2014 Honda Rancher 420 Service Manual Repair 2014 Trx420

HOW TO USE THIS MANUAL
A Few Words About Safety

Service Information
The service and repa,r infoonaboo contained in this manual is intended for use by qualified. professional technicians. Attempting
service or repairs without the proper training, tools. and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe oondilion.
This manual describes the pt'oper methods and procedures for periormlng service, maintenance and repairs Some procedures
reqUire the use of specially designed tools and dedicated equipment. Ally person who intends to use a replacement part, servICe
procedure or a tool that is not recommended by Honda, must determine the risks 10 their personal safety and the safe operation of
the vehicle
If you need to reptace a part. use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
thai you do not use replacement parts of mferior quality
For Your Customer's Safety
Proper service and maintenance are essen!Jallo the customer's safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation. damage to the vehicle, or injury 10 others.
AWARNING
Improper service or repairs can create an unsafe
condrtion that can cause your customer to be
senously hun or killed.
Follow the procedures and precautlons In this
manual and other service materials carefully
For Your Safety

Because this manual is intended for the professional service technician, we do nol provide warnings about many basic shop safety
practices (e.g., Hoi parts-wear gloves). If you have not received Shop safety training or do nol feel confident about your knowledge
of safe servicing practice, we recommend that you do not attempt to perform the procedures described In this manual.
Some of the most important general service safety precautions are given below However, we cannot wam you of every
conCEt1vable hazard that can arise in perfom1lng service or repair procedures. Only you can decide whether or not you should
perform a gIVen task.
AWARNING
Failure to property follow InstructIOns and
precauhons can cause you 10 be senously hurt or
killed.
Follow the procedures and precautions in this

manual carefully.
Important Safety Precautions

Make sure you have a dear understanding of all baSIC shop safety practices and that you are wearing appropriate clothing and
uSing safety equipment. When performing any service task. be especially careful of the following:
Read all of the InstructIOnS before you begin and make sure you have the tools, the replacement or repair parts, aod the skins
reqUIted to pertorm the tasks safely and completely.
Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill , gnod, pry or work around
pressurized air or liquids, and springs or other slored-energy components. If there IS any doubt. put on eye protection.
Use other protective wear when necessary, for example gloves or safety shoes Handling hot or sharp pans can cause severe
bums or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves
Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle. either with a hOist or a Jack.
make sure that II is always securely supported Use jack stands.
~1ake sure the engine is off before you begin any servicmg procedures, unless the instruction tells you to do otherwISe. This will
help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust Be sure there IS adequate ventilation whenever you run the engine.
Bums from hot parts or coolant. lei the engine and exhaust system cool before wortting 10 those areas
InjUry from moving parts If the instruction tells you to run the engine. be sure your hands. fingers and dothlng are out of the way
Gasoline vapors and hydrogen gases from battenes are explosive. To reduce the poSSibility of a fire or explosion, be careful when
worklOg around gasoflne or batteries.
Use only a nonflammable solvent. not gasoline, to clean parts
Never dram or store gasoline in an open container.
Keep all cigarettes, sparks and flames away from the battery and all fuel·related parts.
How To Use This Manual
This manual describes Ihe service procedures for the TRX420TM1ITE1 /FM1 /FM2IFEl fFAl fFA2.
Sections 1 and 3 apply to the whole vehicle. Section 2 Illustrates procedures for removal/Installation of components that may be
required to perform service described in the follow ing sections.
Section 41hrough 25 describe parts of the vehicle, grouped according to location.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition .
Perlorming the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period .
Find the section you want on this page, then turn to the table of contents on Ihe first page of the section .
Most sections start with an assembly or system Illustration , service information and troubleshooting for the section. The subsequent
pages give detailed procedure.
Refer to the troubleshooting in each section according to the malfunction or symptom . In case of an engine trouble, refer to PGM-FI
section troubleshooting first.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course , it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good Judgement.
You will find important safety information In a variety of forms including:
Safety Labels - on the vehicle
• Safety Messages- preceded by a safety alert symbol ! and one of three signal words, DANGER, WARNING, or CAUTION .
These signal words mean:
tNl@~m9;1 You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.
M14i ;!W Ut, You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions
t1MiW'V' You CAN be HURT if you don't follow instructions.
• Instructions - how to service this vehicle correctly and safely.
As you read this manual. you will find information that is preceded by a IHOT!Cf' symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part{s) with new one(s) before assembly.
Use the recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example:
• Molykole@ BR-2 plus manufactured
• Multi-purpose M-2 m,,,',,,,,,
Use molybdenum disulfide paste
equivalent).
Example:
Molykole® G-n Paste manufactured by Dow Corning U SA
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Racel Limited, U.K.
f-________I-_~R~O~CO~I~P~'~s~te~m='~
nufactured by Sumico Lubricant, Japan - - - - - - - - - - - - - - - - 1
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified .
Use fork or suspension fluid.

CONTENTS
GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
PGM-FI SYSTEM
-J IGNITION SYSTEM
5 F=~~~==~~=======================
ELECTRIC STARTER
~ F=~~~==~===========================
(,) FUEL SYSTEM
~ F=~~~~~=============================
UJ COOLING SYSTEM
c F=~~~~~~~====================
Z LUBRICATION SYSTEM
< F====================================
Z CYLINDER HEADNALVE
~
~
F========================================
CYLINDER/PISTON
~ F=======~====~======~=================
> CLUTCH /GEARSHIFT LINKAGE (Except FA1/FA2 models)
0::
C DUAL CLUTCH TRANSMISSION (FA1 /FA2 models)
~ F=====~~~~~====~~==========~=====
ALTERNATOR/STARTER CLUTCH
~ F=~==~~~==~~~~~==~~~==~===
UJ CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
ENGINE REMOVAUINSTALLATION
FRONT WHEEUSUSPENSION/STEERING
!!1 REAR WHEE USUS PENSION
III
~ BRAKE SYSTEM
:I:
(,) FRONT DRIVING MECHANISM (Except TM1ITE1 models)
REAR DRIVING MECHANISM
.J BATTERY/CHARGING SYSTEM
~_ F===========================================
~ LIGHTS/METERS/SWITCHES
~ F=============================~============
() ELECTRIC SHIFT PROGRAM (ESP : TE1 /FE1 models)
~ F=~==================~==========~==~====
ELECTRIC POWER STEERING (EPS: FM2/FA2 models)
WIRING DIAGRAMS
INDEX
MEMO
1. GENERAL INFORMATION
SERVICE RULES ····· ·····································1-2 LUBRICATION & SEAL POINTS ··············· 1-20
MODEL IDENTIFICATION ························ ···· 1-3 CABLE & HARNESS ROUTING ················· 1-23
SPECIFICATIONS ·········································1-5 EMISSION CONTROL SYSTEMS ·············· 1-35
TORQUE VALUES ······································ 1-13
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don', meet Honda's design
specifications may cause damage to the vehicle.
2. Use the speciallools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners.
4. Install new gaskets, O-rings. cotter pins, and lock plates when reassembling.
5. When lightening bolts or nuts, begin with the larger diameter or inner boll first. Then tighten to the specified torque diagonally in
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
B. Route all electrical wires as shown in the Cable & Harness routing (page 1-23).
9. Do not bend or twist control cables. Damaged control cables will not operates smoothly and may stick or bind .
10.00 not tow your ATV behind a car or other vehicle.
ABBREVIATION
Throughout this manual, the following abbreviation are used to identify the respective parts or systems.
IACV
MAP sensor·- - - - - -
MeS
MIL
TP sensor
1-2
GENERAL INFORMATION
MODEL IDENTIFICATION
This manual covers 7 types of TRX420 models:
Model name TM1 TE1 F~ '--- FM2 FE1 FA1 FA2

Manual transmission 0 0 0 0 0
Dual clutch transmission - 0 0
2WD 0 0
,WD 0 0 0 0 0
left fool operated gearshift 0 0 0 -
ESP 0 0
EPS 0 0
Be sure to refer to the procedure Ihat pertains to the appropriate version of the TRX420.
FA2 model shown :
SERIAL NUMBERS/LABELS
The Vehicle Identification Number (VIN) {I J is stamped on the The engine serial number [1] is stamped on the left side of the
front side of the frame under the front fender. rear crankcase.
""'_ _- 111
o
111 I \ '---" --'
1-3
GENERAL INFORMATION
The throttle body identification number is stamped on the The safety certification label [1] is attached on the left front
lower side of the throttle body. frame down pipe.
11)
The color label (1] is attached on the left front frame down The vehicle emission control information label is attached on
pipe. When ordering color-coded parts, always specify the the left front frame pipe.
designated color code. - U.S.A. and Canada types (1]
- Canada type only [2)
11 ) (2)
1-4
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
~
ITEM SPECIFICATIONS
DIMENSIONS Overalllen,~gl"h_ __ __ 2,103 mm (!I2.8 in)
Overall wid th 1.205mm (47.4 in)
overa~"~he~;tgh~'====----':=-----l~
--
1,174 mm (46.2 in)
Wheelbase 1,268 mm (49.9 in)
Front tread 860 mm (33.9 in)
Rear tread 890 mm (35 .0 in)
Seat height 856 mm (33 .7 in)
Footpeg heig,~h~'~::;;:;;::;==:.,
_ ~ mrn (13 .5 in)
Ground clearance 183 mm (7.2 in)
Curb weight U.S.A. TMl 260 kg (573 Ibs)
TEl 261 kgJ575lbs)
FMl 276 kg (608 Ibs)
FM' 282 kg (622 Ibs)
FEl
- 277 kg (611 Ibs)
FAl 284 kg (626 Ibs)
FA' 290 kg (639 Ibs)
FMl 277 kg (611 Ibs)
FM' 283 k!;! (624 Ibs)
FEl 278 kg (6 13Ibs)
FA' 291 kg (641 Ibs)
220 kg (485 Ibs)
FRAME Double cradle
Double wishbone
170 mm (6.7 in)
Double tube
Swingarm (trailing type)
170 mm (6.7 in)
Rear damper Double tube
Front tire size AT24 x 8-12 . . -
Rear tire size AT24 x 10-11 _ ..
~
Front rim size 12x6.0AT
Rear rim size 1lx7.SAT
Front tire brand M977 (Maxxis )
Rear tire brand M978 (Maxxis)
-
-
Front brake Hydraulic disc brake
Rear brake
Caster angle ,.
Mechanical drum brake
Trail length 5 mm (3116 in_

l _
Camber angle O·
Fuel lank capadty US gal. 3.23 Imp gal)
Fuel lank reserve capacity gal, 1.08 Imp gal)
1-5
GENERAL INFORMATION
ITEM SPECIFICATIONS
ENGINE Cylinder arrangement Single cylinder, longitudinally installed
Bore and stroke t-- 86.5 x 71 .5 mm (3.41 x 2.81 in)
Displacement 420 cm 3 (25.6 cu-jn ~
h Compression ratio 9.9 : 1
Valve train OHV
<
- I- go BlOC al 1 mm lift
Except FAl l Intake ~~ens
FA2 valve closes 44° ABDC at 1 mm lift
Exhaust opens 36° BBoC at 1 mm lift
valve I- ~Ioses 7° AToe al1 mm lift
FAlIFA2 Intake opens 9° BTDC at 1 mm lift
valve closes 46° ABDC at 1 mm lift
Exhaust opens 46° BBOC at 1 mm lift
valve closes 4· ATOe at 1 mm lift
~~bricalion system Forced pressure and wet sump
~S>il pump type Trochoid
Cooling system liquid cooled
-
Air filtration Oiled double urethane foam
Engine dry weight TMl 49.3 kg (108.7 Ibs)
-
TEl 50.3 kg t! 10.9 Ibs)
FM 1/FM2 49.7 kg (109.Slbs)
FEl 50.7 kgJ 111.8Ibs)
FA1fFA2 56.2 kg (123.9Ibs)
FUEL DELIVERY Type PGM-FI
SYSTEM Throttle bore ~34 mm (1.3 in)
DRIVE TRAIN
(Except FA1 /FA2)
Clutch system
Clutch operation system
- +- Centrifugal and multi-plate wet clutches
Automatic
Transmission Constant mesh , 5-speeds with reverse
Primary reduction 2.103 (61 /29)
Secondary reduction 1.818 (40/22 )
Final reduction TM1fTE1 Rear 3.153 (41 /13 )
Except , Front 3.230 (42113)
Gear ratio
TM1fTE1 Rear
", - t- ~.153 (41 /13)
3.857 (54/14 ) ~
"-Tnd 2.235( 38/ 17)
3,d 1.571 (33121 )
41h 1.178 (33/28)
- 51h 0.848 (28/33 )

I-=====~----i- Reverse,---+-;4;C."8,3~,,'(,,46,;,1-,14;o'~2;f'
51,,1..
7)'--.~_ _
Gearshift pattern TM1 1 R N 1 2 3 4 5
FM1 /FM2 Left fool operated return system
TE1 /FE1 R - N - 1 - 2 - 3-4-5
Electric shift (left hand operated) return system
DRIVE TRAIN' --t~C~IU~l~C~h~'~Y'~I~em~=======_ __ Centrifugal and 2 multi-plate wet clutches
(FA 1fFA2) Clutch operation system Automatic
Transmission Automatic, 5-speeds with reverse
Primary reduction 2.680 (67125)
Secondary reduction 1.480 (37/25 )
Final reduction Front 3.230 (42/ 13)
Rear 3.153 (41 / 13)
Gear ratio 1st 3.058 (52/ 17)
2nd 2.157 (41 / 19)
3rd 1.541 ( 37:;.12~4;!)_ _ _ _ _ __
4th 1.178 33/28 )
5th 0.848 (28/33
_~---"R",e""ve,"",,"e"-+,3::,c.,,99,,;6~(,"4~51,,1,;6~x 27/19) -=:==== = = = = =
Gearshift pattern R - N-1-2 - 3 - 4 - 5
Automatic and Electric shift (left hand operated)
_ _ _ _ _L~'e~lu~'~n"system _ _ __ _ _ _ _ _ _ _ _ __
1·6
GENERAL INFORMATION
ITEM SPECIFICATIONS
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter molor
Charging system Triple phase output alternator
Regulator/rectifier FET shorted , triple phase full-wave rectification
Lighting system Battery
PGM-FI SPECIFICATIONS
ITEM SPECIFICATIONS
tAT sensor resistance (20·C/6"'B"
-F"l- - - - -- - - +
EeT sensor resistance (40~·£C~i1~04~·~F~l=====-
Fuel injector resistance (20·Cf68°F)
+ 2.2 -2~c.7~k~O~=======
1,0- \ ; kO
11.1 - 12.30
0 2 sensor heater resistance (20· C"'I"6Bo.·"'F"l - - - + 6.7 - 9.5 0
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Spark plug BKR5E·l1 (NGK), KI6PR-Ul1 (DENSO)
Spark plug gap 1.0 1.1 mm (0.039 0.043 in)
Ignition coil primary pe:fJa~ k ""
vo01It§a~ge
~=----- 100 V minimum
CKP sensor peak voltage 0.7 V minimum
~gnlbon liming ("F~':m"a;c,'i!kli'-------- 10· BToC at idle
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Throttle body identification number GaBKA
Idle speed
Throttle lever freeptay
1,400 100 ~",~m:::;-====_
:t
3 - 8 mm ( 1/8 - 5/16 in )
Fuel pressure al idle 331 - 367 kPa (3.4 - 3 .7 kgf/cm 2, 48 - 53 psi)
Fuel pump flow (at 12 V)' -_ _ _ _ _ __ 356 cm J (12 .0 US oz, 12.5 Imp oz) minimum/ tO seconds
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Coolant capacity Replacement 1.5 liters {1 .6 US qt, 1.3 C
lm;;:pC:qOOll- -- -
1.6 liters (1 .7 US qt, 1.4 Imp qt)
~
After disassembly
Radiator cap relie'!f:Ep~'e'$!~'"~'~e:;;;~~~~=::. 108 - 137kPa(I.I-I.4kgflcm 2, 16 20 psi)
Thermostat I Begin to open 80 - 84 ' C (176 183 F) Q
95 C (203"F)
Q
Fully open
Varve lift 8 mm (0.3 in ) minimum at 95 C (203°F)
Q
Recommended antifr;;;e;;;e;;,eC:-~==-- Pro Honda HP Coolant or an equivalent high quality ethylene

, glycol antifreeze containing silicate-free corrosion inhibitors
Standard coolant concentration ~ 1 : 1 mixture with distilled water
1-7
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit· mm (in)
[" ITEM STANDARD SERVICE LIMIT
I Engine oil Except After draining - 2.6 liters (2.7 US qt, 2.3 Imp qll -
capacity FA1/FA2 After draining/filter cha oge 2.7mers {rg US qt, 2.4 Imp qll
After disassembly 3.3Iiler5(3.5 Os qt, 2.9 Imp qll
FA1/FA2 After draining 3.4 liters {3.6 US qt, 3.0 Imp qll
After drainingffiller cha oge 3.6 liters {3.B US qt, 3.2 Imp qll
After disassembly 4.0 liters (4.2 US qt, 3.5 Imp qll
- Pro Honda GN4 4-stroke oil (U.S.A. and
Canada) or equivalent motor oil
API service ctassification: SG or higher
(except oils labeled as energy
conserving on the circular API service
-
label)
JASO T 903 standard: MA
Viscosity: SAE lOW-3D
Oil ressure al 5,000 rpm (80°C/176°F) 510 kPa (5.2 kgffcm , 74 pSi)
Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)
CYLINDER HEADNALVE SPECIFICATIONS

Unit: mm
valve,val'"T~iiiiOll:----a£~~~~~~--=fi~~
guide
Valve spring
Rocker arm
Shaft
Camshaft Camlob~e'~---'~~~'
and cam height
follower .377)
(1.382)
I Cam follower
Follower bore I.D.
hC"Y";~od;;;e"."h"ea:O;dOCw"a:o;.'::p:age
CYLINDER/PISTON SPECIFICATIONS
STANOARD
I
Piston , - 86.490
piston ring
, "
I
"
1-8
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (Except FA1/FA2 models)
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Centrifugal Drum 1.0. 140.0 140.2 (5.512 5.520) 140.4 (5.53)
clu tch Weigh t lining thickness 2.0 (0.08) 1.3 (0.05)
Clutch spring height 3.8 (O.lS) _ _ _-;3"'.6"'8 (0 .145)
Clutch weigh t spring free length 24.65JO .97Ol_ _ 25.6 (1.01 )
Change clutch Spring free length TM1 /FM1 /FM2 47.3 (1.86) 45.8 ("1.80)
, TEI /FE1 ___ ~",~,==,---,==-
48.7 (1 .92) ____ --;;47.2 (1.86)
Disc thickness 2.62 2.78 (0.103 0 .109) 2.3 (0.09)
Plate warpage 0.20 (0.008)
Outer 1.0. 29 .000 29.021 (1 .1417 t .1426 )
,
Outer guide 1.0 . 22.000 22 .021 (0.8661 0.8670 )
0.0. 28.959 28.980 (1 .1401 1.1409 )
Mainshaft 0.0. al clutch outer guide 21 .967 21.980 (O .8648 0.8654)
Primary drive Gear 1.0. 29 .000 29 .021 (1.1417 1.1426 )
gear Crankshaft 0 .0. at drive gear 28 .959 28.980 (1 .1401 1.1409)
DUAL CLUTCH TRANSMISSION (FA1/FA2 models)

Unit mm (In)
ITEM STANDARD SERVICE LIMIT ]
----centrifugal Drum t.D. 140.0 - 140.2 (5.512 - 5.520 L) ----:===~
'4t.0~
.4 (5.53)
clutch Weight lining thickness 2.0 (0.08) 1.3 (0.05)
Clutch spring height 3.8 (0.15) 3.68 (0 .145)
I Clutch weight spring free Iength 24.65 (0.970) 25.6 (1.01)
Oil pressure at 5,000 rpm (80°C/176°F ) ;'=-:'line 510 kPa (5 .:n gf/cm2, 74 psi)
Shift clutch 510 kPa (5.2 kgf/cm2, 74 psi)
Shift clutch Initial clearance
'"
2,d
0.70 - 0.90 (0.028 0.035)
0.65 - 0.95 (0.026 0.037)
- Disc thickness 1.88 - 2.00 (0.074 0.079) worn out linin_g
Plate thickness 1.55 1.65 (0.061 0.065) discoloration
Primary drive Gear 1.0. 29 ,000 29.021 (1.1417 1.1426)
gear Crankshaft 0.0. at drive 9 28 .959 28.980 (1.1401 1. 1409)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit: mm (in!
Starter driven gear boss 0.0 . 51 .705 51 .718 (2.0356 2.0361)
1.0. 31 .946 31 .962 (1.2577 1.2583)
Crankshaft 0.0, al slarter driven gear 31 .884 - 31.900 (1 .2553 1.2559)
1·9
GENERAL INFORMATION
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER SPECIFICATIONS
Except FA1 1FA2 models
~
u:;~~
selector 2 ~ 4 (3132 ~ 5132
; J.D. Fmot, rear 13000~11'
~
~
~~; .~ 1.19'~ 1.197) ~
Shaft 0.0. 12.966 ~ 12. . ~
; Gear 1.0. M3 25.000 ~ 25.021 ~
M3
:2, C4, CR
, ;dle ~
.
.
)~:
)~
41
21
1 ~ .104 ~
I
Gear bushing 24:959~24i
~7~' .1026
0.0.
C ' .984 ~:
C C4,CR ' .979 ~: .000 . 1015~ .1024
-
Gear ;". J.D. M3 22 .000 ~: 2.021
;
C4
al M3
al M5
~~
.959 ~: .980 ~= ~
16."";~1~ ~
, ;dle 12.966 ~ 12. ~51,* ~

,
Ruooul ~
0.15 .006)
, "de, 0.8 ' .03)
;
FA1/FA2 models
Unit· mm (in)
ITEM STANDARD SERV ICE LIM IT
Reverse selector lever freeplay 2 4 (3132 5132) ,
Shift fork _ ~D 13.000 13.0 18 (0.5118 0.5125)
Claw thickness 5.93 6.00 (0.233 0.236)
Shaft 0.0. 12.966 12.984 (0.5105 0.5112) ~
Transmission 20.000 20.021 (0.7874 0.7882)

Gear 1.0.
~:
~
25.000 25.021 (0.9843 0.9851) ,

~.
~
_~2 , C4,CR 28.020 28.041 (1.1031 1.1040) ~
C5 31.000 31.025 (1.2205 1.2215) ~
_ ~everse idle 13.000 13.018 (0.5118 0.5125)

Gear bushing
- Ml 19.966 19.984 (0.7861 0.7868)
0.0. M3 24 .959 24.980 (0.9826 0.9835)
QICR 27-:979 - 287:100 (1.1015 1. 1024)
C4 - -
27-:-984 - 28.005 (1.10 17 1.1026)
C5 30.950 - 30.975 (1.2185 1.2195)
Gear bushing 1.0. Ml 17.000 17.018 (0.6692 0.6700)
M3 22.000 22.021 0.8661 0.8670)
C2/CR 25.000 25.013 (0.9843 0.9848)
I C5 ~~OO 28.021 (1.1024 1.1032)
Mainshaft 0.0. at Mt 16.976 16.987 (0.6683 0.6688)
at M3
- 21 .959 21.980 (0.8645 0.8654)
1
I Counlershaft 0.0. at C2ICR 24.959 24.980 (0.9826 0.9835)
, atC5 27 .960 27.980 (1 .1008 1.1016) ,
Reverse idle shaft 0. 0 . 12.966 12.984 (0.5105 0.5112)
Crankshaft Runout 0.15 (0.006)
Big end side clearance 0.05 0.65 (0.002-=-0.026) 0.8 (0.03)
Big end radial clearance 0.006 O.ot8 (0.0002 0.0007) 0.05 (0.002)
1·10
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit' mm (in)
Cold lire pressure Standard 30 kPa (0.30 kgf/cm . 4,4 psi)
, With cargo
1
30 kPa {O.3D kgf/cm~, 4.4 psi} -
Tie-rod distance between the bal! joints 362.5 (14.27 -
Too Toe-out: 1S± 15(9/16 ±9/16)
REAR WHEEL/SUSPENSION SPECIFICATIONS

1o- = = = = = ; -_ --""-
TE" 'M
" - _--,--o==o-_ _ _= = - = = " sT
CAic:N
"'D
,.AC;R'iD-=,---_ _+-S
...ERVICE LIMIT
Cold tire pressure Standard 30 kPa (0.30 kgf/cm , 4.4 psi)
With cargo 30 kPa (0.30 kgflcm , 4.4 psi)
BRAKE SYSTEM SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD _ _-ii- "
S"ER
" ,VICE LIMIT
r
Front brake Recommended brake fluid
Disc
Honda DOT 4 brake fluid
thickn;es~s~~----------:3~.3~~3.~7~(0~.~13~~0~.,;5~)
Disc runou~--:
=t: 3.O (0.12)
0.30 (0.012)
~
Master cylinder 1.0. 14.000 14.043 (0.5512 - 0.5529)
Master piston 0 .0 .
I 13.957 - 13.984 (O.5495 - 0.5506)
Caliper cylinder 1.0. 32.030 32.080 (1.2610 - 1.2630)
I Caliper piston O.D. 31.984 31.998 (1.2578 - 1.2598)
Rear (parking) brake le:c'eC'r"f"re"e"p""a"y_ _ _ _ _ _ _ _ _~1:'i5=2~0&.(19/32 25/32)
I Rear brake pedal free play 15 20 (19/32 25/32) --~16I0][3''L==
Rear brake drum 1.0. 160.0 160.-2 (6.30 - 6.31) 161.0 (6.34)
FRONT DRIVING MECHANISM SPECIFICATIONS (Except TM1/TE1 models)

_ __~===~_____~= Unit: mm (in)
ITEM ==""'
1
SCiT"Ac:NC'D:;:A~R,,D==c------S..ERVICE LIMIT
Front final Oil capacity After draining 210cm (7.1 USoz, 7.4lmpoz)
drive After disassembly 250 cm 3 (8.5 US oz. 8.8 Imp oz) ---j
Recommended oii Hypoid gear oil, SAE 80W-90
--I
Gear backlash 0.05 0.25 (0.002 0.010) 0.4 (0 .02) i
Backlash difference 0.2 (0 .01)
Slip torque 14 17 N·m (1.45 1.75 kgf-m. 12 N·m (1.2
10 -13IbHt) kgf-m.9 1bf-ft)
Face cam-Io-housing distance 3.3 3.7 (0.13 0.15) 3.3 (0. 13)
Differential ring gear depth 6.55 6.65 (0.258 0.262) 6.55 (0.258)
Cone spring free height 2.8 (0. 11) 2.6 (0. 10)
REAR DRIVING MECHANISM SPECIFICATIONS

Unit: mm (in)
Axle runoul + 3.0 (0 .12)
Rear final drive Oil capacity After draining 85 cm J (2.9 US OZ , 3.0 Imp oz)
'-c~:;:;::=J.:jA~ft~e~riid;iisa~s~s~e\;m"'bli'yC-~~--i!100 cm) (3.4 USCiZ,"3.5 Imp oz)
Recommended oil Hypoid gear oil, SAE BOW-gO
Gear backlash ! 0.05 0.25 (0.002 0.010) 0.4 (0 .02)
l Backlash difference
_ _~--"R"';n"'g-'g"'e..
ar"·t"'o__s"'to"p,,p'";n=d"'ea"'r,,'n'"''''e'___ _~'__0".3>.::. 0.6 (0.01 - 0.02)
0.2 (0.01)
1·11
GENERAL INFORMATION
SATTERY/CHARGING SYSTEM SPECIFICA nONS
ITEM SPECIFICATIONS
Battery U.S.A. TM1 ! Type YTX14-BS
TE1/FMl1 Capacity 12 V 14 Ah
FM2/FE1 Charging Normal 1.4NS 10 h
I
current Quick 6.0 Nl h
U.S.A. FA1! Type GYZ16H
FA2 and Capacity 12 V 16 Ah
Canada Charging Normal 1.6 AJ5 10 h
current Quick 8 .0 All h
I
Current TM1 0.012 rnA max.
leakage TE1 /FM1/fM2IFE1 0.27 rnA max.
FA1 fFA2 0.3 mA max.
Voltage Fully charged 13.0 13.2 V
(20'Cf68"F) Needs charging Below 12.3 V
Alternator Capacity Except FA1/FA2 0.416 kW/S,OOO rpm
FA1 /FAZ 0.450 kW/S,OOO r~m
Charging coil resistance (20°C/68"F) 0.1 1.0 (} I
I
LIGHTS/METERS/SWITCHES SPECIFICATIONS
TM1 model
ITEM I SPECIFICATIONS
t-Bulbs Headlight (highllow beam) 12V-35J35Wx2
BrakeftaiUight LED
Neutral indicator 12V-1 .7W
Reverse indicator 12V-1 .7W
Coolant temperature indicator 12V-1.7W
MIL 12V-1 .7W
Low fue! indicator 12V-1 .7W
Fuel level sensor Full 19.0 21.00
resistance Empty
- 772.0 788.00
Fuse Main fuse 30A
Sub-fuse f- 10 A x2, 20 A x 3
Except TM1 model
ITEM SPECIFICATIONS
Bulbs Headlight (high/low beam) 12V-35/35Wx2
Brake/taillight LED
Neutral Indicator LED
Reverse indicator r- LED
I Coolant temperature indicator

MIL
-
LED
LED
Meter light f- LED
EPS indicator (FM2/FA2 only) LED
r-Fuellevel sensor Full 19.0 21.00
resistance
-
Empty 772.0 788.00 -
Fuse Main fuse 30A
Sub-fuse FM1 /FM2 10Ax2,20Ax3
Except FM1/FM2 10A)( 2, 20A x2, 30A
EPS fuse (FM2IFA2 only) 40A
1-12
GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
, , N'm (kgf-m, IbUt) N'm (kgf-m, IbHt)
,
5 mm bolt and nut 5 (0.5, 3.7) 5 mm screw 4 (0.4, 3.0)
6 mm bolt and nut (Include SH 10 (1 .0, 7) 6 mm screw 9 (0.9, 6.6)
flange bolt) 6 mm flange bolt {a mm head, large 10 (1.0, 7)
8 mm bolt and nut 22 (2.2 . 16) -t-{ange!10 mm head) and nut
10 mm bolt and nut 34 (3.S, 25) 8 mm flange bolt and nul 27 (2.8 , 20)
12 mm bolt and nut 54 (5.5 . 40) I 10 mm flange boll and nul 39 (4 .0 , 29)
ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for important fasteners .
• Others should be tightened to standard torque values listed above.
Ir-.S"le;Cp~b'''a~Ck''e''l
-
ITEM
COmC;o"'u·ting
n nut
-fa'TY 4
THREAD
DIA. (mm)
8
TORQUE
N'm (kgf·m',~'bc-
32(3324)
....
ft), ---_ _
REMARKS
Step bracket mounting boll 4 8 32 (3.3, 24)

Muffler cover boll --1-_ 2 ~
6 12(1.2,9) ,
Muffler cover band bolt (front side) - 1
i
- T, 2 (0.2 . 1.5)
~~er cover band bolt (rear side) 1 - j 3.2(0.3. 24)
Front muffler cover band boll
[- 1 - 2 (0.2, 1.5) I
,
Exhaust pipe cover band bolt 3 2 (0.2 . 1.5)
6 (0.6, 4.4) See page 2-10
,
Exhaust pipe stud boll 2 8 I
MAINTENANCE
THREAD TORQUE
ITEM Q 'TY REMARKS
CIA. (mm) N'm (kgf'm , IbHt)
Spark plug 1 14 22 (2.2, 16)
Valve adjusting lock nut 2 6 17 (1.7,13 )
Valve adjusting hole cap 2 36 12 (1.2. 9)
Timing hole cap 1 14 10(1.0,7)
Engine oil drain boft
Front final gear case oil filler cap
1
1
12
30
25 (2.5,18)
12(1.2,9) -
(Except TMlfTE1)
Front final gear case oil drain bolt 1 8 12(1.2, 9)
(Except TMlfTE1 )
Rear final gear case oil check bolt 1 8 12(1.2,9)
Rear final gear case oil filler cap 1 30 12 (1 .2, 9)
Rear final gear case oil drain bolt 1 8 12 (1.2, 9)
Final clutch arm cover bolt 1 6 10(1.0,7)
Front master cylinder reservoir 2 4 1.5(0.2,1.1)
cap screw
~-rod lock nul (knuckle side) 2 12 54 (5.5. 40)
Tie-rod lock nut (steering arm 2 12 54 (5.5, 40) Left hand Ihreads.
I
side) ,
PGM-FI SYSTEM
THREAD TORQUE I
ITEM Q'TY REMARKS
DIA.(mm) N'm (kgf-m , IbHt) I
Sensor unit tOf)( screw (T25) 3 5 3.4 (O A, 2 .5)
EeT sensor 1 10 12 (1.2, 9)
Bank angle sensor mounting bolt 2 6 10{1.0,7)
0 2 sensor 12 24.5 (2.5. 18)
IGNITION SYSTEM
THREAD TORQUE
ITEM Q 'TY REMARKS
DIA. (mm) N'm (kgf'm, IbHt)
Timing hole cap 14 10J1.0.7)
1-13
GENERAL INFORMATION
ELECTRIC STARTER
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N'm (kgf-m, JbHt)
Starter motor case bolt 2 5 4.9 (0.5, 3.6)
Negative brush sel screw 1 5 3.7 (04, 2.7)
FUEL SYSTEM
,
ITEM Q'TY REMARKS
DIA. (mm) N'm tknf., , Ib"')
I , body ; ""ew
~s",,,,ew
Fuelfeed hose, , sccew -H ~~::;
Fuel . I bolt 2
COOLING SYSTEM
,
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
N'm (kgf'm, IbHt)
REMARKS I
Cooling fan nut 1 5 2.7 (0.3, 2.0) Apply locking agent to the threads.
Fan motor bolt 3 5 5.2 (0.5, 3.8)
I Fan motor stay bolt 3 6 8.4 (0.9, 6.2)
CYLINDER HEADN ALVE

THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N'm (kgf'm , IbHt)
Cylinder head nul 4 10 39 (4.0, 29) Apply engine oil 10 the threads and
seating surface.
Spark plug 1 14 22 (2.2,16)
ECT sensor 1 10 12(1 .2, 9)
Upper engine hanger nut 1 10 63 (6.4, 46)
Upper engine hanger bracket bolt 2 8 32 (3.3, 24)
Camshaft bearing setting plate 1 8 27 (2.8, 20) Apply locking agent 10 the threads.
bolt Coating width: 5.0 - B.O mm
(0.20 - 0.31 in) except 2.0 - 5.0 mm
(O.OB - 0.20 in) from lip
Cam chain tensioner pivot bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 1.0 - 2.0 mm
(0.04 - O.OB in) from tip
Cam chain tensioner lifter bolt 2 6
,I 12 (1 .2, 9) Apply locking agent to the threads .
Coating width : 6 .5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 - 4.0 mm
(0.12 - 0.16 in) from tip
CYlINDERJPISTON
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N'm (kgf'm , IbH!L
-
Crankcase stud boll 4 10 12 (1.2, 9) r-See page 11-:-5
1-14
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE (Except FA1 /FA2 models)
THREAD TORQUE
ITEM
DIA. (mm) N'm (kgf·m. IbHt)
REMARKS
Cenlrifugai clutch lock nut 20 118 (12.0, 87) Lock nut: replace with a new one.
•
~
App ylengine
'ltt 01h0 th rea
dsan
d
seating surface.
Stake.
Change clutch center lock nul 1 18 108 (11.0, 80) Lock nul: replace with a new one.
Apply engine oil to the threads and
seating surface.
Slake.
Clutch spring bolt 4 6 I 12(1 .2, 9)
Shift drum stopper arm pivot bolt 1 6 12 (1.2. 9) Apply locking agent to Ihe threads .
(0.31 ± 0.04 in) except 1.0 - 2 .0 mm
(0.04 - 0.08 in) from tip
Gearshift cam bolt 1 6 16 (1.6, 12) Apply locking agent to the threads.
I Coaling width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 - 4.0 mm
I (0.12 - 0.16 in) from tip
Gearshift spindle A stopper bolt 1 8 27 (2.8, 20) Apply locking agent to the threads .
I
(TM1JFM1 JFM2 only) Coating wid th: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 6.0 - 8.0 mm
~ J 0.24 - 0.31 in) from tip

,
ITEM Q'TY ~ READ TORQUE
REMARKS
Centrifugal clutch lock nut
- - , DIA 2~mm ) _ N·m (kgf·m , IbUt)
118 (12.0. 87)
I
Lock nut: replace with a new one.
I
Apply engine oil to the threads.

