
(4)
(9)
Requisite Service
Disassembly Order
Starter motor cover bolt
(2)
Front cover
(3)
Packing
(4)
Insulator washer
(5)
Shim
(6) Rear Cover
(7) Packing
(8)
Shim
(9) Armature
(10) Brush holder
I Q'ty
(1)
,,
,
,,
,,
Remarks
Assembly is in the reverse order of disassembly.
20-7
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
21. Lights/Meters/Switches
Service Information
21-1
21-5
System Location
21-2
21-5
Headlight
21-3
21-6
21-3
21-3
21-6
21-7
Position Light
21-4
21-4
21-8
21-4
21-10
Service Information
~en
headlight bulb becomes very hot while the headlight is ON, and remain hot for a while after it is turned
OFF. Be sure to let it cool down before servicing .
Use an electric heating element to heat the water/coolant mixture for the fan motor switch inspection. Keep all
flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye,
protection.
Inspection method
Remarks
Horn
Handlebar switches
Ignition switch
Check for continuity on the continuity chart of Switch connectors are located behind the
the Wiring Diagram, section 22.
instruments (page 1-25}.
Neutral switch
--
Oil pressure
switch/indicator
light
,
Fan motor switch
21-1
Lights/Meters/Switches
System Location
Standard model shown:
(2) BANK ANGLE SENSOR
'-----
I, I,
21-2
Lights/Meters/Switches
Headlight
(1) CONNECTOR
(2) "TOP" MARK
(3) BULB
(4) RETAINER
Bulb Replacement
Remove the middle fair"mg inner cover (page 2-7).
Disconnect the connector and remove the dust cover.
Remove the bulb by removing the bulb retainer.
Install a new headlight bulb.
CAUT"'O,,N
failu.~'e:.~
NOTE
Install the dust cover with its 'TOP" mark facing up.
(1) BULB
SOCKET
Bulb Replacement
Remove the rear view mirror (page 2-8).
Remove the bulb socket by turning it counterclockwise.
Remove the bulb by turning it counterclockwise while pushing
in the bulb.
J,
';::
NOTE
replace it if
neCeCeC,,~a~,"y~.
.
------
'I,
,
"
I,"
(n BULB ..----,;:-
y/
NOTE
'-----'--
...J
21-3
Lights/Meters/Switches
(11 BULB
(1) 3P CONNECTOR
Inspection
Remove the left side cover (page 2-2).
Disconnect the side stand 3P connector (green) and check
for continuity between each terminal as shown below.
There should be countinuity between the C-C) positions on
the continuity chart.
Green/
White
Side stand down
Side stand up
Yellow/
Black
Green
(4) DOWN
.rv
Replacement
Remove the pivot cover (page 2-5).
Diconnect the 3P connector (green} and release the wire
from the clamp.
Remove the bolt and side stand switch.
Install the side stand switch aligning the stop pin on the
frame with the cut out of the switch and the pin on the
switch with the hole in the side stand
Secure the side stand switch with the bolt.
Torque: 10 Nom (1.0 kg-m , 7 ft-Ibl
Install removed parts in the reverse order of removal.
21-4
ifi;/
"<,
t?g!
(3IALlGN
(4) BOLT CUT OUT
Lights/Meters/Switches
Inspection
Remove the upper fairing (page 2-9).
Turn the ignition switch "ON" and measure voltage between
the following terminals of the bank angle sensor with the
3P connector (green) connected.
Terminals
Standard voltage
I-
0-3.0V
10.0-14.0V
(2l3P CONNECTOR
50~
(1) NORMAL
POSITION
(approximately]
0'
~-
NOTE
If you repeat this test, first turn the ignition switch
"OFF~, then back to "ON" before you try the test
again
Installation is in the reverse order of removal.
(eoorcxunetefvl
ABS;TCS MODEl:
STANDARD MODEl:
y/1
! /") '~\\L
t t s.
//(;,
".. . . .':c. -
, ,
:'
- - - -
~-/:,
"I
I
7;0~~~i~1 :
;
I"
... I
'il
I,
i-----i-
1I
Standard
f
Between
the BI/W (+) and body ground Battery voltage
(-) with the ignition switch "ON".
'should register
Continuity
Continuity
Continuity
(2) 4P CONNECTOR
21-5
Lights/Meters/Switches
c0
u.s.ei.
21-6
.:
;~,' ;\"U_~'
I I ,
Lights/Meters/Switches
(5)--------i~A
-...
'
"~"
Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with
the engine stopped. Do not smoke or allow flames or sparks in your work area or where gasoline is stored .
Keep away from flames or sparks. Wipe up spilled gasoline at once.
Requisite Service
Q'ty
Remarks
-
Removal Order
(1) Fuel outlet tube
(2) Fuel pump/level sensor connector
(3) I Fuel pump mounting nut
(4)
Fuel inlet tube
(5)
Fuel pump assembly
(6) Base packing
3
6
1
1
1
21-7
Lights/Meters/Switches
Cl\"",::.::::::::::;;-__~_~~
9 (D.9,
6.5)
(5)
, ,,
(4)
Requisite Service
Q'ty
Remarks
-
Removal Order
(' ) Meter mounting bolt
(2)
Collar
(3) Speedometer cable
(4)1 Meter connector
15) , Meter assembly
21-8
3
3
,
3
lights/Meters/Switches
ABS/TCS Model
141
~'~-------=111
9 (0 "9 ,
6.51
(21
131
(31
Requisite Service
Instrument panel removal/installation (page 2-7)
Procedure
(1)
(2)
(3)
(4)
Removal Order
Meter mounting bolt
Speedometer cable
Meter connector
Meter assembly
O'tv
Remarks
Installation is in the reverse order of removal.
3
1
5
1
21-9
Lights/Meters/Switches
(31
(17)
Requisite Service
Combination meter removal/installation (page 21-8)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11);
(12)
(13)
(14)
(15)
(16)
(17)1
(18)1
Disassembly Order
Nut/washer
Screw
Meter visor
Reset knob
Screw/Band
Indicator housing
Screw
Cover
Indicator lens
Terminal screw
Fuel gauge
Temperature gauge
Screw
Speedometer gear box
O-ring
Speedometer
Screw
Tachometer
21-10
Q'W
Remarks
Assembly is in the reverse order of disassembly.
2/2
5
1
1
3/3
1
2
1
1
6
1
1
4
1
1
1
2
1
Lights/Meters/Switches
ABS/TCS Model
(11)
(13)
(3)
(19)
(4)
11\
(6)
___-12}
(5)
18}
Requisite Service
Combination meter removal/installation (page 21-9)
Procedure
(11
(2)
(3)
(4)
(5)
(6)
171
18)
(9)
(10)
( 11)
(12)
( 13).
( 14)
(15)
(16)
(17)
(18)
(19)
(20)
(21 )
(22)
(23)
Disassembly Order
Nut/washer
Screw
Meter visor
Reset knob
Screw
Lens/case
Harness band
Screw/band
Screw
Cover
Indicator housing
Screw
Cover
Indicator lens
Terminal screw
Fuel gauge
Temperature gauge
Screw
Speedometer gear box
O-ring
Speedometer
Screw
Tachometer
O'tv
Remarks
Assembly is in the reverse order of disassembly.
2/2
5
1
1
4
1/1
1
2/2
2
1
1
2
1
1
6
1
1
4
1
1
1
2
1
21-11
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
TAClOIETER
5 ~L
PRESSURE
2 FUELINDICATOR
FUEL GAUGE
SPEEDOMETER
IADlJGHT RElAY
(L.o)
~~:/;BI===~~l
4PR
~;t
~~~::'/BI;::==mn
CLUTCH DIODE
~!~r
4PW
IADl.lGHTS
1~2Y45/45W12
12Y32/3CP
a./II
WIBl
IIIV
ViR
Ill/Ii
will
Ill/R
Brill
rlBI
BI
o
Br
G/R
II/Ill
Br/R
ill",
.
FUSE BOX
A lOA
(NEUTRAL_OIL_ TEMPeTACHO-
~~R~;~SOR
HORN)
ill ~
c:r-
C 20A (HEADLIGHT)
0- '-0
\..
PR
PL
Lo
-0
( )--0- k)
DIMMER SWITCH
.J
}--Q
(FAN MOTOR)
REAR BRAKE)
Lo
IN)
Hi
HORN SWITCH
Hi
~BAT3
FREE
PUSH
STARTER SWITCH
IG
BAT2
BAT!
0- -0
PUSH
BAH
0-1-
FREE
OFF
RUN
ST
0- -0
JGI<T
:ATOR
Il HJlCATOR
IGNmON CONTROL
MODULE
ENGINE STOP
SENSOR RELA V
.~
ENSOR
~iii
III
I/W
I/G
1/11
.a
riG
.b
I/Br
12V32C'
!D]
'T"!D]
,W
,II
12Y3213CP Xl
'I~I
o ~EUTRAL J
r
IG"TKlN
PULSE GENERATOR
.:,~.~~~ ~>->~
SWITCH
'=
II lD
>
'CPRE~S_~~
ilJrJ
~II/W
IGNITION COILS
---1......
o~:; ~ ~
REGULAToojRECTIFIER
-=-
12Y32CP
f
BI
Y
Bu ....
ALTERNATOR
G
R
W
BLACK
Br
BROWN
YELLOW
ORANGE
BLUE
GREEN
Lb
1-&.