, Oil feed pipe setting cap 1 24 21 (2 .1, 15)
Stake.
Orifice relief valve socket bolt 1 10 34 (3.5, 25) Do not remove unless necessary.
l Sealing bolt
- 1
- 8 16 (1.6, 12) Do not remove unless necessary.
Shift clutch lock nut 1 18 108 (11.0, 80) Lock nut: replace with a new one- .- -
Apply engine oil to the threads and
seating surface.
Stake.
Shift drum stopper arm pivot bolt 1 6 12 (1.2'9~ Apply locking agent to the threads.
(0.31 ± 0.04 in) except 1.0 - 2.0 mm
(0.04 - 0.08 in) from tip
Shift drum center bolt 1 + 8 23 (2.3, 17 ) Apply locking agent to the threads.
(0.26 ± 0.04 in) except 3.0 - 4.0 mm
(0.12 - 0.16 in) from tip
Shift drum guide plate bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
Coating width : 6.5 ± 1.0 mm
(0.26 ± 0 .04 in) except 3.0 - 4.0 mm
(0.12 - 0.16 in) from tip
i Shift spindle angle sensor socket I 2 I 5 6 (0,6, 4.4) Apply locking agent to the threads~
bolt Coating width: 5.0 ± 1.0 mm
(0.2 ± 0.04 in) except 1.0 - 2.0 mm
(0.04 - 0.08 in) from tip
I Shift drum position switch wire
clamp bolt
2
+ 6 12 (1.2 . 9) I Apply locking agent 10 the threads.
(0.26 ± 0.04 in) except 3.0 - 4.0 mm
I
(0.12 - 0.16 in) from tip

Shift drum position switch 6 12 (1.2. 9) Apply locking agent to the threads.
retaining bolt Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) excepl 3.0 - 4.0 mm
(0.12 - 0.16 in) from tip
t=E~O~T~s.~n~s~°fu'~=============t==~==t===i'~D====t===f
[ Reverseswitch 10 '13(1.3.1
8~('R·8F,~'3)
.,0.,,)_ - '_ _ _ _ _ __
-j
I
1-15
GENERAL INFORMATION
AL TERNATORIST ARTER CLUTCH
ITEM C'TY REMARKS
CRANKCASEfTRANSMISSIONfCRANKSHAFTIBALANCER
r -THREAD TORQUE
ITEM O 'TY
DlA. (mm) N'm (kgf-m, JbHt)
REMARKS
Mainshaft bearing setting bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
(Except FA1/FA2) Coating wid th: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 1.0 - 2.0 mm
(0.04 - 0.08 in) fro m tip
Shift drum bearing selting bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
(FA1IFA2 only) Coating wid th: 5.0 ± 1.0 mm
(0.20 ± 0.04 in) except 1.0 - 3.0 mm
(0.04 - 0.12 in) from lip
THREAD TORQUE
ITEM C 'TY REMARKS
DIA. (mm) N'm (kgf'm, IbHt)
~-
Lower engine hanger nul 10 63 (6.4, 46)
Upper engine hanger nut 10 63 (GA, 46)
Upper engine hanger bracket bolt 2 8 32 (3.3, 24)
Front final gear ~r mounting nut 2 10 44 (4.5, 32) Lock nut: replace with a new one.
(Except TMlfTE1
Gearshift pedal Pinl~~ bolt 1 6 20(2.0,15)
(TM1/FM1/FM2 only
1-16
GENERAL INFORMATION
FRONT WHEEUSUSPENSION /STEERING
ITEM a 'TY
THREAD TORQUE
REMARKS
OtA.(mrn) N'm (kgf-m, Ibf·ft )
Front master cylinder holder bolt 2 6 12 (1.2, 9)
Throttle housing cover screw 3 4 1.5 (0.2. 1.1)
Front wheel nul B 10 64 (6.5, 47)
Front brake disc boll 8 B 42 (4 .3, 31) ALoe bolt: replace with a new one
Upper and lower arm ball joint nut 4 12 29 (3.0. 21) Castle nut: lighten to the specified
torque and further tighten unlillts
grooves align with the cotter pin
hole.
Tie-rod joint nut 54 (5.5, 40) LOC~k~n~U"'~,,~e~p'-la~ce=W~'"'h~a~new one.
Splash guard bolt 11 (1 .1, 8) ALOe bott: replace with a new one.
Front wheel hub nut 137 (14 .0,101) Castle nut: tighten to the specified
torque and further tighten unli! its
I hole .
...-----t---Apply sealant to the threads.
1_ Fmn' brake cal;per moun';ng bolt " - 4 8 30 (3.1, 22) + ALOe bolt: replace with a new one.
Outboard guard bolt
[ Brake hoseClamp bolt I
4
7
6
6
11 (1.1, 8)
-+_",':i2'T(1.2, 9)
+ AlOe bolt: replace
_=~=~~
with a new one.
Steering shaft end nut 14 108 (11 .0. 80) Lock nut: replace with a new one.
(Except FM2/FA2 )
Lower steering bearing holder nut 3 10 33.5 (3.4. 25) Lock nut· replace with a new one.
(Except FM2/FA2)
~--
Steering shaft holder bolt
EPS untl mounting nut
_~__2~_ _ _--iB
3 10
32 (3 .3, 24)
33.5 (3.4 , 25)
:-_====
Lock nut: replace with a newone.
(FM2IFA2 only)
EPS untl output shaft end nut 14 108 (11 .0. 80) lock nul: replace with a new one.
(FM2IFA2 only)
Steering shaft pinch bolt 1 10 60(6.1, 44) ALoe bolt: replace with a new one.
(FM2IFA2 only)
REAR WHEEUSUSPENSION
THREAD TORQUE
ITEM a 'TY REMARKS
DIA.(mm) N·m (kgf'm, IbUt)
Rear wheel nut B 10 64 (6.5. 47)
Shock absorber lower mounting 12 113 (11 .5. 83) (Lock nut: replace with a new one.)
bolt
Universal jOint guard bolt 2 6~ 10 (1.0, 7) ALOe bolt: replace with a new one.
~
Swingarm pivot nut 2 12 130(13.3,96) U-nul: replace with a new one.

t Trailer hitch mounting nut 2 t 10 _ 34(3.5,25)- Lock nut: rel?l~ce with a new one.
1-17
GENERAL INFORMATION
BRAKE SYSTEM
,
THREAD TORQUE
ITEM O'TY REMARKS
CIA. (mm) N'm (kgf'rn , IbHt)
Front brake caliper bleed valve 2 8 5.4 (O.6, 4.0)
Front master cylinder reservoi r 2 4 2 (0.2, 1.5)
cap screw
Front brake caliper mounting bolt 4 8 30 (3.1, 22) ALOe bolt: replace with a new one.
Pad pin 2 10 17.2 (1.8, 13)
Pad pin plug 2 10 2.4 (0.2. 1.8)
Front brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
Front brake lever pivot nut 1 6 5.9 (0.6, 4.4)
Front brake switch screw 1 4 1.2 0.1,0.9)
Front master cylinder holder bolt 2 6 12 (1.2, 9)
Brake hose oil bolt 3 10 34 (3.5, 25)
Front brake caliper slide pin 2 8 22 (2.2, 16) Apply locking agent to the threads.
Outboard guard bolt 4 6 11 (1.1,8)
Rear brake arm nut 1 8 20 (2.0,15)
~~r brake panel drain bolt 1 8 12 (1.2, 9)
Rear wheel hub nut 2 20 137 (14.0,101) Castle nut: tighten to the specified
torque and further tighten until its
hole .
I Apply sealant to the threads.
FRONT DRIVING MECHANISM (Exc eptTM1fTE1 models)
ITEM Q'TY REMARKS
i a new one.

THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m , IbHt)
Rear final gear pinion bearing lock 1 64 98 (10.0. 72) l ock nut: replace with a new one.
00'
Rear final gear case cover bolt 2 10 46 .5 (4.7, 34)
Stake.
Apply locking agent to the threads.
6 8 25 (2.5. 18)
Rear final gear case mounting bolt 8 10 74 (7.5, 55)
Rear brake panel mounting nut 4 10 46.5 (4.7. 34) lock nut: replace with a new one.
Rear wheel hub nut 2 20 137 ( 14.0, 101) Castle nut: tighten to the specified
torque and further tighten until its
hole .
I Apply sealant to the threads.
1-18
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES
~
ITEM Q'TV THREAD TORQUE REMARKS

•_ _--,-_,---_~
D1"'
A ·5(mm ) N'm (kgf'm , Ibf·cc
' "-
) _ _ __ _ _ __ _
Combination meter mounting 3 0.8(0.1, 0.6)
screw
Front brake sWitch screw
Rear brake light sWitch screw (rearc-r---
brake lever side)
1
;;;c---'-~
4
4
1.2 (Q. 1. O!.9~)
1.2(0.1,0.9)
======:-------
Gear position sWitch wire clamp
boll (Except FA1/FA2l
2 6 ""- =,
12 (1.2, 9) Apply locking agent to the threads,
Coaling width: 6.5 ± 1.0 mm
(0.2 ± 0.04 in) except 1.0 - 2.0 mm
(0.04 - 0.08 in) f"m"m""lip____
4WD select SWitch ~-,-_ _-,,
10,---_ _----,-
1.2 (1.2. 9)
ELECTRIC SHIFT PROGRAM (ESP: TEl /FE! models)
THREAD TORQUE
ITEM
Shift spindle angle sensor
bolt
sockei a 'TY
2
CIA. (mm)'-,--,"
5
N~·m
"o'(kgf. m , IbHt)
6 (0.6, 4.4)
REMARKS
Apply locking agent to the threads.
Coating width: 5.0 1: 1.0 mm
(0.2 ± 0,04 in) except 1.0 - 2.0 mm
(0.04 - 0.08 in) from lip
OTHERS
THREAD TORQUE
ITEM a 'TY
DtA. (mm) REMARKS
N·m (kgf'm , IbHt)
Gearshift spindle relum spring pin 8 ----'2 (2.2. 16) Apply locking agent lo·the threads.
(0.26 ± 0.04 in) excepl3.0 - 4.0 mm
(0. 12 - 0.16 in) from tip
Brake pipe jOint bolt 2 10 14 (1.4, 10)
Rear brake lever PiVOt bolt 1 6 9 .8 (1 .0 , 7 .2)
Rear brake lever PiVOt nut 1 6 9.8 (1.0, 7.2)
Parking brake lock lever pivot 1 6 6.9 (0.70,51)
screw
1-19
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
REMARKS
I ;
Except FA1 fFA2
IIi
; contacting
surface
Starter reduction gear teeth
Reverse stopper shaft journal surface
Sta rterspragcuc I t h W hDe
I surface
Mainshaft and countershaft journal surfaces
Shift fork shaft whole surface
I
I Shift drum grooves
Collar and bushing journal surfaces Except FA1 IFA2
Each bearing rotating area
Each O-ring whole surface
I Each oil seal lip
Molybdenum oil Camshaft cam lobes
solution (a mixture of Rocker arm shaft sliding surface
112 engine oil and 1f2 Valve stem (valve guide sliding surface)
molybdenum disulfide Change clutch outer guide inner and outer surfaces Except FA1 fFA2
grease) Crankshaft starter driven gear sliding surfaces
Piston pin outer surface
-
Starter reduction gear shaft whole surface
Waler pump shaft journal
Mainshaft gear and bushing sliding surfaces
Countershaft gear and bushing sliding surfaces
Starter motor shaft splines
locking agent Gear position switch retaining boll threads TE1 fFE1 only
(0.26 ± 0.04 in) except 3.0 - 4.0 mm
(0.12 - 0.16 in) from tip
Recoil starter assembly mounting bolt threads Canada type only
Coating Width . 6.5 ± 1.0 mm
(026 ± 0 04 in) except 3 0 - 40 mm
I Mobilith SHC 100 Recoil starter driven pulley oil seal lips
(0.12 - 0.16 in) from tip _
Canada type only
(EXXON).~~~__+-~~~~~~~~~~~~~~~
UNIREX N3 grease
Electric shift reduction gear teeth and journals (front
__~~~~~*,~~
TE1 fFE1 fFA 1/FA2 only
_ _____ ~
(EXXON ) crankcase cover) 2 - 4 g (0.07 - 0.14 oz)
TE1 /FE1 : See page 24-23
FA1 /FA2: Seepage 13-48
1·20
GENERAL INFORMATION
MATERIAL LOCATION REMARKS
liquid sealant + Fron! crankcase cover mating surface Except FAlIFA2: See page 12·7
FA1 /FA2: See page 13-39
Allemalor/CKP sensor Wife grommet sealing surface
Gear position switch ~ire gr?mmel sealing surface TEt /FE1only
Shift drum position switch wire grommet sealing surf'~aceO:;;:---';F~A~'~IF~A2C\-o~n~'y'c---
Rear crankcase cover mating surface =~--iSee page 14-9
Crankcase mating surface See page 15-19
Reduction gear cover mating surface TE1/FE1fFA lIFA2 only
TE l IFE 1: See page 24-24
FA1/FA2: See page 13-48
FRAME
MATERIAL LOCATION T REMARKS
Multi-purpose grease Throttle cable end
Throttle cable outer threads
Rear (parking) brake lever pivot
Parking arm pin
Steering shaft bushing sliding surface 2 3g{O.07 O.11oz)
Rear brake cam dust seal lips
Rear brake cam spindle 0.2 0.3 g (0.007 0.011 oz)
Rear brake shoe cam contacting surfaces 0.2 0.3 g (0.007 0.011 oz)
Rear brake shoe anchor pin contacting surfaces 0.2 0.3 g (0.007 0.011 oz)
Rear brake drum cover dust seal lips
Rear brake panel O·ring
Rear brake panel dust seal lips
-Rear brake panel bearing 4 5g(0.14 0.180z)
Rear brake pedal pivot
Rear brake pedal pivot dust seal lips
Rear brake cable ends (lever and pedal side)
Front final gear case oil seal lips (for drive shafts) _ _ _-iExcept TMlfTEl
Front final gear case cover O-ring Except TMlfTEl
Fronl final oil filler O-ring Except TM1fTEl
seal Except TMlfTEl
_ _ _-iExcept TM1fTEl
arm Except TM 1fTEl
;
Front final clulch joint oil seal lips =:==3Except TM1fTE1
Front final clutch case O-ring :::: Except TM1fTE1
Fronl axle shaft splines (wheel side) __---T~M"'1 fTE1 only
Rear final gear case oil seal lips (for propeller shaft) _ _ _ __ _
Rear final gear case oil seal lips (for ring gear)
t- Rear final gear oil filler cap O-nng 1
left axle housing 0 ring
left axle housing dust seal lip
Swingarm 0 ring
Pro Honda Foam Filter-t-A~'~',~c!;'e~a~o~e,~e~'~em;;:;;e~nt~i"'n'side 17 - 23 9 (0.6 0.80z)
Oil or equivalent
Honda Bond A or Pro -~~~~~"J~~~"
Handlebar grip rubber inside
Honda Handgrip Air cleaner housing-to--connecting tube mating area
Cement (U.S.A only) Air cleaner housing-to--ductlube mating area
or eqUIvalent Air cleaner housing-ta-IAT sensor grommet mating ar~e~a,-_~=-----
Air cleaner housing breather hose joint grommet mating
_ _ _-"a~'e~a~s Qnner and outer surfaces)
1-21
GENERAL INFORMATION
grease
Front propeller shaft splines
"
I i Ii
NKG70B (Kyodo Yushi)
Front drive shaft inboard joint inside
ir grease
minimum
i i
1·22
GENERAL INFORMATION
CABLE & HARNESS ROUTING
Inside of front fender:
HEADLIGHT SUB-WIRE
HARNESS
REAR (PARKING) BRAKE CABLE

THROTTLE CABLE
/
FRONT BRAKE HOSE A
IGNITION SWITCH WIRE

DRIVE MODE SELECT SWITCH
WIRE (FA1/FA2 only)
REVERSE
1!c~2t~I-;------'~~-- FRONT SUB-WIRE HARNESS
SELECTOR CABLE
H-~'---HANOlEBAR SWITCH WIRE
BANK ANGLE SENSOR

3P (Black) CONNECT OR
1-23
GENERAL INFORMATION
IGNITION FRONT SUB-WIRE BANK ANGLE SENSOR TM1: INDICATOR SOCKET lOP (Gray)
SWITCH WIRE HARNESS 3P (Black) CONNECTOR CONNECTOR
Except TM1 ; FRONT SUB-WIRE
HARNESS12P CONNECTOR
HANDLEBAR SWITCH
CONNECTOR
DRIVE TM1/FMlIFM2: 8P (Green)
SELECT TElIFElIFA1/FA2: l4P (Green)
SWITCH WIRE ==:1===::;~
(FAlfFA2 only) '- L-~""
SWITCH WIRE
IGNITION SWITCH
4P CONNECTOR
HEADLIGHT SUB-
WIRE HARNESS
DRIVE MODE SWITCH2P 3P CONNECTOR
(Black) CONNECTOR (FAlIFA2 only)
DLC 4P (Red)
FRONT FINAL GEAR CASE

BREATHER HOSE
_
~~\~l~~~~~~~
FRONT BRAKE PIPE
FRONT BRAKE HOSE B FRONT BRAKE HOSE B
FRONT VS SENSOR 3P (Black)

CONNECTOR (FA1IFA2 only)
1-24
GENERAL INFORMATION

WIRE (FA l/FA2 only)
Front
HANDLEBAR
SWITCH WIRE
HANDLEBAR SWITCH WIRE
(To front brake switch)
HEADLIGHT SUB·WIRE FRONT FINAL GEAR CASE

HARNESS 3P CONNECTOR BREATHER HOSE (Except TMlfTE1)
OVERFLOW HOSE
SIPfiONHOSE WATER HOSE

(Thermostat.le-radiator)
1-25
GENE RAL INFORMATION
MAIN WIRE
HARNESS ---ofr - Inside
2 p (Brown)
EPS EeU R (FM2IFA2 only)
CONNECTO Gray)
EPS ECU 2P «(FM2/FA2 only)

CONNECTOR
EPS ECU 21P (Gray)

CONNECTOR
(FM2IFA2 only)
FUEL PUMP
8REA THER HOSE
ER HOSE
WAT.
(Radiator. to-water pump)
Reverse SI"de of radialor:
FAN MOTc~RN;rECTOR
(Natural)
r---___ FAN MOTOR aSE

BREATHER H
FRONT FINAT~~;:~OSE
CASE BREA
1·26
GENERAL INFORMATION
TORQUE SENSOR 3P (Gray) CONNECTOR (fM2/FA2 only)
EPS MOTOR 3P (Gray)

CONNECTOR only)
FRONT BRAKE HOSE 8
2WD/4WD SELECTOR MAIN WIRE HARNESS

CABLE (Except TMlfTE1) (To solenoid valves) (FAlIFA2 only)
DUAL CLUTCH PC SOLENOID VALVE WATER PIPE/HOSES

2P (Black) CONNECTOR (FA1/FA2 only) (Thermostat-la-water pump)
/T
SHIFT CONTROL MOTOR SO'lE IN OIOVALVE 2P (Brown)

(TE1fFE1/FA1IFA2 only) CONNECTOR (FAlfFA2 only)
1-27
GENERAL INFORMATION
WATER HOSE
Left _Q (Radiator-Io-water pump)
SHIFT CONTROL MOTOR 2P (Black)

CONNECTOR (TE1IFE1/FA1/FA2 only) 2WD/4WD SELECT SWITCH
CONNECTOR (Except TMI/TE1)
EDT SENSOR 2P (Black)

CONNECTOR (FAlfFA2 only)
MAIN RELAY
FUEL PUMP RELAY
STARTER INHIBITOR RELAY
REAR FINAL GEAR

CASE BREATHER HOSE
SPARK WIRE
Eel SENSOR 2P CONNECTOR
1-28
GENERAL INFORMATION
REVERSE SELECTOR CABLE PCM/ECM FUEL PUMP

BREATHER HOSE
THROnLE CABLE
UP
MAIN WIRE
HARNESS
MAIN WIRE HARNESS

REAR(PARKING) (To Iront VS sensor)
REAR BRAKE (FAlIFA2 only)
BREATHER HOSE ALTERNATOR WIRE BRAKE CABLE
FUEL PUMP FUEL PUMP UNIT 4P

BREATHER HOSE (Gray) CONNECTOR
~~ FUEL FEED HOSE
MAIN WIRE HARNESS

JOINT CONNECTOR
1-29
GENERAL INFORMATION
IGNITION COIL PRIMARY WIRE

CONNECTOR
SPARK PLUG WIRE
MAIN WIRE HARNESS

IGNITION COIL PRIIMAHYWII.E
(To ECT sensor)
CONNECTOR (Green/yellow)
INJECTOR 2P (Gray)
FUEL FEED HOSE THROTTLE CABLE
CONNECTOR
IACV 4P (Black)
CONNECTOR
O. SENSOR4P
(Black) CONNECTOR IAT 2P
ALTERNATOR WIRE
(Gray) CONNECTOR
SENSOR UNIT 5P
(Black) CONNECTOR
1-30
GENERAL INFORMATION
02 SENSOR 4P (Black)
CONNECTOR
:\ ,
\
VS SENSOR REAR "'OALu',",
CONNECTOR (E)(cept TM1) CASE BREATHER HOSE
GROUND CABLE REAR BRAKE SWITCH

ALTERNATOR WIRE CKP SENSOR 2P (Gray)
(Engine-to-frame) 2P (Black) CONNECTOR
CONNECTOR
REAR BRAKE
BREATHER HOSE
STARTER MOTOR CABLE FRAME GROUND POINT
1-31
GENERAL INFORMATION
Except FAlIFA2: GEAR POSITION SWITCH WIRE

FA1/FA2: SHIFT DRUM POSITION SWITCH WIRE REAR BRAKE
BREATHER HOSE
ENGINE SUB-WIRE
HARNESS (Excepl TM1)
VS SENSOR 3P (Black) REVERSE SWITCH

CONNECTOR (Except TM1) CONNECTOR (FA1/FA2 only)
SHJFT ANGLE SENSOR 3P (Black) REVERSE

CONNECTOR (Except TM1 /FM1 /FM2) SELECTOR CABLE
Except FA1 IFA2: GEAR POSITION ENGINE SUB-WIRE HARNESS

SWITCH 8P (Gray) CONNECTOR ~~~~,J~:::J!Tr.-:C~ONNECTORR.~~~~nl'lI
FAt /FA2: SHIFT DRUM POSITION .-
SWITCH lOP (Gray) CONNECTOR -'~::~1i1~J
r-;---!-+-- SELECTOR
REVERSE
CABLE
FRAME GROUND POINT
----l.S
REAR BRAKE
LIGHT SWITCH
ENGINE SUB-WIRE
HARNESS CONNECTOR
TElIFElIFA1 /FA2: 6P (Black)
FM1IFM2: 3P (Black)
GR'DU"D CABLE
(Engine-to-frame)
LEVER (PARKING)
BRAKE CABLE PEDAL
BRAKE CABLE
1-32
GENERAL INFORMATION
LEVER REAR (PARKING)

BRAKE CABLE
I
PEDAL REAR REAR BRAKE

BRAKE CABLE BREATHER HOSE
REGULATOR/RECTIFIER BRAKEIT AILLIGHT 3P

3P (Black) CONNECTOR ,_ - - - - (Black) CONNECTOR
ALTERNATOR
3P (Gray) CONNECTOR
CONDENSER
(Canada type only) r~-_ BATIERYPOSITIVE
(+) CABLE
CONDENSER
2P CONNECTOR _-----'
SWITCH
STARTER2PRELAY
CONNECTOR
(Green ) --;r'6~~!~~~:;~~cs~~~~~;~
STARTER
MOTOR CABLE
EPS FUSE
FUSE BOX (FM2IFA2 only)
1-33
GENERAL INFORMATION
MAIN WIRE HARNESS

(To brake/taillight)
Right
WIRE GUIDE
TOOL BOX LID MAIN WIRE HARNESS
1-34
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S Environmental Protection Agency (EPA). the California Air Resources Board (CARB). and Environment Canada (EC)
require that off-road ATVs comply with applicable exhaust emiSSions standards during their useful life, when operated and
maintained according to the Instructions provided .
SOURCE OF EMISSIONS
The combustion process produces oxides of nitrogen (NOx). carbon monoxide (CO) and hydrocarbons (HC). Controlling oxides of
nitrogen and hydrocarbon emissions is very important because, under certain conditions, they react to fonn photochemical smog
when subjected to sunhght. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen. and hydrocarbons.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of the PGM-FI system, and no adjustments should be made. The exhaust
emission control system is separate from the crankcase emission control system.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body.
AIR CLEANER
THROTTLE BODY
BREATHER HOSE
<:: I Fresh air
_ Blow-by gas
SERVICING THE HONDA

U.S.A. Only
Maintenance, replacemen t or repair of the emission control devices and systems may be performed by any ATV repair
establishment or individual using parts that are -certified" to EPA standards.
PROHIBITED ACTIONS
The following prOhibitions apply to everyone with respect to the engine's emission control system.
You may not remove or disable any device or element of design that may affect an engine's emission levels. This restriction applies
before and after the engine In placed in service.
1-35
GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE EMISSION CONTROL SYSTEM IS PROHIBITED: U.S. Federal law prohibits, or Canadian
provincial law may prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other
than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any vehicle for Ihe
purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use: or (2) the use of any vehicle after
such device or element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS:
1. Removal of, or puncturing Ihe muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. lack of proper maintenance.
4. Removing or disabling any emissions compliance component, or replacing any compliance component with a non-compliant
component.
FUEL PERMEATION EMISSION CONTROL SYSTEM
This ATV complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA), the
California Air Resource Board (CARB) and Environment Canada. The fuel tank. fuel hoses, and fuel vapor charge hoses used on
this ATV incorporate fuel permeation control technologies. Tampering with the fuel tank, fuel hoses, or fuel vapor charge hoses to
reduce or defeatlhe effectiveness of the fuel permeation technologies is prohibited by federal regulations.
REBUILT ENGINE
When you rebuild the engine including a major overhaul in which you replace the engine's piston or power assemblies or make
other changes that significantly increase the service life of the engine, the vehicle will continue to comply with all emissions
regulations if you:
- Make sure you are technically qualified to rebuild the engine and have the proper tools
- Diagnose and respond to all Diagnostic Trouble Codes (OTC), and erase all OTCs after addressing their cause
- Use only Genuine Honda parts or equivalents
- Make sure to maintain all specifications as described in this Service Manual
,,
1-36
2. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION ················· ············2-2 ENGINE GUARD ............ ............................... 2-5
TROUBLESHOOTING ············ ······················· 2-2 FRONT FENDER/CARRIER ···················· .... ·2·6
BOOY PANEL LOCATIONS ························· 2-2 STEP BRACKET ........................................... 2-7
SEAT················ ·········· ·········· ·········· ················ 2-3 SKID PLATE ·················································2·7
RADIATOR CAP LlD ····································· 2-3 REAR FENDER COVER ........................... .... 2-8
OIL CHECK LlD·············································2-3 TOOLBOX LID ····································· ···· .... ·2-8
TANK COVER ASSEMBLY ··························2-4 REAR FENDER/CARRIER ···························2-8
MUDGUARD······································· ···········2·5 EXHAUST SYSTEM ·············· ···················· .. 2·10
2-1
SERVICE INFORMATION
GENERAL
This section covers removal and installation o f the body panels and exhaust system.
Always replace the gaskets when removing the exhaust system.
Always inspect the exhaust system for leaks after installation.
TROUBLESHOOTING
Excessive ex haust noise
• Broken exhaust system
• Exhaust gas leaks
Poor performance
Deformed exhaust system
Exhaust gas leaks
• Clogged muffler
BODY PANEL LOCATIONS

FA2 model shown :
[1 [
[7)
[8)
[4[
[9)
,
, •
,, •
[1 ,, ,,
•
[12[ [10]
(1) RADIATOR CAP LID (page 2-3) [8) REAR FENDER COVER (page 2-8)
[2) HANDLEBAR COVER (page 23-5) [9) TOOL BOX LID (page 2-8)
•
[3) OIL CHECK LID (page 2-3) [10) SKID PLATE (page 2-7)
[4) FRONT FENDER/CARRIER (page 2-6) [11[ REAR FENDER/CARRIER (page 2-8)
[5) ENGINE GUARD (page 2-5) [12) STEP BRACKET (page 2-7)
[6) TANK COVER ASSEMBLY (page 2-4) [13[ MUDGUARD (page 2-5)
(7) SEAT (page 2-3)
2-2
SEAT
Unlock the seal [1) by pulling the release lever [2] up.
Raise the rear of the seat, slide it rearward and remove [4) [3]
it. [5]
Instailihe seat by inserting the center prong (3) into the
fuel tank cover [4] and hooking the front prongs (5) to
the seat retainers [5} of the frame .
Push the seat forward and align the mounting bosses
[71 with the rubber mounts [8], then press down to lock
it.
[6] [S[ [7] [2[
RADIATOR CAP LID

Release the boss 111 from the grommet [2] and remove
the radiator cap lid [3}. ['[ [3[
~
Install the radiator cap lid by inserting the tabs [4) into
the slols [5) and aligning the boss with the grommet.
[2[ [5]
OIL CHECK LID

Release the bosses [1] from the grommets [2] and
remove the oil check lid [3J.
Install the oil check lid by inserting the labs [4J into the
slots [5] and aligning the bosses with the grommets.
_ 'i: ['[
[1]
1---_______ ~
[3[
2-3
TANK COVER ASSEMBLY
REMOVAL/INSTALLATION
Remove the seal (page 2-3).
Release the side Remove the tank cover assembly [l J by releasing the
bosses first before eight bosses [2J from the grommets.
the tvio top bosses.
Installation is in the reverse order of removal.
Align the tabs [3J with the slots.
• Be careful not to dislodge the grommets.
[31 131
DISASSEMBLY/ASSEMBLY
Remove the following:
- two (TM1fTE1 : three) screws (1)
- six trim clips [2]
- TM1fTE1 only: side pocket [3]
- side covers [4] from the tank cover [5)
Assembly is in the reverse order of disassembly.
1
I
2-4
MUDGUARD
NOTE :
• Take care nol to scratch the front and rear fenders
when removing and installing the mudguard.
Remove the lank cover assembly (page 2-4).
- two setting bolls [1) and step [2J
- bolt [3} and nul [4]
- ten trim clips [5) and washer [6)
- mudguard [7)
Right side only: Release the waler hose [8] and bleed hose (9) from the
mudguard.
~
,
111---:
,
ENGINE GUARD
[7[ [3[ [2[
J
Remove the two trim clips [1] and eight setting bolts [2].
Release the hooks [3] by sliding the engine guard [4]
rearward to remove it.
[1[
2-5
FRONT FENDER/CARRIER
REMOVAUINSTALLATION
Remove the tank cover assembly (page 2-4).
Disconnect the headlight 3P connector [1J.
- ten trim clips {2] and two washers [3]
- two setting bolts [4]
- six mounting bolls [5]
fuel lank cap [6]
- front fenderfcarrier assembly [7J
Install the fuel lank cap.
Inslallation is in the reverse order of removal.
j
1
1
I
DISASSEMBLY/ASSEMBLY j
Loosen the nuts [1] .
{5{
- setting bolts (2]
- bolts [3] and flange collars (4)
~==&41~171
- front carrier (5) and front carry pipe [6] assembly
Remove the nuts and bolts (7] and separate the fronl
carrier and front carry pipe.
For headlight removal/installation, see "Lightsl 16]
meters/Switches" section (page 23-3).
{7]
,
{2]
[3]114] "'--{2{
2·6
Remove the fourteen trim clips [1] and separate the
following: 12J
- fronl center cover [2]
- right front fender [3] ®
/'
- left front fender [4]
- front grille [5]
141
9 ,
15]
, 111
STEP BRACKET
Remove the mudguard (page 2-5).
- mounting bolts (short) [1]
- mounting nuts [2] and bolts (long) [3]
- slep bracket [4)
Installation is in the reverse order of removal,
TORQUE:
Mounting bolts and nuts :
32 N'm {3.3 kgf'm , 24 IbHt)
SKID PLATE
Remove the two bolts 11], setting bolt [2] and the skid
plate [3] .
Install the skid plate with new bolts .
2-7
REAR FENDER COVER
• Be careful not to scratch the cover with the carrier r-----c---,-,----- - - ---,-,-,
[1[ [5[ [5[ [4[
pipe.
Remove the seal (page 2-3).
Unhook the retaining strap [1] from the tool box lid.
Release the bosses [2] from the grommets 13] and
remove the rear fender cover [4] by sliding it forward .
Be careful not to Installation is in the reverse order of removal.
disloclge the • Align the tabs (5] with the slots.
grommets.
[3[ [2[
TOOLBOX LID
Remove the brakeltaillight (page 23-4).
- brake/taillight wire [11
- toolbox lid (2]
REAR FENDER/CARRIER
REMOVAU[NSTALLAT[ON
- lank cover assembly (page 2-4)
- rear fender cover (page 2-8)
- battery [1) (page 22-5) [31
Disconnect the stator 3P (Gray) connector [2] and
regulator/rectifier 3P (Black) connector [3).
Remove the following from the rear fender: 121
wire clips (4]
- starter relay switch (5)
- fuse boxes [6)
- Canada type only: condenser [7]
Release the wire clamps [8] and remove the wires and
cables from the rear fender.
1
[5[
J
1
J
,
[6[ .J
1
2·8
[4)
- six trim clips [1]
- two bolts [2] and nuts [3)
- two setting bolts [4]
- six mounting bolts [5]
- rear fender/carrier assembly (6]
[6)
[5)
)~
[3)
[1)
[2)
Remove the bolts (1), flange collar [2J and separate the
rear carrier (3) from the rear fender [4] . [1)/[2)
Assembly is in the reverse order of removal.
[4)
[3)
2-9
EXHAUST SYSTEM
Disconnect the 02 sensor 4P (Black) connector {1].
- joint nuts [2]
- muffler (3) (from Ihe mounting grommets [4])
- gasket [5]
Installation is in Ihe reverse order of removal.
Always replace the gasket with a new one.
Apply soapy water 10 Ihe mounting grommets.
After installation , inspect the exhaust system for
leaks.
151 ~
EXHAUST PIPE STUD BOLT
REPLACEMENT
Thread two nuts to the stud bolt [1] and tighten them r -:-- -- -- - - -- - - - - - -'
together. then use a wrench on them to turn Ihe stud I1 1
bolt out
Install and tighten new stud bolts into the cylinder head
Install the stud bolts
with rheirrounded to the specified torque.
+--j
end facing out.
TORQUE: 6 N'm (0.6 kgf·m. 4.4 IbHt)
After tightening the stud bolts , check that the length
from the bolt head to the cylinder head surface is within 22.5 - 23.5 mm
specification.
1. .10.89 - 0.93 <oi
50 mm (2.0 in)
•,
•,
•,
2-10
For 02 sensor removal/ins tallation, refer to "PGM-FI SYSTEM" section (page 4-37).
12 N-m (1.2 kgf.m . 91bHI) - - - - . .
FRONT MUFFLER COVER
2 N'm (0.2 kgf-m. 1.5Ibf-ft)
EXHAUST PIPE COVER

MUFFLER COVER
3.2 N-m (O.3 kgf-m.
~,\\
2.4 IbHt)
- fN:,
2 N -m (0.2 kgf-m, ~~
1.5IbHt)
~ MUFFLER
MUFFLER LOWER COVER

I
2-11
MEMO
,
1
,
1
I
j
••
,
•
3. MAINTENANCE
SERVICE INFORMATION ····························· 3-2 FRONT AND REAR FINAL GEAR OIL······· 3-22
MAINTENANCE MINDER INDICATOR ········ 3-3 2WD /4WD SELECT SYSTEM

(Except TM1 /TE1 models) ......................... 3-24
MAINTENANCE SCHEDULE ························ 3-4
BRAKE FLUID .. .. ······· ································· 3-24
FUEL LINE·····················································3-6
BRAKE SHOE WEAR ...................... ........... 3-25
THROTTLE OPERATION ····························· ·3-6
BRAKE PAD WEAR ................................... 3-25
AIR CLEANER······················· ························ 3-7
BRAKE LIGHT SWITCH ............................. 3-26
AIR CLEANER HOUSING DRAIN TUBE ······ 3-9
BRAKE SYSTEM ··················· ········· ············ 3-26
SPARK PLUG ······· ···· ············· ······· ··· ···· ········ 3-10
REVERSE LOCK SYSTEM ...................... ... 3-27
VALVE CLEARANCE·································· 3-11
GUARDS ............................... ........ .... .......... 3-28
ENGINE OIL (E xcept FA1 /FA2 models) ·· ··3-15
CLUTCH SYSTEM
ENGINE OIL (FA1 /FA2 models) ················· 3-17 (Except FA1IFA2 models) ························ ·3-28
ENGINE OIL FILTER SUSPENSION ············ ·················· ········ ······· 3-28

(Except FA1 /FA2 models) ··························3-1 8
SPARK ARRESTER .. .. ···· ·· ·············· ·········· · 3-29
ENGINE OIL FILTER (FA1 /FA2 modelsl ··· 3-19
NUTS , BOLTS, FASTENERS ................... .. 3-29
ENGINE IDLE SPEED ································ ·3-19
WHEELSITIRES ....................... .. ................. 3-29
RADIATOR COOLANT ······ ······ ··· ················ 3-20
TIE-ROD AND JOINT BOOTS ················ ···· 3-30
COOLING SYSTEM ····· ················ ················ 3-20
STEERING SHAFT HOLDER BEARING· ··· 3-30
DRIVE TRAIN BOOTS ·· ······························3-22
STEERING SYSTEM ·· ······················ ······ ····· 3-30
3·1
MAINTENANCE
SERVICE INFORMATION
GENERAL
• Place the vehicle on level ground before starting any work.
TOOLS
Valve adjusting wrench set
07908-3230000
MAINTENANCE MINDER INDICATOR

Tne maintenance minder indicator [1] appears when the mileage [2] or , - - - - -- - -- - - - - - - - - - - - - - ,
operating hour reaches the maintenance interval specified on the [11 1
maintenance schedule (page 3-3). j
j
Maintenance minder indicators:
I~ I
Initial Maintenance
®
Appears al100 miles (150 km) or 20 operating hours,
whichever comes first. @ N
Regular Maintenance Interval 1
Appears 600 miles (1,000 km) or 100 operating hours
after the Inilial Maintenance or Regular Maintenance
Intel'\lal 2 is performed and maintenance minder is
) [2J i
~
reset. whichever comes fi rst in the maintenance
schedule. 131 ~
Regular Maintenance Interval 2
Appears 600 miles (1,000 km) or 100 operating hours
after Regular Maintenance Interval 1 is performed and
maintenance minder is reset, whichever comes firs t in
•
~
the maintenance schedule.
When the maintenance tripmeter or hourmeler reaches a (zero), the

maintenance minder display will blink to indicate the required maintenance
interval (lor 2).
Reset the maintenance tripmeter/hourmeter after Ihe maintenance is
performed.
To reset the maintenance tripmeter and maintenance hourmeler, press and
hold the mode bullon (3] and turn the ignition switch to ON (I). Continue to
hold the mode bullon, the maintenance minder indicator will light up, and
after 2 seconds wi!! flash twice, the maintenance minder indicator is reset.
Also Ihe maintenance tripmeter and maintenance hourmeter will reset.
NOTE :
The reset operation will be cancelled if Ihe mode select bullon is
released before the indicator blinks twice. •,
1
,
j
•
3-2
MAINTENANCE
MAINTENANCE SCHEDULE
Except FAlIFA2 models
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I Inspect and clean , adjust, lubricate or replace jf necessary. C: Clean. R: Replace. A: Adjust. l: lubricate.
FREQUENCY WHICHEVER
COMES
INITIAL REGULAR MAINTENANCE
MAINTENANCE INTERVAL
FIRST REFER
mi 100 600 1,200 TO
km 150 1,000 2,000 PAGE
MONTH 1 6 12
ITEMS HOURS -+- 20 100 200
FUEL LINE
THROTILE OPERATION<::=!=::;;;:;:;:::::;=--
, 3-5
3-5
AIR CLEANER NOTE 1 C C 3-6
r AIR CLEANER H~-0'"'U"S"'N'"Go--+--:N'"0"T"E"2i--- 3-6
I DRAIN TUBE - - - --+-- - -_t_
SPARK PLUG 3-9
VALVE CLEARANC--E~_=t====~
3-10
ENGINE OIL _ INITIAL = 100 mi (150 km). operating hours or 1 month: R - 26 3-14
ENGINE OIL FilTER REGULAR = every 600 mi (1 ,000 km), 100 operating hours or 12 3-17
months: R
ENGINE IDLE SPEE:"D~_- -_-_ -=-=Tf=-~-~-~-~-~-~-=-="'-=-
RADIATOR C00LP:.~~jT NOTE 3
-
3-18
3-T9""'
COOLING SYSTEM NOTE 2
+ _--i_ _ ---;3-19
DRIVE TRAIN BOOTS _ _- '_ _~ '---_ _=- 3-21
FRONT AND REAR FINAL'- - + - - - - - - - +
(R: Every
GEAR OIL 3-21
2 years)
(Except TM1fTE1 model"' s)'--_ _- -__
REAR FINAL GEAR OIL - - + - - - '(R Eve:::
" c - -- --
3·21
(TM1fTE1 models) 2 years)
2WD/4WD SELECT"-'S"Y"S"'T'EM"~--
3·23
,,
1.::m"od=e""s,-)_~--;",,_
(Except TMlfT"Ec.
BRAKE FLUID NOTE 3 , 3-23
+ - -i
BRAKE SHOES WEAR NOTE 1, 2 3-24
BRAKE PADS WEAR NOTE 1, 2 , 3·24
BRAKE LIGHT SWITCH'---_~__ , , 3· 25
BRAKE SYSTEM , , 3· 25
,
f
-
REVERSE LOCK SYST""E"M, - - - - --
,I , 3·26
GUARDS
CLUTCH SYST,,,E,.M"---_ _ _ _-
-
,
,
,, 3-27
3-27
SUSPENSION 3-27
~SPARK ARRESTER , C C 3·28
• NUTS , BOLTS, FA;~S~T~ E"-NE§lR~Ss:::::;::::==_ ~--,-----
3·28
•• WHEELSfTlRES 3-28
~
c..-_ T,;;',.E-ROD AND JOI N
" T""'BiiO"O"T"S-l-_ __ 3-29
;- STEERING SHAFT HOLDER + +
3-29
BEARING
-..·· ~ST;;;EER'NG SYSTE"M ::.------ ~--"3-29
Should be serviced by an authorized Honda deater, unless the owner has proper tools and service data and is mechanically
qualified .
•• In the interest of safety. we recommend these items be serviced only by an authorized Honda dealer.
NOTES·
1 Service more frequenlly when riding in dusty areas, sand or snow
2. Service more frequently after riding in very wet or muddy conditions.
3. Replace every 2 years. Replacement requires mechanical skill.
3-3
MAINTENANCE
FAlIFA2 models
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.
I: Inspect and clean , adjust, lubricate or replace if necessary. c: Clean. R: Replace. A: Adjust. l: Lubricate.
FREQUENCY WHICHEVER
INlTIAL REGULAR MAINTENANCE
COMES
MAINTENANCE INTERVAL
FIRST REFER
mi 100 600 1,200 TO
km 150 1.000 2.000 PAGE
,
MONTH 1 , 6 12
ITEMS HOURS I 20 100 200 -
··FUEL LINE
THROTIlE OPERATION
-
I
I
3-5
3-5
AIR CLEANER NOTE 1 C C ; 3-6
AIR CLEANER HOUSING NOTE 2
DRAIN TUBE
SPARK PLUG
~-VALVE CLEARANCE I I
I
I
I
-,
I
I
I
I
3-8
3-9
3-10
1
ENGINE OIL INITIAL 100 mi (150 km), 20 operating hours or 1 month: R 3-16
REGULAR::; Every 600 mi (1,000 km), 100 operating hours or 12
ENGINE OIL FILTER 3-18
months: R
~ ~NGINE IDLE SPEED I , I I 3-18
RADIATOR COOLANT NOTE 3 I I 3-19
I. COOLING SYSTEM NOTE 2 I I 3-19
DRIVE TRAIN BOOTS I I 3-21
FRONT AND REAR FINAL (R: Every
GEAR OIL
I 3-21
2 years)
· 2WD/4WD SELECT SYSTEM
·----+sRAKE FLUID NOTE 3 I
I
I
3-23
3-23
· BRAKE SHOES WEAR NOTE1 , 2 I 3-24
· BRAKE PADS WEAR NOTE1 , 2 I I 3-24
~ BRAKE LIGHT SWITCH I I I 3-25
t-. ~~VERSE
BRAKE SYSTEM
LOCK SYSTEM
,
,
I
I
I
I
I
I
3-25
3-26
GUARDS I I 3-27
• SUSPENSION I I 3-27
· SPARK ARRESTER
, ;
C C 3-28
....· i l-
-
, NUTS, BOLTS , FASTENERS--- I I 3-28
WHEELSfTlRES I I I 3-28
.. TIE-ROD AND JOINT BOOTS

STEERING SHAFT HOLDER
I I I
I
3-29
3-29
BEARING
•• STEERING SYSTEM _L I 3-29
Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified .
•, In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES:
1. Service more frequenlly when riding in dusty areas, sand or snow.
2. Service more frequently after riding in very wet or muddy conditions .
3. Replace every 2 years. Replacement requires mechanical skill.
3-4
MAINTENANCE
FUEL LINE
Check the fuel feed hose [1] for deterioration , cracks,
damage or leakage .
Replace the fuel feed hose if necessary.
THROTTLE OPERATION
Check for any deterioration or damage to the throttle
cable . Check the throttle lever [1] for smooth operation,
Check that the throllle opens and automatically closes
in all steering positions.
If the IhrotUe lever does not return properly, overhaul
and lubricate the throttle housing (page 17-9).
If the throttle lever still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure thai the idle speed does not
change. If idle speed increases, check the throttle lever
freeplay and the throttle cable connections .
L 3 - 8mm
( 118 - 5116 in )
Measure Ihe throttle lever freeplay at the tip of the

throttle lever.
THROTTLE LEVER FREEPLAY :
3 - 8 mm (118 - 5/16 in)
Throttle lever free play can be adjusted at either end of
the throttle cable. Minor adjustments are made with the
upper adjuster.
Slide the rubber boot [1J off the adjuster.
Loosen the lock nut [2] . turn the adjuster [31 as required
and lighten the lock nut.
Install the rubber boot securely.
3-5
MAINTENANCE
Major adjustments are made with the lower adjuster.
Remove the seat (page 2-3).
Slide the rubber boot 111 off the adjuster.
Loosen the lock nut [2], turn the adjuster [3] as required
and tighten the lock nut.
Install the rubber boot securely_
Recheck the throtlle operation and install the seat
(page 2-3).
AIR CLEANER
NOTE -
• If the vehicle is used in dusty areas, sand or snow,
more frequent inspections are required.
Remove the seat (page 2-3).
Release the four retaining clips [1] and remove the air
cleaner cover [2].
I
1
Loosen the band screw [11 and remove the air cleaner 1
element assembly [21. 1
~
I
Remove the dust filter [1] from the element holder in the
air cleaner housing.
3-6
MAINTENANCE
Remove the element band [1] and the element core (2]
from the air cleaner element [3] .
.,""\
12] 13]
Wash the element and filter in non~flammable or high ;:::==========:----====;
flash point solvent.
Squeeze out the solvent thoroughly. and allow the
element and filter to dry.
Wash Squeeze out
Apply 17 - 23 g (0.6 - 0.8 oz) of Pro Honda Foam Filter ~=====-------__:_~----

Oil [IJ or equivalent oil from the inside of the element. [1]
Place the element into a plastic bag [2] and spread the
oil evenly by hand.
12]
Install the element core (11 into the air cleaner element
[21 properly.
Inslalilhe element band (3] onto the element flange.
3-7
MAINTENANCE
Clean the inside of the air cleaner housing and cover.
Install the dust filter [lllnlc the element holder.
Install the element assembly (2) over the connecting
lube on the housing .
Be sure 10 rest the element onto the stepped area [3) of
the element holder and lighten the band screw [4).
Make sure the air cleaner cover seal 111 is in good

condition and replace illf necessary.
Inslall the alf cleaner cover [2) with the arrow [3) facing
forward by aligning the stepped area [4J with the
element.
Secure the cover with the four retaining clips.
Install the seat (page 2-3).
1
AIR CLEANER HOUSING DRAIN TUBE
NOTE :
• If the vehicle is used In very wet or muddy
conditions, more frequent inspections are required.
Remove the drain lube [I] from the bottom of the air
cteaner housing to empty any deposits.
Install the drain tube securely.
3-8
MAINTENANCE
SPARK PLUG
Remove the left fuel tank side cover (page 2-4).
Clean with Disconnect the spark plug cap [1] and clean around the
compressed air spark plug base.
before removing the
Remove the spark plug [2].
plug, and be sure
thaI no debris is
allowed to enter into
the combustion
chamber.
Check the insulator [1] for cracks or damage . and the

electrodes for wear, fouling or discoloralion. Replace 121 131 I
the plug if necessary.
RECOMMENDED SPARK PLUG :

BKR5E·11 (NGK), K16PR-U11 (DENSO)
Clean the center electrode [2] and side electrode [3)

with a wire type brush or special plug cleaner.
111
Check the gap between the center and side electrodes
with a wire-type feeler gauge.
~
SPARK PLUG GAP: 1.0 - 1.1 rnm (O.039 - 0.043 in)
If necessary. adjust the gap by bending the side

1.0 - 1.1mm
(0.039 - 0.043 in) 1
electrode care-fully_
Thread the spark plug in by hand to prevent cross-
threading and tighten it with a spark plug wrench.
TORQUE: 22 N·m (2.2 kgf-m , 161bHt)
Connect the spark plug cap and install the left fuel tank
side cover (page 2-4).
3-9
1
MAINTENANCE
VALVE CLEARANCE
NOTE :
• Inspect and adjust the valve clearance while the
engine is cold (below 3S"C/9S0F).
Disconnecllhe fuel pump unit 4P connector [1] .
Remove the following from the ECM stay (2] :
- fuel tank breather hose (3]
- wire harness clip 14]
- ;oinl connector [5)
- PCMfECM (6)
- fuel hose [1J

- 0011121
Remove the wire harness clip [3) from the snorkel ducl.
Disconnect the ECT sensor 2P connector [1] and spark

plug cap 12]. and remove the plug wire (3] from the heat
guard 14].
Remove the rear final gear breather hose (5] from the
ECM slay [6].
Release the ECM slay from the tab [7).
Remove the ECM stay (1) by releasing its bosses (2]

from the grommets [3].
Remove the main wire harness [4] from the heat
protector.
Remove the brake panel breather hose {51 from the
ECM stay.
••
1
3-10
MAINTENANCE
Remove the trim clip (1J, loosen the band screw 12] and
remove the snorkel duct 131.
Remove the fuel hose [1J from the heat protector.

Remove the fuel tank mounting bolt [21-
Release the heat protector retaining tab [31 .
Remove the two trim clip [1[ from the front center cover.
Raise the rear of the fuel tank [1] and support it with a
socket wrench (2].
Remove the heat protector [3] from the left frame pipe
and raise it.
3-11
MAINTENANCE
Remove the valve adjusting hole caps 111.

- three bolts [1]
- crankshaft hole cap [21
- liming hole cap [31
"the or mark is Rotate Ihe crankshaft clockwise to align the "T~ mark (11
passed when /rymg on Ihe flywheel with Ihe index nolch [2] on the
10 align it with the crankcase.
~--
IndeX notch, rotate Make sure the piston is at TDG (Top Dead Center) on
the compression stroke, (
the crankshaft only
clockwise again
and align. This
This position can be obtained by confirming that there is
slack in both rocker arms. If there is no slack, rotate Ihe
,
~
-""I
must be done to crankshaft one full turn and match up Ihe T mark again.
prevent the one-
way decomprossor
system from III "'" - - ,
functioning and 10
obtain the correct
-1_ 1_
valve clearance.
~en checking the Check the valve clearances by inserting a feeler gauge
clearance, slide the (1] between the adjusting screw and valve stem.
feeler gauge from
the centertoward VALVE CLEARANCE :
the outside. IN : 0.15:t 0.02 mm (0.006 t 0.001 In)
EX : 0.23 :t 0.02 mm (0.009 t 0.001 in)
3-12
MAINTENANCE
Adjust by loosening the lock nut [1] and turning the
adjusting screw [2) with the special tool until there is a
slight drag on the feeler gauge .
TOOL:
Valve adjusting wrench set [3] 07908-3230000
Hold the adjusting screw and tighten the lock nut.
TORQUE : 17 N'm (1 .7 kgf-m , 13 Ibf-ft)
After lightening the lock nut, recheck the valve
clearance.
Coat new D-rings (1] with engine oil and install them r"'~r-,,=~-;:~':7T
into the groove in the valve adjusting hole caps [2].
Instal! the valve adjusting hole caps and tighten them .
TORQUE: 12 N'm (1.2 kgf'm , 9 Ibf-fl)
Coat a new D-ring [1J with engine oil and install it onto
the timing hole cap [2J.
Instal! the timing hole cap and tighten it
TORQUE: 10 N'm (1.0 kgf'm , 7 lbHt)
Coat a new D-ring (1] with engine oil and install it into
the crankcase cover groove.
Install the crankshaft hole cap (2] and tighten the three
bolts 131.
3-13
1I
MAINTENANCE
Install the removed parts in the reverse order of
removal.
Align the lug of the snorkel duct wi th the groove in
the snorkel hose.
Route the wire harness and hoses properly
(page 1-23).
ENGINE OIL (Except FA1/FA2 models)

LEVEL CHECK
Remove the oil check lid (page 2-3).
Place the vehicle on level ground.
Start the engine and let it idle for 3 - 5 minutes.
If the air temperature is below 10· C (50·F), let the
engine idle for an additional 5 minutes (a total of
10 minutes).
Stop the engine and wait 2 - 3 minutes.
Remove the oil filler capfdipstick [1] and wipe it clean.
Check the oil level by inserting the oil filler capfdipstick
into the engine without screwing it in.
The engine contains a sufficient amount of oil if the oil [2J
level is between the upper level mark [2] and lower level
mark [3] on the dipstick. [3J
If the oil level is near or below the tower level mark, add
the recommended engine oil to the upper level mark.
•,
RECOMMENDED ENGINE OIL:
Pro Honda GN4 4-stroke 011 (U.S,A. & Canada) or
equivalent motorcycle oil
API service classification: SG or higher (except
oils labeled as energy conserving on the circular
API service label)
JASO T 903 standard : MA
Viscosity: SAE 10W-30
NOTE :
Other viscosities shown in the chart may be used , - - - - - - - - - - -- -
when the average temperature in your riding area is
within the indicated range. Oil VISCOSITIES
Reinstall the oil filter cap/dipstick. I I· .
-1'tiI'! _t'l1#!' _
Install the oil check lid (page 2-3).
1111
I III
..
-30
-20
.2h
0 20
0
co
10
&I
20 3fJ"
80
40
100
~·c
120' f
3·14
MAINTENANCE
OIL CHANGE
NOTE :
• Change the oil wi th the engine warm to assure
complete and rapid draining.
Start the engine and let it idle for a few minutes.
Stop the engine.
Remove the drain bot! (1), sealing washer [21 and the oil
filler cap/dipstick 13]10 drain the engine oil.
After the oil has drained , inslallthe drain boll with a new
sealing washer.
TORQUE: 25 N'm (2.5 kgf-m , 18lbf-ftj
Pour the recommended oil (page 3-14) into the engine
to the upper level mark on the dipstick.
Oil CAPACITY:
After draining :
2.6 liters (2.7 US qt, 2.3 Imp qt)
After drainingffilter change:
After disassembly :
Install the filler cap/dipstick.

Check the oil level (page 3-14).
Reset the maintenance minder indicator after changing
the engine oil (page 3-2).
3-15
MAINTENANCE
ENGINE OIL (FA1/FA2 models)
LEVEL CHECK
If the air temperature is below 10·C (50·F), let the
engine idle for an additional 5 minutes (a total of
10 minutes).
Stop the engine and wait 2 - 3 minutes.
Remove the dipstick [1J and wipe it clean.
Check the oil level by inserting the dipstick into the
engine without screwing it in.
The engine contains a sufficient amount of oil jf the oil
level is between the upper level mark [2] and lower level
mark [3] on the dipstick.
1j
1- -12J
"- -13J ;
If the oil level is near or below the tower level mark,
remove the tank cover assembly (page 2-4) and the oil
filler cap 11J, and add the recommended engine oil to
the upper level mark on the dipstick.
1
RECOMMENDED ENGINE Oil:
Pro Honda GN4 4-stroke oil (U.S,A . & Canada) or
equivalent motorcycle oil
API s ervice classification: SG or higher (except
oils labeled as energy conserving on the circular
API service label)
JASO T 903 standard : MA
Viscosity : SAE 10W·30
NOTE:
Other viscosities shown in the chart may be used , - - - - - - - - - -- - - - - - - ,
when the average tempera ture in your riding area is
within the indicated range. OIL VISCOSITIES
I~~: r I ~
Reinstall the fiUer cap and the dipstick.
IOW-30 IOW,40
Inslalilhe tank cover assembly (page 2-4).
SW·30
[ [Lila"
·30 ·211
I
·10 0 lD 20 :J.O
L •
40 SO' C
_20 0 20 '0 &0 &0 100 lZO'F
3-16
MAINTENANCE
OIL CHANGE
NOTE
• Change the oil with the engine warm to assure
complete and rapid draining.
I
Start the engine and let it idle for a few minutes.
Stop the engine.
Remove the drain bolt [11. seaHng washer [2] and the oil
filler cap [3] 10 drain the engine oil.
After the oil has drained, install the drain bolt with a new
sealing washer.
TORQUE: 25 N'm (2.5 kgf'm , 181bHt)
Pour the recommended oil into the engine through the
oil filler hole to the upper level mark on the dipstick
(page 3-16),
OIL CAPACITY:
After draining :
After draining/filter change:
After disassembly:
Install the filler cap and the dipstick.
Check the oil level (page 3-16).
Reset the maintenance minder indicator after changing
the engine oil (page 3-2).
ENGINE OIL FILTER (Except FA1/FA2

models)
Drain the engine oil (page 3-15). -'~ [61
Place shop towels Remove the following :
under the filter
- three bolts [1J
cover because oil
- filter cover !2J and O-ring !3]
will flow ou/.
- oil filter [4]
- setting spring [5]
- O-ring [6J
Coal new O-rings with engine oil and install them into
each groove in the filter cover and fronl crankcase
cover.
/y
Installing the oil Instalilhe setting spring onlO the lugs and a new oil filter
filter backwards will with the rubber sea l 171 facing oul, away from the 111 -,
result in severe engine (OUT-SIDE mark 18] on the fil ter is visible), then
engine damage. set the filler cover onto the filler and tighten the bolts
while holding the cover. ~ [31 121
Fill the crankcase with the engine oil (page 3-15)
Instail ihe tank cover assembly (page 2-4).
3-17
MAINTENANCE
ENGINE OIL FILTER (FA1/FA2 models)
Drain the engine oil (page 3-17).
Place shop towels Remove the following:
under the filter
- three bolts (1)
cover because oil
- filter cover [2) and O-ring [3J
will flow out.
- setting spring [4J
- oil filter (5)
Coat a new O-ring with engine oil and install it into the
groove in the filter cover.
Install a new oil filter onto the engine boss wi th the
Installing the 0;1 filter
backwards will · OUT-SIDE" mark [5] facing out (rubber seal side
result in severe facing in).
engine damage. Install the spring onto the filter boss, then install the
filter cover with the triangular mark [7J facing up and
with the spring between the locating tabs [B].
Tighten the bolts securely while holding the cover.
Fill the crankcase with the engine oil (page 3-17).
Install the tank cover assembly (page 2-4)
,1,
ENGINE IDLE SPEED
Inspect the idle speed after all other engine
maintenance items have been performed and are
within specifications.
,1
Before checking the idle speed, inspect the following •
items.
- No DTG and MIL blinking (page 4-6)
- Spark plug condition (page 3-9)
- Air cleaner condition (page 3-6)
The engine must be warm for accurate idle speed
inspection.
This system eliminates the need for manual idle
speed adjustment compared to previous designs.
Use a tachometer with graduations of 50 rpm or
smaller tha t will accurately indicate a 50 rpm
change.
Start the engine and warm it up to coolant temperature
BO°C (175°F).
Stop the engine and connect a tachome ter according to
the tachometer manufacturer's operating instructions.
Start the engine and let it idle. Check the idle speed.
ENGINE IDLE SPEED : 1,400 ± 100 rpm
•
If the idle speed is out of the specification, check the
following:
Throttle operation and throttle lever freeplay (page
3-5)
Intake air leak or engine top-end problem
(page 10-3)
IACV operation (page 7-21)
3-18
MAINTENANCE
RADIATOR COOLANT
Check the coolant level of the reserve tank [1] with the
engine running at normal operating temperature.
The level should be between the upper level line [2) and
lower level line (3] with the vehicle upright on a level
surface.
If the level IS low, add the coolant as follows:
Remove the radiator cap tid (page 2·3),
Remove the reserve tank cap (1). and fill the tank up to
the upper level line wi th a 1: 1 mixture of distilled water
and antifreeze.
RECOMMENDED ANTIFREEZE :
Pro Honda HP coolant or an equivalent high
quality eth ylene glycol antifreeze containing
silicate-free corrosion inhibitors
Check to see if there are any coolant leaks when the
coolant level decreases very rapidly.
If the reserve tank becomes completely empty, there is
a possibility of air getting into the cooling system.
Be sure to remove any air from the cooling system
(page 8-5).
COOLING SYSTEM
NOTE
• If the vehicle is used In very wet or muddy
conditions, more frequent inspections are required.
Check for any coolant leakage from the water pump,
water hoses [1) and hose joints.
Check the water hoses for cracks or deterioration and
replace if necessary
Check that all hose clamps are tight.
3-19
MAINTENANCE
Except FM2/FAZ" Remove the trim clips [1 J and radiator grille cover [2J
from the right side while releasing the tabs and fan
moior breather hose (3). 1
I
fM2/FA2: Remove the radiator reserve tank (page 8-9).

Remove the trim clips [1] and radiator grille cover [2J
from the left side while releasing the tabs and front final
drive breather hose [3].
[11 [21
Remove the center radiator grille cover [1) by releasing
the lab from the radiator grille cover.
1
1
Check the radiator air passage for clogs or damage.

Straighten bent fins with a small, flat blade screwdriver
and remove insects, mud or other obstructions with
compressed air or low pressure water.
Also, clean the radiator grille thoroughl y.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
removaL
3-20
MAINTENANCE
DRIVE TRAIN BOOTS
Raise all the wheels off the ground by supporting Ihe
frame securely .
Check the drive shaft boots (except TM1rrE1) (1].
propeller shaft boot (excep t TM1fTE1) [2] and universal
joint boot [3] for cuts, damage or leaking grease.
If the boot is damaged, replace it.
- fron t driving mechanism (page 20-5)
- rear driving mechanism (page 21-5)
FRONT AND REAR FINAL GEAR OIL

REAR FINAL GEAR OIL
LEVEL CHECK
Place the vehicle on a level surface.
Remove Ihe oil check bolt [1J and check thai the oil
flows out of the check boll hole.
Check for leaks if there is no oil flow.
Remove the oil filler cap [2) and pour the oil slowly
through the filler hole until oil starts to flow out of the
check bolt hole.
RECOMMENDED OIL : Hypoid gear oil, SAE 80W·90
Install the check boll with a new sealing washer [3) and
tighten it.
TORQUE: 12 N·m (1.2 kgf·m , 91bHt)
Coat a new O-ring [4] with grease and install it into the
cap groove.
Install the filler cap and tighten it.
TORQUE : 12 N·m (1.2 kgf·m , 91bHt)
3-21
MAINTENANCE
Oil CHANGE
Remove the drain boll 11] and sealing washer [2] . and
the filler cap [3110 drain the oil.
When the oil is completely drained. install the drain bolt
wi th a new sealing washer.
TORQUE : 12 N'm (1.2 kgf'm , 9 tbHt)
Fill the rear final gear case with the recommended oil
(page 3-21 ).
OIL CAPACITY:
85 em' (2.9 US OZ, 3.0 Imp oz) after draining
100 em' (3.4 US OZ, 3.5 Imp oz) after disassembly
111
FRONT FINAL GEAR OIL (Except TM11
TE1)
LEVEl CHECK
Remove the oil filler cap [11 and check thai the oil level
is up to the lower edge I21 of the oil filler hole.
Check for leaks if the oil level is low.
Pour the oil into the filler hole until it reaches the lower
edge of the hole.
RECOMMENDED OIL: Hypoid g ear oil, SAE 80W·90
Coat a new D-ring [3] with grease and install it into the
cap groove.
Install the filler cap and tighten it.
TORQUE: 12 N'm (1.2 kgf'm , 9lbHt)
j
OIL CHANGE
Remove the drain bolt [1] and the oil filler cap [2J to
drain the oil.
When the oil is completely drained, install the drain bolt
with a new seating washer [3).
TORQUE : 12 N'm (1 .2 kgf'm , 9 IbHt)
Fill the front final gear case with the recommended oil
(page 3-22).
OIL CAPACITY:
210 em' (7.1 US oz, 7.4tmp oz) after draining
250 em] (8.5 US OZ , 8.8 Imp oz) after disassembly
3-22
MAINTENANCE
2WD/4WD SELECT SYSTEM (Except
TM1/TE1 models)
2WD/4WD SELECTOR CABLE
ADJUSTMENT
Remove the boll (1] and the clutch arm cover [2] by
releasing the two labs [3].
Shift the select lever to the 2WO position.
Be sure the clu tch arm [4J position is between the 2WD
marks [5].
Temporarily loosen the adjusting nut [6] by turning it
counterclockwise.
Turn the adjusting nut clockwise until the joint pin [7)
just touches the clutch arm slot (8) with the nut ends [9)
are contacted the jOint pin (cutout IS nol seated). Then
further turn it clockwise 1/4 of a turn to seallhe cutout in
the nut onto the joint pin.
Make sure that the clearance between the joint pin and
arm slot is 0 ,25 - 2 mm (0.01 - 0.08 in).
After adjustment. check the select lever for smooth
operation.
Install the arm cover by aligning the slits with the tabs
and tighten the bolt.
TORQUE: 10 N'm (1 .0 kgf'm , 7 IbHt)
BRAKE FLUID
I NOTICE
Spilling fluid can damage painted. plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE
Do nol mix different types of fluid . as they may not
be compatible with each other.
Do not allow foreign material to enter the system
when filling the reservoir.
When the fluid level is low, check the brake pads for
wear (page 3-24). A low fluid level may be due to
wear of the brake pads. If the brake pads are worn
and the caliper pistons are pushed out. this accounts
for a low reservoir level. If the brake pads are not
worn and the fluid level is low, check the entire
system for leaks (page 3-25).
3-23
MAINTENANCE
Tum the handlebar to the left side so the reservoir is
level and check the reservoir fluid level through the
sight glass [1J .
If the fluid level is near the "LOWER" level mark [2),
remove the screws [3J reservoir cap [4), sel plate and
diaphragm and fill the reservoir with DOT 4 brake fluid
from a sealed container to the casting ledge (5J .
Install the diaphragm, set plale and reservoir cap, and
lighten the cap screws .
TORQUE: 2 N'm (0.2 kgf·m. 1.5 IbHt)
BRAKE SHOE WEAR

Replace the brake shoes if the wear indicator plale [1[
aligns with the reference mark (2] on the brake panel
1
when the rear brake lever or brake pedal is applied.
See Brake System section for brake shoe replacement
(page 19-12).
l
BRAKE PAD WEAR
Replace the brake pads if the wear indicator (1] aligns ~;::::;:::::.::;::;=::;:=::,
j
with the reference mark (lug) (2) on the caliper body I
when the front brake is applied ,
See Brake System section for brake pad replacement
[1)
1
(page 19-7). ,,I
I
J
I
I
3-24
MAINTENANCE
BRAKE LIGHT SWITCH
The front brake light Check that the brake light comes on just prior to the
switch does not brake actually being engaged.
require adjustment.
If the light fails to come on , adjust the rear brake light
switch so that the light comes on at the proper time.
Hold the switch body [1] and turn the adjusting nut [2J .
Do not turn the switch body.
BRAKE SYSTEM
FRONT BRAKE
Firmly apply the front brake lever and check that no air
has entered the system.
If the brake lever feels soft or spongy when operated,
bleed the system.
See Brake System section for air bleeding procedures
(page 19-6).
Inspect the brake hoses (1) and fittings for deterioration,
cracks. damage or signs of leakage.
Tighten any loose fittings.
Replace hoses. pipes and fittings as required.
REAR BRAKE
Make sure the Check the brake cable, brake lever and brake pedal for
brake pedal loose connections. excessive play or other damage.
operates smoothly Replace or repair if necessary.
and that the brake
For cable lubrication: Disconnect the brake cable at the
pedal posi/ion is
brake lever or pedal. Thoroughly lubricate the cables
correc/.
and their pivot points with a commercially available
Make sure Ihe
cable lubricant or a lightweight oil.
brakes do not drag.
Measure the rear brake lever freeplay at the end of the
lever.
FREEPLAY: 15 - 20 mm (19132 - 25132 in)

I,
I
15 - 20mm
(19132 - 25132 in)
3-25
MAINTENANCE
Measure the rear brake pedal freeplay at the end of Ihe
pedal.
FREEPLAY: 15 - 20 mm (19132 - 25/32 in)
Make sum the Adjust the brake lever free play by turning Ihe upper
cutout in the adjusting nut [1] at the brake arm.
adjusting nut;s
Adjust the brake pedal freeplay by turning the lower
seated on the brake
adjusting nut [2] at the brake arm.
arm pin.
1
REVERSE LOCK SYSTEM

Check the reverse selector cable and lever for loose , . - - - - - - - - -
connections, excessive play or other damage.
Replace or repair if necessary.
Release the dust cover [1].
Measure the lever freeplay al Ihe lever end near the
cable.
FREEPLAY : 2 - 4 mm (3132 - 5/32 in)
NOTE :
If necessary. watch the reverse selector arm on Ihe
crankcase to see when it moves while determining
freeplay.
Slide the rubber boot [11 off the adjuster.