LIGHT B1LUE
LIGHT GREEN
REO
WHITE
P
Gr
GRAY
PINK
IGNITION SWITCH
FAN
ON
IG
BAT!
0- -0- -0
OFF
LOCK
22-1
Wirig Diagram
METER LIGHTS
THERMO!
r- :
~G'-==--"
" R
Will
m'~G:;:==+i:tl
"W
Ill/il
W/P
"6<
CD!~t
RIGHT FRONT TURN SIGNAL
HEADLIGHTS
IZV3213CP
Ill/II
Will
~~/II
~W/II
~O/W
rr---t:g~~rGi:==I=t===-..:::;-ttt-tn~~;;dEE_"I_-+~:::l=0
Lm FRONT TU
RN SIGNAL
O/W
11V3213CP
A IDA (
mtlIM
~~~
lli+ :',
-,.CI<
'i
"!/.
22-2
B lOA
C IDA
FUSE BOX
IGNITKlN SWITCH
(HEADLIGHT)
ETERLIGHT' TAIL)
D IDA
E lOA
F IDA
G IDA
(FAN MOTOR)
(IGNITION. START
(TURN SIGN
ER. ALTERNATOR)
IGNITION CONTROL
MODULE
~~~Y/FiJ
FiJ/Y
ENGINE STOP
SENSOR RLAY
81/W
G
BI~
1m
~iii
iD
!D]
-.. .,. . . "'t-!D]
12V3213CPX2
~:::::c::=()
ill
f
IGNITION COILS
ALTERNATOR
LEFTREAR TURN
12Y32CP
BI
Y
BLACK
Br
BROWN
YELLOW
au
BLUE
GREEN
Lb
ORANGE
LIGHT BLUE
I..g
LIGHT GREEN
RED
WHITE
PINK
GRAY
G
R
W
Gr
IGNITION SWITCH
FAN
ON
IG
BAT!
V-r-v- -0
OFF
LOCK
0030Z-MAJ-AOOO
~NAL
5
6
NEUTRAL INDICATOR
METER LIGHTS
12V 3.4 W x 7
OA,"OM':::(~~f?
~_c
:~.., m30H~TS'Wi -~
=:
...J:~av-
-:
oo
--
l;liiii
11l=I&:o8I/Br
!t"oG/B1
I---
1 t1
~
(
FUELGAUGE(~~
SPEEDOMETER
HEADLIGHT RELAY
ID~~~,~~~~il
(HIGH)~;~I~~~~rn
I!ill.FJU/~~
BI
CLOCK 12 V 1.7 W
3P~
(M/~
b~
3P G' b/W_
G
~~
~~
~_
~m ~t
-'aJ
HEADLIGHT
~r.?
~~
Lb-
iL
1f
a.=::;l>-: :n rr=!-J
m
t-UI~
(MINI
",CLUTCH:t
cO ~iii~ lf1:"ll~l!l~JII
D a:: 0011 >OIODE
C' !!'
>iii"'';;00" o_iii -' '>' -' ,
rn
co
If
HER'
ssns
CD
'E
::::l
~ co
CJ
nI
ml
.:5
CJ
f i3
J2UvR~~'2'rL
12V45/45WX~2 G
~ , r<
Ii~ 119'~~~~1
~~~ ~~
RIGHT FRONT
U~I
W/BI
ENGINE STOPSTARTER
LIGHTING SWITCH
L..-
b... d'M~i,
~i~r
Lb
il
I
lIflflfiT ~
J! 'I" ~ ~
e HUl'~.lii
Br/W
rn
';;,~
[Ilill
I~~-'~:=
...
-~
BI/Y BIIW
BU/B-,H1~~~~~'!:R:~~~~m:n#FW~rt-ttittP
~I+f+-"""
W/~::
= G~
YIR
G/Y
Y/G
WIG
Lgo
V/B
Bu/R Br/B
Gr/BI LbG/BI I/Br
o G-
BI
GIR
GIW BI/B,
R BrlW
Br/R
"~ t1J ~ - ~
111
~~ I~j ~~! }; "'~~ I~~~~'~~~Ii
It
~M~
lJ.t:4t~t!P~~
:rt]
SIGNAL'DIMM~'
1
CLUTCH SWITCH
cD
TURN
HORN SWITCH
m o
a:l
r-. 10 k)
W
DIMMER SWITCH
PR
Pl
(NI
HI
A
B
C
D
E
F
G
H
10 A
10 A
20 A
10 A
10 A
10A
10 A
5A
ON
10ro
OFF
LOCK
FAN
IG
r
I
t~~~Wlo~:
"'~'"
BAn
BAT
BAT
OP, OP2
lO 1010101-0
~IN"~
0 ~~G'L
TURN SIGNAL
RELAY
PUSH
'").
k)
SWITCH
IGNITION SWITCH
HO BATJ
~ .c:I~G~N~'T~'O~N
_H ABCDE FG
FUSE BOX
<,
FREE
:.i
HORN SWITCH
LO
a:
~t
It t1
ACCESSORY
GI
(
Wirig Diagram
ENGINE STOP
SWITCH
IGNITION
CONTROL
MODULE
FAN MOTOR
SWITCH
BANK ANGLE
SENSOR
:'~/----"
,
BIlF'b~OR
LAMP
CHECK
UNIT
REAR
BRAKE
LIGHT
~
SWITCH
,
,PIMINI)
RMO
ISOR FUEL UNIT
'
a;~
~2P
"'81
C>&:
~~INI)m
ii5"'~
a:
Q5mCij
~~a
~liIMINI)
0<3
miD
82P
'ifIX'NI)
~~
",,,,
~~
iii iii
BANK
ANGLE
SENSOR
RELAY
?;J;ii5~
a:
Ol
VI
r~
IiBu
GIY~.12V 32/3CP x 2
~...t~t-~~
~>-~.5'
--,
>
4P
W
>-~
C>
0. ~
~'E~~'"
4P
MI
~~~
mm
CUT RELAY~~INI)
--' FUEL
~~
3P
~2P
I' .,
>-alOl
NEUTRAL
SWITCH
CD
IGNITION
PULSE
GENERATOR
OIL PRESSURESWITCH
~#13' Y/Bu
~BI/W
~~r,o;
IGNITION COILS
ALTERNATOR
.,
BLACK
YELLOW
Sr
BROWN
ORANGE
Bu BLUE
Lb LIGHT BLUE
Lg LIGHT GREEN
GREEN
REO
WHITE
Gr GRAY
PINK
0030Z-MAJ-A200
22-3
Wiring Diagram
LEFTTURN SIGNALINDIATOR
FUELINDICATOR
res OFFINDICATOR
9 res ACTIVATION
'10 res INDICATOR
'1'1 ABSINDICATOR 1
'12 ASSINDICATOR 2
B
SIDESTAND INDICATOR
RIGHTTURN SIGNALINDICATOR
FRONTBRAKELIGHTSWITCH
12'
STARTE,.,NGINE STOP
~ ~'GHTING
SWITCH
ASSles WAI
COOLANTTEMPERATURE GAUGE
FUELGAUGE
SPEEDOMETER'
lEFT FRONTT(Th;URN
SIGNAL
,,>J----"-
,"J~~~l
~~~~~~~~F
res SWITCH
\ j
r 2P~~~ II
3P
W
~~~
Cla Cl~
1J.
oru O
o~WG
12V32/3CP
O/W
3P
"~
Cl~c.:J
ASSCONTROL UNIT
IMlNllb
'U
TURN SIGNALRELAY
FRONT
rosrnox
A~H~.~~~~~:ci~~IL
IDA
NEUTRALOILT
15A
HEADLIGHT LOW
15A
HEADLIGHT
IDA
IDA
IDA
IDA
IGNITION5TARTERALTERNATOR
E
F
G
22-4
HIGH
TURN SIGNALFRONTREARBRAKE
CLOCK
FANMOTOR
~ ~
R SWITCH
H
I
ST BAT2 GND HL
ABS MAIN
lOA
'J
FRONTSOLENC'IO
lOA
20A
lOA
B2
REAR SOLENOID
PUMP
MOTOR
TCS/IGNITION
CONTROL MODULE
THERMOSTATCSWITCH
- -
l
/
WARNING LIGHTSWITCH
ENGINESTOP SENSOR
FAN MOTOR
FUEL UNIT
FRONTPUMP MOTORRELAY
REARPUMP
rm;~RELAY
r."..
ENGINESTOP
CHECKER
SOLENOID RELAY
II
FUEL INDICATOR
oa~
2P
ar
SENSCR RELAY
~~
iiic:ll.:/
iii-
ii5C'~
STARTERRELAYSWITCH
~iiiiii~
FUSE(MAIN)
ii5iii
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IGNITION
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ur e
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as >->->-
PEGUlATOR RECTIFIER
8~3P
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~ ~~ 1~",,",
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--L.r-------JD"BlfW
IGNITIONCOILS
...........
...........
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R ...........
W ..........
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GREEN
lb
19
RED
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"
. ....... BROWN
. ........ ORANGE
.......... LIGHT BLUE
LIGHT GREEN
PINK
0030Z-MY3-6900
ENGINESTOPSWI
LEFTTURN SIGNALINDIATOR
2
3
4
HIGHBEAMINDICATOR
SIDESTANDINDICATOR
RIGHTTURN"SIGNALINDICATOR
fUEL INDICATOR
....