Adjust by loosening the lock nut [2) and turning the
adjuster [31.
Tighten the lock nul.
Install the dust cover properly.
3-26
MAINTENANCE
GUARDS
Check the inboard guard (except TM1fTE1) PI,
outboard guard (except TMlfTE1) [2J. engine guard [3J
and skid plale [4] for cracks, damage or looseness.
Tighten any loose fasteners. Replace the guard or skid
plate as required.
CLUTCH SYSTEM (Except FA1/FA2

models)
loosen the lock nut [1] and turn the adjusting screw [2]
one full turn clockwise.
Slowly turn the adjusting screw counterclockwise unlil
resistance is felt, then turn the adjusting screw 1{4 turn
clockwise.
Hold the adjusting screw and tighten the lock nul.
Start the engine and check for proper clutch operation.
Install the tank cover assembly (page 2-4).
121 111
SUSPENSION
Loose, worn or Check the action of the front and rear shock absorbers
damaged by compressing them several times.
suspension parts Check the entire shock absorber assembly for signs of
impair vehicle leaks. damage or loose fasteners.
stability and control. Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Raise the rear wheel off the ground by supporting the
frame securely.
Check for worn swingarm bushings by grabbing the rear
axle and attempting to move the swingarm side to side.
Replace the swingarm if any looseness is noted (page
18-5).
3-27
MAINTENANCE
SPARK ARRESTER
Remove the arrester bolt [1].
Block the end of the muffler with a shop towel.
Start the engine with the transmission in neutral, and
purge accumulated carbon from the muffler by
momentarily rewing the engine several times.
Stop the engine and allow the exhaust system to cool.
Install the bolt and tighten it securely.
NUTS,BOLTS,FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-13).
Check that all cotter pins. safety clips, hose clamps and
cable stays are in place and properly secured .
WHEELSITIRES
Tire pressunI Check the tire pressure with a tire pressure gauge .
should be checked
when the tires are RECOMMENDED TIRE PRESSURE
cOld. Standard : 30 kPa (0 .30 kgflcm 2, 4.4 psi)
With cargo : 30 kPa (0.30 kgf/cm 2 , 4.4 psi) ,
Check the tires for cuts, embedded nails, or other ,•
damage.
Raise the wheel off the ground and check the bearings
1
in the knuckle for excessive play or abnormal noise. 1,
3·28
MAINTENANCE
TIE·ROD AND JOINT BOOTS
Check the tie-rod ball joint nuts [1] and the suspension
arm ball joint nuts [2] for looseness.
Check the boots of the tie-rod ball joints [3] and
suspension arm ball joints [4J for tears or other damage.
Check for looseness of the lie-rod ball joints or
suspension arm ball joints by grabbing each front wheel
side to side with the wheels on the ground.
If any looseness is noted , inspecllhe following .
- tie-rod (page 17-32)
- suspension arm (page 17-20)
STEERING SHAFT HOLDER BEARING

Make sum me Raise the front wheels off the ground and support the
cables do not vehicle securely.
in/erlere with the Check that the handlebar moves freely from side to
rolation ofrhe side .
handlebar. If the handlebar moves unevenly , binds , or has
horizontal or vertical movement, inspect the steering
shaft holder bushing and bearing.
- Except FM2/FA2: page 17-24
- FM2/FA2 : page 17~27
FM2JFA2 only: Place the vehicle on the ground.
Compare the required steering force with the engine
running and with the engine stopped .
If the steering force is same. check the EPS system
(page 25-2).
STEERING SYSTEM
Place the vehicle on level ground with the front wheels
facing straight ahead.
r------:::;;;;;::;;;:;:;::;7)c;-----i
Mark the centers of the tires with chalk to indicate the
axle center height.
Align the toe-gauge [1) with the marks on the tires as
shown .
Check the readings on the gauge scales.
3-29
MAINTENANCE
Slowly move the vehicle back until the wheels have Front
turned 180" so Ihe marks on the tires are aligned with
the gauge heighl on the rear side.
Measure the loe on Ihe rear part of the tires at the same
points with no load on the vehicle.
Toe-cut: 15:t 15 mm (9116 ± 9f16 in)
NOTE:
Toe-in means Ihe rear measurement is greater Ihan
the front measurement.
Toe-out means the front measurement is greater
than the rear measurement.
When the toe Is out of specification . adjust it by

changing the length of the tie-rods [1] equally by
loosening the lock nuts {2] and turning the tie-rods while
holding the ball joints.
After adjusting each tie-rod, rolate both ball joints in the
same direction , along the tie-rod axis until they stop
against the ball joint stud.
I
~
Using a 22 mm wrench, hold the ball joint ends {flats}

[1] so thai the relative angle of both ball joints may turn
into specified angle. Then , tighten each lock nut [21 .
I J
121
I
1
making sure not to force Ihe ball joint end against the 1
ball joint stud [3] .
TORQUE: 54 N'm (5.5 kgf-m , 40 IbUt)

After tightening the lock nuts, rotate the tie-rods to
make sure the ball joints operate properly and have an
equal range of movement.
~
[2[ [11 13[
SIeering Side
------t--
16· 30'
Knuckle Side
3-30
4. PGM·FI SYSTEM
SERVICE INFORMATION ····························· 4·2 MIL CIRCUIT INSPECTION ············ ·········· ·· 4·30
COMPONENT LOCATION ····· ·······················4·2 SENSOR UNIT (MAP/TP SENSOR) ........... 4·32
SYSTEM DIAGRAM ······································ 4·3 ECT SENSOR ··········································· ·· 4·34
TROUBLESHOOTING INFORMATION ········ 4·5 BANK ANGLE SENSOR ............................. 4·34
SYMPTOM TROUBLESHOOTING ··············· 4·8 PCM/ECM .................................................... 4·35
DTC INDEX ·················································"' 4·8 0 , SENSOR ................................................. 4·37
DTC TROUBLESHOOTING ························4·10
4-1
PGM·FI SYSTEM
SERVICE INFORMATION
GENERAL
A faulty PGM·FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
Use a digital lester for PGM-FI system inspection.
The engine stop switch line is connected to the PCMfECM via the fuel pump relay coil. lis signal permits the PCMfECM to
controllhe fuel pump, fuel injector and ignition coil.
The following color codes are used throughout this section.
BI: Black Bu: Blue Gr: Gray Lg: Light green P: Pink V: Violet Y: Yellow
Br: Brown G: Green Lb: Light blue 0: Orange R: Red W: White
,
TOOLS
i
SCS Service Connector Pin Probe Male (2 pack) I
070PZ-ZY30100 07ZAJ-RDJA110
1i
COMPONENT LOCATION
FA2 model shown: IGNfTlON SWITCH
ENGINE STOP SWITCH
BANK ANGLE SENSOR
FUEL INJECTOR
DLe ,
0 2 SENSOR
FUSE BOX c...c-:,r-- FUEL PUMP UNIT
-- (30 A) -r".;<:=;;;g~~~~
MAIN FUSE 1 (10A)
MAINFUSE2 ___~",~ RELAY BOX
- IGN FUSE (20 A) f;::::;:f-- - MAIN POWER RELAY
- ACC FUSE (20 A) - FUEL PUMP RELAY
- DIODE
ECT SENSOR
IACV
SENSOR UNIT (MAPrTP SENSORS)

CKP SENSOR
VS SENSOR
Except FA1 fFA2: POSITION SWITCH
IAT SENSOR FA1fFA2: SHIFT DRUM POSITION SWITCH
4-2
PGM-FI SYSTEM
SYSTEM DIAGRAM
Except FA1 /FA2 models
,~ ..
T"'IIF"""''''2 FAN FUSE (20 II)
TEl/FE' ES FUSE (30A)
REGULATOR! I
g
MAIN POWER RECTifiER
RELAY
,-,
BATIERY
,---P:5;;;r~ '~ <0 -

MAIN FU SE 1(30011)
IGNITION SWITCH
- 'tl="'~.' -r- ~
r- "-111
IGN FUSE 120,0,)
P~W.lIl
/lee Fuse (2OA)
R'8I
," -I-
R_
L. R1f11~ "Iv [B] ,

MA.IN FUSE 2 (lOA) DIODE
0, SENSOR
HEATER
@(23)
OzSENSOR
~
'
=
,. ~" O,HT
A'Q 0,
~
~,
"' ..
oW
@(21l G.W
'"
'"A
SENSOR
O .r:-+
o;),. ~ Bll pcp
~U' ero
o.~ow
- -
FUEL PUMP RELAY
.. ~TOP
=-::1 . .
SWITCH
~ ~ ~
,~,
ANGLE
SENSOR
~
' r-l~
@I~I
SENSOR UNIT fUEL PUMP
i~~iF[·El·~~·t~o;;w~~ r - - """ -
OW ~, "'J ~
~.
GW
"
S14 Tli
6Jl
~ fUEL
" ~
~ ,INJECTOR
I ~,
@(12) 8:
SENSOR
!9~._. __ _ " B" "" >GN S"
'" ••
IGN ITiON
'"
SENSOR • S:>6 TA COil
@(91 PCM/ECM SPARK

ow -!/LUG
.~ Bl' 'fW
.... ,
~
w:v· '''' ~
m Io'.CV IB "0 IACV

SENSOR !N:-'MA 83() ,,~
@1291
'..cV.2lI
,""
@m
- - -- - - - - -- - ------ ,
w_ ~, g,·w 8 ""R _ i
LTMIT'I£d.!"_ _ _ _ ~MJL_ _ _ _ __ =-~ J
... ·n«H.W.l.21 r-': -l"AA' - S

E.>;cepl MIL
~F;---:J.....
LIt"' ~-----.S;g~BINAl:JQN ME!~R_ _ _ _ _ ~J
- I
...
0 A;'~ CPR • "~
OC • "" ~
~25{b
..• .. ~
.." OP N
,0 W< ..... GP. ] Dl.C 5es SERVICE CONNECTOR
1<27GP2 'AA , 111---<:0--1\.; , ww _

o " "
.•
~~,
COOLING FAN MOTOR
, ~, .n
~==ll
,
~
... ,3 CP5
"
~,
SHIFT DRUM
POSITION SWITCH
'"
ffi' "'.
@141) M
"
PGM-FI SYSTEM
FA1/FA2 models
REGULATOR! I
RECTIFIER I
I IGNI [ION S' VITCH I
L ~~~ ~~_ , _+- _____

MAlNFUSE2{IOAI OlooE
~, ~
"""
SENSOR
@(SoIJ
~
c=::;;;'="* '" - ~ FUEL
INJECTOR
j
I
@(12I S
~' t; IGNITION
COil
1
SPARK
J.P!.UG
1
'"
SENSOR
@m
,
~ r- m
Off
I (~ IACV
@(29) ,1
1
'~"fJ:j e."
~,
~
f- - - ~
SENSOR .L ~
@(66J =
, , .,," J,-
~:~6:'W
@(67)
~~~;;;;:::::]
J,.
~ __. LW." ]Jl
~ -,.. " ~
-f"""'" Ole scs SERVICE CONNECTOR
==:!-~ --
, - .-@-~ . ~ --
rl o '.- COOLING FAN MOTOR
SHIFTORUM
POSITION SWITCH
I~
@(41)
"-" B.-l ."
@( ) Mil Blink
9: Engine CIOeI ~ .tart
"""'" dfllflC\ing OTC
dl SIlOtIlerminaIs!of
MAdtngOTC
4-4
PGM·FI SYSTEM
TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure
The term ~intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does nol come on , check
for poor contact or loose pins al all connectors related 10 Ihe circuit thai of the troubleshooting. If the Mil was on, but then went out,
the original problem may be intermittent.
Opens and Shorts
· Opens· and · Shorts· are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will nol work al all. WIth PCMf
ECMs this can mean something may work, but not the way it's supposed 10.
tf the Mil has come on
Refer to DTC READOUT (page 4-6)
If the MIL did not stay on
If the Mil did not stay on, but there is a driveabillty problem, do Ihe SYMPTOM TROUBLESHOOTING (page 4-8).
SYSTEM DESCRIPTION
SElF·DIAGNOSIS SYSTEM
The PGM-FI system IS equipped with the self-diagnostic system. When any abnormality occurs in the system, the PCMIECM turns
on the MIL and stores a OTC in its erasable memory.
FAil-SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system. When any abnormality is detected by the self·diagnosls function, running capability is maintained by pre-programmed
values in the simulated program map. When any abnormality is detected in the fuel Injector and/or CKP sensor, the fall·safe
function stops the engine to protect it from damage.
MIL Blink Pattern
If the MCS is not avaitable. OTC can be read from the PCMfECM
memory by blink. pattern of the Mil [1]. 111
The number of Mil blinks is equivalent to the main code of the OTC (the
sub code cannot be displayed by the Mil).
The MIL will blink. the current OTC, in case the PCM/ECM detects the
problem at present, when the ignition switch ON or idling. The MIL will
stay ON when driving.
The Mil has two types of blinks, a long blink and short blink. The long
blinking lasts for 1.3 seconds, the short blinking lasts for 0.5 seconds.
® ,-c
LI.
One long blink is the equivalent of ten short blinks. For example. when '1 .. ,....
two long blinks are followed by five short blinks, the Mil is 25 (two long
blinks = 20 blinks , plus five short blinks).
When the PCM/ECM stores more than one OTC, the Mil will indicate
them by blinking in the order from the lowest number 10 highest number.
MIL Check
When the ignition switch is tumed ON , the Mil will stay on for a few seconds. then go off. If the MIL does not come on. troubleshoot
the MIL circuit (page 4·30).
CURRENT DTC/FREEZE OTC
The DTC is indicated in two ways according to the failure status.
In the case that the PCMIECM detects a problem at present, the Mil will come on and will start to blink as its DTC. It is possible
to readout the Mil blink pattern as the current OTC.
In the case that the PCM/ECM does not detect any problem at present but has a problem stored In its memory, the Mil will not
light and blink. To retrieve the past problem code, readout the freeze OTC by follOWing the OTC readout procedure.
4-5
PGM-FI SYSTEM
MCS INFORMATION
• The MeS can readout the DTG, freeze data, current data and other PCMlECM condition.
How to connect the MeS
Remove the radiator cap lid (page 2-3),
Turn the ignition switch OFF.
Remove the dummy connector [1 J from the OLe {2].
Connecllhe MeS to the OLe.
Tum the ignition switch ON, and check the OTC and freeze data.
NOTE
Freeze data indicates the engine conditions when the first malfunction
was detected.
DTC READOUT
Slartihe engine and check the MIL (1J.
(1(
• When the ignition switch is turned ON. the Mil will stay on for a few
seconds, then go off.
It the MIL slays on or blinks, connect the MeS to the OLe (page 4-6). read \
ICOUJII
the DTG , freeze dala and follow the troubleshoo ting index (page 4-8).
To read the OTC with the MIL blinking, refer to the following procedure. ® j
@ I'J ,
- 'i "'UI 1
Reading OTC with the MIL

Remove the dummy connector (page 4-6).
Turn the ignition switch OFF. ,
Short OLC terminals using the special tool.
Connection : Brown - Green
TOOL :
1
SCS Service Connector (1( 070PZ·ZY30100
Turn the ignilion switch ON, read, note the MIL blinks and refer to Ihe
j
troubleshooting index (page 4-8). j
NOTE
If the PCM/ECM has any DTC in its memory, the MIL will start blinking .
•
ERASING DTC 1
NOTE
• When eraSing the PGM·FI DTC, the OCT DTC or ESP DTC would also be erased at the same lime. Check the gear position
indlcalor blinks and troubleshoot the OCT or ESP system before erasing the PGM-Ft OTC.
1
Connect Ihe MCS to Ihe DLC (page 4-6). •
Erase the OTC with Ihe MCS while the engine is stopped. ,l
To erase the DTC without MCS, refer to the fallowing procedure.
4·6
PGM-FI SYSTEM
How to erase the OTG with SCS s ervice connec tor
1. Turn the ignition switch OFF .
2. Remove the dummy connector (page 4-6).
3. Short OLe terminals using the special tool.
TOOL:
SCS Service Connector (1] 070PZ-ZY30100
Connection: Brown - Green

4. Turn the ignilion switch ON .
5. Remove the special 1001 from the DLe.
6. The Mil wit! light for approximately 5 seconds. While the MIL lights,
short the DLe terminals again with the special 1001. The self-diagnostic
memory is erased jf Ihe MIL goes off and starts blinking.
NOTE :
The OLe must be jumped while the MIL is illuminated . If nol, the MIL will
not start blinking .
Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking .
CIRCUIT INSPECTION
INSPECTION AT PCM/ECM CONNECTOR
Always clean around and keep any foreign material away from the PCMI ~
[11
ECM connector before disconnecting it.
A faulty PGM-FI system is often rela ted to poorly connected or corroded
connections. Check those connections before proceed ing, '1~~~~~
In testing at PCM/ECM connector (wire harness side) terminal. always
use the test probe. Insert the test probe into the connector terminal, then
attach the digital multimeter probe to the test probe.
TOOL:
Pin Probe Male (2 pack) (1) 07ZAJ-RDJA110
4-7
PGM·FI SYSTEM
SYMPTOM TROUBLESHOOTING
When the vehicle has one of these symptoms, check the DTG or MIL blinking, refer to the DTC index (page 4-8) and begin the
appropriate troubleshooting procedure. If there are no DTG/Mll blinking stored in the PCM/ECM memory. do the diagnostic
procedure for the symptom, in sequence listed below. until you find cause.
, J
2. Inspect Ihe ignition system (page ~:~;z~':~ strainer screen
3. Inspect Ihe cylinder compression P or dogged fuel hose
(page 10-6). - Pinched or dogged fuel lank
4. Inspect the fuel supply system (page 7-12). breather hose
5. Check Ihe IACV (page 7-21), - Faulty fuel pump
- Faulty fuel pump circuits
Intake air leak
Contaminated/deteriorated fuel
Faulty fuel injector
; Faulty bank angle sensor or
(No fuel pump operation sound malfunction (page 4-35) related circuil
when turning the ignition 2. Inspect the fuel supply system (page 7-12). Faulty fuel pump relay or related
switch ON and engine stop circuit
; IACV (page 7-21). Restricted fuel hose

rough idling 2. Inspect the fuel pressure (page 7-10). Contaminated/deteriorated fuel
3. Inspect the fuel flow (page 7-11). Intake air leak
4. Inspect the ignition system (page 5-5). Restricted fuel tank breather hose
5. Inspect the cylinder compression
~Aft,""um""ieii~~,",;;aJ<in;lr,,"~a'1i;i;jgiilikmsystem (page 5-5).

t
rI-~m~*~::~:~~}~~::,:~';::~~;
and poor fuel economy
system (page 5-5).
Inspect the fuel pressure (page 7-10).
Inspect the fuel flow (page 7-11
Pinched or clogged fuel hose
Faulty pressure regulator
Inspect the air cleaner element 3-6). Faulty fuel injector
2. Inspect the fuel pressure (page 7-10).

3. Inspect the fuel flow (page 7-11).
4.
; I
,
~",.df;oa';o""" fast idle too (page 3-5). Engine lop end problem
Check the tACV (page 7-21)
DTC and MIL blinking) Inspect the system (page S-S).
, __ -+~~i~,;~:,~~~~~;::e:~;~:~(page 3-6)._+_
MIL never comes ON at al
MIL stays ON at all
••
(No DTC set)
DTCINDEX
DTC
Refer
(MIL Function Failure Symptom/Fail.safe function
blinks)
to
I ,-, (') MAP sensor circuit low voltage
· MAP sensor or its circuit malfunction
· Engine
· Engine
operates normally
Pre-program value: 64 kPa
4·10
1·2 (1)
MAP sensor circuit high voltage
··Loose or poor contact of the MAP sensor connector
·· operates normally
Pre·program value: 64 kPa 4·12
I
MAP sensor or its circuit malfunction
ECT sensor circuit low voltage
· ECT sensor or its circuit malfunction
· Hard to start at a low
temperature
7·, (7) · Pre·program value: 78.BoC/
173.S·F
4-13
I I · Cooling fan turns on
4-8
DTC
(MIL Function Failure
blinks)
Eel sensor circuil high voltage
Loose or poor con tact of the Eel sensor connector
7-2 (7) • EeT sensor or its circuit malfunction
TP sensor circuillow voltage

8-1 (8) • Loose or poor contact of the TP sensor connector
• TP sensor or its circuit malfu,n,"";o,n' -_ _ _ _ _ _ _ _ _~~===~====~--------
TP sensor circuit high voltage-
8-2 (8)
• TP sensor or its circuit malfunction
lAT sensor circuit low voltage
9-1 (9)
• IAT sensor or its circuit malfunction
tAT sensor cirCUit high vo!lage

9-2 (9) • Loose or poor contact of the IAT sensor connector
• IAT sensor or its circuit malfunction
11-1(11) VS sensor no signal
(Except Loose or poor conlact of the VS sensor connector
TM1/FA1/ • VS sensor or its circuit malfunchon
FA2)
Fuel Injector circuil malfunction
12-1 ( 12)• Loose or poor contact of the fuel injector connector
_____--1-,,' Fuel Injector or its circuit malfunction
0 , sensor malfunction
21-1 (21) • loose or poor contact of the 0 2 sensor connector
• 0, sensor or its circuit malfunction
0 2 sensor heater circuil malfunction ---t--C'' 'E'''ngine operates normally - - - - -- - - j
23-1 (23)
··
Loose or poor contac t of the O? sensor connector
0< sensor heater or its circuit malfunction
4-24
I
IACV circuil malfunction ·
Engine stalls, hard to start, rough
29-1 (29)
··
Loose or poor contact of Ihe IACV connector
lACY or its circui t malfunction
idling 4-25
41-1 (41)
(Except
Gear position switch malfunction
·
Loose or poor contact of the gear position switch
Engine operates norma!1y
ESP does not work
·· 24-18
FA1IFA2)
connector ·
Gear position indicator blinks"-"
·
Gear position switch or its circuit malfunction
Shift drum position switch malfunction Engine operates normaUy ·
41-1 (41)
(FA1IFA2
only)
·
Loose or poor contact of the shift drum position switch
connector
·
Gearshift function does not work
(2nd, 4th or reverse gear only)
13-26
·
Shift drum position switch or its circuit malfunction ·
Gear position indicator blinks"- "
EOT sensor circuit low voltage Engine operates normally ·
44-1 (44)
(FA1IFA2
only)
·
EOT sensor or its circuil malfunction
(2nd, 4th Of
·
g.af o n * 13-28
··
Gear position indicator blinks "-"
f.'.".
44-2 (44)
I EOT sensor circuit high voltage
·
Loose or poor contact of Ihe EOT sensor connector
Cooling fan turns on
Engine operates normally
··
I
(FAlIFA2 ·
EOT sensor or its circuit malfunction (2nd, 4th or reverse gear only) 13-29
only) ·
Cooling fan turns on ·
I Bank angle sensor circuit low voltage Engine operates normally ·
54-1(54) ·
Loose or poor contact of the bank angle sensor
connector
·
Bank angle sensor control stops
4-27
·
Bank angle sensor or its circuit malfunction I
Bank angle sensor circuit high voltage Engine operates normally ·
54-2(54)
66-1 (66)
·
Bank angle sensor or its circuil malfunction
Rear VS sensor no si g nal
··
Bank angle sensor control stops
En g ine operates normall y
4-28
,_,(F"Ai"i''i
I 'FtA,2.--+"=L"0'i0"'.,,,0:cfoPcOcocfCWc'Onlc:a~'~'i'o"fOlh".",f.,a"f,V"S","',.,-
only)
67-1 (67)
Rear VS sensor or its circuit malfunctionn_
Front VS sensor no signal
'O_f_w
_n_n_._'_'O_f_ _-c-~G~.:::a,,"~hc;ft=f"cno'ctlc°,-ncdco~·c'onic°c',W~0"f_
(2nd , 4th or reverse gear only) k _1-13-30
Engine operates normally
j
(FA1/FA2 Loose or poor contact of Ihe front VS sensor connector Gearshift function does not work 13-31
L_,o,n~IY")_--,__· -,F,-fo,n,-lcVcS.-<,,,,ensor or its circuit malfunction (2nd, 4th or reverse gear only)
4-9
PGM·FI SYSTEM
OTe TROUBLESHOOTING
DTe 1 (MAP SENSOR)
Before starting the inspection , check for loose or poor contact on the sensor unit 5P (Black) connector and
PCMlECM 33P connectors, and recheck the OTG.
5V
MAP SENSOR
J SV
1'Cf~ 1T1-- S,IW
~ f - - - Lg
T... PCMIECM
~ I-'...r-- GIW
~ -
Probable cause
Open circuit in Brown/white wire between the MAP
sensor and PCMJECM
Open or short circuit in Light green wire between Ihe
MAP sensor and PCM/ECM
Open circuil in Greenlwhite wire between the MAP
sensor and PCMfECM
Faulty sensor unit (MAP sensor)
Faulty ECM
DTe 1-1 (MAP SENSOR LOW VOLTAGE)
1. MAP Sensor System Inspection
Turn the ignition switch ON.
Check the MAP sensor with the MeS.
Is about 0 V indicated?
YES - GO TO STEP 2 .
NO - Intermittent failure.
2. MAP Sensor Input Voltag e Inspection
Turn the ignition switch OFF .
Disconnect the sensor unit 5P (Black) connector 111
(page 4-32).
Measure the voltage at the wire harness side 5P
connector 11} terminals.
Connec tion : Brown/white (+) - Green/white (-)
Is the voltage within 4.75 - 5.25 V?

YES - GO TO STEP 4 . •,
GIW
NO - GO TO STEP 3.
4-10
PGM·FI SYSTEM
3. MAP Sensor Input Line Open Circuit Inspection
Disconnect the PCMIECM 33P (Gray) connector
I
(page 4-35), B3
Check for continuity between the wire harness side
33P (Gray) connector [1] and 5P (Black) connector
[2J terminals.
TOOL:
Pin Probe Male (2 pack) 07ZAJ·RDJA 110
Connection : B3 - Brown/wh ite

Is there continuity?
YES
NO
- Replace the PCM/ECM with a known good
one (page 4-36), and recheck.
- Open circuit in the Brown/while wire
111
/
4. MAP Sensor Output Line Short Circuit
Inspection
Check for continuity between the wire harness side [11
5P (Black) connector [1J terminal and ground.
Connection : Light green - ground
Is there continuity'?
YES - Short circuit in the Light green wire
NO - GO TO STEP 5.
L9
5. MAP Sens or Inspection

Replace the sensor unit with a known good one.
Erase the DTC (page 4-6).
Turn the ignition switch OFF and ON .
Check the MAP sensor with the MCS.
Is OTe 1·1 indicated?
YES - Replace the PCM /ECM with a known good
NO - Faulty original sensor unit (MAP sensor)
4·11
PGM·FI SYSTEM
DTC 1·2 (MAP SENSOR HIGH VOLTAGE)
1. MAP Sensor System Inspection
Turn the ignition switch ON .
Check the MAP sensor with the MeS.
YES - GO TO STEP 2.
NO - ' Intermittent failure
• l oose or poorly connected sensor unit
5P connector.
2. MAP Sensor Inspection
Turn the ignilion switch OFF.
Disconnect the sensor unit 5P (Black) connector 111
(page 4-32).
Connect the wire harness side SP (Black) connector
111 terminals with a jumper wire (21 ·
Connection: Light green - Green/white
Check the MAP sensor wi th the MeS.
Is about 0 V Indicated?
YES - Faulty sensor unit (MAP sensor)
NO - GO TO STEP 3.
121 1
3. MAP Sensor Input Voltage Inspection
Remove the jumper wire.
1
Measure the voltage between the wire harness side
5P connector (1) terminals.
Connection : Brown/white (+) - Green/white (-)
/s the voltage within 4.75 - 5.25 V?

1
NO - Open circuit in the Green/white wire GM!
•
1
4. MAP Sensor Output Line Open Circuit

Inspection
Disconnect the PCM/ECM 33P (Gray) connector [11 121
(page 4-35).
33P (Gray) connector (1) and SP (Black) connector
\
[2] terminals.
TOOL:
Pin Probe Male (2 pack) 07ZAJ-ROJA 110
Connection: B25 - Light green

~7:~
825 L9
YES - Replace the PCMfECM wi th a known good
NO - Open circuit in the Light green wire
4-12
PGM-FI SYSTEM
OTC 7 (ECT SENSOR)
Before starting the inspection. check for loose or poor contact on the EeT sensor 2P (Black) connector and
PCM/ECM 33P connectors, and recheck the oTC.
5V
Eel SENSOR
BllBu L PCMIECM
L f - - GMI -
""l
Probable cause
Open or short circuit in Blacklblue wire between the
EeT sensor and PCM/ECM
Open circuit in Green/white wire between the EeT
sensor and PCMfECM
Fau!ty Eer sensor
Faulty PCMIECM
OTe 7·1 (EeT SENSOR LOW VOLTAGE)
1. EeT Sensor System Inspection
Check the Eel sensor with th e MeS.
YES - GO TO STEP 2.
NO - Intermittent failure
2. Eel Sensor Inspection
Disconnect the EeT sensor 2P (Black) connector
(page 4·34).
Check th e ECT sensor with the MCS.
YES - GO TO STEP 3.
NO - Faulty ECT sensor
3. ECT Sensor Short Circuit Inspection
Disconnect the PCM/ECM 33P (Gray) connector
(page 4·35). 111
w1
ECT sensor 2P black [1] connector terminal and
ground.
Connection: Black/blue - ground
YES - Short circuit in the Black/blue wire
NO - Replace the PCM/ECM with a known good
one (page 4·36). and recheck .
BI/Bu
4-13
PGM·FI SYSTEM
j
DTC 7·2 (EeT SENSOR HIGH VOLTAGE)
1. Eel Sensor System Inspection
Check the EeT sensor with Ihe MeS.
YES - GO TO STEP 2.
NO Intermittent failure
• Loose or poorly connected EeT sensor
2P (Black) connector
2. Eer Sensor Inspection
11]
Disconnect Ihe Eel sensor 2P (Black) connector I
(page 4-34 ).
Connect the wire harness side 2P (Black) connector
[1]lerminals with a jumper wire [21. \ 1
Connection: Black/blue - Green/white
cjf
., ,
J
Check Ihe EeT sensor with the MeS.
BlfBu GMI
YES - Faulty Eel sensor
NO - GO TO STEP 3.
\]
3. EeT Sensor Line Open Circuit Inspection
Turn Ihe ignition switch OFF.
Remove the jumper wire. 11] 121
62
/
Disconnect the PCMJECM 33P (Gray) connector
~
(page 4-35).
Check for continuity between the 33P (Gray)
connector [1] and ECT sensor 2P (Black) connector
{2] terminals.
TOOL:
\
Connection; BlfBu
B27 - Black/blue
Q
627 GMI
B2 - Green/white
Is there continuity? ,
YES - Replace the PCM/ECM with a known good
one (page 4-36). and recheck.
NO Open circuit in the Black/blue wire
• Open circuit in the Greenfwhite wire
4·14
PGM·FI SYSTEM
OTe 8 (TP SENSOR)
Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and
PCMfECM 33P connectors, and recheck the oTC.
5V
TP SENSOR
B,NY ~ PCM/ECM
E -BuIBI-
GNY
~r
Probable cause
Open or short circuit in Brown/white wire between
the TP sensor and PCMfECM
Open or short circuit in Blue/black wire between the
TP sensor and PCMIECM
Open circuit in Green/white wire between the T P
sensor and PCMIECM
Faulty sensor unit (TP sensor)
Faulty PCMfECM
OTC 8·1 (TP SENSOR LOW VOLTAGE)
1. TP Sensor System Inspection
Check the TP sensor with the MeS with the throttle
fully closed.
Is abo ut 0 V indicated?
YES - GO TO STEP 3.
NO - GO TO STEP 2.
2. TP Sensor Inspection
Check that the TP sensor voltage increases
continuously when the throttle is moved to fully
closed position to fully open position, using the data
list menu of the MeS.
Does the voltage increase continuously?
YES - Intermittent failure
• Loose or poorly connected sensor unit
5P connector.
NO - Faulty sensor unit (TP sensor)
3. TP Sensor Input Voltage Inspection
Disconnect the sensor unit 5P (Black) connector III
(page 4-32).
5P (Black) connector [1) terminals.
Connection : Brown/white (+) - Green/white (-)
Is the voltage within 4. 75 - 5.25 V?

YES - GO TO STEP 5.
B,NY GNY
NO - GO TO STEP 4.
4·15
PGM·FI SYSTEM
4. TP Sensor Input Line Open Circuit Inspection
83
(page 4-35).
33P (Gray) connector [1] and 5P (Black) connector
[2] terminals.
TOOL:
Connection : B3 - Brown/white
one (page 4-36), and recheck. [1[ 12]
NO - Open circuit in the Brown/white wire
5. TP Sensor Output Line Open Circuit Inspection
Disconnect the PCMfECM 33P (Gray) connector 11[
I
\
(page 4-35).
33P (Gray) connector [1] and 5P (Black) connector BulBI
[21 terminals.
TOOL:
Pin Probe Male (2 pack) 07ZAJ·RDJA 110 ]
Connection : B14 - Blue/black

/
YES
NO
- GO TO STEP 6.
- Open circui t in the Blue/Black wire
811 Q
6. TP Sensor Output Line Short Circuit Inspection

Check the Blue/Black wire for continuity between
the wire harness side 5P (Black) connector [1] 11]
terminal and ground.
Connection : Blue/Black - ground
\ 1
j
15 there continuity?
YES - Short circuit in the Blue/Black wire
NO - GO TO STEP 7.
BulBI
Replace the sensor unit with a known good one
(page 4-32).
Tum the ignition switch ON.
Check the TP sensor with the MCS.
15 OTe 8·1 indicated?
NO - Faulty original sensor unit (TP sensor)
4-16
PGM-FI SYSTEM
OTe 8·2 (TP SENSOR HIGH VOLTAGE)
1. TP Sensor System Inspection
Check the TP sensor with the MeS with the throttle
fully closed.
YES - GO TO STEP 3.
NO - GO TO STEP 2.
Check that the TP sensor voltage Increases
continuously when the throttle is moved to fully
closed position to fully open position, using the data
list menu of the MeS.
Does the voltage Increase continuously?
3. TP Sensor Resistance Inspection
Turn the ignition switch OFF
Disconnect the sensor unit 5P (Black) connector
(page 4-32).
Measure the resistance between the TP sensor side
5P (Black) connector [1] terminals .
Connection: C - 0 o o o
Is the resistance within 1.0 - 3.0 kfl
YES - GO TO STEP 4.
c o
4. TP Sensor Input Voltage Inspection

Measure the voltage between the wire harness side PI
Connection : Brownlwhite (+) - Green/white (- )
/s the voltage within 4.75 - 5.25 V?

one (page 4·36), and recheck.
NO - Open circuit in the Greenlwhite wire
GNV
I
J
4-17
PGM·FI SYSTEM
OTe 9 (IAT SENSOR)
Before starting the inspection , check for loose or poor contact on Ihe tAT sensor 2P (Black) connector and
PCM/ECM 33P connectors, and recheck the OTG .
5V
tAT SENSOR
- Gr - L PCMIECM
L f - - GNI -
""l
Probable cause
Open or short circuit in Gray wire between the tAT
sensor and PCM/ECM
Open circuit in Greenfwhile wire between the tAT
sensor and PCMfECM
Faulty tAT sensor
Faulty PCMIECM
OTe 9-1 OAT SENSOR LOW VOLTAGE)
1. tAT Sensor System Inspection
Check the tAT sensor with Ihe MeS.
YES - GO TO STEP 2.
NO - Intennittent failure
2. tAT Sensor Inspection
Disconnect Ihe tAT sensor 2P (Black) connector
(page 7-17).
Check the tAT sensor with the MCS.
YES - GO TO STEP 3.
NO - Faulty IAT sensor
3. IAT Sensor Output Line Short Circuit Inspection
Disconnect the PCM/ECM 33P (Gray) connector ' -- -[-, [- - -- - - - - -- ----,
(page 4-35).
Check for continuity between the wire harness side \
IAT sensor 2P (Black) connector [1] terminal and ' _li-:;2'l",
ground. )-
Connection : Gray - ground
YES
NO
- Short circuit in the Gray wire
- Replace the PCMfECM with a known good
Gc
! '---{ Q
4-18
PGM-FI SYSTEM
OTe 9·2 (IAT SENSOR HIGH VOLTAGE)
1. IAT Sens or System Inspection
Check the IAT sensor with the MeS .
YES - GO TO STEP 2.
• loose or poorly connected tAT sensor
2P (Black) connector
2. tAT Sensor Inspection
Disconnect the IAT sensor 2P (Black) connector [11
(page 7-17).
[1J terminals with a jumper wire [2J.
Connection : Gray - Green/white
\
/-
Check the tAT sensor with the MeS.
G, GrN
YES - Faulty IAT sensor
NO - GO TO STEP 3.
[21
3. tAT Sensor Open Circuit Inspection
Remove the jumper wire. [1J
B2
Disconnect the PCMfECM 33P (Gray) connector
(page 4-35).
33P (Gray) connector [t[ and 2P (Black) connector
[2] terminals.
TOOL:
\
1
Pin Probe Male (2 pack) 07ZAJ-ROJA 11 0
Connection : B26 - Gray Q

/
~J
B2 - Green/white B26
Is there continuity? G,
121
YES - Replace the PCMIECM with a known good
NO Open circuit in the Gray wire
• Open circuit in the Green/white wire
4-19
PGM·FI SYSTEM
OTC 12 (FUEL INJECTOR)
Before starting the inspection, check for loose or poor contact on the fuel injector 2P (Btack) connector and
PCMJECM 33P connectors, and recheck the DTC.
EeM
From IGN
FUSE (20 A)
FUEl
INJECTOR 'IB'r
C r--- GfB1 - •
Probable cause
Open circuit in Black/red wire between the engine
stop relay and fuel injector
Open or short circuit in Greenlblack wire between
the fuel injector and PCM/ECM
Faulty fuel injector
Faulty PCMlECM
DTC 12·1 (FUEL INJECTOR)
1. Fuel Injector System Inspection
Erase the DIG (page 4-6).
Tum the ignition switch OFF and ON, and check the
fuel injector with the MeS.
Is the DTe 12·1 indicated?
YES - GO TO STEP 2.
• Loose or poorly connected fuel injector
2P (Black) connector.
2. Fuel InJector Resistance Inspection
Tum the ignition switch OFF.
Disconnect the fuel injector 2P (Black) connector 111
(page 7-22).
Measure the resistance between the injector side
2P connector (1) terminals.
Standard : 11 .1 - 12.3 Q (20°CI68°F)
Is the resistance within the standard values? J
YES - GO TO STEP 3.
NO - Faulty fuel injector
4-20
PGM-FI SYSTEM
3. Fuel Injector Input Voltage Inspection
Measure the volta ge between the wire harness side (11
2P (Black) connector [1) terminal and ground.
Connection: Blacklred(+) - ground (- )
Is there battery voltage?
YES - GO TO ST EP 4.
NO - Open circuil in the Black/red wire
4. Fuallnjector Signal Line Open Circuit Inspection

Turn the ignition sw itch OFF.
(page 4-35).
I 111 (21
\=
33P (Gray) connector [lJ and fuel injector 2P (Black) \J
connector [21 terminals.
TOOL :
Connection : B33 - Green/black

, I r
\ / "
\ ~ /
YES
NO
- GO TO STEP 5.
- Open circuit in the Greenlbtack wire
5. Fuel Injector Signal line Short Circuit Inspection
L 833 G/SI
J
Check for continuity between the wire harness side , - - - 111
2P (Black) connector [I ) terminal and ground.
Connection: Greenfblack - Ground
YES - Short circuil in the Greenfblack wire
NO - Replace the PCMfECM wi th a known good
one (page 4-36) , and recheck.
Q
G/SI
4-21
PGM-FI SYSTEM
DTC 21 (0, SENSOR)
Before starting the inspection , check for loose or poor contact on the 0 1 sensor 4P (Black) connector and
PCM/ECM 33P connectors, then recheck the DTC .
5V
-r
0 1 SENSOR
PCMlECM
Probable cause
Open circuit in Gray or Greenlwhite wire between
the 0 2 sensor and PCM/ECM
Open or short circuil in Black or Yellow/red wire
between the en sensor and PCM/ECM
Faulty 0 2 sensor
Faulty PCM/ECM
DlG 21-1 (0: SENSOR)
1. 0 2 Sensor System Inspection
Warm the engine until the coolant temperature is
80°C (176°F).
Check the 0 2 sensor with the MeS.
Standard : 0.1 V - 1.2 V
,
Is the voltage as specified?
YES - Ched< the fuel pressure (page 7-10). If the
system is correct. GO TO STEP 4.
NO - GO TO STEP 2.
2. 0 2 Sensor Open Circuit Inspection
Turn the ignition switch OFF . 1
Disconnect the 0 :< sensor 4P (Black) connector 1
(page 2-10) and PCM/ECM 33P connectors (page
4-35).
33P (Black) connector [11 and 4P (Black) connector
[21. and between the 33P (Gray ) connector [3) and
4P (Black) connector.
TOOL: Al0 VIR
Pin Probe Male (2 pack) 07ZAJ ·RDJA110
'-----{ Q )----'
Connection : A10 - Yellow/red
B2 - Green/white
Is there continuity? 121

YES - GO TO STEP 3. 1
NO Open circuit in the Yellow/red wire
• Open circuit in the Greenlwhile wire
GIW
.2
4-22
PGM·FI SYSTEM
3. 0 2 Sensor System Short Circuit Inspection
Connect the ECM 33P connectors.
Check for continuity between the O~ sensor 4P 111
(Black) connector (1) at the wire side and ground,
Connection: Yellow/red - Ground
YES - Short circuit in the Yellow/red wire
NO - GO TO STEP 4.
YIR
4. O. Sensor Inspection
Connect the ECM 33P (Black) connector.
Replace the 02 sensor with a known good one
(page 4-37).
Erase the DTCs (page 4-6).
Warm the engine until the coolant temperature is
80·C (176· F).
Check the 02 sensor with the MeS .
Is OTC 21 - 1 indicated?
NO - Faulty original 02 sensor
DTC 23 (0, SENSOR HEATER)

Before starting the inspection, check for loose or poor contact on the 02 sensor 4P (Black) connector and
PCM/ECM 33P connectors, then recheck the DTC.
From IGNITION
SWITCH
02 SENSOR HEATER
PCMIECM
Probable cause
Open circuit in Green/orange or White wire between
the 02 sensor heater and PCM/ECM
Open circuit in Black/red or White wire between the
02 sensor heater and ING fuse (20 A)
Faulty 02 sensor heater
Faulty PCM/ECM
4-23
PGM-FI SYSTEM
OTe 23·1 (01 SENSOR HEATER)
1. 0 2 Sensor System Inspec tion
Erase the DTCs (page 4-6).
Start the engine and check the 0 2 sensor heater
with the MeS.
Is OTe 23·1 indicated?
YES - GO TO STEP 2.
2. 0 2 Sensor Heater Resistance Inspection
Disconnect the 0 2 sensor 4P (Black) connector 111
(page 2-10).
Measure the resistance between Ihe sensor side 4P
(Black) connector [1) terminals.
Connection: White - White
1
Is the resistance within 6.7 - 9.5 {} (20"C/68 F) ?
G
w w
YES - GO TO STEP 3.
NO - Faulty en sensor 1
j
<
3. 0 2 Sensor Heater Input Voltage Inspection ,I
Measure Ihe voltage between Ihe wire harness side 111
4P (Black) connector [1] and ground .
Connec tion : Black/red (+) - Ground (-)
Dose the battery voltag e exist?

YES - GO TO STEP 4 . ffi
NO - Open circuit in the Black/red wire
V
4. Ol Sensor Heater line Open Circuit Inspection

Disconnect the ECM 33P (Gray) connector (page 4- [21 A11 [1 I
35).
33P (Black) connector [1) and 4P (Black) connector
[2)
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
Connection : A11 - Green/orange G/O

Q
YES - GO TO STEP 5.
NO - Open circuit in the Green/orange wire
4-24
PGM-FI SYSTEM
5. 0 2 Sensor Heater Line Short Circuit Inspection
4P (Black) connector [1 1and ground .
Connection : Green/orange - Ground
Is there continuity ?
YES - Short circuit in the Green/orange wire H of.-_- G10
DTC 29 (IACV)
Before starting the inspection . check for loose or poor contact on the IACV 4P (Black) connector and peM!
ECM 33P (Gray) connector. then recheck the DIG.
PCM/ECM
IACV
tT'---_ Y - - - I ll
! - - YIG -
f----- Y/Bu -
f-- BrlY - - I 1I
Probable cause
Open or short circuit in the Yellow wire , Yellowfgreen
wire, Yellow/blue wire andlor Brownfyellow wire
between the IACV and PCMfECM
Faulty IACV
Faulty PCM/ECM
OTC 29-1 (lACV)
1. OTC Recheck
Start the engine and recheck the DTe with the
MCS .
Is the DTe 29-1 indicated?
YES - GO TO STEP 2.
Loose or poorly connected IACV 2P
connector.
4-25
PGM-FI SYSTEM
2. IACV Short Circuit Inspection
Disconnect the IACV 4P (Black) connector (page 7-
21).
4P connector 11] terminals and ground.
Connection: Yellow - Ground
Yellow/blue - Ground
Brown/yellow - Ground
Yellow/green - Ground
j
YES - Short circuit in the fonowing:
1
Short circuit in the Yellow or Yellowl
green wire
• Short circuit in the Yellow/blue or
Brown/yellow wire
NO - GO TO STEP 3.
3. IACV Circuit Continuity Inspection
1
(page 4-35). 121 1
Check the IACV wires for continuity between the
wire harness side 33P (Gray) connector [1] and 4P
1
(Black) connector [2J terminals. 89
TOOL:
~
Connection: 88 - Yellow 1
85 - Yellow/green /~
830 - Yellow/blue
Y
89 - 8rown /y ellow 88 85 YIG
Are there continu i ties ? 830
Q
111 Y/Bu 8,f'(
YES
NO
- GO TO STEP 4.
- Open circuit in the following: ,
.
Open circuit in the Yellow or Yellow/
green wire •
Open circuit ;, the Yellow/blue 0'
~
Brown/yellow wire
4. IACV Res istance Ins pec tion
Measure the resistance between the wire harness
,
side IACV 4P connector [1) terminals.
11 )
Connection: 1A - 1 B
2A-2B
Standard: 99 - 1210 (20°C/68°F) 18

i"o
Js the resistance within the s tandard values ?
28 2A
•
NO - Faulty tACV ~
4-26
PGM·FI SYSTEM
DTC 54 (BANK ANGLE SENSOR)
Before starting the inspection, check for loose or poor contact on the bank angle sensor 3P (Black)
connector and PCM/ECM 33P connectors, and recheck the OTC .
5V
BANK ANGLE 5V
SENSOR
PCM/ECM
Bcrw
BI/G
Grw
Probable cause
Open circuit in the Brown/white wire between the
bank angle sensor and PCMIECM
Open Of short circuil in Black/green wire between
Ihe bank angle sensor and PCMIECM
Open circuil in Green/white wire between the bank
angle sensor and PCM/ECM
Faulty bank angle sensor
Faulty PCMIECM
DTC 54·1 (BANK ANGLE SENSOR LOW VOLTAGE)

1. Recheck DTG
Check the bank angle sensor with the MeS.
15 about 0 V indicated?
YES - GO TO STEP 2.
• l oose or poor contact of the bank angle
sensor 3P (Black) connector
2. Bank Angle Sensor Power Input Voltage
Inspection
Disconnect the bank angle sensor 3P (Black) 111
connector (page 4-34).
Measure the vol tage between the wire harness side
bank angle sensor 3P (Black) connector [1]
terminals. Grw
--.-oq.l.-4:..., ----
__ Bcrw
Connection: Brown/white (+) - Green/white {-I

YES - GO TO STEP 3.
J
4-27
PGM-FI SYSTEM
3. Bank Angle Sensor Output Line Short Circuit
Inspection
Disconnect the PCMlECM 33P (Gray) connector
(page 4·35).
I'
[1

bank angle sensor 3P (Black) connector (1)Ierminai
and ground .
Connection: Black/green - Ground
Is there contlnu(ty?
YES - Short circuit in the Black/green wire.
NO - GO TO STEP 4.
4. Bank Angle Sensor Inspection

Replace the bank angle sensor with a known good
one (page 4·34 l.
Erase the OTG (page 4-6). 1
Connect the bank angle sensor 3P (Black)
connector.
•
Check the bank angle sensor with the MeS.
Is DTe 54· 1 indicated?
YES - Replace the PCMfECM with a known good
NO - Faulty original bank angle sensor,
oTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)

1. Recheck OTC \
Erase the DTe (page 4-6).
Check the bank angle sensor with the MCS.
1
Is about 5 V Indicated? •
YES - GO TO STEP 2.
NO Intermittent failure.
• Loose or poor contact of the bank angle
sensor 3P (Black) connector.
2. Bank Angle Sensor Inspection
[1] terminals with a jumper wife [2].
Connection : Black/green - Green/white

Check the bank angle sensor with the MCS.
YES - Faulty bank angle senSOf
GfN
NO - GO TO STEP 3.
121
4·28
PGM-FI SYSTEM
3. Bank Angle Sensor Power Input Voltage
Inspection
bank angle sensor 3P (Black) connector [1]
terminals. +J-Lt~---- BerN
Connection: Brown/white (+) - Greenfw hite H
YES - GO TO STEP 4.
NO - Open circuit in the Green/white wire
4. Bank Angle Sensor Input Line Open Circuit

Inspection
(page 4-35). B3
33P (Gray) connector [1} and 3P (Black) connector
[2) terminals .
TOOL:
Pin Probe Male (2 pack) 07ZAJ·RDJA110
Connection: 83 - Brownfwhite
/s there continuity?
YES - GO TO STEP 5.
BerN
NO - Open circuit in the Brown/white wire 111 121
5. Bank Angle Sensor Output Line and Ground
Line Open Circuit Inspection
Disconnect the PCM/ECM 33P (Gray) connector 86 82
(page 4-35).
PCM/ECM 33P (Gray) connector [1 J and bank angle
sensor 3P (Black) connector [2J terminals.
TOOL:
Connection: B22 - Black/green
YES
B2 - Green/white
- Replace the PCM/ECM with a known good
[2)
L _ _ _ __
\ 111
NO Open circuit in the Black/green wire

• Open circuit in the Green/white wire
4-29
PGM-FI SYSTEM
MIL CIRCUIT INSPECTION
Except TM1 model
Turn the ignition switch ON and check that the MIL [1J
[1 [
comes on for about 2 seconds and goes off.
If the MIL does not come on at all. inspect the
,--
combination meter (page 23-4).
If the MIL stays on wi th Ihe gear position indicator
continuously blinking •- H, check the serial ®
communication line (page 23-7).
@ Lt,
000 '-I 10'",
If the MIL stays on, check as follows:

[11
Tum the ignilion switch OFF .
Disconnect the PCM/ECM 33P (Gray) connector (page
4-35).
Check for continuity between Ihe wire harness side
PCM/ECM 33P (Gray) connector [1) and ground .
TOOL:
Q ,
~
Connection : 829 - Ground B29
1
If there is continuity, check for short circuit in the
Brown/red wire between Ihe DLe and PCM/ECM . 1,
If there is no continuity , replace the PCM/ECM with L _ _ __ _ _ __ _ _ _ __ __ _ _.J
a known good one (page 4·36), and recheck.
TM1 model
Turn the ignition switch ON and check that the M!L [t)
11
comes on for about 2 seconds and goes off.
If the MIL does not come on . check as follows:
® ®
®~~
1. Indicator Power Input Line Inspection

l ,
,
Check the other indicator operation.
Do they operate properly?
YES - GO TO STEP 2.
NO - Open circuit in the Black/red wire between
the fuse box and joint connector
4-30
PGM·FI SYSTEM
2. Mil line Open Circuil Inspection
Disconnect the PCMIECM 33P (Black) connector I1J
(page 4-35).
Ground the wire harness side 33P (Black) connector
(1) terminal wi th a jumper wire.
TOOL:
Connection: A21 - ground

Turn the ignition switch ON and check the MIl.
Does the MIL come on? A21

NO Open circuit in the Brownlwhite wire
between the ECM and MIL
Faulty Mil bulb
Open circuit in the Blacklred wire
between the MIL and joint connector
If the MIL does not go off within about 2 seconds after
the ignition switch is turned ON, check as follows:
1. MIL Line Short Circuit Inspection
Disconnect the PCMfECM 33P (Black) connector [1J
(page 4-35).
Check for con tinuity between the wire harness side
33P (Black) connector [1) terminal and ground .
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA 110
Connection : A21 - ground

Q A21
YES - Short circuit in the Brown/white wire
NO - GO TO STEP 2.
2. SCS Line Short Circuit Inspection

Disconnect the PCMfECM 33P (Gray) connector ~--------
(page 4-35). [1J
Check for continui ty between the wire harness side
33P (Gray) connector [1]lerminal and ground.
TOOL:
Pin Probe Male (2 pack) 07ZAJ·ROJA 11 0
Connection : B29 - ground

Q
YES - Short circuit in the Brown/red wire
629
NO - Replace the PCM/ECM wi th a known good
4·31
PGM·FI SYSTEM
SENSOR UNIT (MAP/TP SENSOR)
NOTE:
If the sensor unit has been removed, perform the TP
sensor reset procedure (page 4-32).
Always clean around the throttle body before the
sensor unit removal to prevent dirt and debris from
entering the air passage.
Do not remove the sensor unit unless it is replaced.
Remove the left mudguard (page 2-5).
Disconnect the sensor unit 5P (Black) connector [1].
Remove the three torx screws (T25) [2] and the sensor
unit (3l from the throttle body.
Install a new O-ring (1) into the groove of the throttle

body.
Inslall the sensor unit [2J to the throttie body by aligning
the sial wi th the throttle shaft end.
Install and tighten the torx screws (T25) to the specified
torque.
TORQUE: 3.4 N'm (0.3 kgf'm , 2.5 IbHt)
Inslall the removed parts in the reverse order of
removal.
Perform the TP sensor reset procedure (page 4-32).
TP SENSOR RESET PROCEDURE

NOT E:
Make sure that the OTC is not stored in the PCMI
ECM memory. If the OTC is stored, the reset mode
will not start.
1. Remove the OLC from the dummy connector
(page 4-6).
2. Short the OLC [1J terminals using the special tool.
Connection : Brown/red - Green
TOOL:
•
(2] SCS service connector 070PZ-ZY30100
4·32
PGM·F[ SYSTEM
3. Disconnect the ECl sensor 2P (Black) connector
[1 [.
Short the Wife harness side connector terminals with
a Jumper wire {2J.
Connec tion : Blac k/blue - Green/red
4. Turn the ignition switch ON, then disconnect the

jumper wire from the ECT sensor 2P (Black)
connector within 10 seconds while the MIL is
blinking (reset receiving pattern).
[2J
5. When the resel procedure is complete. the MIL

blinking changes from Resel Receiving Pattern to
Confirmation Pattern.
If more than 10 seconds elapse or the procedures are Incorrect, the MIL stays on. Repeat the reset
procedures from the step 4.
~ Within 10 sec. tt:i

U -, ---'=.:...:..:.:."-----, U!:
1.3 sec. ' 1
0.1 sec.' 1 ,I 0.3 sec.:--:--: 0.3 sec.
MIL
' -In'--In
0:: ~ ..-- - -r" n,-
,.~------------v-----------~------v-------
ruul_
Reset ReceiVing Pattern Reset Confirmallon Pattern
(Stay on: Reset procedure is not complete)
ON
IGNITION
SWITCH
OFF
6. Connect the ECl sensor 2P (Black) connector.

7. Disconnect the speciatlool from the DLG .
8. Install the dummy connector to the DLC (page 4-6).
9. Check the engine idle speed (page 3-18).
10.lnstal1 the removed parts In the reverse order of
removal.
4-33
PGM·FI SYSTEM
ECT SENSOR
REMOVAUINSTALLATION
Drain the coolant (page 8-5).
Disconnect the spark plug cap (1] and EeT sensor 2P
connector (2].
Replace the ECT Remove the Eer sensor 13] and D-ring (4] .
sensor while the
Coal a new O-ring with engine oil and install it onlo the
engine is cold. Eel sensor.
Install the EeT sensor into the cylinder head and
1
lighten it. I
TORQUE : 12 N·m (1 .2 kgf'm, 9Ibf-ft) J
Connect the Eel sensor 2P connector and spark plug
cap.
Install the tank cover assembly (page 2-4).
Fill the cooling system with recommended coolant
(page 8·5). 1
BANK ANGLE SENSOR
REMOVAUINSTALLATION
j
Remove the front fender/carrier (page 2-6).
Oisconnect the bank angle sensor 3P (Black) connector
111.
Remove the two mounting bolts 121 and bank angle
sensor [31 from the frame.
Inslalithe bank angle sensor [11 with its ·UP· mark [2]
facing up .
I 111
removal,
TORQUE;
Mounting bolt : 10 N'm (1 .0 kgf'm, 7 lbHt)
121
4-34
PGM·FI SYSTEM
OPERATION INSPECTION
NOTE
• Before you perform this inspection, check thai the
engine idle speed is normal (page 3-18).
Remove the bank angle sensor [11 with the bank angle
60· ± 5" BANK ANGLE POSITION
sensor 3P (Black) connector is connected (page 4-34),
~
• Do not disconnect the bank angle sensor 3P (Black)
connector during inspection.
111
',.
<!I',.
Place the bank angle sensor is hOrizontal (normal
posilion) as shown, and tum the ignition SWitch ON.
Start the engine. 60· ± 5" C.
Incline the bank angle sensor 60~ ± 5 to the left or right
Q
with keeping with Ihe engine running.

~
iiP60"~
The bank angle sensor is normal if the engine slops HORIZONTAL
when the bank angle sensor Inclined.
I
'\'
INSPECTION WITH MCS

Connect the MCS (page 4-6).
60" t S" BANK ANGLE POSITION
Remove the bank angle sensor [1 ) with the bank angle
~
sensor 3P (Black) connector is connected (page 4-34).
111
' o ,.
Place the bank angle sensor horizontal as shown,
<!I',.
Read the voltage with the MCS. 60" tS" C
Standard: 3.6 - 4.4 V
~
Incline the bank angle sensor 60° ± 5° to the left or right ,'
with keepmg the ignition switch ON.
,~
,
Read the voltage with MeS.
Standard: 0.7 -1 .3 V :'\ 60· ± S"
PCM/ECM
POWER/GROUND LINE INSPECTION
Tum the ignition switch OFF .
Disconnectlhe PCM/ECM 33P (Gray) connector [11.
4-35
PGM-FI SYSTEM
GROUND LINE
Check for continuity between the wire harness side 33P , - - -- -- - - - - - - - - - -- ,
connector [1] terminals and ground. 810 [1~1 82
TOOL: _
Pin Probe Mate (2 pack) 07ZAJ·RDJA 110
Connection:
Power ground: 810 - ground
821 - ground I
Sensor ground : 82 - ground
Logic ground: 813 - ground Q Q j
There should be continuity at all times.
I
If there is no continuity, check for an open circuil in the
Green or Green/white wires.
POWER INPUT LINE
111
33P connector [1] terminal and ground.
TOOL:
\ "
Pin Probe Male (2 pack)
Connection : 81 (+) - ground (-)

07ZAJ-RDJA110
:'\
There should be battery voltage.
If there is no voltage, check the following : f.";\
- discharged battery (page 22-5) (-) V (' 1 81
open circuit in the Red wire between the battery and
MAIN fuse (30 A)
blown MAIN fuse 1 (30 A)
open circuit in the Red/black wire between the MAIN
fuse 1 (30 A) and MAIN fuse 2 (10 A)
blown MAIN fuse 2 (10A)
open circuit in the Red/yellow wire between the
MAIN fuse 2 (10 A) and diode
faulty diode (page 22-8)
open circuit in the Red wire between the diode and
ignition switch
ignition switch (page 23-9)
open circuit in the Black wire between the ignition
switch and IGN fuse (20 A)
blown IGN fuse (20 A)
open circuit in the Black/red wire between the IGN
fuse (20 A) and PCMIECM
REMOVAUINSTALLATION
Remove the following from the ECM stay [1]=
- joint connector [2]
- PCM/ECM [3]
Disconnect the following connectors from the PCM/
ECM:
- 33P (Gray) connector (4]
- 33P (Black) connector [5]
- SP (Black) connector [6]
4-36
PGM·FI SYSTEM
0 2 SENSOR
REMOVALIINST ALLA TION
NOTICE
Do not get grease, oil or other materials In the 0 2
sensor air hole.
The 0 2 sensor may be damaged If dropped.
Replace it with a new one, if dropped.
NOTE
Do nol service the 02 sensor while it is hoI.
• Do not use an impact wrench while removmg or
Installing the 0 2 sensor, or it may be damaged .
Remove the muffler (page 2-10).
121
Remove the O. sensor [IJ using the special 1001.
TOOL:
FRXM17 (Snap on) or equivalent [2]
TORQUE: 24.5 N-m (2.5 kgf'm , 18 IbHt)
4-37
MEMO
•I
•
I
j
•
••
•
5. IGNITION SYSTEM
SERVICE INFORMATION ····························· 5-2 IGNITION SYSTEM INSPECTION ................ 5-5
TROUBLESHOOTING········· ·························· 5-3 IGNITION COIL ............................................ . 5-7
COMPONENT LOCATION ···························· 5-4 IGNITION TIMING ················· ········· ··············· 5-7
SYSTEM DIAGRAM ······································ 5-4 CONDENSER (Canada FM1 fFM 2IFE1 models
only) ...................................................... ········ 5-8
5-1
j
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
NOTICE
j
The PCMlECM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the PCMlECM. Always tum the ignition switch OFF before servicing.
Use spark plugs with the correct heat range . Using spark plugs with an incorrect heat range can damage the engine,
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
When servicing the ignition system, always follow the checks described in the troubleshooting chart (page 5-3).
This ignition system is controlled by PCM/ECM.
Tile transistorized ignition system uses an electrically controlled ignition liming system. No adjustments can be made to the
ignition timing .
A faulty ignition system is often related to poor connections. Check those connections before proceeding.
Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking
speed as wel1 as no spark at the spark plug.
The engine stop switch line is connected to the PCMIECM via the fuel pump relay coil. Its signal permits the PCMIECM to
control the fuel pump, fuel injector and ignition coil.
1
CKP sensor removall instal1ation (page 14-6).
Ignition switch servicing (page 23-9)
Engine stop switch inspection (page 23-10)
The following color codes are used throughout this section .
61: Black Bu: Blue Gr: Gray Lg : Light green P: Pink v; Violet Y: Yellow
Br: Brown G: Green Lb: Light blue 0 : Orange R: Red W : While
TOOLS
IgnilionMate peak voltage tester Peak voltage adaptor Pin Probe Male (2 pack)
MTP07-0286 (U.S.A. only) 07HGJ·0020100 (not available in 07ZAJ-RDJA 110
U.SA)
with commercially available digital

multimeter (impedance 10 MOIDCV
minimum)
5-2
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing the system:
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Waler gal into the spark plug cap (leaking the ignition coil secondary voltage)
"Initial voltage" of the ignilion primary coil is the battery voltage with the ignition switch turned to ON. (The engine is not cranked
by the starter motor,)
No spark at spark plug
UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order)
Ignition coil No initial voltage with the 1. Faulty circuit between Ihe battery and IGN fuse (20 A) (page 4-36)
primary ignition switch turned to ON. 2. An open circuil in the Black/red wire between the IGN fuse (20 A) and
voltage (Other electrical components ignition coil
are normal.) 3. loose or poor connection ollhe primary terminal, or an open circuit in
Ihe primary coil
4. Faulty PCMIECM (in case when the initial voltage is normal with the
PCMfECM (Gray) connector disconnected)
I!~ps
I tnltl,r volt,ge I, noem,t, bot it
by 2 - 4 V while cranking
the engine.
1. Incorrect peak voltage adaptor connections (System is normal if
measured voltage is over the specifications with reverse
connections.)
2. Battery is undercharged. (Voltage drops largely when the engine is
started.)
3. No vol tage at the Black/red wire of the PCMfECM (Gray) connector,
or loose or poorly connected PCMfECM (Gray) connector
4. Loose or poor connection, or an open circuit in the Green (ground)
wire of the PCMfECM
5. Loose or poor connection, or an open circuit in the Green/yellow wire
between the ignition coil and PCMIECM
6. A short circuit in the ignition primary coil
7. No vollage al the Gray/red wire of the PCMIECM (Gray) connector, or
loose or poorly connected PCMfECM (Gray) connector.
8. Faulty CKP sensor (Measure the peak voltage.)
9. Faulty PCMfECM (in case when above No.1 through 8 are normal)
Initial voltage is normal but 1. Incorrect peak voltage adaptor connections (System is normal if
there is no peak voltage while measured voltage is over the specifications with reverse
cranking the engine. connections.)
2. Faulty peak voltage adaptor
3. Faulty CKP sensor (Measure the peak voltage.)
4. Faulty PCMfECM (in case when above No.1 and 3 are normal)
Initial voltage is normal but 1. The multimeter impedance is too low; below 10 MOfDCV.
peak voltage is lower than the 2. Cranking speed is too slow. (Battery is undercharged.)
standard value. 3. The sampling timing of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Faulty PCMfECM (in case when above No.1 through 3 are normal)
-"rncitcI,"rc'=n=d'pe='"k~voCr"t,CgCeC,c,ce=e~-I-;,c.~F~,"""It:'yC,=p~'~rl<2p~t"Cg"-!:oe~'leaking ignition coil secondary current
r-~~==~_--;n"oOeOm~,~r~b~",t~n~0~,:,p;'cek"!,J"omOP",,._ _+-~2C-' Faulty ignition coil..- =====
I CKP sensor 1, The multimeter impedance is too low; below 10 MOfDCV.
Low peak voltage.
2. Cranking speed is too stow. (Battery is undercharged.)
3. The sampling timing of the tes ter and measured pulse were not
synchronized . (System is normal if measured voltage is over the
standard voltage alleast once.)
4. Faulty CKP sensor (in case when above No. 1 through 3 are normal)
No peak voltage . 1. Faulty peak voltage adaptor
~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...L_2~.c'.
F~,~"r,,!
ly CKP senso
~e_ __ _ _ _ _ _ _ _ _ _ _ _ __
5-3
IGNITION SYSTEM
COMPONENT LOCATION
FA2 model shown :
IGNITION SWITCH
ENGINE STOP SWITCH ------"0;;:

IGNITION COIL
,
I
PCM/ECM ---..,4"...,.
-FUSE
MAINBOX:
FUSE 1 (30 A) -~~~~::::3
- MAIN FUSE 2 (10 A)
- IGN FUSE (10 A) j
- DIODE
SPARK PLUG
BATTERY
(Canada type only) eKP SENSOR
SYSTEM DIAGRAM
rCONDENSERi
PCMIECM
~ Ii
G R
I Canada type
1r
~ !
1---'
R
From regulatorl
---<l rectifier
L- G,/R
FUEL PUMP RELAY
----1::;.:Ooi
"Orl---+--
ENGINE STOP SWITCH
BI/W ------o--(:>---~ ,
I I
BolY G~ SI/R
CKP SENSOR
G SIIR
DIODE IGNITION SWITCH I
c:
~0- 81 -o.-ro--J
l 'GNITION
RIY EEj R R
COIL IGNFUSE
G
(20 A)
~ RlBI ---0.-/"'0----- R J
O~ MAIN FUSE 2
(10A)
MAIN FUSE 1
(30 A)
rno__oo:-.,
SPARK PLUG !
8
BATTERY
5-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
NOTE
If there is no spark at the plug . check aU connections
for loose or poor contact before measuring the peak
voltage.
Use a commercially available digital muttimeler with
an impedance of 10 MO/DCV minimum.
The display value differs depending upon the
internal impedance of the multimeter.
Use the peak vol tage lester or connecllhe peak voltage r---------------12
-1-~
adaptor [1) to the digital multimeler [2J.
TOOL :
Ignition Mate peak voltage tester MTP07"()2B6
(U.S.A. only) or
Peak Voltage Adaptor 07HGJ-0020100
(not available in
U.S.A.)
with commercially available digital multimeter
(Impedance 10 MO/DeV minimum)
111
IGNITION COIL PRIMARY PEAK
VOLTAGE
NOTE
Check all system connections before this inspection .
Poor connected connectors can cause incorrect
readings.
Check thaI the cylinder compression is normal and
the spark plug is installed correctly in the cylinder
head ,
Remove the tank cover assembly (page 2-4 ).
Disconnect the spark plug cap [1) from Ihe spark plug ,
Connect a known good spark plug [2] to the spark plug
cap and ground the spark plug to the cylinder head as
done in a spark test.
With Ihe connector connected, connect the peak
voltage tester or adaptor probes to the ignition coil
primary terminals.
Connection : Greenfyellow (+) - Ground (-)
Turn the ignition switch ON and engine stop switch "ft.
Check the initial voltage at this time.
The battery voltage should be measured.
If the initial voltage cannot be measured , follow the
checks in the troubleshooting chart (page 5-3).
Shift the transmission into neutral.
Crank the engine with the starter motor and read the
ignition coil primary peak voltage .
PEAK VOLTAGE: 100 V minimum
If the peak voltage is lower than the standard value,
follow the checks described in the troubleshooting chart
(page 5-3).
5·5
IGNITION SYSTEM
CKP SENSOR PEAK VOLTAGE
NOTE:
Check that the cylinder compression is normal and
the spark plug is installed correctly in the cylinder
head.
Remove the lank cover assembly (page 2·4),