NEUTRAL INDICATOR
.,2
.12V
3WX8
IG BI
OFF
RUN
ASSINDICATOR 1
ASSINDICATOR 2
1.7WX2
TACHOMETER
lCS
COOLANTTEMPERATURE GAUGE
FUELGAUGE
i
-
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12V32/3CP
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'il ~~
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3P ~~Cl
-~ClUTCHSWITCH
(MINI~
TURNSIGNALPASSINGDIMMER
HORNSWITCH
FUSEBOX
IGNITION SWITCH
I~
RDN
L
f--O
PASSINGSWITCH
PR
PL
0- :::0
0--0- FO
~
0
BAT4 HI
"U
TURN SIGNALRELAY L -
FRONT MODULATOR
TURN SIGNALSWITCH
ABSCONTI
IGNlTION SWITCH
<,
ON
OFF
LOCK
FAN
IG
BAll
0::::::0:: -0
lOA
fRONT POSITIONM EW
NEUTRALOILTACHQT
15A
15A
HEADLIGHT
lOA
lOA
IGNITION S1ARTERAL T
C
D
E
F
G
lOA
lOA
LOW
HEADLIGHT HIGH
nTCH
Wirig Diagram
STARTER SWITCH
<,
ST BAT1 GND
0- l-o
fREE
PUSH
H
I
HL
J
K
0- --0
RLIGHTTAIL
[MPHQRN
fERNATOR
EAR BRAKE
ASS MAIN
FRONT SOlENOID
.2
REAR SOLENOID
PUMP MOTOR
CONTROL MODULE
THERMOSTATC SWITCH
/~-s
FAN MOTOR
FUELUNIT
~
_
iil~
ENGINESTOP SENSOR
FUELINDICATOR
CHECKER
REARBRAKE
2P
~ B1
U
~~
9~
.-
LlGerrHT
SWITCH
1lI~~ "
SE;NSOR
RELAY
iiiii5
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>:
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ENGINE STOP
"'::"'
~~~
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ROL UNIT
lOA
20A
lOA
reS/IGNITION
iSWlTCH
lOA
;;;iiiiii~
FUSE(MAIN)
~l~
~5
~5
OIY----t+--tt---ftt---H--++---+l~-__1__l_.u.IUJ.UUJ I
BIIW
RIO
WIO
. .~1It: jlr~~~
./Bu
RIGHTREARTURN SIGNAL
BIIY VIR
19fBI
V/Gr
1r*=ti======"=~J1fiD~
BIISr
V/G
V/81
-8r/81
L,
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glEn.
af~r
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GIW
G d D R TURNSIGNAL
Lola
G/R
R
12V32CP
BllBu
ertR
BI/O
r/lll
GISr
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IGMITION
fEUTRAl SWITCJ
PULSE GENERATOR
mit o->
BI
~r
~ BI~
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m
o ....
CIt::!
oM
REAR MODULATOR
REGULATQRRECTIFIER
~~ l~m. ",.
IGNITION COILS
~~~ ~~
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BI ......... BLACK
Y
YELLOW
Br
....... BROWN
ORANGE
Bu ......... BLUE
lb
........ GRAY
........ GREEN
RED
Lg
P
WHITE
Gr
LIGHT BLUE
0030Z-MAJ -A 100
22-5
Wirig Diagram
11
12
13
~
~
'
1,
2
3
FUEL GAUGE
SPEEDOMETER
~BI~I
Wffl~~=:=;il
W~':
B'ffl~Ettt
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~':I
BU/B11=
HEADLIGHT
~'i.'lflfmll-.:..::=::~~~~-JjlllLIII
w~,
SIGNAL~
12V 32/3CP
3P Gr
m $O
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g
om
~;;
m' "..,.,.
(Q~
mlfllo",
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FRONTWHE
SPEED SENS'6-R
~
~
TURN SIGN
D1MMER.HO~L~PSASSING.
WITCH
~.
CLUTCH
SWITCH
MOTOR DRIVER
ACCESSORY
A lOA
B15A
C 1SA
D lOA
E lOA
F lOA
G lOA
H 5 A
POSITION, METER 1I
HEADLIGHT LOW
HEADLIGHT HIGH
IGNITION, STARTER
TURN SIGNAL
. ALTERNATOR
CLOCK
' BRAKE
FANMOTOR
ACCESSORY
FRONT MODULATOR
n:s-----=22-6
;tNE STOP
ITCH
LIGHTING SWITCH
<,
'"
TLGN[
HL
"
TCS/
IGNITION CONTROL MODULE
30A
ASS MAIN
30 A
tOA
IR
FRONT
MODULATOR
CONTROL
MOTOR RELAY
I MODULATOR
rROL
0!JLAY
~~~
FAN MOTOR
SWITCH
REAR BRAKE
LIGHT
"~x?~ "om"
,
I'
.:
I~
"'"'7I Q
!I::t~""
LAMP CHECK
BANK ANGLE
ASS
FUSE BOX
~ ~~~<~
iiiiD
~W'M''''
~~
~i~
MAIN FUSE 30 A
iDiD
~I"""
~t3
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II
r
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ill!lliliiiB.f
tJSWITCH
ffl
0;;:-
BI:
W'G
GW
"'"
"'G'
'''0
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~
G~
O~
ae
G
REAR WHEEL
SPEED SENSOR
~
REAR MODULATOR
IGNITION SWITCH
<,
,., 'G
BAT!
~~i ~~~
ON
0"
LOCK
ALTERNATOR
0030Z-MAJ-A300
SIGNAL
['92-'95]
23-1
[After '95]
23-10
[After '91]
23-23
23-1
Technical Features
The braking effectiveness and balance of the motorcycle can be significantly affected by the way the front and rear brakes
are applied. This ABS system is characterized by high deceleration and follow-up performance thanks to its quick response
to a variety of road surface conditions. It is also characterized by its compact size, which is achieved by collective
arrangement of the hydraulic control components in the modulator.
CD ASS
INDICATOR LIGHT 2
:J) ASS
INDICATOR LIGHT 1
LIGHT SWITCH
:~
REAR WHEEL
SENSOR
<.
<:>
ct FRONT WHEEL
\ __ -'.L~-..J
SENSOR
'::5) FRONT
MODULATOR
~)
FRONT PULSER
RING
23-2
Technical Features
System Construction
Modulator:
The modulator controls and supplies the brake fluid that is essential for the ABS operation. The motorcycle is equipped with
separate and independent front and rear modulators.
The modulators are sealed type containing the brake fluid and constituent parts, and are maintenance free. Additionally. they
have no reservoir pipe and are light-weight and compact. These features make the modulators well suited for motorcycles.
The modulator consists of the following parts;
Expander piston:
Operates in accordance with the change in the piston fluid pressure and adjusts the caliper fluid
pressure.
Back-up piston: Pushes the expander piston up when fault occurs.
Limit switch: Detects the pressure in the system by detecting the back-up piston position.
Pump motor: Drives the pump to generate puressre in the system.
Inlet valve/Outlet valve: Adjusts the puressure in the system.
(5) EXPANDER
(6) CALIPER
PISTON
(7} BACK-UP
PISTON
(8) LIMIT SWITCH
(4) MASTER
CYLINDER
(12) CUT-OFF
VALVE
WlI
1/
(9)
PUMP MOTOR
(3)
----OUTPUT
l.'::::=== (4)
POWER
---
,-----,
,
,
''
,,
:'
:,
'
,
:'
:,
'
,
'
;'
I
! ii
1
: _1
I,-----
,-----
! !
i !
i
i
___J
23-3
Technical Features
ASS control unit (ECU):
The ASS control unit consists of two systems that monitors each other:the main CPU and the sub CPU. The control unit
is designed to activate the solenoid valve and pump motor only when the calculation results of both systems agree with each
other.
ASS/TeS INDICATOR
LIGHT SWITCH
t t
SUB
CPU
.1
RR. PUMP
MOTOR RELAY
FR.PUMPI
MOTOR
RR. PUMP
MOTOR
The control unit detects the wheel speed as it receives the signal from each wheel sensor. When the unit senses that the
wheel are about to lock, it controls the caliper fluid pressure by activating the solenoid valve of each modulator.
The control unit also includes a change-over function to the regular system that monitors the system condition by receiving
signals from the limit switch, pump motor etc. It stops theABS function and switches back to the regular brake system when
the control unit detects an abnormality in the ASS.
Indicator lights
!r___.....~.J''~'~.~"~o!:=--~
~~
<r
{11 CUT-OFF
VALVE
{2) BACK-UP
PISTON
il Ii 'V
{3{L1MIT
SWITCH
./
r__~
,
,
Rear wheel
sensor
(4) PUMP
Front wheel
senSOr
MOTOR
23-4
Technical Features
Self-diagnosis function
When the engine starts, the ASS control unit evaluates the hydraulic circuit condition by activating the pump motors and
solenoid valves and receiving the signal from the limit switch, The ASS indicator light blinks when an abnormality is detected
in the circuit. When the circuit is normal, the ASS indicator light stays ON indicating that the control unit is in the stand-by
mode for the wheel sensor signal. The wheel sensors send signals to the ECU after the motorcycle starts to move (approximately 10km/h or above}. The ASS indicator light goes off when the ECU receives signals from the wheel sensor and the
wheel sensor system is found to be normal.
The ASS control unit monitors the main function while the motorcycle is moving, too.