Turn the ignition switch OFF and disconnect the PCMI
ECM 33P (Gray) connector [1] .
Connect the peak voltage tester or adaptor (2) probes to
the wire harness side 33P (Gray) connector terminals
TOOL:
Connection : 823 (+) - Ground (-)

Turn the ignition switch ON and engine slop switch -()". ,
Crank the engine wi th the starter moior and measure ,
the CKP sensor peak voltage.
PEAK VOLTAGE: 0.7 V minimum
11)
If the voltage measured altha PCMlECM connector is
abnormal , measure the peak voltage at the CKP sensor
connector.
B23
,
Remove the air cleaner housing (page 7-11).
Tum the ignition switch OFF and disconnect the CKP
sensor 2P (Gray) connector [1].
Connect the peak voltage tester or adaptor [2] probes to
the CKP sensor side connector terminals .
Connection : Blue/yellow (+) - Green (-)
In the same manner as at the PCMfECM connector,

measure the peak voltage and compare it to the voltage
measured at the PCMfECM connector.
If the peak voltage measured at the PCMfECM
connector is abnormal and the one measured at the
CKP sensor connector is normal, the Bluefyellow or J
Green wire has an open or short circuit, or loose
connection.
I
If both peak voltages are abnormal, follow the I
checks described in the troubleshooting chart (page 11)
5-3).
If the CKP sensor is faulty, replace the alternator statorl
CKP sensor assembly (page 14-6).
,
12) j
5-6
IGNITION SYSTEM
IGNITION COIL
Remove the ECM stay (page 3-10).
Disconnect the ignition coil primary wire connectors [1J.
Remove the bolts [2] and ignition coil Pl.
IGNITION TIMING
NOTE:
• Before you performing this inspection , check the
engine idle speed (page 3-18).
Remove the right mudguard (page 2-5 ).
Start the engine and warm it up to operating
temperature.
Stop the engine and remove the timing hole cap from
the rear crankcase cover.
Connect the liming light [1] and tachometer.
Start the engine, let it idle and check the ignition timing .
The ignition timing is correct if the "F" mark [1] on the

flywheel aligns with the index notch [2) on the rear
....................................~
~~==:::"........~=
crankcase cover at idle.
'-I
Coat a new O-ring [1] with engine oil and install it onto
the timing hole cap (21 .
Install and tighten the timing hole cap to the specified
torque.
TORQUE : 10 N-m (1.0 kgf'm , 7lbHt)

removal.
5-7
IGNITION SYSTEM
CONDENSER (Canada FM1/FM2/FE1
models only)
REMOVAUINSTALLA nON
Remove the rea r fender cover (page 2-8).
Disconnect the battery negative (- ) cable (page 22-5).
Disconnect the condenser 2P connector (1) and remove
the condenser (2].
Instanation is in the reverse order of removal.
INSPECTION
NOTE :
• Pertorm this inspection using a fully charged battery.
Disconnect the condenser 2P connector 11) (page 5-8). r-----cII~I---------------,
Connect the battery negative H cable (page 22-5).

condenser 2P connector terminals. R G
Connection : Red (+) - Green (- I
Standard : Battery voltage at all time

If there is no voltage. check the following:
- MAIN fuse 1 (30 A). MAIN fuse 2 (10 A) andlor
-
-
related circuits
diode
open circuil in the Red or Green wires
If there is voltage, check the condenser as follows:

j
III
1. Disconnect the battery negative (-) cable and
connect the condenser 2P connector [1}.
2. Connect the battery negative (-) cable for a few
seconds and charge the condenser.
3. Disconnect the battery negative (- ) cable and
discharge the condenser.
4. Disconnect the condenser 2P connector and check
the resistance between the condenser side
connector terminals. Q
Se/ecl the k() range The condenser is normal if the resistance comes
of/he tesler. near 00 once and eventually becomes 00.
If the resistance stays at 00 or does not change .
replace the condenser.
NOTE :
If the inspection is interrupted. connect the
condenser 2P connector and restart the procedure
from the step 1.
j
5·8
6. ELECTRIC STARTER
SERVICE INFORMATION ····························· 6-2 STARTER MOTOR ....................................... 6-4
TROUBLESHOOTING································· ··6-2 STARTER RELAY SWITCH ························· 6-6
COMPONENT LOCATION ·· ·········· ················ 6-3 STARTER INHIBITOR RELAY/STARTER

RELAY SWITCH DIODE ............................... 6-8
SYSTEM DIAGRAM ··································· .. ·6-3
6·1
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
NOTICE ~
If the current ;s kept flowing through the starter motor to tum it while the engine is not cranking over, the starter mOlor may be I
damaged.
~
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
The starter motor can be serviced with the engine in the frame.
When checking the starter system. always follow the steps in the troubleshooting (page 6-2).
A weak battery may be unable to turn the starter motor quickly enough , or supply adequate ignition current. 1
,
Refer to each section for the following components information.
- Starter clu tch (page 14-11)
- Ignition switch (page 23-9)
- Engine stop switch and starter switch (page 23-10)
- Front brake switch (page 23-11)
- Except FA1 /FA2 : Gear position switch (page 23-10)
- FA1 /FA2 : Shift drum position switch (page 13-50)
Bf: Brown G: Green Lb: Light blue 0 : Orange R: Red W:White
TROUBLESHOOTING
Unusual condition Probable cause (Check in numerical order)
Starter motor Starter motor does not turn 1. Weak battery
2. Loose connection or open circuit in the battery cable(s)
3. Loose connection or open circuit in the starter motor cable
4. Faulty starter relay switch (page 6-7)
5. Open circui t in starter relay switch ground circuit (page 6-6)
6. Faulty starter relay switch power input line (page 6-7)
- Faulty circuit between the battery and IGN fuse (page 4-36)
- Open circuit between the fuse box and engine stop switch
- Faulty handlebar switch (engine stop switch and/or starter switch)
- Open circuit between the starter switch and starter inhibitor relay
- Faulty starter inhibitor relay (page 6-8) or its circuits
- Open circuit between the starter inhibitor relay and starter relay
•
switch
7. Faulty starter motor
8. Except FA 1/FA2 : Faulty gear position switch or its circuits
9. FA1 / FA2: Faulty shift drum position switch or its circuits
1u.>0""" front brake switch or its circuits
PCM/ECM
slowly
2.
3.
4.
5.
does not turn 2.

3.
4. motor i
,,
6-2
ELECTRIC STARTER
COMPONENT LOCATION
FA2 model shown: STARTER SWITCH
IGNITION SWITCH
ENGINE STOP SWITCH _ _~== ~ _ _ _ _ FRONT BRAKE SWITCH
FUSE BOX:
- MAIN FUSE 2 (10 A) PCM/ECM ---4;"':'~
- IGN FUSE (20 A)
- OIODE
RELAY
- STARTER INHIBITOR RELAY
- STARTER RELAY SWITCH DIODE
STARTER
SWITCH
Except FA lIfA2: GEAR POSITION SWITCH

STARTER MOTOR FA lIFA2: SHIFT DRUM POSITION SWITCH
SYSTEM DIAGRAM
o 8
BATTERY
Y /R, - MAl N 1 FUSE , - _ RlBI --------f;:;::::~-_,

Lg/R (40
AI 1-o..ro-
RlBI - . - RIY ~ R -t;;;;;;~
STARTER RELAY
SWITCH
STARTER MAIN2FUSE ~ IGNITION
INHIBITOR (10 A) DIODE SWITCH
RELAY STARTER 81
G ~ Y/R
SWITCH I
ENGINE STOP SWITCH ~~~~\USE
G Bu --0'--0- 811\'V --0~ BI/R ~
DIODE 0
*' B,/W
- vvv
Bu
,- Y /R ------o~Bl/Br ~p
FRONT BRAKE
INHIBITOR SWITCH P
0
2 0
UGHT
FUSE
1~-----'-'1--- ~ (20 A)
M STARTER
MOTOR
LgIR - - - - - - - - + 0 . - 9
PCMlECM
O~ ~~~SOR OR ~;ARPOSITION
BuiY -Il G
(NEUTRAL)
SWITCH
..;..
6·3
ELECTRIC STARTER
5T ARTER MOTOR
REMOVAUINSTALLATION
Disconnecllhe battery negative H cable (page 22-5).
- terminal nul (1] (open the rubber cap (2])
- slarter motor cable [3]
- two mounting bolts (4) and ground cable [5)
Remove the starter motor [1] from the rear crankcase ..,,~~::"
cover.
Remove the O-ring (2) from the slarter moior.
Coat a new a·ring with engine oil and install it into the
starter motor groove.
Apply molybdenum oil solution to the starter motor shaft
splines [3).
removal.
OISASSEMBL YIASSEMBL Y
I NOTICE I
The anna/ure coil may be damaged if the magnet in the motor case pulls the annature against the case.
ARMATURE
SEAL RING Ell

MOTOR CASE
NUT
Align
,OIL SEAL ~
WASHER
BRUSH
SPRINGS
Ji V
TERMINAL
STOPPER POSITIVE
:RUSH SET Align
REAR COVER
BRUSH HOLDER
NEGATIVEBRUSHSET~
~ Af/{;¢ , TERMINAL
BOLT
FRONTC~
3.7 N'm (004 kgf-m, 2.7Ibf-ft) 4.9 N'm (0.5 kgf-m, 3.6 Ibf-ft)
6-4
ELECTRIC STARTER
INSPECTION
Check the oil seal [1] and ball bearing [2] in the front
[21
cover for wear or damage.
[1]
Check the commutator bars [I] for damage or abnormal

wear.
Check the commutator bars of the armature [2) for
discoloration .
Clean any metal debris from between commutator bars.
NOTE:
• Do not use emery or sand paper on the commuta tor.
11]
Check for continuity between pairs of commutator bars
CONTINUITY:
11 I·
There should be continuity.
Check for continuity between each commutator bar [I]

NO CONTINUITY : [2]
and the armature shaft {2].
There should be no continuity.
6-5
ELECTRIC STARTER
Check for continuity between the starter motor cable
terminal 11] and positive brushes 12].
Check for continuity between the positive brushes [1J ~======:;:~==~~=====~

and the rear cover (2].
Check for continuity between the negative brushes [31
and the rear cover.
Check for continuity between the positive and negative
brushes.
j
STARTER RELAY SWITCH
OPERATION INSPECTION
Remove the rear fender cover (page 2-8).
Turn the ignition switch ON and engine stop switch "O~.
Shift the transmission into neutral or apply front brake . ,

Push the starter switch.
The relay coil is normal if the starter relay switch [1]
clicks.
If you don't hear the switch "CLICK", inspect the relay
,
switch using the procedure below.
CIRCUIT INSPECTION
Ground Line :
Disconnect the starter relay switch 2P (Green) , - - - - - - - - - - - - - - - - - ,
Check for continuity between the wire harness side 2P
(Green) connector [1J terminal and ground.
Connection : Green - Ground
There should be continuity at all limes.
6-6
ELECTRIC STARTER
Power Input Line;
Disconnect the starter relay switch 2P (Green) - - - - - -- - - - -- -- -
connector (page 6-7 ). [1)
Turn the ignition switch ON and engine stop sWitch yt .
Shift the transmission into neutral or apply front brake.
Measure the voltage between the Wife harness side 2P
(Green) connector 111 terminal and ground .
Connection : Yellow/red (+) - Ground H
There should be battery vollage only when the starter
switch IS pushed.
CONTINUITY INSPECTION
Remove the starter relay switch [1J (page 6-7).
L
Connect the fully charged 12 V [2) battery to the starter
relay switch 2P (Green) connector [3J terminals .
Connection: Battery (+) terminal - Yellow/red
Battery (-) terminal - Light green/red
There should be continuity between the cable terminals 111
while the battery is connected , and no continuity when
the battery is disconnected.
Lg/R
®
(31 121
REMOVALIINSTALLATION
Disconneclthe battery negative H cable (page 22-5).
Disconnect the starter relay switch 2P (Green)
connector [1].
Remove the terminal nuts [2). spring washers [3).
battery positive (+) cable [4) and starter motor cable [5].
Remove the starter relay switch [6] from the rear fender
with the shock rubber (71.
Remove the starter relay switch from the shock rubber.
6-7
ELECTRIC STARTER j
STARTER INHIBITOR RELAY/STARTER
RELAY SWITCH DIODE
INSPECTION
j
Remove the PCMfECM from the ECM stay (page 4-36).
I
Remove the screws [1] and relay box lid [2J.
Remove the starter inhibitor relay [1) and starter relay

switch diode [2).
Connect an ohmmeter to the starter Inhibitor relay [1] , - - - - - , - , - -- - - - - - - - - - - - ,

terminals as shown and check for continuity. {1 J
There should be continuity. \
Connect a 12 V battery to Ihe relay terminals as shown.
There should be no continuity only when the 12 V
battery is connected.
Check for continuity between the terminals of the diode ~===============~

III III
When Ihere is continuity, a small resistance value will
register.
If there is continuity in one direction . the diode is
•
normal.
6·8
7. FUEL SYSTEM
SERVICE INFORMATION ····························· 7-2 FUEL TANK ················································7-16
SYSTEM COMPONENTS······························7-3 AIR CLEANER HOUSING .......................... 7-17
FUEL LINE TROUBLESHOOTING·· ·············7-4 THROTILE BODy ...................................... 7-18
FUEL LINE INSPECTION ······························7-5 lAC V .... _.... _.... .. _... _................. _.. _...... _._ ....... _. 7-21
FUEL PUMP UNIT ·······································7-11 FUEL INJECTOR · .... · .... ·· .... ··· .... · .. ····· .. · .. ····7-22
7-1
FUEL SYSTEM
SERVICE INFORMATION
GENERAL
This section covers service of the mechanical system of the PGM-FI system and the fuel supply system. For electrical system
service of the PGM-FI system, see PGM-Ft System section (page 4-2).
Before disconnecting the fuel feed hose, relieve pressure from the system (page 7-5).
Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bend, resulting in loss of
1
vehicle control.
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion .
,
Do nOI snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle
operation.
Seal the cylinder head intake port with tape or a clean cloth to keep dirt and debris from entering the intake port after the throttle
body has been removed.
Do not damage the throttle body. It may cause incorrect throttle valve operation.
Prevent dirt and debris from entering the throttle bore, IACV, sensor hole and fuel feed hose . Clean them using compressed air.
The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
Do not loosen or tighten the white painted screws and nut of the throttle body. loosening or tightening them can cause throttle
body malfunction.
Tighten the yellow painted screws of the throttle body to the specified torque.
When disassembling the fuel system parts, note the location of the O-rings. Replace them with new ones upon reassembly.
When servicing the fuel feed hose , be careful nolto bend or kink it.
TOOLS
Fuel connector remover Fuel pressure gauge Pressure gauge manifold
070MF-HP50200 0740B-0040004 07ZAJ-S5A0111 (not available in
U.S.A.)
1
•
or 07AMF-001A100 (U .S.A. only~or(U.S.A.

07406-004000C or 07406-0040008
Hose attachment, 9 mm/9 mm

only)
Pressure manif'~
ol"d~h~o~,~e-------1---CA"d<-,~p~le~,~,~m~'~le;---------~
•
07ZAJ-S5A0120 (not available in 07AMJ-HW3A100 (U.S.A. only) 07AAJ-S6MA200 (U .S.A. only)
U,SA)
Adapter, female
07AAJ-SBMA400 (U .S.A. only)
7-2
FUEL SYSTEM
SYSTEM COMPONENTS
1.8 N·m (O.2 kgf-m, 1.3IbHI)
7-3
FUEL SYSTEM
FUEL LINE TROUBLESHOOTING
For the following symptoms, always follow the steps in the troubleshooting flow chart.
- engine stall after warm up the engine
- rough idling after warm up the engine
- engine lacks power after warm up Ihe engine
Before starting the inspection, check for pinched or clogged fuel tank breather hose and fuel feed hose.
1. Fuel pump operation inspection
Turn Ihe ignition switch ON and engine stop switch ~O".
You should hear the fuel pump operation sound for a few seconds.
Do you hear the fuel pump operation sound?
YES - GO TO STEP 3.
NO - GO TO STEP 2.
2. Fuel pump Input Voltage inspection
Inspect the fuel pump input vol tage (page 7-12).
YES - Faulty fuel pump
NO Open circuit in the Brown wire and/or Green wire
Blown IGN fuse (20 A)
Faulty fuel pump relay (page 7-11) and its circuits
Faulty engine stop switch (page 23-10)
Open circuit in the power/ground lines of the PCM/ECM (page 4-35)
3. Fuel flow inspection
Inspect the fuel flow (page 7-11).
Is the fuel flow specified volume?
YES - GO TO STEP 5.
NO - GO TO STEP 4.
4. Fuel pump filter inspection
Inspect the fuel pump filter for clogged (page 7-14).
Is the fuel pump strainer screen normal?
YES - Replace the fuel pump with a new one (page 7-12), and recheck.
NO - Replace the fuel pump filter (page 7-14), and recheck the fuel flow (page 7-11).
5. Fuel pressure inspection
Inspect the fuel pressure (page 7-10).
Is the fuel pressure within specification?
YES - ' Inspect the ignition system (page 5-5).
• Inspect the cylinder compression (page 10-6). ••
NO - Replace the fuel pump with a new one (page 7-12), and recheck.
•
•
•
•
7-4
FUEL SYSTEM
FUEL LINE INSPECTION
FUEL PRESSURE RELlEV[NG
NOTE :
Before disconnecting fuel feed hose, relieve
pressure from the system as following procedures.
1. Remove the tank cover assembly (page 2-4).
2. Turn the ignition switch OFF.
3. Disconnecllhe fuel pump unil 4P connector [1].
4. Start the engine, and let it idle until the it stalls.
5. Turn the ignition switch OFF.
6. Disconnect the battery negative (-) cable
(page 22-5).
QU[CK CONNECT FITTING REMOVAL

NOTE '
• Do not bend or twisllhe fue l feed hose.
FUEL PUMP SIDE
1. Relive the fuel pressure (page 7-5).
2. Check the fuel quick connect fitting (1] for dirt, and
clean if necessary.
I
Place a shop towel [2] over the quick connect fitting. ~~r~%~~~~~~~
3. Pull and release the connector damper [1J from Ihe ~[1=[=============[2=[===~
retainer.
4. Hold the connector (2] with one hand and squeeze
the retainer tabs [3J with the other hand to release
the locking pawls [4) from the connector, and pull the
connector off the fuel pipe.
NOTE .
Absorb the remaining fuel in the fuel feed hose from
flowing oul with a shop lowel.
[3[
Be careful not to damage the hose or other parts.
Do not use any lools to disconnect the connector.
[4)
If the connector does not move, keep the retainer
tabs pressed down, and alternately pull and push
the connector until it comes off easily.
7-5
FUEL SYSTEM
5. Remove the retainer and connector damper from the
fuel pipe.
To prevent damage and keep foreign matter Qui,
cover the disconnected connector and fuel pipe end
with the plastic bags [1].
INJECTOR SIDE
1. Relive the fuel pressure (page 7-5).
Remove the snorkel duct (page 3-10).
Remove the bolt [1], clamp (2] and setting rubber 13J.
2. Check the fuel quick connect filling [1) for dirt, and
clean jf necessary.
Place a shop towel [2) over the quick connect fitting .
i
"
121 "
7-6
FUEL SYSTEM
3. Pull and release the connector damper [1] from the
re tainer.
4. Hold the connector [2J with one hand and squeeze
the retainer labs [3J with the other hand to release
the locking pawls [4] from the connector, and pull the
connector off the fuel pipe.
[3[
tf using the specialtQol:
Pull and release the connector damper from the
retainer as shown.
Set the special 100110 the retainer labs and push and
release them from the locking pawls.
[4[
TOOL:
Fuel connector rem over [5] 070MF·HP50200or
07AMF.()01A100
(U.S.A. o n ly ) 111
Pull the connector off the injector jOint.
NOTE :
Absorb the remaining fuel in the fuel feed hose from
flowing out with a shop towel.
Be careful not to damage the hose or other parts.
Use the specified special tool only.
If the connector does not move , keep the retainer
tabs pressed down, and alternately pull and push
the connector until it comes off easily.
5. Remove the retainer and connector damper from the

injector joint.
To prevent damage and keep foreign matter out,
cover the disconnected connector and injector joint
with the plastic bags [1] .
[11
7-7
FUEL SYSTEM
QUICK CONNECT FiniNG
INSTALLATION
NOTE:
Always replace the retainer and connector damper
of the quick connect fitting when the fuel feed hose is
disconnected .
If any retainer needs replacing , use the same
manufacturer's retainer as the ones being removed
(The various manufactures feature different relainer
specifications).
Do not bend or twist fuel feed hose.
FUEL PUMP SIDE
1. Insert a new retainer [1] into the connector [21 .
]2]
NOT E:
Align the relainer locking pawls with the connector
grooves.
....0-'
]1]
Align
2. Set a new connector damper [1] onto the fuel pipe

as shown. 12J
Then press the quick connect fitting [2] onlo the pipe
until both locking pawls [3] lock wi th a · ClICK".
If it is hard to connect, put a small amount of engine
oil on the pipe end.
13]
g ]lJ
3. Make sure the connection is secure and tha t the

locking pawls [1] are firmly locked into place: check 13] ]2]
visually and by pulling the connector [21.
4. Make sure the connector damper [31 is positioned
correctly (between the pipe [4] and re tainer tabs [5!).
5. Install the tank cover assembly (page 2-4).
6. Increase the fuel pressure and check Ihallhere is no
leakage in fuel supply system (page 7- 10).
]lJ
]4J
7-8
FUEL SYSTEM
INJECTOR SIDE
1. Insert a new retainer [1] into the connector [2J.
[2[
NOTE:
Align the retainer locking pawls with the connector
grooves.
[1[ g
Align
2. Set a new connector damper [1] onto the injector ~=================~

joint as shown. [3]
Then press the quick connect fitting [2] onto the
injector joint until both locking pawls [3] lock with a
"CLICK",
If it is hard to connect, put a small amount of engine
oil on the injector joint.
[2[
[1) g
3. Make sure the connection is secure and that the
locking pawls \11 are firmly locked into place; check [2[
visually and by pulling the connector [2J.
4. Make sure the connector damper [3J is positioned
correctly (between the injector joint [4J and retainer
labs [5)).
[3[
[1 [
r¢\
[5[ [4)
5. Instalilhe selling rubber [1) and clamp [21_

NOTE:
Align the clamp end with the groove in the clamp
stay.
Install and tighten the bolt [3).
6. Install the snorkel duct (page 3-10).
7. Increase the fuel pressure (page 7-10) and check
that there is no leak.age in fuel supply system .
7-9
,
FUEL SYSTEM
FUEL PRESSURE INCREASING
1. Connect the fuel pump unit 4P connector [1]. j
2. Connect the battery negative (-) cable (page 22-5).
3. Turn the ignition switch ON and engine stop switch
~O~ .
NOTE :
Do not start the engine.
4. The fuel pump will run for about 2 seconds, and fuel
pressure will rise .
Repeat this procedure 2 or 3 times, and check that
there is no leakage in the fuel supply system.
I
S. Install the lank cover assembly (page 2-4),
j
FUEL PRESSURE INSPECTION
Disconnect the quick connect fitting from the fuel pump r--------------~~,__'"
(page 7-5),
Attach the special tools between the fuel injector and
fuel feed hose .
Except U.S.A. TOOLS:
Fuel pressure gauge (1] 07406-0040004
Pressure gauge manifold [2] 07ZAJ-S5A0111
Hose atlachment, 9 mm/9 mm (3) 07ZAJ-S5A0120
U.S.A. TOOLS;
Fuel pressure gauge, 100 psi 07406-004000C or
07406-0040008
Pressure manifold hose 07AMJ-HW3A100
Adapter, male 07AAJ-S6MA200
Adapter, female 07 AAJ-S6MA400
Connect the fuel pump unit 4P (Gray) connector.

Connect the battery negative (- ) cable (page 22-5).
Start the engine, let it idle and read the fuel pressure .
Standard:
331 - 367 kPa (3.4 - 3.7 kgf/cm 2, 48 - 53 psi)
If the fuel pressure is higher than specified pressure,

replace the fuel pump unit (faulty fuel pump or fuel
pressure regulator).
If the fuel pressure is lower than specified , inspect the
fOllowing:
- fuel flow (page 7-11 )
- fuel pump (page 7-12)
- clogged fuel pump filter (page 7-14)
Wrap a shop towel Relieve the fuel pressure (page 7-5) and remove the
around the special tools from the fuel pump and fuel feed hose.
attachment to soak
Connect the quick connect fitting to the fuel pump (page
up any spilled fuel.
7-8).
7-10
FUEL SYSTEM
FUEL FLOW INSPECTION
Disconnect the quick connect filling from the fuel pump , - - - - - !
(page 7-5).
Connect the special tools to the fuel feed hose.
~~.;O>""-",,~,:!'7;7-~ir:(§~-~-
;C
Except U.S.A . TOOLS :
Hose attachment, 9 mm /9 mm [1] 07ZAJ ·S5A01 20
U.S.A. TOOLS :
Pressure manifold hose 07AMJ-HW3A100
Adapter, male 07 AAJ -S6MA200
Fuel pressure gauge, 100 psi 07406·Q04000C or
07406-004000B I
)
Note: The fuel pressure gauge must be installed for
these tests . 111
Place the end of the hose attachment Into an approved
gasoline container. 121
Remove the fuel pump relay (page 7-11).
Connect the wire harness side fuel pump relay
- I
connector [2J terminals with a jumper wire (3]. .>< ' i" l
Connection : B rown - Black/red -
Temporarily connect the battery negative (-) cable to
the battery (page 22-5),
Tum the engine stop switch "0" for 10 seconds and tum
It "~" to measure the amount of fuel flow. '-\
Amount of fuel flow: 131
356 cm J (12.0 US oz, 12.5 Imp oz) m i nimum!
10 seconds
If the fuel flow is less than specified . inspect the
following:
- fuel pump (page 7-12)
- clogged fuel pump filter (page 7-14)
Wrap a shop towel Remove the special lools from Ihe fuel pump.
around Ille
Connect the quick connect filling to the fuel pump (page
attachment 10 soak
7-8).
up any spilled fuel.
FUEL PUMP UNIT

FUEL PUMP RELAY INSPECTION
Remove the relay box lid (page 6-8).
Remove the fuel pump relay [1].
7-11
FUEL SYSTEM
,
Connect an ohmmeter to the terminals of the fuel pump
relay [1].
[1 [ ~
Connect a 12 V battery to the fan motor relay terminals

as shown .
There should be continui ty when the 12 V battery is
\
connected and no continuity when the battery is
disconnected. ~ il:
L
@ e Ell
INSPECT[ON
Remove the tank cover assembly (page 2-4),
Turn the ignition switch ON and engine stop switch "0 · ,
and confirm that the fuel pump operates for a few
seconds.
If the fuel pump does nol operate, inspect as follows:
Disconnect the fuel pump 4P (Gray) connector [1].
Turn the ignition switch ON and measure the voltage

between the terminals of the wire harness side 4P
(Gray) connector [11.
Connection : Brown (+) - Green (-)

There should be battery voltage for a few seconds after
the ignition switch turned ON.
If there is battery voltage. replace the fuel pump unit.
If there is no voltage. check the following:
- open circui t in the Brown or Green wires
fuel pump re!ay (page 7-11)
- open circuit in the Black/white wire between the
engine stop switch and fuel pump relay [1 [
- open circuit in the Gray/red wire between the fue!
-
pump relay and PCMfECM
powerfground lines of the PCMfECM (page 4-35)
,,
REMOVAL
Remove the ECM stay (page 3- 10).
Disconnect the quick connect fitting [1 } from the fuel
pump (page 7-5).
Disconnect the fuel pump breather hose [21.
Remove the fuel pump cover [3}.
7·12
FUEL SYSTEM
Remove the locking ring [1) by rotating it
counterclockwise using the fuel tank lock ring wrench
as shown .
TOOL:
Fuel tank lock ring wrench [2J OTC6599
Remove the fuel pump unit (1) and O-ring [2].

• Be careful not to damage Ihe fuel level sensor.
INSTALLATION
Install a new O-ring (1) .
Clean the O-ring sealing area of the fuel tank, and
be sure thai no foreign materials are allowed .
Always replace the O-ring with a new one.
Install the fuel pump unit [2J aligning its tab with the
arrow marl...
• Be careful not to damage the fuel level sensor.
Install a new locking ring [1).

• Always replace the locking ring with a new one
Tum the locking ring dockwise using the fuel tank lock
ring wrench until the marks [2] of the fuel lank align with
the grooves of the locking ring.
TOOL:
Fuel tank lock ring w rench (3) OTC6599
Connect the quick connect fitting to the fuel tank unit
(page 7-8).
removal.
7-13
FUEL SYSTEM
OISASSEMBL Y/ASSEMBL Y
NOTE :
Clean Ihe inside of the reservoir. fuel pump and filler
1
with clean gasoline. Never use commercially
,
available carburetor cleaners.
Always replace all O-rings with new ones when the
fuel pump has been disassembled.
Be careful not to damage the fuel pump and fuel
level sensor wires. 1
Disconnect the connectors [1) and release the wires ,----:=":':":~----.--..,Il""'"=----,
from Ihe guides [2] .
Unhook the tab 111 and remove the fuel level sensor (2) ~===~~:;~:::~:;;~~~;,;;~==~
upward.
,
111 1
Remove the E-rings [1]. reservoir (2J and spring [3].

12J
13J
7-14
FUEL SYSTEM
Remove the return jet [1] and strainer case [2] from the
reservoir [3].
• Unhook the hooks as shown .
l ~[1[
Remove the fuel pumpffilter assembly [1] from the ;:::;;;;;:;;;;;;;;;::==:;;;::[=3:[ =:::=""'"""~=~
strainer case.
Remove the fuel pump wire [2] by disconnecting the
fuel pump 2P connector [3].
-
- ,
1[1[/ [2[
Remove the O-ring [1] and spacer (2).

[1[
Check the filter [3) for clog or damage .
If the filter is clogged or damaged . replace the fuel
pump unit assembly.
\ [3[
Remove the bracket [1] and pressure regulator [2).

[3[
Remove the O-rings [3] and back-up ring [4) from the
pressure regulator.
[1 [ [4[ 1
7-15
FUEL SYSTEM
Remove the bracket [1) from the strainer case [2).
1
, j
I
~

Install the fuel level sensor aligning its groove with
the strainer case lab.
FUEL TANK
Remove the ECM stay (page 3-10).
Disconnect the quick connect fitting [1] from the fuel
pump (page 7-5),
Disconnect the fuel pump breather hose [2].
,•
Remove the bolts [1J and collar [2).
7-16
FUEL SYSTEM
Remove the two torx bolts (T30) [1), collars [2] and fuel
tank [3].
• Quick connect fitting installation (page 7-8)
AIR CLEANER HOUSING

Remove the snorkel duct (page 3-10).
{5] {6]
Disconnect the following:
- IAT sensor 2P (Black) connector [1 J
- crankcase breather hose [2J {1]
~~
- 01 sensor 4P (Black) connector (3)
- trim clips (4)
Loosen the connecting tube band screw [5), position the
air cleaner tabs to allow clearance from the frame and
rear fender tabs, and remove the air cleaner housing
16].
{4{
{3]
7-17
FUEL SYSTEM
THROTTLE BODY
REMOVAL
NOTE:
If the sensor unit is removed from the throtUe body,
the TP sensor reset procedure must be performed
after installing the throttle body (page 4-32).
- quick connect fitting [1] from the injector jOint (page
7-5)
- IACV 4P (Black) connector [2J I,
- fuel injector 2P (Black) connector [31
- sensor unit 5P (Black) connector [4] ~
Remove the harness clip [5] .
Remove the screw [1].

Remove the throttle drum cover [2] while releasing its
lab (3] from the throttle body slot [4] .
Slide the rubber boot [5) off the adjuster [61.
Loosen the IhrotUe cable adjuster lock nut [7], remov e
the adjuster from the throttle body and disconnect the
cable end (8] from the throttle drum [91 .
loosen the throttle body side insulator band screw [1).

Remove the throttle body [2] from the insulator.
loosen the cylinder head side insulator band screw [1].

Remove the insulator [2] from the cylinder head .
7-18
FUEL SYSTEM
OISASSEMBLY/CLEANINGI
ASSEMBLY
I NOTICE I
The throttle body is factory pre-set. Do not , - - - - -- - - - - - - - - - - - ,
disassemble in a way other than shown in this
manual.
Do not snap the throttle valve from full open to full
close after the throttle cable has been removed. It
may cause incorrect idle operation.
Do not damage the throttle body. It may cause
incorrect throttle valve operation.
Do not loosen or tighten the while painted screws [1 J
and nut (2J of the throttle body. Loosening or
lightening them can cause throttle valve and idle
control failure.
Always clean the throttle body before disassembly to
prevent dirt and debris from entering tile passages.
Do not remove the sensor unit unless it is replaced.
,-::
r
1'=] ==================
14] 13] 15]
- screw [1) and wire harness clamp stay [2J ~
- screw [3] and fuel feed hose clamp stay [4]
- IACV [5J (page 7-21)
fuel injector [6] (page 7-22)
- sensor unit [7] (page 4-32)
Cleaning the air Clean the air passage of the throllle body using ~======='""=========~
passages and compressed air.
sensor hole with a Check the air passage for clogs.
piece of wire will
damage the throttle
NOTE :
body. • Do not use high pressure air or bring the nozzle too
close to the throttle body.
TORQUE :
Wire harness clamp stay screw:
3.4 N'm (0.3 kgf'm , 2.5 IbHtj
Fuel feed hose clam p stay screw:
3.4 N'm (0.3 kgf·m, 2.5 IbHtj
NOT E:
Install the wire harness clamp stay and fuel feed
hose clamp stay by aligning each stay hole with the
pin of the throllle body.
7-19
FUEL SYSTEM
INSTALLATION
Face the "HR3" Install the insulator [1] onto the cylinder head by
mark 12l/oward the aligning the groove with the Jug.
throttle body.
Align the cylinder head side insulator band hole with the
insulator boss.
Tighten the cylinder head side insulator band screw [1]

so that the distance between the band labs is as
shown. 11 .0-13.0mm
(0.43 - 0.51 in)
Install the throttle body [11 into the insulator by aligning

the lug with the groove.
Align the throttle body side insulator band hole with the
insulator boss.
Tighten the throttle body side insulator band screw [2] in
the same way as the cylinder head side.
Connect the throttle cable end [IJ to the throttle drum

[21· •
Trghren the lock nut Install the throttle cable adjuster (3] to the throttle body
and install the and temporarily tighten the lock nut (4].
adjuster rubber boot
Instalilhe throttle drum cover [6] by aligning the locating
(5J after adjusting
tab (7] with the slot (a) in the throttle body.
the throttle lever
froop/ay. Install and tighten the screw (9) to the specified torque.
TORQUE: 1.8 N'm (O.2 kgf'm, 1.3IbHt)
removal.
• Quick connect fitting installation (page 7-9)
7-20
FUEL SYSTEM
IACV
INSPECTION
The IACV is installed on the throttle body and is . - - - - - - - - -.....-
operated by the step motor. When the ignition switch
is turned ON , the IACV operates for a few seconds.
Turn the ignition switch ON and check the IACV [1].
If the step motor operating sound is heard, the IACV is
normal.
The IACV operation can be checked visually as follows:

1. Remove the IACV (page 7-21).
2 . Connect the IACV 4P (Black) connector [lJ.
3. Tum the ignition switch ON and check the IACV
operation.
REMOVAUINSTALLATION
Clean the throttle body to prevent dirt and debris from
entering the IACV passage.
Disconnect the IACV 4P (Black) connector [1J.
Remove the two tor:'( screws (T20) [2), retainer plate [3)
and IACV [4).
Install a new O·ring (1] onto the IACV [2J .

Before installing the IACV. turn the slide valve (3]
clockwise untillighUy seated on IACV.
7-21
FUEL SYSTEM
Inslall the IACV (1) into the throttle body by aligning the
valve groove with Ihe guide pin in the throttle body.
•
I
Install the retainer plate (1] by aligning the groove with
Ihe valve boss.
Install and lighten the two lorx screws (T20) (2) to the
specified torque.
TORQUE: 2.1 N'm (0.2 kgf'm , 1.5IbHt)
I
Connect the IACV 4P (Btack) connector (3] .
Install the tank cover assembly (page 2-4 ).
FUEL INJECTOR
1
1
REMOVAUINSTALLATION
Remove Ihe lank cover assembly (page 2-4).
Clean the throttle body to prevent dirt and debris from
entering the combus tion chamber.
Remove Ihe JACV (page 7-21).
•
Disconnect the quick connect fitting [1] from the injector
joint (page 7-5) ,•,
Disconnect the fuel injector 2P (Black) connector [2] .
Remove the fuel Injector mounting bolts [3) and fuel
injector assembly (4] from the throttle body.
Remove the fuel Injector [1) from the injector joint [2).
•
Remove the D -ring [3). dust seal ring [4) and seal ring
151·
Installation is in the reve rse order of removal.
Always replace the D-ring and cushion ring with new
ones.
Apply engine oil to the D-ring and seal ring .
TORQUE :
Fuel Injector mounting bolt:
5.1 N·m (0.5 kgf·m, 3.8Ibf-ft)
7·22 •
8. COOLING SYSTEM
SERVICE INFORMATlON ···· ····················· .. ·· B·2 THERMOSTAT .............................................. 8-6
TROUBLESHOOTlNG ...... · .. ·· .. · .. · .... ·.... · ...... ··8-3 RADIATOR/COOLING FAN .......................... 8-7
SYSTEM FLOW PATTERN .......................... ·8-4 RADIATOR RESERVE TANK ...................... · 8-9
SYSTEM TESTING .. · ...... · .. · ...... · .. · ...... · .. · ...... ·8-5 WATER PUMP .............................................. 8-9
COOLANT REPLACEMENT ........................ ·8-5
8·1
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
AWARNING
Removing the radiator cap white the engine is hot can allow the coolant to spray out, seriously scalding you.
Always lei the engine and radiator cool down before removing the radiator cap.
- -- ' - - -- -
If any coolant gets in your eyes, rinse them wi th water and consult a doctor immediately.
If any coolant is swallowed, induce vomi ting . gargle and consult a physician immediately.
If any coolant gels on your skin or clothes, rinse thoroughly with plenty of water.
I NOTICE I
1
,
Using coo/ant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages.
Using tap water may causa engine damage.
Add cooling system at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
Avoid spilling coolant on painted surfaces,
After servicing the system, check for leaks with a cooling system tester.
For cooling fan system inspection, refer to OUghts/Meters/Switches" section (page 23-13).
i
I
TOOLS
Remover weight Driver Remover shaft, f5 mm ,
07741 -00 10201 07749-0010000 07936-KC10100 (not available in
•
U.S.A.)
•
•
•
or 07936-371020A (U.S.A. only) ---h""",,;;-;;==;-
Bearing remover, 15 mm -----+-.M"e~c~h~a~o~lca;;;,-,,"aal driver attachment
Remover head, 15 mm
07936-KC10200 (not available in
U.S.A.)
07936-KC 10500 (U.S.A. only) 07945-4150400 ,•
I Mechaolcal ,eal loslalle,

07965-415000A (U.S.A. only)
8-2
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
Thermostat stuck closed
Faulty radiator cap
Insufficient coolant
Passage blocked in radiator, hoses or water jacket
Air in system
Faulty cooling fan motor
Faulty water pump
Engine temperature too low
• Thermostat stuck open
Coolant leaks
Faulty water pump mechanical seal
Deteriorated O-rings
Faulty radia tor cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or clamp
Damaged or deteriorated hoses
8-3
COOLING SYSTEM
SYSTEM FLOW PATTERN
RES"RV' TANK
RADIATOR
,
,
4
1
•
•
·
•
WATER
8-4
COOLING SYSTEM
SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cap lid (page 2-3).
Remove the radiator cap [1].
Wet the sealing surfaces of the cap, then install the cap
onto tester [2].
TOOLS :
Cooling system pressure tester SVTS4AH
Cooling system adaptor OTCJ33984A
Pressurize the radiator cap using the tester.

Replace the radia tor cap if it does not hold pressure, or
If relief pressure is too high or too low. It must hold the
specified pressure for at least 6 seconds.
RADIATOR CAP RELIEF PRESSURE :
108 -137 kPa (1 .1 -1 .4 kgf/cm 2 , 16 - 20 psi)
Pressurize the radia tor, engine and hoses using the

tester, and check for leaks.
I NOTICE I
Excessive pressure can damage the cooling system
components. Do no/ exceed 137 kPa (1.4 kgflcm2,
20 psi).
Repair or replace components if the system will not hold
the specified pressure for at least 6 seconds. [1]
Remove the tester and install the radiator cap .
lnsta il i he lid in the reverse order of removal.
COOLANT REPLACEMENT
REPLACEMENT/AIR BLEEDING
• When filling the system with coolant. place the
vehicle on a flat, level surface.
The engine must be Remove the following:
cool before
- radiator cap lid (page 2-3)
servicmg the
- tank cover assembly (page 2-4)
cooling system.
Place a lunnel Drain the coolant from the system by removing the
under the water drain bolt [1] and sealing washer [2] on the water pump.
pump to catch and the radiator cap [3].
coolant in a
Reinstall the drain bolt with a new sealing washer
container.
securely.
8-5
COOLING SYSTEM 1
Remove the boll [1), trim clips [21 and reserve tank [3J,
then open the lank cap to drain the tank ,
j
Disconnect the siphon hose [4]10 remove the tank. I
Rinse the inside of the reserve tank with water.
Reconnect the siphon hose and install the reserve tank
~
with the bolt and trim clips.
Fililhe system with the recommended coolant up to the
1
filler neck [5].
Bleed air from the system as follows:
1
1. Shift the transmission into neutral.
2. Snap the throttle 3 - 4 times to bleed air from the
system.
3. Stop the engine and add coolant up to the filler neck.
4. Inslallthe radiator cap.
Fill the reserve tank to the upper level line [61 and install
the tank cap.
Install the rem oved parts in the reverse order of
removal.
THERMOSTAT
Drain the coolant from the system (page 8-5).
Remove the bons [1), thermostat cover [2) and
thermostat [3}.
Make sure the rubber seal (4] on the thermostat is in
good condition.
Apply coolant to the rubber seal.
• Install the thermostat into the housing with the bleed
hole (5) facing inboard.
Fill and bleed the cooling system (page 8-5).
·
•
INSPECTION ·
Visually inspect the thermostat [1 1 for damage.
Replace the thermostat if the valve stays open at room 111 [2J
temperature.
Do not let the Heal a container of water with an electric heating
themwstat or element for 5 minutes.
thermometer (2} Suspend the thermostat in heated water to check its
touch the pan, or operation.
you will get 8 false
THERMOSTAT BEGIN TO OPEN :
reading.
80 - 84°C (176 _ 183°F)
VALVE LIFT:
8 mm (0.3 in) minimum at 95°C (203°F)
Replace the thermostat if the valve opens at a
temperature other than those specified.
8-6
COOLING SYSTEM
RADIATOR/COOLING FAN
RADIATOR REMOVAL/INSTALLATION
NOTE:
• Take care not to damage the radiator fins while
servicing the radiator.
Drain the coolant from the system (page 8-5).
- front fender/carrier (page 2-6)
- radiator reserve tank (page 8-9)
- FM2IFA2 only: EPS ECU (page 25-29)
Release the front final gear case breather hose [1].
Remove the following;
- trim clips [2]
- radiator grille cover [3]
- radiator grille center cover [4]
Release the fan molor breather hose [1J.

- trim clips [2]
- radiator grille cover [3J
Remove the boll [1].

- fan motor 2P connector [2)
- water hose [3]
Remove the bolt [1).

Disconnect the water hose [2}.
Remove the radiator assembly [3] .
8-7
COOLING SYSTEM
Install the radiator assembly aligning it bosses with
the grommets.
Route the fan motor breather hose properly
(page 1·23).
Fill and bleed the coohng system (page 8-5),
COOLING FAN REMOVAL!

INSTALLATION
Remove the washer-bolts [1] and motor/stay assembly
121·
,•
Remove the nut [1 J and cooling fan [2].
Remove the following~
- connector [ 1]
- three bolts 12J
- fan molor [3]
• Apply locking agenllo the cooling fan nut threads.
TORQUE:
Cooling fan nut : 2.7 N-m (0.3 kgf'm, 2.0 tbHt)
Fan motor bolt: 5.2 N'm (0.5 kgf-m, 3.8 IbHt)
Fan motor stay bolt: 8.4 N'm (0.9 kgf-m , 6.2 IbHt)
8-8
COOLING SYSTEM
RADIATOR RESERVE TANK
Remove the radiator cap lid (page 2-3).
Remove the bolt (1], trim clips 121 and reserve tank PI,
then open the tank cap to drain the lank.
Disconnect the siphon hose (4) to remove the lank.
Connect the siphon hose and install the reserve tank
with the two bolts.
Fill the reserve tank to the upper level line [5J and install
the tank cap.
WATER PUMP
MECHANICAL SEAL INSPECTION
Remove the tank cover assembly (page 2-4). I
Check the bleed hose [1J of the water pump for signs of
coolant leakage.
If water leaks through the bleed hose, replace the
mechanical seal (page 8-9). 11 1
If oil leaks through the bleed hole, repla ce the oil seal
(page 8-9),
Make sure that there are no continuous coolant leakage
from the bleed hose while operating the engine.
NOTE
• A small amount of coolant weeping from the bleed
hose is normal.
MECHANICAL SEAL REPLACEMENT

NOTE:
• When replacing the mechanical seal , the Impeller
and pump shaft must be replaced with new ones.
Remove the front crankcase cover.
- Except FA1/FA2: page 12-5
- FAlIFA2 : page 13-33
- five bolts [1] and sealing washer [2]
- pump cover [3]
- O-ring [4] (from the cover)
8·9
COOLING SYSTEM
Remove the impeller assembly from the pump shaft by
tapping the inside of the impeller [1 ] through the pump {11
shaft [2], using a screwdriver or equivalent.
{31
Remove the mating ring and cup gasket of the
mechanical seal from the impeller.
- pump shaft
- thrust washer [3J
Remove the mechanical seal [1].
TOOLS :
Remover Head, 15 mm 07936·KC10200
Remover Shaft, 15 mm 07936·KC1 01 00
Remover Weight 07741-0010201
U.S.A . TOOLS :
Bearing remover, 15 mm 07936·KC10500
Remover w eight 07936·371020A
Remove the oil seal [1].

Apply molybdenum oil solution to the lips of a new oil
seal.
Install the oil seal with the flat side faCing oul until it is
fully seated.
Be careful not 10 Drive a new mechanical seal {1] in until it is sealed.

damage rhe sliding
surface orrhe TOOLS :
mechanical seal. Driver [2J 07149..0010000
Mechanical seal driver 07945-4150400
attachment [3]
U.S.A. TOOL :
Mechanical seal installer 07965-415000A
(U.S.A. only)
8-10
COOLING SYSTEM
Be careful nollo Install a new cup gasket (1] over a new mating ring [2] .
damage the sliding
Apply coolant around the cup gasket. Install the gasket! {1{ !!:!~
surface of the
mating ring.
ring assembly into a new impeller [3) with the gasket
faCing the impeller until it is fully seated.
""'"
{3{
Donolgefoilonthe Apply molybdenum oil solution to the journal [1J of a

mechanical seal. new pump shaft (2).
Inslall the washer [3] onto the pump shaft, and insert
the shaft into the crankcase cover.
Never allow dirt or Degrease [1) the press fitting areas of the impeller [2]
dus/to get onto the and shaft [3J. and Ihe sliding surfaces of the mechanical
sliding surfaces of seal and mating ring. [2{
the mechanical seal Press the impeller assembly onto the shaft.
and mating nng.
Check that the pump shaft turns smoothly wi thout
[1{ """"==-fi
binding.
[3{
Install a new O-ring 111 into the cover groove [21 .

[1{
8·11
COOLING SYSTEM
Install the pump cover (1] and the five bolts (21 with a
new sealing washer (3J in position as shown (triangular
mario: (4]). Tighten the bolts in a crisscross pattern in
several steps.
Instalilhe fronl crankcase cover.
- Except FA1 / FA2: page 12-7
j
- FA1/FA2: page 13·37
1
•
1,
,
j
•
•
8-12
9. LUBRICATION SYSTEM
SERVICE INFORMATION ···· ·········· ···············9-2 OIL PUMP (Except FA1 / FA2 models) ·········9-6
TROUBLESHOOTlNG··································· 9-3 RELIEF VALVE

(Except FA1 /FA2 models) ··························· 9-7
LUBRICATION SYSTEM DIAGRAM
(Except FA1 /FA2 models) .. ························ .. 9-4 OIL PRESSURE CHECK
(FA1/FA2 models) ······ ·································· 9-8
LUBRICATION SYSTEM DIAGRAM
(FA1 /FA2 mode ls)·········································9-S OIL PUMP/RELIEF VALVE
(FA1 /FA2 models) ········ ································ 9-9
9-1
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, il is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
I
This section covers seNice of the oil pump and relief valve. The service procedures in this section can be performed with the
engine installed in the frame.
When removing and installing the oil pump. use care nOl to allow dust or dirt to enter the engine.
If any portion of the oil pump is wom beyond the specified service limits, replace the oil pump as an assembly.
Oil level check and oil change
- Except FA1 /FAZ models: page 3·14
1J
- FA1fFA2 models: page 3-16
Oil filler replacement
·
~
- Except FA1IFA2 models: page 3-17
- FA1 IFA2 models: page 3-18 •
TOOL
Oil pressure gauge set •
07406-0070002
•
f
or 07ZMJ-HN2A100 and 07AMJ-

HN8Al00 (U.S.A. Only) •
9-2
LUBRICATION SYSTEM
TROUBLESHOOTING
Qillev el too low - h igh oil consumption
Normal oil consumption
External oil leak
Worn piston rings or incorrect piston ring installation
Worn cylinder
Worn valve guides or stem seals
l ow oil pressure (only for FA1 /FA2 models )
Oil tevellow
Oil pressure relief valve wear
Clogged oil strainer or filter
Faulty oil pump
Internal Dilleak
Incorrect oil being used
No oil pressure (on ly for FAlIFA2 models)
Oil level too low
Oil pressure relief valve stuck open
• Damaged oil pump
• Internal oil leak
High oil pressure only for (FA1fFA2 models)
Oil pressure relief valve stuck dosed
• Clogged oil gallery or entice
• Incorrect oll being used
Oil contamination
Oil or filter not changed often enough
Worn piston fings or incorrect piston ring installation
• Worn valve guides or stern seals
• Clogged oil slrainer screen
Oil emuls ifi cation
Blown cylinder head gasket
Leaky coolanl passage
Waterenlry
9-3
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM (Except FA1/FA2 models)
CYLINDER
HEAD COVER
1_--- CYLINDER HEAD
CENTRIFUGAL 11 - - - - CYLINDER
I
.J
j
I
I
•
REAR CRANKCASE COVER
,
OIL TER ,
MAINSHAFT
FRONT CRANKCASE COVER
OIL PUMP
OIL STRAIN"R
SCREEN
COUNTERSHAFT
9-4
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM (FA1/FA2 models)
CYLINDER HEAD COVER _ _ _ _~ t~ ;- ~
- -Wi'Bf '1 ~
mi'~
I
-,
44- - - CYLINDER HEAD
CYLINDER _____
OIL FILTER · '1
MAINSHAFT
,,
rl
I
RELIEF VALVE
1st SHIFT
SHIFT VALVE 2nd SHIFT COUNTERSHAFT
CLUTCH
BODY CLUTCH
,
'1 K ~
,-- - - - - OIL PUMP
OIL TANK ~
l E -
.::~;?J,
OIL STRAINER SCREEN
9-5
LUBRICATION SYSTEM
OIL PUMP (Except FA1/FA2 models)
REMOVAUINSTALLATION j
Remove the front crankcase cover (page 12-5).
Remove the three bolts [1] and oil pump (2].
Install the oil pump [11 onlo the crankcase by aligning , - - - -

j
the pump shaft end 12J with the balancer shaft groove
(31·
Inslall the removed parts in the reverse order of
removal. J
OISASSEMBL Y/ASSEMBL Y I
I
Remove the boll 11] and rotor side plate [2].
1
•
j
•
•
Remove the pump shaft [1] and drive pin {2]

Remove the inner rotor [31 and outer rotor (4] from the
pump body [51.
Dip all parts in dean engine oil.
Assemble the oil pump in the reverse order of
disassembly.
121
9·6
LUBRICATION SYSTEM
INSPECTION
Inspect the following parts for abnormal wear or
damage. Replace or clean if necessary.
- oil pump shaft
- drive pin
- inner and outer rotors
- oil pump body
Measure the oil pump clearances according to
(page 1-8).
If any of the measurement is oul of the service limit,
replace the oil pump as an assembly.
RELIEF VALVE (Except FA1/FA2

models)
Remove the front crankcase cover (page 12-5),
Remove the relief valve assembly [1] from the front
crankcase cover.
Remove the O-ring from the relief valve body.
Check the operation of the relief valve by pushing on
the piston.
Replace the relief valve assembly if necessary.
Coat a new O-ring [11 with engine 011 and Inslalill inlo
the relief valve body groove.
Install the relief valve assembly [2[ into the front
crankcase cover.
Install the front crankcase cover (page 12-7).
9-7
LUBRICATION SYSTEM
OIL PRESSURE CHECK (FA1/FA2
models)
Failure to warm the Check the oil level and add the recommended oil if
angll1f/ will cause necessary (page 3-16).
very high oil Also, warm the engine to normal operating temperature
pressure readings. and check for extemalleaks.
EKlamal leaks wil'
cause low oil Remove the tank cover assembly (page 2-4).
pressurereadmgs. Remove the oil gallery sealing bolt [1] and washer [2)
on the right side of the front crankcase cover.
NOTE-
Clean around the sealing bolt with compressed air
before removing the bolt, and be sure that no dirt
enters the oil gallery.
Connect an on pressure gauge and adapter to the oil

gallery hole.
TOOLS;
Oil pressure gauge set (1) 07406-0070002
U.S .A. TOOLS :
Oil pressure gauge 0-160 psi 07ZMJ ·HN2A100
and
Adapter, banjo 8)( 1.25 mm 07 AMJ -HNSA 100
Start the engine and check the oil pressure.

OIL PRESSURE (80"Cf176" F) :
510 kPa (5.2 kgflcm l , 74 psi) at 5,000 rpm
Stop the engine and remove the oil pressure gauge and
l
hose.
Install the sealing bolt [11 with a new sealing washer [2)
and tighten the bolt securely.
Start the engine and make sure there are no oil leaks.
1,
~·
,
•
••
I
•
j
1
j
9-8 ,•,
LUBRICATION SYSTEM
OIL PUMP/RELIEF VALVE (FA1/FA2
models)
OISASSEMBLY
Remove the front crankcase colier and spacer (page ,----- - - - - -- - - - - - ----,
13-33).
- five bolts [1)
- oil pump body A [2J
- outer rotor C {1]

- inner rotor C [2]
- drive pin [3]
- oil pump body B (1]

- pressure relief valve [2)
- D-ring [3] (from the relief valve)
- two dowel pins (4)
- oil pump shaft [1)

- drive pin [2J
- outer rotor A [3]
- inner rotor A [4]
Clean all the disassembled parts thoroughly.
9-9
LUBRICATION SYSTEM
INSPECTION
Inspect the following parts for abnormal wear or
damage. Replace or clean if necessary.
- oil pump shaft
drive pins
1
inner rotors A and C
outer rotors A and C
oil pump body B
front crankcase cover spacer (oil pump body) 1
Check the operation of the relief valve by pushing on
the piston.
Replace the rehef valve assembly if necessary.
Measure the oil pump clearances according to
(page 1-8),
If any of the measurement is out of the service limit,