When it detects a problem with the system, it blinks the ASS indicator light and stops the system immediately. When the
control unit detects a problem while the ASS is active, it stops the system and blinks the ASS indicator light, notifying the
rider of the problem and that the system is diactivated.
Change-over function to the regular system
When the ASS contol unit detects a problem in the system by the self-diagnosis function, the control unit activates the ASS
main relay and shuts off the ground circuits of the front and rear solenoid valves to stop the solenoid valve. The ASS stops
its function when the system is faulty and switches to the regular brake system.
Problem code storage function
The problems can be memorized and stored in the control unit (up to two codes), and can be retrieved and indicated by the
number of blinks of the ASS indicator light (page 16-A-6).
23-5
Technical Features
ABS main relay:
The secondary side contact points of the ASS main relay is the normal open type, where the electric current does not
normally flow. When the current flows to the primary side relay coil, the contact points close forming the ground circuit of
the solenoid valve.
1---(1} ASS
CONTROL
UNIT (ECU)
(2)
1)~~~?E:R~:::::t===-REARSOLENOID VALVE
=~(3)
FRONT SOLENOID VALVE
{3)ASS/TCS INDICATOR
LIGHT SWITCH
LIGHT 1
~~
I
TCa
1$1
\\\
23-6
Technical Features
ASS Operation
Regular brake system operation:
Brake fluid pressure is accumulated fully in the system. When the pressure drops, the pump motor operates to accumulate
pressure. The expander piston and back-up piston are supported by this brake fluid pessure. The cut-off valve is pushed by
the expander piston as it opens at this time and the master cylinder and caliper are interconnected with a passage. The fluid
pressure in the master cylinder is transmitted to the caliper by way of the cut-off valve; allowing the brake to operate.
As the outlet valve closes, the high pressure of the brake fluid is maintained in the chamber and the expander piston is not
affected by the operation of the regular brake system.
This condition is the same as when the ASS is in the stand-by mode.
14)
/ " LIMIT SWITCH
""'------j10
p
IB) RESERVOIR/
23-7
Technical Features
When ABS is working:
Pressure DECREASE
When the control unit detects that the wheels are about to lock, the control unit sends signals to activate the pump motor
and to open the outlet valve, while closing the inlet valve. The brake fluid in chamber B flows through the outlet valve into
the reservoir side and pushes the expander piston back. Then, the cut-off valve, supported by the expander piston, is closed
by the spring force shutting the passage between the master cylinder and caliper. Simultaneously, as the expander piston
moves backward, the volume of chamber A increases and, the caliper fluid pressure is reduced.
Pressure HOLD
When both the outlet valve and inlet alve are closed, the brake fluid pressure in chamber A is maintained.
The caliper fluid pressure can then be maintained at a given level.
Pressure INCREASE
When the pressure is increasing, the outlet valve closes and the inlet valve opens; this allows the brake fluid from the pump
to flow through the inlet valve to chamber B. The brake fluid then pushes the expander piston forward and fluid flows to the
caliper.
The ABS control unit controls the brake fluid pressure and prevents a wheel from locking by performing the sequential
operations of the above "Pressure Decrese", "Pressure Hold" and "Pressure Increase" in accordance with the wheel rotation.
When the control unit senses that the possibility of wheel lock has passed, it closes the outlet valve and opens the inlet valve
to move the expander piston to the forward-most position. This in turn opens the cut-off valve and the passage between the
master cylinder and caliper to restore regular brake operation (page 23-7).
Pressure DECREASE
(2} CHAMBER B
Pressure HOLD
Pressure INCREASE
(3) PUMP
MOTOR
(1) CHAMBER A
Caliper fluid
pressure
Inlet valve
Outlet valve
Electric signal
Pressure relief
passage
Electic signal
Pressure relief
passage
Decrease
ON
Closes
ON
Open
To maintain
braking force
Hold
ON
Closes
OFF
Closes
To apply
braking force
Increase
OFF
Opens
OFF
Closes
To release braking
force
23-8
Technical Features
When trouble occurs:
When the fluid pressure in the chambr (page 23-7) cannot be maintained for some reason, the back-up piston is pushed
forward by the mechanical back-up spring force, which in turn pushes the expander piston up and the cut-off valve opens
fully. Fluid pressure in the master cylinder can then be transmitted by way of the cut-off valve to the caliper. Regular brake
operation can then be maintained.
As the back-up piston spring is preloaded enough to with stand the maximum brake pressure from the master cylinder the
expander piston cannot move backward during regular brake operation.
~O
(5) BACK-UP SPRING
fn~_
(9) RESERVOIR /
23-9
Technical Features
MASTER CYLINDER
EXPANDER
CALIPER
PISTON'
- - rr=/irnY\i
\~'
I~
'~~J
1
BACK-UP
PISTON
MASTER
CYLINDER
CONTROL PISTON
LlJ~"
LIMIT SWITCH
-/
~~~~FF~ 'Ii'I:::WtclU~~
CRANK ANGLE
SENSOR
I 'UJ...):J
""':1""''''''
BACK-UP SPRING
WLrcli.l1i--'=i'i~i&or"-
~=='I PUMP
OUTLET VALVE
CONTROL MOTOR
INLET VALVE
CONVENTIONAL ABS
23-10
MOTOR
NEW ABS
Technical Features
CD ABS
indicator lights
Blinks or stays ON when a problem occurrs in the ABS.
(z; Pulser ring
Rotates together with the wheel and detects the wheel speed using the wheel speed sensor.
:j:: Wheel speed sensor
Inputs the pulse signal, generated proportionally to the rotating speed of the purser ring, in the ASS control unit (ECU).
:'1: ABS control unit (ECU)
Controls ABS by monitoring the input signals of each sensor.
:~) Motor driver
Receives control signal from the ASS control unit (ECU} and delivers high-amperage electrical power output to the
modulator's motor for quick changes in operation.
(E' Modulator
Adjusts the caliper fluid pressure.
(f) Modulator control motor relays (front and rear}
When the ASS control unit (ECU) detects abnormality, power to the motor driver is shut off by the control motor relays as
it receives the final from the ASS control unit (ECU).
@ ASSrrCS indicator light switch
A common switch for the ASS and TCS. When ASS indicator lights 1 and 2 blink, ASS indicator light 1 can be dimmed and
indicator light 2 can be turned OFF in order not to interfere with the rider's vision. The ASSfTCS indicator light switch is
also used to output the problem code.
23-11
Technical Features
System Construction
FRONT MODULATOR
Pedal input route
WHEEL SPEED SENSOR
OJ
REAR WHEEL
REAR MODULATOR
CONTROL MOTOR
3-STAGE CUT-OFF
VALVE
FILTER
Inlet
(from master cylinder)
Outlet
(to calipers)
.1r~tl\u;r,~LRiErD_U_C_T_'OIiN
~~111CONTROL
GEAR
CRANK ANGLE
SENSOR
CRANK ANGLE SENSOR
CRANKSHAFT
PISTON
~RANKSHAFT
\>~:;J_' ~/
,'"
CONTROL MOTOR
BACK-UP SPRING
23-12
BACK-UP SPRING
Technical Features
Wheel Speed Sensor/Pulser Ring:
The wheel speed sensor is the contactless sensor that detects front and rear wheel speed. Consisting of a permanent magnet
and Hall element, the sensor is connected to the ABS control unit. When the projection on the outer circumference of the
pulser ring that is rotating with the front/rear wheel passes across the wheel speed sensor, a pulsar signal is generated at the
sensor. The ABS control unit detects the wheel speed as it receives the pulse signal, because the frequency of the signal
increases proportionally to the wheel speed.
HALL ELEMENT
PERMANENT
MAGNET
' - - - - - - OUTPUT
l!::::===~ POWER
PULSER RING
SIGNAL
, !
l,
-
::
i i
.._---_.i
,:
i': i,
,
.----_.:
eue"H RING
c----
MAIN CPU
ASSfTCS INDICATOR
LIGHT SWITCH
1--.
.--.
,------J
..
SUB-CPU
----
'-----.
1
MOTOR DRIVER
The ABS control unit (ECU) detects the wheel speed as it receives the signal from each wheel speed sensor. When the unit
senses that the wheel are about to lock, it controls the caliper fluid pressure by activating the control motor of each modulator.
The control unit also includes a change-over function to the standard LBS operation that monitors the system condition by
receiving signals from the wheel speed sensor, crank angle sensor, etc. It stops the ASS function and switches back to the
standard LBS operation when the control unit detects an abnormality in the ABS.
23-13
Technical Features
Modulator motor control
The ABS control unit monitors both front and rear wheel speed sensors and the modulator crank angle sensors that provide
precise readings of each modulator's crankshaft positioning (i.e., control piston position). The ASS control unit directs its
control signals to the motor driver that delivers high-amperage electrical power output to the control motors and operate the
system.
Self-diagnosis function
When the ignition switch is ON, the ASS control unit evaluates the control motor relays. The indicator light blinks when an
abnormality is detected in the system. When the system is normal, the ASS indicator light stays ON indicating that the ASS
control unit is in the stand-by mode for the wheel speed sensor and modulator crank angle sensor signals. The wheel speed
sensors send signals to the ASS control unit after the motorcycle starts to move (approximately 10 km/h or above), then the
ASS control unit evaluates the system condition by activating the modulator control motors and receiving the signal from the
crank angle sensors. The ABS indicator light goes off when the system is found to be normal.