replace the oil pump as an assembly.
ASSEMBLY
Assembly is essentially in the reverse order of
disassembly.
Dip the inner rotors. ou ter rotors and pump shaft in
clean engine oil.
Replace the 0·rin9 with a new one.
Coat O-ring with engine oil.
FRONT CRANKCASE COVER SPACER

PRESSURE RELIEF VALVE
g~
,
"
O-RING 1
PUMP BODY B ~ (J~
DOWEL PIN - - - - - . . ."" ~~"

&? ~~~ OUTER ROTOR A ,
INNER ROTOR A ---"1

DRIVE PINS
DOWEL PIN •
OUTER ROTOR C ,
-:7J PUMP SHAFT

PUMP BODY A
9-10
10. CYLINDER HEADNALVE
SERVICE INFORMATION ···························10-2 CYLINDER HEAD COVER ························· 10-6
TROUBLESHOOTING································· 10-3 CYLINDER HEAD ································ .... ·10-10
SYSTEM COMPONENTS···························· 10-4 CAMSHAFT······································· ·······. 1 0 - 1 6 .
CYLINDER COMPRESSION ······················· 10-6
10·1
CYLINDER HEADNALVE
SERVICE INFORMATION
GENERAL
This section covers service of the rocker arms , cylinder head , valves and camshaft. These services can be done with the engine
installed in the frame.
When disassembling, mark. and store the disassembled parts to ensure that they are reinstalled in their original locations.
Clean all disassembled parts with cteaning solvent and dry them by blowing them off with compressed air before inspection .
j
Rocker arm and valve lubricating oil is fed through oil passages in the cylinder head and head cover. Clean the oil passages
before assembling cylinder head.
Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do nol strike the
cylinder head too hard during removal.
j
TOOLS
Valve spring compressor Valve guide driver, 6 mm Valve guide reamer, 6 mm
07757-0010000 07942-6570100 07VMH-MBB0200
f-,===-.,=::-7i ""'''"'___ --+,,===.,.,=''''v:i''''

Seat cutter, 40 mm (IN 45~) Seat cutter, 33 mm (EX 45°)
___-t-~OFlat
Ci':c.07VMH-MBB020A (U.S.A. only)
culler, 38.5 mm (IN 32°)
07780-0010500 07780-0010800 07780-0012400
G B (J <
,
or equivalent commercially available in
U.S.A.
U.S.A.
U.S.A.
,
~
Flat cutter, 33 mm (EX 32°) Interior cutter, 37.5 mm (IN 60°) Interior culler, 34 mm (EX 60' )
07780-0012900 07780-0014100 07780-0014700
1
1
(J G ~
<:. . ..
:.:.(.~.}:.

U.S.A.
U.S.A.
0'U.Seq"''''ool
.A.
commo,"a", avalla: : j
10-2
CYLINDER HEADN ALVE
Culler holder, 6 mm
07VMH-MBB0100

U.S.A.
TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test. or by
tracing lop-end noise with a sounding rod or stethoscope.
If the performance is poor at low speeds, check for a white smoke in the crankcase breather hose. If the hose is smoky, check
for seized piston ring (page 11-4).
Compression too low, hard starting or poor performance at low speed
Valves
~ Incorrect valve adjustment
- Burned or bent valves
- Incorrect valve timing
- Broken valve spring
- Uneven valve seating
- Valve sluck open
Cylinder head
- Leaking or damaged cylinder head gasket
- Warped or cracked cylinder head
- Loose spark plug
Cylinder/ piston problem (page 11-2)
Compression too high
• Excessive carbon build-up on piston head or combustion chamber
• Worn or damaged decompressor system
Excessive smoke
Worn valve stem or valve guide
• Damaged stem seal
• Cylinderfpiston problem (page 11-2)
Excessive noise
Incorrect valve clearance
Sticking valve or broken valve spring
Excessively worn valve seat
Worn or damaged camshaft
Worn rocker arm and/or shaft
Worn rocker arm follower or valve stem end
Worn or damaged push rod and /or cam follower
Worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Cylinder/piston problem (page 11-2)
Rough idle
• Low cylinder compression
10·3
CYLINDER HEADNALVE
SYSTEM COMPONENTS
12 N'm (1.2 .9IbHt)
39 Nrr, (4.lIK9'·m , 291bHt)
"""1_ - - - 22 N'm (2.2 kgf-m, 16 IbHt)
" _ - - - - 39 N'm (4.0 kgf-m. 29 IbHI)

1
63 N'm (6.4 kgl'm , 46 Ibf·ft) 1
,
•
32 N'm (3.3 kgf·m. 24 IbUt)
10-4
CYLINDER HEADNALVE
27 N'm (2.B kgf-m, 20 IbUt)
;/'
/
()
12 N'm (1.2 kgf·m, 9lbHt)
12 N'm (1.2 kgf·m. 9lbHt)
10-5
CYLINDER HEADNALVE
1
CYLINDER COMPRESSION 1
Warm up the engine to normal operating temperature.
III l
Stop the engine and remove the spark plug (page 3-9). j
Inslall the compression gauge [1) into the spark plug I
hole.
Open the throttle all the way and crank the engine with
1
the starter motor until the gauge reading slops rising.
The maximum reading is usually reached within 4 - 7
j
seconds.
TIIa cylinder COMPRESSION PRESSURE :
1
compression 500 kPa (5.1 kgflcm 2 , 73 psi) at 400 rpm
specification is
comparatively low Check that there is no leakage at the gauge connection.
because the low compression can be caused by: o
camshaft has a
decompression - blown cylinder head gasket
device installed. - improper valve adjustment
- valve leakage
- worn piston ring or cylinder
High compression can be caused by:
- carbon deposits in combustion chamber or on piston
head
CYLINDER HEAD COVER

REMOVAL
Raise the left side of the heat protector and set Ihe r - - - - - - - - - -- - - - - - - -,
piston position to Top Dead Center on the compression
stroke (page 3-10).
If you plan to remove the rocker arms, loosen Ihe two
rocker arm shaft retaining bolls 11J.
- eight cylinder head cover bolts [2)
- cylinder head cover [3]
•
J
Mark the push rods - push rods (1)

so they can be - gasket (2)
placed back in their - two dowel pins {3]
original locations.
,
•
1
10-6
CYLINDER HEADNALVE
DISASSEMBLY
Remove the two rocker arm shaft retaining bolts [1) and , - - - - - - -- - - - - -- - --,
sealing washers [2].
Push each rocker arm shaft [1) with a small screwdriver ~=================~
through the bolt hole unlillhe C-ring [2J on the shaft is [~l
removed out of the head cover.
- rocker arm shafts
- rocker arms [3]
- setting plates (4)
- O-rings
INSPECTION
Inspect the following parts for damage . abnormal wear,
deformation, burning or clogs in oil passages. Replace
or clean if necessary.
- Rocker arm
- Rocker arm shaft
- Push rod
Measure each part and clearance according to
CYLINDER HEADNALVES SPECIFICATIONS (page
1-B).
Replace any part if it is out of service limit.
If the push rod is worn or damaged , check the cam
follower and camshaft (page 10-16).
10-7
j,
CYLINDER HEADNALVE
ASSEMBLY 1
EXHAUST ROCKER ARM
1
/ 1
SETTING PLATE "'+::-~'"- - ,
<,
INTAKE ROCKER ARM
g SEALING WASHER ....J]

--
RETAINING BOLT ~ -~
~ ROCKER ARM SHAFT

D-RING
Blow through the oil passages in the cylinder head

cover with compressed air.
Coal new O-rings [1J with engine oil and install them
into the grooves in the rocker arm shafts [21-
Apply molybdenum oil solution to the sliding surfaces of
the rocker arm shafts.
st~ [1[
Place the setting plates [1] on the cylinder head cover ~=================~
as shown.
•
,
1
,
,
•
10-8
CYLINDER HEADNALVE
Intake rocker arm Install the intake rocker arm [3] and exhaust rocker arm
has "IN"maf1( [1} [4] properly, and insert the rocker arm shafts.
and exhaust rocker
arm has "EX· maf1(
{2j.
Align the boll holes in the cylinder head cover and ~;::=~~--===========~
rocker arm shaft by tuming the shaft with a screwdriver. .....,
~
Instal! the rocker arm shaft retaining bolts {11 with new
sealing washers [2].
111
INSTALLATION
Clean the mating surlaces of the head cover and
cylinder head, being careful not to damage them.
Install the push rods {1] onto the cam followers.
Make sure the piston is TOC (Top Dead Center) on the
compression stroke by checking the push rod height.
If the exhaust side push rod height is high . rotale the
crankshaft clockwise one full turn and align the "T" mark
with the index notch again .
Install the two dowel pins [11 and a new gasket [2] .
Rest the push rods onto the gasket grooves as shown.
10-9
CYLINDER HEADNALVE
1
Apply engine oil to the rocker arm followers and
adjusting screw, and install the cylinder head cover [1).
Make sure there is no clearance al the mating surface
of the cylinder head and cover.
Install the eight bolls [2J and tighten them in a I
crisscross pattern in several steps.
Tighten the rocker arm shaft retaining bolts [3).
Adjust the valve clearance (page 3-10).
l
j
CYLINDER HEAD
REMOVAL
- throttle body (page 7-18)
exhaust system (page 2-10)
thermostat (page 8-6)
cylinder head cover (page 10-6)
Spark plug 111
Eel sensor [2) and O-ring [3]
Loosen the water hose band screw [4J and disconnect
the hose from the cylinder head.

- upper engine hanger nul [1] and bolt (frame side) [21
·"
,
- upper engine hanger bolts (engine side) 13]

- engine hanger bracket 14] and mounting rubbers 15]
,
•
Loosen the two cylinder bolts [1].

Be careful not to let Loosen the cylinder head bolt 12] and nuts {3J in a
the nuts and crisscross pattern in several steps, and remove the boll,
washers fat/ Into the nuts and washers.
crankcase.
Remove the cylinder head {4], being careful not to ......"'!II
damage the mating surfaces .
I
•
10-10
CYLINDER HEADNALVE
Remove the gasket I1J and two dowel pins 12].
DISASSEMBLY
Remove the cylinder head (page 10-10).
To prevent loss of Remove the valve spring cotters using the valve spring
tension. do not compressor [1].
compress the valve
spnngs more than
TOOL:
necessary. Valve spring compressor 07757-0010000
Mark all the parts Remove the following:

so they can be
- spring retainer [1]
placed back in their
- outer and inner valve springs [2]
ongmallocalions.
- valve [3]
- stem seal [4]
121
~.
- spring seal [5]
'\
.~ \ [41
INSPECTION
Inspect the following parts for damage. abnormal wear,
deformation , burning or clogs in oil passage . Replace or
clean if necessary.
- cylinder head
- valve springs
- valves
Measure each part according to CYLINDER HEAD!
VALVE SPECIFICATIONS (page 1-8).
10·11
CYLINDER HEADNALVE
VALVE GUIDE REPLACEMENT
Mark new valve guide at the specified height indicated
below, using a maker.
I
,
Chill the new valve guides in a freezer for about an
hour.
Be sure fa WBar Heal the cylinder head to 130 - 140 ·C (275 - 290 OF)
heavy gloves 10 with a hoi plate or oven. Do nol heal the cylinder head
avoid bums when beyond 150·C POQoF). Use temperature indicator
handling the heated sticks, available from welding supply stores, to be sure
cylinder head. the cylinder head is heated to the proper temperature.
Using a torch /0
Support the cylinder head and drive the valve guides
heal the cylinder
out of the cylinder head from the combustion chamber
head may cause
side.
warpage.
TOOL:
Val ve guide driver, 6 mm [1] 07942-6570100
Remove the new valve guides from the freezer.
While the cylinder head is still heated, drive each valve
guide in the cylinder head from the rocker arm side until
the exposed height is at the specified value (at the
mark).
TOOL:
Valve guide d river, 6 mm [1] 07942-6570100
VALVE GUIDE PROJECTION :

IN/EX: 14,8 - 15.0 mm (0.58 - 0.59 in)
Let the cylinder head cool to room tempera ture.
Use cutting oil on Ream the new valve guides.

the roamer during Insert the reamer from the combustion chamber side of
this operation. Take the cylinder head and always rotate the reamer clock-
care not to till or wise.
lean the reamer in
TOOL:
the guide while
roaming. Valve g uid e reamer, 6 mm [1] 07VMH ·MBB0200 or
07VMH ·MBB020A
(U .S.A. o nly)
Clean the cylinder head thoroughly to remove any •

metal particles after reaming and reface the valve seat
(page 10-13).
VALVE SEAT INSPECTION/REFACING

INSPECTION
Clean all intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Pruss ian Blue to each valve
seat.
Tap the valve against the valve seat several times
without rotating the valve, to check for proper valve seat
contact.
1)[
00 c:::::> 0 0
~
10-12
CYLINDER HEADNALVE
REFACING
Reface the valve seat using the following tools ,
TOOLS :
Seat cutter, 40 mm (IN 45°) 07780..()010500
Seat cu tter, 33 mm (EX 45°) 07780-0010800
Flat cutter, 38.5 mm (IN 32°) 07780-0012400
Flat c utter, 33 mm (EX 32°) 07780-0012900
Interior cutter , 37.5 mm (IN 60°) 07780.0014100
Interior cutter, 34 mm (EX 60°) 07780.()014700
Cutter holder, 6 mm 07VMH·MBB0100
or equivalent commercially available in U.S.A .
VALVE SEAT WIDTH : 1.2 mm (0 .05 in)
NOTE '
Follow the fetacer manufacturer's operating
instructions.
Be careful not to grind the seat more than
necessary ,
G
1. Use a 45 seat cu tter, remove any roughness or
irregularities from the seal.
2. Use a 32° flat cutter. remove the top 114 of the
existing valve seal material.
3. Use a 60° interior cutter. remove the bottom 1/4 of
the existing valve seat matenal.
4. Using a 45 ~ seat cutter, cut the seat to the proper
width.
5. After culling the seal. apply lapping compound to the
valve face, and lap the valve using light pressure.
NOTE
Excessive lapping pressure may deform or damage
the seal.
Change the angle of hand lapping tool 111 frequently 111
to prevent uneven seat wear.
Do not allow lapping compound to enter the guides.
After lapping. wash any residual compound off the
cylinder head and valve and recheck the seat contact.
10-13
CYLINDER HEADNALVE
ASSEMBLY
VALVE COTTERS - _ __ ~
INNER SPRING
SPRING RETAINER
OUTER VALVE SPRING

---~~'"
,
1
;
f! STEM SEAL
j
I
SPRING SEAT
j
/
VALVE GUIDE
~
•
i
,
J
INTAKE VALVE
EXHAUST VALVE
I
,
,
Blow through the oil passage in the cylinder head with
compressed air.
. - - - - -/11
- - - - - - -- -
rJ ,•,
Instalilhe spring seals 111 and new slem seals [2J.
Lubricate the valve slem sliding surface with •
molybdenum oil solution.
Insert the valve [3J Into the guide while turning it slowly
to avoid damaging the stem seal.
•I
••
•
s- •
111
••
Install the inner and outer valve springs with the tightly ~====::-
wound coils facing the combustion chamber [1]. •
Install the spring retainer.
•
••
••
111
•
10-14
CYLINDER HEADNALVE
Grease the colters Install the valve spring cotters using the valve spring
to ease installation. compressor {1 ).
To prevent/oss of
tension. do not TOOL:
compress the valve Valve spring compressor 07757-0010000
springs more than
necessary.
Support the cylinder Tap the valve stems gently with a plastic hammer and
head so the lIa/lle shaft as shown to seat the cotters firmly.
heads will not
Install the cylinder head (page 10-15).
contact anything
!hal cause damage.
INSTALLATION
Clean the mating surfaces of the cylinder and cylinder , - - - - - - . , - - - -- - - - - - - - - - ,
head. being careful not to damage them .
Install the two dowel pins {1/ and a new gasket [2/ with t.=~..s~r...t-"':!==!!'!l:l'
the mark facing up.
Install the cylinder head on the cylinder.

Be careful no/to tet Apply engine oil to the threads and seating surface of C~ .....
thenutsand the cap nuts [11 and flange nuts [2/. and install the
washers (all into the washers [3J and nuts.
crankcase. Tighten the nuts in a crisscross pattern in several steps.
TORQUE : 39 N'm (4.0 kgf'm , 29 IbUt)
Install the cylinder head bolt [41 and tighten it.
Tighten the two cylinder bolts [5].
10-15
CYLINDER HEADNALVE
Install the mounting rubbers (1] onto the hanger bracket
bushing [2] with Ihe large 1.0. side facing in.
[21
Insert the 10 mm Install the engine hanger bracket with Ihe B mm bolts
(frame side) boll [11,10 mm bolt [21 and nut [3].
from the fronl side.
Tighten the engine hanger bolts and nut
TORQUE :
10 mm nut: 63 N'm (6.4 kgf'm, 46 IbHt)
8 mm bolt: 32 N'm (3.3 kgf'm , 24 Ibf-ft)
Connect the waler hose to the cylinder head and lighten

the hose band screw [1].
Coat a new O-ring (2) with engine oil and install it onto
the ECT sensor (3).
,,
1
Inslallthe Eel sensor and lighten it.

TORQUE : 12 N'm (1 .2 kgf'm , 9lbHt)
Inslall the spark plug [4] and tighten it.
TORQUE: 22 N'm (2.2 kgf-m , 16 IbUt)
Install the following:

1
- cylinder head cover (page 10·9)
- exhaust system (page 2-11)
- thermostat (page 8-6)
CAMSHAFT
REMOVAL
- cylinder (page 11-4)
- Except FA1fFA2 models: change clulch/primarr
drive gear (page 12-t2)
- FA1/FA2 models: shift clutch/primary driven gear
(page 13-61 )
Mark the followers Remove the cam followers [11 from the crankcase .
so they can be
placed back in their
originallocat/O()s.
10-16
CYLINDER HEADNALVE
Push in the tensioner lifter shaft [1[ while pressing the
ratchet pawl [2J and insert a pin into the hole [3J to hold
the tensioner lifter shaft.
Remove the two bolts [4J and cam chain tensioner lifter
[5[.

- tensioner pivot bolt [1]
- cam chain tensioner [2J
- washer [3J
- bolt {1J and bearing selling plate [2J
Remo ve the bearing of the camshaft [11 from the

crankcase, derail the cam chain [2] from the timing
~===~;~~:!~~
sprocket [3J of the crankshaft. and remove the camshaft
and cam chain.
10-17
CYLINDER HEADNALVE 1,
INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning or clogs in oil passages. Replace
or clean if necessary.
- Camshaft
- Cam sprocket
- Cam chain tensioner
- Cam follower
Measure each part according to CYLINDER HEADI
VALVES SPECIFICATIONS (page 1-8),
Replace any part if it is oul of service limit.
OECOMPRESSQR OPERATION
Check the decompressor cam [1] operation.
Press on the decompressor cam as shown.
As you press on one side, the decompressor cam
should lock above the base circle of the exhaust cam
lobe.
As you press on the other side, the decompressor lobe
will drop below the base circle of the exhaust cam lobe.
CAM CHAIN TENSIONER liFTER

Check the tensioner lifter operation:
- The tensioner lifter shaft should not go into the body
when it is pushed.
- When the ratchet pawl is pressed in, the tensioner
shaft should be pushed into the lifter body and the
shaft springs out of the body. ,
@'
INSTALLATION
~.:=§ =-' ., .. '"~ - "-~ --.

Coverthepiston Rotate the crankshaft to align the ~T" mark [1] on the , - - - - - - - - - - -- - - - - - ,
10·18
CYLINDER HEADNALVE
Lubricate the camshaft bearing and journal with engine
oil.
Apply molybdenum oil solution to the cam lobes.
Install the camshaft into the crankcase.
Lubricate the cam chain [1] whole surface with engine

oil and install it on the cam sprocket [21 .
Loosely instalilhe camshaft [3] into the crankcase.
Donortumthe Line up the camshaft pin (1) and index mark (V) [2] on
crankshaft during the crankcase and insl allthe cam chain over the timing
ins/aliation. sprocket on the crankshaft
Install the camsha ft into the crankcase completely and
make sure that the camshaft pin and index mark (V )
line up.
Apply locking agent to the setting plate bolt (1) threads

(page 1-14).
Install the bearing setting plate [2] onto the crankcase
and tighten the bolt to the speCified torque.
TORQUE; 27 N'm (2.8 kgf'm , 20 IbHt)
10-19
CYLINDER HEADNALVE
Apply locking agent to the tensioner pivot bolt [1]
threads (page 1-14).
1
Install the washer 12]. cam chain tensioner [3] and pivot
bolt, and tighten the bolt to the specified torque.
TORQUE: 12 N'm (1 .2 kgf-m, 9Ibf-ft)
Push in the tensioner lifter shaft [1] while pressing the

ratchet pawl [2] and insert a pin [3) into the hole to hold
the tensioner lifter shaft.
Apply locking agent to the tensioner lifter bolt {1 J

threads (page 1-14),
Install the tensioner lifter {2] and tighten the bolts to the
specified torque.
TORQUE: 12 N'm (1 .2 kgf-m, 9lbHt)
Remove the pin from the tensioner lifter.
Make sure thai the camshaft pin and index mark (9 )
line up when the "r mark on the flywheel is aligned with
the index notch on the crankcase cover.
Be careful not to Apply engine oil to the whole surfaces of the cam
scratch the sliding followers (1] and install them into the crankcase with the
surfaces of the opening facing up
followers and
bores.
- Except FA1/FA2 models: primary drive gear/change
clutch (page 12-15)
- FA1/FA2 mode!s: primary driven gear/shift clutch
(page 13-70)
- cylinder (page 11-7)
•
•
10-20
11. CYLINDER/PISTON
SERVICE INFORMATION .... ·• .. ·...... •.. •.. ·.... ·11 -2 SYSTEM COMPONENTS .......................... · 11 -3
TROUBLESHOOTING .... ·........ ·· ...... · .. ·...... ·· 11 -2 CYLINDER/PISTON .................................... 11 -4
III
11-1
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
The cylinder and piston can be serviced with the engine installed in the frame.
Take care not to damage the cylinder wall and piston .
Be careful not to damage the mating surfaces when removing the cylinder.
Rocker arm and valve lubricating oil is fed through the oil passage in the cylinder. Clean the oil passage before installing the
cylinder.
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
Leaking cylinder head gasket
• Worn , stuck or broken piston ring
• Worn or damaged cylinder and piston
Compression too high , overheating or knocking
• Excessive carbon build-up on piston head or combustion chamber
Excessive smoke
Worn cylinder, piston or piston rings
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
Abnorm al noise
Worn piston pin or piston pin hole
Worn connecting rod small end
Worn cylinder, piston or piston rings
11-2
CYLINDERIPISTON
SYSTEM COMPONENTS
/
/
/
()
=
12 N'm {1.2 kgf-m. 91bHtJ
,~ r
/ ' c,
11-3
CYLINDER/PISTON
CYLINDER/PISTON
CYLINDER REMOVAL
Remove Ihe cylinder head (page 10-10)
Remove the two bolts [1].
Do nor damage the lift the cylinder (2) and remove it, being careful nol to
mating surface with damage the piston and piston rings with Ihe stud bolls.
a screwdriver.
•
;
Remove the gasket [1J and the two dowel pins [2].
1
PISTON REMOVAL
Place a etean shop towel over the crankcase to prevent ~-
the piston pin clip [1] from falling into Ihe crankcase.
Remove Ihe piston pin clips with the pliers.
Push the piston pin (2] oul of the piston [3] and
connecting rod, and remove the piston.
00 nor damage the Spread each piston ring and remove it by lifting up at a ~~~~~~~~~~~~:l.I~~III!"iI~1I
piston ring by point opposite the gap.
spreading the ends
too far.
11-4
CYLINDER/PISTON
Never use a wire Clean carbon deposits from the ring grooves with a ring
brush; it will scratch thai will be discarded.
the grooves.
INSPECTION
Inspect the following parts for scratch , damage ,
abnormal wear, deformation, burning or clogs in oil
passage. Replace or clean if necessary.
cylinder
- piston
- piston rings
- piston pin
- connecting rod small end
Measure each part and clearance according to
CYLINDERJPISTON SPECIFICATIONS (page 1-8),
CYLINDER STUD SOLT

REPLACEMENT
Thread two nuts onto the stud and tighten them ~------------
together . and use a wrench on them to turn the stud bolt

oul.
Install new stud bolts and lighten them.
TORQUE : 12 Nom (1.2 kgf-m, 9lbHt)
Be sure to verify the stud height from the cylinder

mating surface of the crankcase.
Adjust the height if necessary.
11-5
CYLINDER/PISTON
PISTON RING INSTALLATION
Carefully install the piston rings into the piston ring
1
grooves with the markings [1] facing up. 111 [1]
NOTE: 1
Do not confuse the top ring (2] and second ring [3].
~
• To install the oil ring [4J, install the spacer [5) first,
then install the side rails [6].
0
Stagger the piston ring end gaps 120 degrees apart
C- ,
1
from each other.
~
Stagger the side rail end gaps as shown.
,,
~
,
,
,
1
j
[5] 1
1
~
~
PISTON INSTALLATION 1
Place a clean shop towel over the crankcase to prevent
the piston pin clip (1] from falling into the crankcase.
Apply engine oil to the piston pin hole and connecting
rod inner surface.
Apply molybdenum oil solution to the piston pin [2] outer
surface.
Install the piston [3] with the "IN" mark (4) toward the
intake side and insert the piston pin through the piston
and connecting rod.
Install new piston pin clips into the grooves in the piston
•
pin hole.
NOTE:
Make sure that the piston pin clips [1) are seated
securely.
•
Do not align the piston pin clip end gap [2] with the
piston cutout [3).
11] 13]
11-6
CYLINDER/PISTON
CYLINDER INSTALLATION
Clean the maling surfaces of the cylinder and
crankcase thoroughly, being careful not to damage
them, and being careful not to allow gasket material to
enter the crankcase.
Blow through the oil passage in the cylinder with ~..._ .....~
compressed air.
Install the two dowel pins [1) and a new gasket [21 .
Apply engine oil to the cylinder (1] wall , piston [2) outer ~~~~~~~IIIiIll.::.I...........&.:,,-::::~~
surface and piston rings [3].
Install the cylinder over the piston while compressing
the piston rings with your fingers.
Make sure thai the cylinder touches the crankcase

evenly.
::~~~===~~=~~===~:::~=
Install the two bolts PI.
Inslalilhe cylinder head (page 10-15).
11-7
MEMO
j,
,,•
•
,
•
•1
,
12. CLUTCH/GEARSHIFT LINKAGE (Except FA1/FA2 models)
SERVICE INFORMATION ··· ··················· .... ·12-2 CENTRIFUGAL CLUTCH ······················ .... · 12-8
TROUBLESHOOTING·············· ··· ······· ········· 12-3 CHANGE CLUTCH ··············· ···················· 12-12
SYSTEM COMPONENTS ····························12-4 GEARSHIFT LINKAGE ············ ················· 12-17
FRONT CRANKCASE COVER ················· .. 12-5
12-1
CLUTCH/GEARSHIFT LINKAGE (Except FA1/FA2 models)
1
SERVICE INFORMATION
GENERAL
This section covers service of the clutch (centrifugal clutch and change clutch) and gearshift linkage. To service the reverse
stopper shaft and gearshift spindles, the engine must be removed from the frame.
The crankcase must be separated when the transmission. shift drum and shift forks require service (page 15-6),
Engine oil viscosity and level and the use of oil additives have an effect on clutch operation. Oil additives of any kind are
specifically not recommended. When the clutch does not disengage or the vehicle creeps, inspect the engine oil and oil level
before servicing the clutch system .
Engine lubricating oil is fed through the oil passages in the front crankcase cover. Clean the oil passages before installing the
,•· •
crankcase colier.
The TE1 /FE1 models are equipped with the electric shift program (ESP). ESP service (page 24-4)
TOOLS
1
Oriller Attachment, 32 )( 35 mm Pilot, 15 mm
07749-0010000 07746-0010100 07746-0040300
1
,
I
Clutch center h;;;o~'d<'e;;,c---------1

Driller, 22 mm 1.0.
07746-0020100
Puller. 35 )(. 1.0 mm
07933-HABOOOO 07 JMB-MN50302
j
I
•,
01
07HGB-001010B and
or 07933-HB3000A (U.cS".A
.::.-=o,,'-'.
'Y,-) _ _ +--;O~
7"H =:
G;B-001020B (U.S.A. only)
Clutch holder set Clutch holder plale Clutch holder pin
07ZMB-HN20001 07ZMB-HN20101 (nol available in 07ZMB-HN20200 (not available in I
U.S.A.) U.SA)
-C) - -!IVj I
- - -
or 07ZMB-HN2A 101
~--------~-----
•
12-2
CLUTCH/GEARSHIFT LINKAGE (Except FA1 /FA2 mod els)
Remover weight Bearing remover shaft Bearing remover head, 15 mm
07741·0010201 07936-KC 10 100 (not available in 07936-KC10200 (not available In
U.SAI U.SAI
c::-
or 07936-371020A (U SA-'O
Bearing remover, 15 mm
_".:.
07936·KC1050Q (U .S.A. only)

IY'-
I _ __ _ c::/_ 1
~I
I /'
TROUBLESHOOTING
Clutch slips when accelerating
Incorrect clutch adjustment (page 3-27)
Worn clutch discs
Weak clutch springs
Faulty clutch lifter
Improper oil viscosity or oil additive used
Clutch will not disengage
• Faulty clutch lifter
• Warped clutch plates
The vehicle creeps
• Faulty centrifu gal clutch
Clutch operating feels rough
Worn clutch ouler and center grooves
Warped clutch plates
loose clutch lock nut
Faulty clutch lifter
Improper oil viscosity or oil level
Hard to shift
Incorrect clutch adjustment (page 3-27)
Worn or damaged gearshift linkage componen ts
f aulty clutch lifter
Improper engine oil viscosity
Faulty gearshift spindle
Faulty shift forks/shaft or shift drum (page 15-4)
Transmission jumps out of gear
Broken shift drum stopper arm
Weak or broken shift hnkage return springs
Worn or damaged gearshift cam
Faulty gearshift spindle
Faulty shift forksJshaft or shift drum (page 15-4)
Faulty transmission gears (page 15-4)
12·3
SYSTEM COMPONENTS J
TE1/FE1 models shown:
118 N'm (12.0 kgf-m , 87Ibf·ft)
108 N'm
('1 .0kgf·m,
801bHt) ••
,
•
•
12 N'm (1.2 kgf'm,

I
9lbHt)
,
•
I
16 N'm
12lbf-ftj
•
•
••
(
12-4
FRONT CRANKCASE COVER
REMOVAL
Drain the coolant (page 8-8).
- mudguards (page 2-5)
- FM1 1FM2/FE 1 models only: front propeller shaft
(without removing the left drive shaft) (page 20-11)
- TE1/FE1 models only: shift control motor and
reduction gears (page 24-22)
Disconnect the water hoses [1) from the front crankcase
cover.

- fifteen bolts [1]
- front crankcase cover [2]
- lifter cam plate [1]

- two dowel pins [2)
- joint coliars [3)
- O-rings [4]
- output shaft oil seal [1]

- gearshift spindle oil seal [21 (TE1/FE1 models only)
12-5
j
CRANKSHAFT BEARING
REPLACEMENT
1
Check the crankshaft bearing (1].
If the inner race does nol turn smoothly, quietly, or if the
outer race fits loosely in the cover, replace the bearing
as follows :
Remove the crankshaft bearing with the special tools.
TOOLS:
Bearing remover shaft [2] 07936·KC10100
Bearing remover head, 15 mm [3J 07936·KC10200
Remover weight (4) 07741-0010201
U.S.A . TOOLS:
Remover weight 07936·371020A
Apply engine oil to a new bearing.

Drive a new bearing squarely with the sealed side
facing down until it is fully sealed .
TOOLS:
Driver [1] 07749-0010000
Attachment, 32 x 35 mm [2] 07746-0010100
Pilot, 15 mm [3) 07746-0040300
CLUTCH LIFTER REMOVAL

INSTALLATION
Check the clutch lifter plate assembly and cam plate for r.~-----------;c:c-----,
wear or damage , replace them if necessary.
•
Remove the lock nut (1) and washer [2].
•
•
Remove the adjusting bolt/lifter plate assembly (1] and

O-ring [2].
Remove the adjusting bolt from the lifter plate
assembly.
Install the adjusting bolt into the lifter plate assembly.
Coat a new O-ring with engine oil and install it onto the
•
adjusting bol t.
Install the adjusting bolUlifter plate assembly by aligning
the groove with the stopper pin.
Temporarily install the washer and lock nut.
12-6 •
INSTALLATION
Clean the mating surfaces of the front crankcase cover
and crankcase thoroughly, being careful not to damage
them.
Blow through the oil passages in the front crankcase
Apply engine oil to the boss of the adjusting plate.
Install a new output shaft oil seal [1J into the fronl ~~~=~~~~~~==~~::::,,,,,,,;;-:~
crankcase cover.
TE1 /FE1 models only: Install a new gearshift spindle oil
seal [21 into the front crankcase cover.
12J 111
Install the jOint collars [1] and dowel pins [2l
Coat new O-rings [3] with engine oil and install them.
~
111 11
Apply liquid sealant (TB1215 or equivalent) to the ;:::=====~----========~
mating surface (shadowed area ) of the fronl crankcase
cover as shown.
12·7
Apply engine oil to the oil seal [1] lips.
Be careful not to Install the crankcase cover [2], being careful not to
drop the lifter cam damage the oil seal lips.
plate.
Install the fifteen bolts [3] and tighten them in a
Connect the water hoses [1] to the crankcase cover.

•
Inslallthe following: ' .~r;;;;:::~
- TE1fFEl models only: reduction gears and shift ~
control motor (page 24-23)
- FMlIFM2IFEl models only: front propeller shaft
(page 20-35)
Adjust the clutch system (page 3-27).
Fill the engine with recommended oil (page 3-15).
Fill and bleed the oooling system (page 8-5).
Check the engine oil level (page 3-14).
•
CENTRIFUGAL CLUTCH
REMOVAL
Remove the front crankcase cover (page 12-5).
Be careful nor to Unstake the clutch lock nul [1].
damage the
crankshaft threads.
1
•
Hold the clutch drive plate using the special tool and ~~~~~~~~~~~iIIII~~~=.:JI~~
loosen the lock nut.
TOOL:
Clutch ho lder set (1] 07ZMB·HN20001
- holder plate 07ZMB ·HN20101
- holder pin 07ZMB·HN20200
U.S.A . TOOL :
Clutch holder 07ZMB-HN2A 101
Remove the lock nut [2J and washer [3J.
[2[
12·8
Remove the centrifugal clutch assembly [1 ] using the
special 1001.
TOOL:
Puller, 35 x 1.0 mm (2] 07933-HASOOOO or
07933-HB3000A
(U.S.A. only)
D[SASSEMBLY
You should be able to turn the clutch weight assembly ~------------
[1J counterclockwise smoothly. but the assembly should

not turn clockwise.
Remove the clu tch weight assembly from the clutch
drum [2] while turning it counterclockwise.
)
[2]
Remove the E-clips [1) using a screwdriver while

compressing the clutch spring .
;::==============-=-;
- outer plate {2J
- clu tch spring (3]
- inner plate [4]
Remove the clutch weights [1J and springs (2) from the ;::===========:==:':::===~
drive plate.
12-9
j
INSPECTION 1
Inspect the following parts for scratch , damage, I
abnormal wear and deformation . Replace if necessary.
- clutch drum 1
- sprag clutch
- drive plate
-
-
clutch weights
clutch weight springs
1
Measure each part according to CLUTCH/GEARSHIFT
LINKAGE SPECIFICATIONS (page 1-9).
Replace the clutch weight springs as a set.
• Replace the clutch weights as a set.
ASSEMBLY
DRIVE PLATE
CLUTCH WEIGHTS
WEIGHT SPRINGS
CLUTCH SPRING
OUTER PLATE
\ • )
\ ~
~
.\J' • CLUTCH DRUM
©
©
©
,CJ' ~
•
•
r
INNER PLATE
E-CLIPS
•
~ SPRAG CLUTCH
Instal/with/he Install the clutch weights [1] and springs [2J onto the , - - - - - - - - - - - - - - - - - - - - .
spnng's open ends drive plate as shown.
facing in.
12-10
Install the inner plate [1) with flange side facing up.
Install the clutch spring {2] with concavity side facing
down .
Install the outer plate [1] with the pins facing up.
Be careful nolto Install the E-ctips [2] into the spindle grooves with their
damage the clutch gaps facing towards the pins [3] by using the pliers
weights while while compressing the clutch spring .
compressing .., .:..,
~ r:- L J
--"
131 12] 11]
Apply engine oil 10 the sprag clutch [1] whole surface
and the sprag clutch contacting surface of the clutch
drum.
Install the sprag clutch into the clutch drum with the
"OUT SIDE" mark [2] facing up.
' 11] ,
Apply engine oil 10 the sprag clutch contacting surface ;======--'----::======1
===~
of the drive plate boss.
Install the clutch weight assembly (1] while turning it
counterclockwise.
12-11
INSTALLATION
Set the centrifugal clutch assembly [11 onto the . , . - - - - - - - :
crankshaft by aligning the splines of the drive plate and
crankshaft, and Ihe splines of the clutch drum and
primary drive gear.
Be careful not to Tap the drive plate to seat it.
damage the
crankshaft threads.
TOOL:
Driver, 22 mm 1. 0 . [2J 07746-0020100
Apply engine Oil 10 the threads and seating surface of a ~::::::::::::::::~=~IIIIIIIIIIIIIIIIIIIIIIII~

new lock nut [1}.
Install the washer [2] and lock nut.
Hold the drive plate of Ihe centrifugal clu tch assembly
with the special tool and tighten the lock nut.
TOOL:
Clutch holder set [3J 07ZMB·HN20001
- holder plate 07ZMB·HN20101
U.S.A . TOOL:
Clutch holder 07ZMB·HN2A101
TORQUE : 118 N·m (12.0 kgf'm , 87 IbHt)

Be careful no/to Stake the lock nul into the crankshaft groove.
damage the
Install the front crankcase cover (page 12-7).
crankshaft threads.
·•
CHANGE CLUTCH
DISASSEMBLY
- centrifugal clutch assembly (page 12-8)
- TE1/FE1 models: shift arm spring. gearshift spindle
and washer (page 12·17)
- TM1fFM1fFM2 models: clutch lifter lever (page 12-
17)
- lifter bearing [1J and collar [2) •,
12-12
Loosen the clutch spring bolts [I] in a crisscross pattern
in several sleps, and remove the boits, lifter plate [2]
and clutch springs (3).
Be careful nor to Unstake the clutch center lock nut [1).

damage/he
mainshaft threads.
Install the dutch center holder (1] onto the pressure

plate bosses wi th the four clu tch spring bolls.
TOOL:
Clutch center holder 07JMB·MN50302
U.S.A. TOOLS:
Holder plate 07HGB-001010B
Holder collar A 07HGB-001020B
Hold the clu tch center and loosen the clutch center lock
nut.
Remove the lock nut and washer.

- clutch center [I]
- TEt/FE1 models: six discs [2J and five plates [3J
- TM1fFMlIFM2 models: seven discs [2] and six
plates [3J
- pressure plate [4]
12-13
•j
-
-
thrust washer (1]
clutch ouler [2]
1
,
- clutch outer guide [1]
Remove the primary drive gear (1] and washer (2] from
the crankshaft. I
1
INSPECTION
Inspect the following parts for scratch, damage.
abnormal wear and deformation. Replace if necessary.
- clutch lifter bearing/cam plate/plate/collar
clutch springs
clutch discs/plates ,
clutch center
clutch outer
clutch outer guide
primary drive gear
mainshaftlcrankshaft
Replace the clutch springs as a set.
• Replace the clutch discs and plates as a set.
12-14
ASSEMBLY
Apply engine oil to the primary drive gear [1] sliding
surfaces of the crankshaft.
Install the thrust washer [2] and the drive gear onto the
crankshaft.
Apply molybdenum oil solution to the inner and outer

surfaces of the dutch Quter guide [1).
~~:~;~~~~si~~~~rni~
Install the outer guide onto the mainshaft.
Install the clutch outer [1] and thrust washer [2].
Coat the clutch discs with clean engine oil.
Install the discs and Install the following:

plate allemalely.
- pressure plate [2J
s/8t1ing with the
- TE1/FE1 models: six discs [3] and five plates [4J
disc.
- TM 1/FM1/FM2 models: seven discs (3) and six
Selthe outside
plates [4)
clutch disc labs into
- clutch center [5]
the shallow slots [I}
in the clutch ouler.
12-15
Install the washer [11.
Apply engine oil to the threads and seating surface of a .-=---c- - - - - - - - - - - - - - ,

new lock nut [1]. and install it.
Install the clutch center holder [2] onto the pressure
plate bosses with the four clutch spring bolts.
TOOL:
Clutch center holder 07JMB·M N50302
U.S.A. TOOLS :
Holder plate 07HGB-001010B
Holder collar A 07HGB-001020B
Hold the clutch cen ter holder and tighten the lock nut.
,
TORQUE: 108 N'm (11 .0 kgf'm, 80 IbHt)
Be careful not to Slake the lock nut into the mainshaft groove.
damage the
mainshaft threads.
•
Install the clutch springs [1] and the lifter plate {2] with ......'11
the "OUT" mark [3] facing out.
Install the clu tch spring bolts [4] and tighten them in a
TORQUE : 12 N'm (1 .2 kgf-rn, 9lbHt)
12-16
CLUTCH/GEARSHIFT LINKAGE (E xcept FA1 /FA2 models)
Apply engine oil 10 the lifter bearing £1J, and install the
lifter collar (2] and bearing.
Inslallthe following:
- TElIFE1 models: washer, gearshift spindle and shift
arm spring (page 12-18)
- TM 1/FM1/FM2 models: lifter lever (page 12-18)
- lifter bearing and coliar
- centrifugal clutch assembly (page 12-12)
GEARSHIFT LINKAGE
REMOVAL
Remove the centrifugal clutch (page 12-8).
TE1IFE1 models. - shift spindle angle sensor (page 24-21)
- shift arm spring [1 J
- gearshift spindle assembly (2] and washer (3]
TM1/FM1/FM2 - clutch lifter lever [1]
u
models: - shift arm spring [21
- tetum spring [3J and gearshift arm [4J
NOTE
• For gearshift spindle service (page 15·7)
121 131
111
- bolt [1J
- guide plate [2)
12-17
- gearshift plate 11]
- TM1 /FM1/FM2 models only: washer from the
gearshift spindle
- gearshift cam (2J (while holding stopper arm with a
screwdriver)
-
-
-
boll 111
stopper arm [2J
washer [3]
,1
- return spring (4] i
Check all parts for wear or damage. Replace if
necessary.
1
I
INSTALLATION
Apply locking agent to the stopper arm bolt [1)lhreads
•
(page 1-15).
lnstailihe return spring [2), washer 13] (between the arm
•
and crankcase). stopper arm (4) and boll, and lighten
the bolt to the specified torque. 1
Hold the stopper arm with a screwdriver and install the

gearshift cam (1] by aligning the pin hole 121 with the
dowel pin [31.
12-18
TM1/FM1fFM2 models only: Inslailihe washer onto the
gearshift spindle.
Install the gearshift plate [1] onto the cam as shown.
Install the guide plate [2J by aligning the lab with the
groove in the cam.
Apply locking agent to the gearshift cam bolt [1] threads

(page 1.15).
Instalilhe cam bolt and tighten it to the specified torque.
TORQUE : 16 N"m (1 .6 kgf'm , 121bHt)
TEf/FEf models. Inslall the washer [1J and insert the gearshift spindle
assembly [2] into the crankcase.
Align the return spring ends with the stopper pin [3].
Hook the shift arm spring {4] to the gearshift arm and
plale.
Install the angle sensor (page 24·21).
TWIFM1/FM2 Inslall the gearshift arm [11 and return spring 12],
u
mrxJels; aligning the spring ends with the stopper pin.
Hook the shift arm spring [3J to the gearshift arm and
plale.
Install the lifter lever [4J by aligning the wide groove with
the wide tooth of the splines.
All models: Install the centrifugal clutch (page 12-12).
(31 (21
L (41
12·19
j
GEARSHIFT SPINDLE A (TM1/FM1/
FM2 models only)
j
Remove the rear crankcase cover (page 14-6).
J
121 Ill e g I
Remo .... e the stopper boll [1 j. washer [21 and gearshift
spindle A 131 from the rear crankcase cover [4J.
Remove the oil seal [5J from the rear crankcase cover. 141
Install a new oit seal.
Apply engine oil to the oil seal lip and install the
1
gearshift spindle A. 1
Apply locking agent to the stopper bolt threads
(page 1-15).
•
Install the washer and stopper bolt, and lighten the bolt I
to the specified torque. [5J--"'7I
TORQUE: 27 N'm (2.8 kgf'm, 20 IbHt) ~
Install the rear crankcase cover (page 14-9). '---_ _ _ _ _.c -=----'
13.c1_ _ _ _ _ _ _ _....
j
•·
•
J
12-20 ,
13. DUAL CLUTCH TRANSMISSION (FA1/FA2 models)
SERVICE INFORMATlON········ ··· ··············· ·13-2 SHIFT CONTROL MOTOR!

REDUCTION GEARS ·· ······························13-47
SYSTEM COMPONENTS ···························· 13-4
SHIFT DRUM POSITION SWITCH ···········13-50
SYMPTOM TROUBLESHOOTING ·············13-6
REVERSE SWITCH ······· ···························13-52
COMPONENT LOCATION ························ 13-11
EOT SENSOR ·.. ································· ······· 13-53
SYSTEM DIAGRAM ·· ························· ·· .... ·13-12
REARVS SENSOR··································· 13-53
TROUBLESHOOTING INFORMATION ···· 13-13
FRONT VS SENSOR ·.. ·························· ··· 13-54
DTC INDEX ·.. ·············································13-15
DRIVE MODE SELECT SWITCH ·············· 13-55
DTC TROUBLESHOOTING ······················ 13-17
SHIFT VALVE BODY ···························.. ·.. 13-56
FRONT CRANKCASE COVER/
SPACER ····················································13-33 DUAL CLUTCH/PRIMARY
DRIVEN GEAR ········································ .. 13-61
CENTRIFUGAL CLUTCH·························· 13-41
GEARSHIFT LINKAGE ····························· 13-71
SHIFT SOLENOID VALVE ························ 13-46
REVERSE STOPPER SHAFT ················· ·13-74
SHIFT SPINDLE ANGLE SENSOR ·········· 13-47
13-1
J
j
SERVICE INFORMATION 1
GENERAL
This section covers service of the electrical and mechanical systems of Ihe Dual Clutch Transmission (OCT).
A faulty OCT system is often related to poorly connected or corroded connectors. Check those connections before proceeding .
Read Ihe "OCT Troubleshooting Information" carefully, and inspect and troubleshoot the OCT system according to the DTG.
Observe e8ch slep of the procedures one by one. Note the DTG and probable faulty part before starting diagnosis and
troubleshooting.
The PCM may be damaged if dropped , Also , jf a connector is disconnected when current is flowing, the excessive voltage may
damage the PCM , Always turn off the ignilion switch before servicing.
The drive mode (Automati c or ESP) is changed electrically with the drive mode select switch .
Oil pump service (page 9-9).
Br: Brown G: Green Lb: Light blue 0 : Orange R: Red W:White
For OCT system Troubleshooting

The OCT system is controlled by the PCM. Therefore some detection items that are shared in the PGM-FI and OCT systems, and
they may affect the operation of both systems.
Before starting any troubleshooting , check the following items and refer to the appropriate troubleshooting.
1. MIL blinks DTC for the PGM-FI system (page 4-6).
2. Gear position indicator blinks DTC for the OCT system (page 13-13).
3. Symptom of the OCT system operation (page 13-6).
Refer to ~PGM-FI Troubleshooting Jnformation~ for the general troubleshooting information (page 4-5).
TOOLS
Pressure gauge set Clutch compressor set SCS Service Connector
07406-0020005 07lAE-PX40000 070PZ-ZY30100
or 07ZMJ-HN2A100 and 07AMJ- or 07GAE-PG40200 or

HN8A100 (U.S.A. only) 07GAE-PG4020A (U.S.A. only)
"d
07lAE-PX40100 (2 required )
Pin Probe Male (2 pack) Lock nut wrench , 32 .5 mm Driver
07ZAJ-RDJA 11 0 07 AMA-HP7 A 100 07749-0010000
13·2
DUAL CLUTCH TRANSMISSION (FA1 /FA2 models)
Attachment. 32 x 35 mm Pilot, 15 mm Driver, 22 mm LO.
07746-0010100 07746-0040300 07746-0020100
Clutch puller. 35 x 1.0 ;;;-- -- - t -CR;;:em=oyCOe;;,COw;;;e"'g"'h.!--------+-8"e;Cao;'"';n:;;g-;c'e;;;m"o;;;y;;;e~r shaft

mm
07933-HA80000 07741-0010201 07936-KC10100 (not available in
U.S.A.)
or 07933-HB3000A (U.S .A. only) or 07936-371020A (U.S.A. only) /

I
Bearing remover head, 15 mm
Q7936-KC10200 (not available in
U.S.A.)
Bearing remover, 15 mm
07936-KC10500 (U.S.A. only)
I Clutch holder sel
07ZMB-H N20001
.-.~
o
C)
or 07ZM8-HN2A 101 (U.S .A. onl"Y)_ --.J

Clutch holder plate Clutch holder pin
07ZMB-HN20101 (not available in 07ZMB-HN20200 (not available in
U.S.A) U.S .A.)
•
•
•
•
•
13·3
SYSTEM COMPONENTS
•
118 N'm (12.0 kgf-m , 871bHt)
21 N·m (2.1 kgf-m, 151bHt)
13-4
108 N'm (11 .0 , 80IbHt)
~~)~"\_23 N'm (2.3 kgf.m . 17 lbHt)
12N·m( 1.2kgrm,
9Ibf-ft)
12 N'm (1.2 kgf-m,

9lbHt)
13-5
GENERAL INFORMATION
If the ATV has any OCT trouble, check the DIG or gear position indicator blinking, refer to the OTG index and
begin the appropriate troubleshooting procedure (page 13-15)
If there are no DI G slored in the PCM memory. do the troubleshoo ting as following symptom and then inspect
the oil pressure and diagnose according to the troubleshooting chart (page 13-10).
i il
(page 3-16)
Oil pressure
;1
(page 3-16)
ieutom,";clmoda, Oil pressure
rpm rises or driving (page 13-8)
shows --" but no DTC

,at
nothing and Mil circuit. the DLC related

,tay"'" al all times (No wire
STARTING CONTROL FAILURE •

Veh icle Does No t A ccelerate
1. Dual Clutc h PC Solenoid Valve Operatio n Sound
Check
1
Remove the tank cover assembly (page 2-4 ),
Check for a "click" sound from the dual clutch PC
solenoid valve [1] when the ignition switch is turned
ON.
Is th ere sound?
Y ES - GO TO STEP 3.
NO - GO TO STEP 2.
2. Dual Clutch PC Solenoid Valve Operation Check

Disconnect the dual clutch PC solenoid 2P (Black)
connector.
Connect a 12 V battery 111 to the solenoid valve
connector [21 terminals as shown.
The solenoid valve should operate (sounds) when
the battery is connected.
Does the solenoid opera te ?
8
YES - GO TO STEP 3.
NO - Faulty dual clutch PC solenoid valve
121 [t[
13·6
3. Vehic le Test-riding
Turn the mode select switch to ESP.
Accelera te the vehicle with the transmission in 2nd
gear.
Does the vehicle ac celerate?
YES - Faulty 1st shift clu tch system (page 13-61).
NO - Hydraulic circui t malfunction is the likely
cause. Check the oil pressure (page 13-8).
Excessive Jerking when Accelerating

1. Vehicle Test-riding
Turn the drive mode select switch to ESP .
Check for acceleration jerking with the transmission
in the 2nd gear.
Is there acceleration jerking with the
transmission in 2nd gear?
YES - Hydraulic circuit malfunction is the likely
NO - Faulty 1st shift clu tch system (page 13-61).
SHIFT CONTROL FAILURE

OCT Does Not Shift
Test-ride the vehicle with the drive mode select
switch at ESP and shift the transmission with the
gearsh ift switch.
/s the transmission shifted?
YES - Faulty TP sensor system. Check the
installation condition (page 4-32).
Faulty VS sensor system. Check the
NO - GO TO STEP 2.
2. Shift Solenoid Valve Operation Check
Disconnect the shift solenoid valve 2P (Brown)
connector [lJ.
13-7
DUAL CLUTCH TRANSMISSION (FAlIFA2 models)
Connect a 12 V battery [11 to the solenoid valve
connector [2J terminals as shown.
The shift solenoid valve should operate (sound)
when the battery is connected.
Does the solen oid valve operate ?
YES - Hydraulic circuit malfunction is likely
NO
- Faulty shift solenoid valve.
e
[21 [1 I
When Shifting in the AUTO (automatic) Mode,
Excessive Shift Shock, Engine rpm Rises or Driving
Power Falls Off
Test-ride the vehicle wi th the drive mode select
switch at ESP. Check above symptoms when
shifting with the gearshift switch.
Are there repeated symptoms ?
YES - Hydraulic circuil malfunction is likely
NO Faulty TP sensor system; Check the
Faulty VS sensor system. Check the
OIL PRESSURE CHECK

NOTE :
If the oil pressure is abnormal. inspect and clean the
parts according to the hydraulic circuit
troubleshooting chart (page 13-10).
Failure to warm the engine will cause very high oil
pressure readings.
Exteroalleaks will cause low oil pressure readings.
Check the oil level and add the recommended engine
oil if necessary (page 3-16).
1
Warm the engine to normal operating temperature and
check for external oil leaks.
LINE OIL PRESSURE
Clean around the sealing bolt [1] with compressed air.
Be sure that no dirt Remove the sealing bolt and sealing washer {2] from
is aI/owed to enter the right side of the shift valve body.
the oil gal/ery.
13·8 I
Connect the oil pressure gauge and adapter to the
sealing bolt hole (hole threads: M8 x 1.25),
Except U.S.A. TOOL:

Pressure gauge set {1] 07406·0020005
U.S.A. TOOLS :
Oil pressure gauge 0-160 psi 07ZMJ-HN2A100 and
Adaptor, banjo 8 x 1.25 mm 07AMJ-HNSA100
Start the engine and measure the oil pressure.
LINE OIL PRESSURE (80 e C/176°F) :
510 kPa (5.2 kgflcm l, 74 psi) at 5,000 rpm
Stop the engine.
Remove the pressure gauge and adaptor.
Instalilhe sealing bolt [1) with a new sealing washer [2J
and tigh ten it.
Inslalilhe tank cover assembly (page 2-4).
SHIFT CLUTCH OIL PRESSURE

Be careful not touch Support the vehicle using a hoist or equivalent and
the rotating wheels raise all the wheels off the ground.
during Inspection.
Clean around the sealing bolts with compressed air.
Be sure that no dirt Remove the sealing bolt (for 1st clutch) [11. sealing bolt
is allowed to enter (for 2nd clu tch) {2] and sealing washers [3] from the left
the oil gallery side of the front crankcase cover.
Connect the oil pressure gauges and adaptors to the

sealing bolt holes (hole threads: Me x 1.25).
E)(cept U.S.A. TOOL:

Pressure gauge set (1) 07406-0020005
U.S.A. TOOLS :
Oil pressure gauge 0-160 ps i 07ZMJ-HN2A100 and
Adapter, banjo 8 x 1.25 mm 07AMJ· HN8A100
Turn the drive mode select switch to ESP.
Start the engine and measure the oil pressure at 1st
gear and 2nd gear.
SHIFT CLUTCH OIL PRESSURE (80°CI176°F):
510 kPa (5.2 kgflcm 2 , 74 psi) at 5,000 rpm
13-9
Stop the engine.
Remove the pressure gauges and adaptors. 1
Inslalilhe sealing bolls (1 ) with new sealing washers 12]
and tighten them.
Inslall the tank cover assembly (page 2-4).
TROUBLESHOOTING CHART OF
HYDRAULIC CIRCUIT
, CHeCK , Blank:
~I elule • • • _
Refer 10
page
• • • r- j
o
a a 13-56
a
o
•
a 13-61 •
13-33
13-10
COMPONENT LOCATION
FA2 model shown :
COMBINATION METER
- GEAR POSITION INDICATOR
UPSHIFT SWITCH IGNITION SWITCH
DOWNSHIFT SWITCH DRIVE MODE

SELECT SWITCH
DLC
RELAY BOX
- MAIN POWER RELAY
FUSE BOX FRONT VS
- MAIN FUSE 1 (30 A) SENSOR
- IGN FUSE (20 A) SHIFT SOLENOID VALVE
- ACe FUSE (20 A)
-DI OD:E-;;:::::;::c:::;;~;'~§~t
EDT SENSOR
BATIERY
DUAL CLUTCH PC
SE"SC>R UNrT SOLENOID VALVE
(TP SENSOR)
REAR VS SENSOR
SHIFT SPINDLE I
ANGLE SENSOR POSITION SWITCH
REVERSE SWITCH
13-11
SYSTEM DIAGRAM
IGNITKlN ION FUSE

SWlTCH (20A)
,~.~ -
__F":in="'i'~~___ R~R-~ MA'N FUse 1 (30 ")
~ ~P w~ ----+-------------+---t-----,
r
LIGHT FUSE
Ace FUSE
(20.0.)
...
FRONT BRAKE
LIGHT SWITCH MIt
~ VIR ::J
"'E......3"
(lOA)
IllS. ~ lIN -f[BJ

..,--' -I--------'
REAR
LIGHT BRAKE
SWlTCI1 8~ ~ GI'r MAIN FUSE 2 (W.o.) DIODE
;'~"~"~'~~~~~~~~~,:;,~~~~~~~~;::;;:~::
"A'''~'
LIGHT SWITCH 61 OIV
.m - - - - - l - - -
(PEDAL) IWR ------~____________~- "'
~~
-----------nL:'
DRIVE MOOE
SELECT SWITCH
'0'
~~~
..r- OLe scs SERVICE CONNECTOR
SENSOR peM
-@'~I [E=E:::=;~~'-F=:::fEa~-;--;;~--------'
SHIFT
At4GLE
SENSOR
SHIFT CONTROl
MOTOR
- (24)
iJ'J :
- (21,22.23)
'00'"'
SENSOR G FAIL-SAfE
REtAV [=.,."'~1'j'- '.m ------ll SHIFT SOlENOID
,
- @(66) :- - @(32) ,~'"
- (15)
'~~~:'''~&~:1~=----'~ ·riITi@'==J~~i~;::~::~==CJ
~,
-@ (61) Wf'l ------l,...~
SOlENOID
DUAL VALVE
CLUTCH
- (4 )
PC
.. --~
R~E ~
o
SHIFT DRUM
POSITION SWITCH
- @(41)
A_11 B_1
- ( ) Gee. PQMio<1
irIdIcat<>" blink I:JIJOt:lcaCQC
@( I MILSIonk =00
cd} S/lort te<Tnonajs for