The ASS control unit monitors the main function while the motorcycle is moving, whether the brakes are engaged or not.
When it detects a problem with the system, it blinks the ABS indicator light and stops the system immediately. When the
control unit detects a problem while the ASS is active, it stops the system and blinks the ASS indicator light, notifying the rider
of the problem and that the system is deactivated.
Change-over function to the standard (LBS) system
When the ASS control unit detects a problem in the system by the self-diagnosis function, the control unit stops the ABS
function. The back-up spring pushes the control piston automatically to open the cut-off valve and restore standard LBS
operation {page 23-16}.
Problem code storage function
The problems can be memorized and stored in the ASS control unit {up to two codes), and can be retrieved and indicated by
the number of blinks of the ASS indicator light (page 16-B-6).
23-14
Technical Features
ABS/Tes Indicator Light Switch:
When a problem occurs with the ASS and ASS indicator lights 1 and 2 blink, ASS indicator light 1 can be dimmed and the
indicator light 2 can be turned OFF by pressing the ABS/TCS indicator light switch.
Dimming and turning off these indicator lights keeps them from interfering with the rider's vision.
Another function of the ABS/TCS indicator light switch is to retrieve the problem codes that are stored in the ASS control unit
according to the problem code storage function explained above. The problem codes are indicated by the number of times the
ASS indicator light blinks. When two problem codes are stored, the last problem code is output first.
ABSTCS INDICATOR
LIGHT SWiTCH
BS
ASS INDICATOR
LIGHT 1
l[~
ASS INDICATOR
LIGHT 2
\ ..
3-STAGE CUT-OFF
VALVE
ORIFICE VALVE
CUT-OFF VALVE
Open
(.o~- Open
CONTROL
PISTON
PISTON--l1t=":::ipill
Closed
23-15
Technical Features
ABS Operation
Pressure DECREASE
When the ABS control unit (ECU) detects any tendency towards wheel lock, it rapidly reduces hydraulic pressure to the brake
caliper by rotating the crankshaft to lower the control pistons, closing the 3-stage cut-off valves.
Pressure HOLD
Following a predetermined decompression interval, the crankshaft is rotated up slightly to move the control pistons into the
pressure HOLD position, which permits the slipping wheel to recover its rotational speed.
Pressure INCREASE
One the ABS control unit detects full wheel speed recovery, it rotates the crankshaft back into its highest position. This rapid
cycle of pressure DECREASE, HOLD, and INCREASE makes possible nearly instantaneous correction of changes in wheel
rotation while ensuring highly accurate control of hydraulic pressure to both independent sets of brake caliper pistons.
Pressure DECREASE
ASS OFF
Pressure INCREASE
CONTROL MOTOR
PISTON
From master
cylinder
To
caliper
CUT-OFF VALVE
BACK-UP SPRING
Caliper
Caliper
CRANKSHAFT
23-16
Technical Features
'Z
23-17
Technical Features
System Construction
--')
REAR CAUPER
DELAY VALVE
FRONT CALIPERS
3-Piston Caliper:
A set of three newly designed 3-piston calipers are controlled by two independent hydraulic systems.
The center piston of all three calipers are operated directly by the brake pedal.
The two outer pistons of the front calipers are controlled by the brake lever, and the two in the rear are controlled by the
servomechanism-actuated secondary master cylinder (page 23-17).
This arrangement delivers a broad, yet easily controlled range of braking force, depending on which either or both of the two
(lever and pedal) brake are engaged.
REAR:
FRONT:
CENTER PISTON
CENTER PISTON
OUTER PISTONS
23-18
OUTER PISTONS
Technical Features
Delay Valve:
The delay valve positioned between the pedal brake master cylinder and the center pistons of the front calipers, the delay
valve engages only the left front caliper at first, effectively reducing the initial front wheel braking force (Fig. A-B).
As pedal pressure gradually increases, the delay valve introduces pressure to the right front caliper, which increases to match
the pressure to the left front caliper at a predetermined level {Fig. C}. The resulting feel is of comfortably even deceleration that
begins at the rear, with little of the rapid forward dive that is usually brought on when the front brakes are suddenly applied.
PEDAL BRAKE
MASTER CYLINDER
L. FRONT
CALIPER
R. FRONT
CALIPER
REAR
CALIPER
DELAY VALVE
'T:,-::g~:
Outlet 1
.-
/,\
/
1'
,-""
Fig. A
B
C[:,-J:': Fig C
,j)- : Alternating Fig. Band C
:J:-':~): Fig
Outlet 2
___........-'.:t.
I
,-,
Inlet pressure
23-19
Technical Features
Link Mechanism/Secondary Master Cylinder:
The system's servomechanism uses the rotational torque exerted on the front caliper when they are engaged to actuate a
secondary master cylinder by way of its caliper mounting linkage.
This secondary master cylinder then applies a corresponding amount of pressure to the rear brake caliper.
.r---;.:.:...:....-----,
REAR
CALIPER
LEFT FRONT
CALIPER
LINK MECHANISM
PCV
Open
Closed
Closed
DECOMPRESSION PISTON
-(2" : Fig. A
'~2~-K: Fig. 8
,~>-:;t:
Inlet pressure
23-20
Fig. C
Technical Features
LBS Operation
When hand brake is applied:
On initial operation, the hand brake works like any conventional motorcycle front brake system. A squeeze on the brake lever
pressurizes the master cylinder which transmits its increased hydraulic pressure to the two outer pistons of the front calipers,
causing a corresponding braking force to be applied to the front wheel.
In response to the braking force applied by the front caliper onto the spinning brake rotor, the caliper is pulled in the direction
of wheel rotation, around its lower caliper pivot. This forward caliper motion also acts on the link arm which is connected to
the secondary master cylinder. This direct pressure on the secondary master cylinder is regulated by the PCV which then
transmits its hydraulic pressure to the outer pistons of the rear caliper.
Front Master Cylinder
___1-- _
Left Front Caliper
,
Right Front Caliper
(Mechanical Linkage)
,
Rear Caliper (Outer pistons)
BRAKE
LEVER
PCV
23-21
Technical Features
When foot brake is applied:
When the brake pedal is pressed, hydraulic pressure from the rear master cylinder is routed through two lines. One connects
directly to the rear caliper and acts on the center piston. The other line runs to the center pistons of the front calipers by way
of the delay valve that slows front brake engagement to minimize its associated dive. As during hand brake operation,
hydraulic pressure from the secondary master cylinder passes through the PCV, and acts on the outer pistons of the rear
caliper. Because hydraulic pressure from the rear master cylinder is also being applied by the rear cali per's center piston, the
braking force applied to the rear wheel is greater than that applied when using the brake lever only.
Delay valve
J
Left Front Caliper
(Mechani~al
Linkagel
J
Secondary Master Cylinder
o
DELAY
VALVE
BRAKE PEDAL
l-l------------1
pev
The system offers the same braking feel as conventional brake systems, but adds a more progressive range of brake control
and enhanced balance of braking capability. Because the two systems are independent of each other, both the brake pedal
and the lever can be used in any combination without resulting in excessive braking force or other unusual responses.
23-22
Technical Features
------
~;:.,TIV
..I ' Tee] L
IA Bel
CFF
_
The TCS adjusts and controls the engine power by adjusting the ignition timing. This helps match the rear wheel torque to
the road surface traction condition.
100%
,,
,,
,,
,,
,,
,,
,,
,,
,,
,
o
Retarded
Normal
(1) IGNITION TIMING
23-23
Technical Features
The TCS/ignition control module (lCM) judges the rear tire traction conditions as it receives the signal from the front and
rear wheel sensors.
When the
is activated the TCS/ICM turns on the
activation light and controls engine power through changes in
ignition timing. The TCS automatically turns ON by turning the ignition switch ON, and can be turned OFF manually as
the rider wishes by pushing the TCS ON/OFF switch.
Note that the TCS cannot be turned OFF when it is active or while the motorcycle is moving.
rcs
rcs
CD TCS
ACTIVATION
LIGHT
(n ABS/TCS
C?! TCS
OFF INDICATOR
I~'
TCS/IGNITION
CONTROL MODULE (fCM)
INDICATOR LIGHT
SWITCH
\ \\
SENSOR
@o FRONT PULSER
RING
:~-
REAR WHEEL
SENSOR
@ REAR PULSER
RING
CD TCS
activation light
Turns ON when the TCS is active.
(~) TCS OFF indicator
Turns ON when the TCS is turned OFF using the TCS switch or when the TCS is not activated because of a problem
with the TCS.
~; TCS indicator light
Blinks when a problem occurs in the TCS. The light stays ON when the pre-start self-diagnosis is not passed.
'Al Pulser ring
Rotates together with the wheel and detects the wheel speed using the wheel sensor.
I~ Wheel sensor
Sends the pulse signal, generated proportional to the rotating speed of the pufser ring, to the TCS/ICM.
@TCS ON/OFF Switch
The TCS can be turned ON and OFF by pushing the TCS ON/OFF switch. The TCS OFF indicator comes ON when the
TCS ON/OFF switch is OFF.
(1) ABS/TCS indicator light switch
The indicator light switch is the common switch between the ASS and TCS.
When the TCS indicator light blinks, it can be turned OFF so it does not interfere with the rider's vision. (The
OFF
indicator stays ON).
~ TCS/ignition control module (ICM)
While receiving signals from the front and rear wheel sensors, the TCS/ICM judges the running condition and it outputs
a signal for appropriate ignition timing.
rcs
23-24
Technical Features
System Construction
TCS/ignition control module (ICM):
The TCS/ICM detects front and rear wheel speed by receiving signals from the wheel sensors. When
exceeds a given ratio of front-to-rear wheel speed, the TCS/ICM judges that the rear driving wheel is
it activates the TCS.
The TCS/ICM body is the ECU that is integrated with the spark unit. As the ignition CPU and the
communicate with each other and the ignition CPU monitors the traction control CPU, the engine
even if the TCS becomes inoperative due to a problem in the system.
When the TCS in inoperative, the TCS indicator light and TCS OFF indicator turn ON.
The TCS/ICM constantly monitors the input signal inside the TCS/ICM, and shuts off the TCS when it detects a problem with the system.
Simultaneously, the TCS/ICM turns ON or makes the TCS indicator light blink notifying the rider of the problem with the
system, and turning the TCS OFF indicator ON to notify the rider of the inoperative state of the TCS.
TCS/IGNITION
CONTROL MODULE
(ICMI
IGNITION COIL
I
I
IGNITION
CPU
t -+
I
TRACTION
CONTROL
CPU
23-25
Technical Features
. Self-diagnosis function
The TCS/ICM starts self-diagnosis as the ignition switch is turned ON. It diagnoses the TCS/ICM itself and the wheel sensor power source. When it detects a problem, it stops TCS operation, makes the TCS indicator light blink and turns on the
TCS OFF indicator light to notify the rider of a fault in the TCS. When the TCS/ICM is found to be normal, it moves to the
stand-by mode for the wheel sensor signal and the TCS indicator light turns ON. (The TCS does not function when the
TCS indicator light is ON).
The wheel sensors send signals to the TCS/ICM after the motorcycle is in motion [approximately 1Okm/h(6 mile/h) or above] , and the TCS indictor light goes OFF after the wheel sensor signal is input and the wheel sensors are found to be as
normal.
If the TCS indicator light stays ON, there is an abnormality with the wheel sensors.
r.... ....-
~ ASS ECU
I S'"'p''' I! ..'..-...-..-.. ~
......
Rear wheel
sensor
Front wheel
sensor
23-26
Technical Features
ABS/TCS indicator light switch:
When a problem with the TCS occurrs, the TCS indicator light blinks and the TCS OFF indicator turns ON. The TCS indicator
light can be turned OFF by pressing the ABS/TCS indicator light switch. Turns off the indicator light prevents the light from
interfering with the rider's vision. The TCS OFF indicator does not go off but stays ON.
TCS ACTIVE)
Tcs
23-27
Technical Features
TCS Operation
When TCS is active:
After receiving the signal from the front and rear wheel sensors, the TCS/ICM judges whether traction control is required
by detecting the rear wheel speed and comparing it to the front wheel speed (i.e vehicle speed). The engine will operate
normally when the TCS is not active. When the rear wheel speed exceeds a given ratio of the front-to-rear wheel speed,
the TCS/ICM judges that the rear wheel is slipping excessively and controls the engine power by determining the suitable
ignition timing. The TCS performs the above operations instantaneously to help prevent the skid from becoming excessive
and to hold it within a specified range .
Sparkplug
Rear wheel
sensor
,
!
Front wheel
sensor
rcs
23-28
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols .
...
Is :;O=ooLI
IOP~OOLI
Use optional tool. Use the same procedure you use to order parts.
Torque specification.
10 (1.0, 7.2)
-:71
-,
..~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Example: Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited. U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Om
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
"I~
Apply sealant
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified.
1) .
24. Troubleshooting
Engine Does Not Start or is Hard
to Start
24-1
24-2
24-3
24-4
Poor Handling
24-4
Good Spark
Compression Normal
j
5. Remove and inspect spark plug - - Wet Plug ------------~.~.
24-1
Troubleshooting
Brake dragging
Worn or damaged wheel bearings
Wheel bearings need lubrication
Final gear bearing damaged
_0
Clutch slipping
Worn clutch discs/plates
Warped clutch discs/plates
Weak clutch spring
Sticking clutch hydraulic system
Check for engine oil additive
4. Accelerate lightly - - - - - - - Engine Speed Does Not Increase----- Starting enrichment valve opened
Clogged air cleaner
Restricted fuel flow
Increases
Clogged muffler
Clogged fuel tank breather
Faulty fuel pump
Faulty fuel pump relay
'loe Speed
------------0-.
Normal
0_.
j
24-2
Lubricated----~
Troubleshooting
Possible Cause
12. Check for engine overheating - - - Overheating - - - - - - - - - - _ . . .
Not Overheating
j
13. Accelerate or run at high speed --Engine K n o c k s - - - - - - - - -
Engine Does Not Knock
---~.-.
Good Spark
24-3
Troubleshooting
Correct
24-4
ST1100P Addendum
How to Use This Manual
Contents
Model Identification
Specification.........
Cable & Harness Routing
Emission Control Information Labels
Seat
Upper Seat Cowling
Seat Cowling
Saddlebag Stay/Amplifier Stay
Fairing Pocket
Instrument Panel
Rearview Mirror
Headlight Aim
Lights/Meters/Switches Location
Rear Turn Signal and BrakelTaillight
Voltmeter
Wiring Diagram
;
:
2
13
20
21
21
22
22
23
24
25
25
26
27
27
29
ST1100P Addendum
Modelldentification
ST1100P Addendum
Specifications
Unit: mm (in)
G enera
Specifications
Item
Dimensions
Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Dry weight (with saddle bag)
Curb weight (with saddle bag)
Maximum weight capacity
2,285 (90.0)
835 (32.9)
1,405 (55.3)
1,555 (61.2)
800 (31.5)
309 (12.1)
145 (5.7)
297 kg (655 Ib)
326 kg (719 Ib)
175 kg (386 Ib)
Frame
Frame type
Front suspension
Front wheel travel
Rear suspension
Rear wheel travel
Front tire size
Rear tire size
Tire brand (Bridgestone)
Tire brand (Dunlop)
Tire brand (Metzeler)
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Fuel tank reserve capacity
Double cradle
Telescopic fork
150 (5.9)
Swingarm
120 (4.7)
110/80-18M/C 58V
160/70-17M/C 73V
G547/G548
FR/RR
FR/RR
FR/RR
-~
-~
ST1100P Addendum
Unit: mm (in)
General cont'd
Item
Engine
Specifications
2 -
270 -
0V
Left
Front
Carburetor
Carburetor tvpe
Throttle bore
Drive train
Clutch system
Clutch operation system
Transmission
Primary reduction
Secondary reduction
Third reduction
Final reduction
Gear ratio 1st
Gear ratio 2nd
Gear ratio 3rd
Gear ratio 4th
Gear ratio 5th
Gear ratio 6th
Gear ratio reverse
Gearshift pattern
Multi-plate, wet
Hydraulic operating
5 speeds
1.829 (75/41 )
Electrical
Ignition system
Starting system
Charging system
Regulator/rectifier type
Lighting system
AC regulator type
2.833
2.266
1.500
1.142
0.916
0.758
(34/12)
(34/15)
(27/18)
(24/21)
(22/24)
(22/29)
ST1100P Addendum
Unit: mm (in)
-
Lubrication
Standard
Item
Service Limit
OIL VISCOSITIES
-1
I
I
1
-I
I
1
I
20
40
60
100'F
80
10
10
20
I
30
I
40'C
r-
Fuel System - - - - - - - - - - - - - - - - - - - , . - - - - - - - - - - - - - - - - . - - - - - - - - - ,
VDBEA
#125
#38
See page 5-12 (2-5/8 turns out)
See page 5-16
See page 5-12
7.0 (0.28)
Within 40 mmHg (1.6 inHg)
No.4 carburetor
1,200 100 rpm
2-6 (0.08-0.24)
360 mmHg (14.2 inHg)
ST1100P Addendum
Unit: mm (in)
~
Cylinder Head
Standard
Item
Cylinder compression
Cylinder compression difference
Valve clearance IN
EX
Cylinder head warpage
Cam lobe height CD IN
EX
Camshaft runout
Camshaft oil clearance A
B
Camshaft journal O. D. A
B
Camshaft holder I. D. A
B
Valve stem O.D. IN
EX
Valve guide I. D. IN
EX
Stem-to guide clearance IN
EX
Valve guide projection above cylinder head IN (h)
EX (h)
Service Limit
24.959-24.980 (0.9826-0.9835)
24.929-24.950 (0.9815-0.9823)
25.000-25.021 (0.9843-0.9851)
25.000-25.021 (0.9843-0.9851)
4.475-4.490 (0.1762-0.1768)
4.465-4.480 (0.1758-0.1764)
4.500-4.512 (0.1772-0.1776)
4.500-4.512 (0.1772-0.1776)
0.010-0.037 (0.0004-0.0015)
0.020-0.047 (0.0008-0.001 9)
15.3-15.5 (0.60-0.61)
15.3-15.5 (0.60-0.61)
24.950 (0.9823)
24.920 (0.9811)
1.0 (0.04)
1.0 (0.04)
41 .72 (1 .643)
41 .72 (1 .643)
1.5 (0.06)
1.5 (0.06)
39.6 (15.59)
39.6 (15.59)
25.978-25.993 (1.0228-1.0233)
26.010-26.026 (1.0240-1.0246)
25.968 (1.0224)
26.040 (1.0252)
4.465
4.455
4.562
4.562
(0.1758)
(0.1754)
(0.1796)
(0.1796)
ST1100P Addendum
Unit: mm (in)
po-
Cylinder/Piston
Item
Standard
73.00~73.015 (2.874~2.8746)
Cylinder I. D.
Cylinder out of round
Cylinder taper
Cylinder warpage
Piston mark direction
Piston O. D. (D)
Piston O.D. measurement point (H)
Piston pin hole I. D. (d)
Service Limit
73.10 (2.878)
0.10(0.004)
0.10(0.004)
0.10(0.004)
(2.8728-2.8736)
19 (0.75)
18.002-18.008 (0.7087-0.7090)
72.850 (2.8681)
18.020 (0.7094)
-df4I
Cylinder-to-piston clearance
Piston pin O. D.
Piston-to-piston pin clearance
Connecting rod-to-piston pin clearance
Top ring-to-ring groove clearance
Second ring-to-ring groove clearance
Top ring end gap
Second ring end gap
Oil ring (side rail) end gap
Top ring mark
Second ring mark
Crankshaft
Connecting rod small end I. D.
Connecting rod big end side clearance
radial clearance
Crankshaft runout
po-
0.010-0.045 (0.0004-0.0018)
17.994-18.000 (0.7084-0.7087)
0.002-0.014 (0.0001-0.0006)
0.016-0.040 (0.0006-0.0016)
0.025-0.060 (0.0010-0.0024)
0.015-0.050 (0.0006-0.0020)
0.15-0.30 (0.006-0.012)
0.30-0.45 (0.012-0.018)
0.20-0.70 (0.008-0.028)
17.98 (0.708)
0.10 (0.004)
0.10(0.004)
0.5 (0.02)
0.7 (0.03)
1.0 (0.04)
18.016-18.034 (0.7093-0.7100)
0.10-0.30 (0.004-0.012)
18.050 (0.7106)
0.40 (0.016)
0.05 (0.002)
0.030-0.052 (0.0012-0.0020)
See page 11-6
0.026-0.048 (0.0010-0.0019)
See page 11-6
0.080 (0.0031)
0.065 (0.0026)
ST1100P Addendum
Unit: mm (in)
r-
Transmission
Standard
Item
31.000-31.025 (1.2204-1.2215)
31 .000-31 .025 (1 .2204-1 .2215)
30.950-30.975 (1.2185-1.2195)
30.950-30.975 (1.2185-1.2195)
28.000-28.021 (1.1024-1.1032)
0.025-0.075 (0.0010-0.0030)
0.025-0.075 (0.0010-0.0030)
27.967-27.980 (1.1011-1.1016)
Service Limit
31.040
31.040
30.930
30.930
28.031
(1.2220)
(1.2220)
(1.2177)
(1 .2177)
(1.1036)
27.960 (1.1008)
M4
=f:
q
0.020-0.054 (0.0008-0.0021)
5.93-6.00 (0.233-0.236)
5.93-6.00 (0.233-0.236)
5.93-6.00 (0.233-0.236)
14.000-14.021 (0.5512-0.5520)
14.000-14.021 (0.5512-0.5520)
14.000-14.021 (0.5512-0.5520)
13.973-13.984 (0.5501-0.5506)
13.973-13.984 (0.5501-0.5506)
13.973-13.984 (0.5501-0.5506)
5.9 (0.23)
5.9 (0.23)
5.9 (0.23)
14.03 (0.552)
14.03 (0.552)
14.03 (0.552)
13.965 (0.5498)
13.965 (0.54,98)
13.965 (0.5498)
------------r--------------,..---------,
94.5 (3.72)
96.9 (3.81)
ST1100P Addendum
Unit: mm (in)
-
Clutch System
Standard
Item
Clutch lever free play
Recommended clutch fluid
Clutch master cylinder I. D.
Clutch master piston O. D.
Clutch outer I. D.
Clutch outer guide O. D.
I. D.
Primary damper shaft O. D. at clutch outer guide
Oil pump drive sprocket I. D.
Clutch center B I. D.
One way clutch inner O. D.
Clutch spring free height
Clutch spring free length
Clutch disc/plate thickness (Total of 10 discs and 9 plates)
Centrifugal clutch drum I. D.
bushing O. D.
Centrifugal clutch center guide I. D.
O.D.
Centrifugal clutch center guide collar height
Centrifugal clutch spring free length
Clutch lining thickness
Crankshaft O. D. at clutch center
-
Cooling System
Coolant capacity (Radiator and engine)
(Reserve tank)
Radiator cap relief pressure
Thermostat begins to open
Thermostat fully open
Thermostat valve lift
.- Drive Train
Recommended final drive oil
Final drive gear oil capacity at disassembly
at draining
Final drive gear backlash
Final drive gear backlash difference between measurements
Ring gear-to-stop pin clearance (A)
Stop pin shim
Ring gear spacer
Pinion spacer
Final drive gear assembly preload
Output gear backlash
Output gear I. D.
Output gear bushing O. D.
I. D.
Output drive shaft O. D.
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim
--
Service Limit
--
--
14.000-14.043 (0.5512-0.5529)
13.957-13.984 (0.5495-0.5506)
14.06 (0.553)
13.94 (0.549)
--
--
34.975-34.991 (1.3770-1.3776)
27.989-28.006 (1.1019-1.1026)
27 .974-27 .987 (1 . 101 3-1 . 101 8)
34.965 (1.3766)
28.016 (1.1030)
--
----
----
43.0 (1.70)
54.72-55.72 (2.154-2.194)
40.0 (1.57)
54.2 (2.13)
---------
---
--
--
--
----
---
0.05-0.15 (0.002-0.006)
0.30--0.60 (0.012-0.024)
See page 12 -1 0
See page 12 - 10
See page 12 - 11
2-4 kg-cm (1 .7-3.5 in-Ib)
0.3 (0.01)
ST1100P Addendum
Unit: mm (in)
Wheels/Tires
Item
Minimum tire tread depth (FR)
(RR)
Cold tire pressure (FR)
(RR)
Front and rear axle runout
Front and rear wheel rim runout (Radial)
(Axial)
Front wheel hub-to-rim distance
Front wheel hub standard surface
Rear wheel hub-to-rim distance
Rear wheel hub standard surface
Wheel balance weight (Front)
(Rear)
Drive chain slack
Drive chain size link (DID)
(RK)
Front Suspension
Front spring free length
Fork spring free length A
B
Fork spring direction
Fork tube runout
Recommended fork oil
Fork oil level
Fork oil level (R)
(L)
Fork oil capacity
Fork oil capacity (R)
(L)
Fork air pressure
Steering bearing preload
Standard
Service Limit
1.5 (0.06)
2.0 (0.08)
474.2 (18.67)
464.7 (18.30)
ST1100P Addendum
Unit: mm (in)
r--
Rear S uspensron
Item
Standard
Service Limit
253.7 (9.99)
258.9 (10.19)
--
--
-------
----
---
--
---
---
--
----
--
---
--
B ra k es
---
DOT 4
---
To the groove CD
WOO
4.8-5.2 (0.19-0.20)
-14.000-14.043 (0.5512-0.5529)
13.957-13.984 (0.5495-0.5506)
27.000-27.050 (1.0630-1.0650)
4.0 (0.16)
0.30 (0.012)
14.06 (0.554)
13.95 (0.549)
27.06 (1.065)
---
--
-26.918-26.968 (1.0598-1.0617)
26.91 (1.059)
---
----
DOT 4
----
---
--
----
-'
un,
r--,
r-"-
....J
10
7.3-7.7 (0.29-0.30)
-12.700-12.743
12.657-12.684
27.000-27.050
26.918-26.968
---
(0.5000-0.5017)
(0.4983-0.4994))
(1.0630-1.0650)
(1.0598-1.0617)
6.0 (0.24)
0.30 (0.012)
12.76 (0.502)
12.65 (0.498)
27.06 (1.065)
26.91 (1.059)
---
ST1100P Addendum
Unit: mm (in)
Standard
0.22-0.26 Q
2.6-3.2 Q
14.2-14.8 V at 5,000 rpm
12 V-12 AH
(Maintenance free battery: YTX14-BS)
----
Ignition System
Spark plug
(Standard NGK)
(Standard OENSO)
(For cold climate/below 5C/41F NGK)
(For cold climate/below 5C/41F OENSO)
(For extended high speed riding NGK)
(For extended high speed riding OENSO)
Spark plug gap
Ignition timing "F" m a rk
Advance starts
stops
Fully advance
Alternator exciter coil resistance (At 20C/68F)
Ignition coil resistance (Primary; at 20CI68F)
(Secondary with plug cap)
(Seconday without plug cap)
Ignition pulse generator resistance (At 20C/68F)
Service Limit
--
----
---
---
-------
13.7 (0.54)
14.4 (0.57)
4.7 (0.19)
12 (0.5)
1.4Ax5h
6Ax1h
13.1 V
Below 12.3 V
2 mA max.
r-
CR8EF 9
U24FER9
CR9EH 9
U27FER9
0.8-0.9 (0.031-0.035)
12 BTOC at 1,000 rpm
2,000 rpm
5,000 rpm
2]0 BTOC at 5,000 rpm
2.16-3.19 Q
22.5-27.5 kQ
13.5-16.5 kQ
405-495 Q
11
ST1100P Addendum
Lights/Meters/Switches - - - - - - - - - - - - - - r - - - - - - - - - - - - - - - - - , , - - - - - - - - ,
Service Limit
Standard
Item
Main fuse
Fuse
Headlight (high/low beam)
Tail/brake light
License light
Position light
Front turn signal/running light
Front turn signal light
Rear turn signal light
Instrument light
Oil pressure indicator
Tail/brake light indicator
Side stand indicator
Low fuel indicator
Coolant temperature indicator
Oil temperature indicator
High beam indicator
Turn signal indicator
Neutral indicator
Reverse indicator
Overdrive indicator
Oil temperature sensor resistance
Fuel unit resistance (At full level)
(At empty)
Fuel pump flow capacity (min./minute)
Thermo sensor resistance (50C/122F)
(80C/176F)
(120C/248F)
Fan motor switch Starts to close (ON)
Stops to open (OFF)
Starti ng System
Starter driven gear 0.0.
Starter clutch outer 1.0.
Starter motor brush length
30A
10AX6,20AX1
12V45/45W X 2
12V32/3CP X 2
--12V32/3CP X 2
-12V32CPX2
12V1.7WX4
12V3.4W
-12V3.4W
12V3.4W
--
-12V3.4W
12V3.4X2
12V3.4W
--
--10Q
90Q
-130-180Q
45-60Q
10-20Q
98-102C (208-216F)
93-9TC (199-20TF)
--
---
-----
----
--
------
--
--------------
'll!
r-
57.749-57.768 (2.2736-2.2743)
74.414-74.440 (2.9297-2.9307)
12.0-13.0 (0.47-0.51)
12
ST1100P Addendum
(3) CONNECTORS
for Optional Equipment
.~
13
ST1100P Addendum
14
ST1100P Addendum
15
~T1100P
Addendum
HT HAZARD
(4) HEADLlGCONNECTOR
SWITCH
ROUND
(17) ENGINE G
CABLE
(16) CARBURETOR
DRAIN TUBE
(14) ALTERNATOR
WIRE
ST1100P Addendum
(3) THROTTLE STOP SCREW CABLE
(5) RADIATOR
OVERFLOW TUBE
(6) THERMOSENSOR
(8) CONNECTORS
for Optional Equipment
(12) CONNECTORS
for Optional Equipment
17
ST1100P Addendum
(3) TO CARBURETOR
AIR CHAMBER
(7) EVAPORATIVE
EMISSION (EVAP)
CANISTER
(10) CLAMP:
(13)No.15TUBE
(14) PULSE SECONDARY
AIR INJECTION (PAIR)
CONTROL VALVE
(FRONT)
~1...L'2Z..:.-t1d~~~~rc~~~_-!_ (15)
18
ST1100P Addendum
No.5 TUBE
19
ST1100P Addendum
T--~U
(2) REAR FENDER
(3)
20
=c================
ST1100P Addendum
Seat
(1)
(4) BOSS
(2) BRACKET
21
ST1100P Addendum
Seat Cowling
Remove the left and right side covers and saddle bags
(page 2-2). Remove the upper seat cowling (page 21).
(1) BOLTS/
COLLARS
(2) SEAT
COWLING
(8) STAY/BOLTS
Remove the four 8 mm bolts, two nuts and the grab rail
center plate.
Remove the relays from the amplifier stay.
Remove the four 8 mm bolts, two washers and the
amplifier stay.
Remove the two 6 mm bolts and the saddlebag stay.
Torque:
Center plate 8 mm bolt: 35 Nm (3.5 kg-m, 25 ft-Ib)
Saddlebag stay 6 mm bolt: 10 Nm (1.0 kg-m, 7 ft-Ib)
8 mm bolt: 35 Nm (3.5 kg-m, 25 ft-Ib)
(7)
(6)
22
ST1100P Addendum
Fairing Pocket
Remove the maintenance cover (page 2-5).
Remove the top shelter (page 2-5),
RIGHT:
(2) SCREWS
(4)
Remove the trim clip, five screws and the fairing pocket.
Left Side only:
Disconnect the connectors.
23
ST1100P Addendum
Instrument Panel
Remove the windshield and garnish (page 2-6).
Remove the four screws and the inner screen.
NOTE
Remove the two screws, release the tabs and remove the
instrument panel from the upper fairing.
(?) INSTRUMENT
(1) SCREWS
PANEL
(3) CLOCK
CONNECTORS
(4) VOLTMETER
CONNECTOR
24
ST1100P Addendum
Rearview Mirror
(1) STAY
Remove the rearview mirror case by carefully releasing
the three bosses from the clips of the upper fairing.
Disconnect the front turn signal connector.
Remove the two bolts, front strobe lamp stay and the
rearview mirror.
(2) CLIPS
=/
(3) CONNECTOR
(4) MIRROR
Headlight Aim
Horizontal:
Insert a screwdriver into the hole in the middle fairing inner
cover, and turn the adjusting screw to adjust the headlight
beam.
Vertical:
Remove the right maintenance cover (page 2-5).
Remove the harness band securing the adjusting knob
(Adjusting knob is located under the right fairing pocket:
page 15).
pull out the adjusting knob, and turn the knob to adjust
the headlight beam.
Ir'l"''''
25
ST1100P Addendum
Light/Meters/Switches Location
(5) BANK ANGLE SENSOR
(18) THRMOSENSOR
(19) TURN SIGNAL
HAZARD SWITCH
(14) BATTERY
(16) SIDE STAND SWITCH
(17) NEUTRAL
SWITCH
26
ST1100P Addendum
(1) BULB
SOCKET
(2) BULB
Voltmeter
Bulb Replacement
Release the instrument panel off the upper fairing (page
24).
Remove the bulb socket and bulb.
Install a new bulb and install the removed parts in the
reverse order of removal.
Remova IIInstallation
(1) VOLTMETER
(2) SCREWS
27
ST1100P Addendum
MEMO
28
ST1100P Addendum
Wiring Diagram
METER LIGHT
12V 1 7Wx4
eerB
INDICATOR
~a
~m !fl~i~R:,_
TACHOMETER
1 LEFT!"" SlGNAt
~<D .,~ ~~ ~~ ~:
SW ITCH 1 2 3
l2V 3. 4Wx7
FRONT BRAKE
liGHT SW I TCH
0:5
SWITCH 4
f
to fO ro to
ro ro lo
10 0
10
1 0 -0
3
""g
ON
0~
OFF
COlOR
SWITCH 5
-,
BAT OUT
lo
ON ( )
OFF
BIBu
SWITCH 78
I
COLOR PBI RY
Slo- -6 0
FUSE BOX
-0
COLOR
COOLANT
TEMPRETURE
GUAGE
Lg W
Bu
GO OBI
G
REAR BRAKE liGHT
SWI TCH
FAN
MOTOR
FUEL GAUGE
~
1r~ENSOR
_ _E
FUEL
lEVEL
SENSOR
SPEEDOMETER
4f~
CLOCK
~BR~~~
~BI/Br===
Re><D<D
HEADLIGHT
HAZARD
~RElAY ~~C~~D
<D~;;'3PMINI3PQ
~~
BI
12V 1. 7W
__ I I
ca
cc
BANK ANGLE
SENSOR
RELAY
:~:P;
~
~;;, GlfTll ~
3P
R
I
ALTERNATOR FUSE
55A
Lg
Br
Br
~BtR
l.!iB:F
BI~R
BI
STARTER RELAY
SWITCH
W/BI
o
Y
BU
G
BI/R
BulBI
cta:
:ITE
Lb
MINI3P
Gr
VOLTMETER
,G/BI
W
B1
,....
,"+-_ _L--_
Lb/W -
G ----<~~
Lb-
12V 1. 7W
--I
I~
=.J
I--'
IBI _ _-+-I'+-_
_::t-
MINI4P
j~1 --t-t+++----.J
-
Y/W
Bu
B1
@d:
Bu
I/Bu .....
L.....-
HEADLIGHT
12V 45/45Wx2
r
Br
R
G/R
G/WB1/BG/BI
Br/R
Bu/R
--=-
I~"X==-
r-I---J
IIII
-=
L- Lb
GhY
~ Lb
Ii
---J
G/Y-
~Br
~INI
fiP
0-
"":i
~~
ABCOE
HO
BAT3
IGNITION SW ITCH
FREE
PUSH
~
ON I
10+0
FAN
TURN SIGNAl
HAZARD SW ITCH
SWITCH 6
_____
~~S
FG
IG BAT!
KEY
ok>R5 KEY
ON
KEY OFF
OFF
t--t--+-I---l-----1
KEY OFF
LOCK
LOCK PIN
IGNITION coSWITCH
FUSE BOX
SWITCH CONTINUITY
HORN SWI TCH
CLUTCH SW ITCH
-G~
.~~~<D;,',~~;;;~~m !~:mu
l2V 21/5Wx2
___
MINI~~
0<3:5
H-U~====:1
SIREN
RELAY
~~~
f- G C a ; D
BGr=~=Br
D,
E,
F,
G,
lOA
lOA
lOA
lOA
ALTERNATOR
BI
Y
Bu
G
R
W
V
BLACK
YELLOW
BLUE
GREEN
RED
WHITE
VIOLET
Br BROWN
0
ORANGE
Lb LIGHT BLUE
Lg LIGHT GREEN
P PINK
Gr DRAY
0030l-MAJ-8300
29