reading OIC
0. "·lJ 1I.-2J
13-12
GENERAL TROUBLESHOOTING
Refer to the "GENERAL TROUBLESHOOT ING" in "PGM-FI system" (page 4-5)
SYSTEM DESCRIPTION
SELF·DIAGNOSIS SYSTEM
The OCT system is equipped with the self-diagnostic system. When any
abnormality occurs in the OCT system, the PCM have the gear position FA1 model shown'
indicator [1] blinking "-" and stores a Ole in its erasable memory for the
relevant system failure.
FAIL·SAFE FUNCTION
The OCT system is provided with a fail-safe function to secure a minimum
running capability even when there is trouble in the system.
When the PCM detects a problem in the OCT system, the PCM stops the : 1I M ILl:
automatic shift and ESP functions, and defaults the transmission into the
2ndl41hlreverse gear position. Also, the gear position indicator blinks "- " to
indicate the oTC ,
INDICATOR BUNK PATTERN
The number of indicator blinks is the equivalent the main code of the L __~1~1~1_____________---.J
oTC (the sub code cannot be displayed by the indicator blinking).
The indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.2 seconds , the short blink lasts for
0.4 seconds. One long blink is the equivalent of ten short blinks. For example. when one long blink is followed by five short
blinks, the OTC is 15 (one long blink = 10 blinks. plus five short blinks),
When the PCM stores more than one OTC. the indicator displays in the order from the lowest number to highest number.
CURRENT OTC /STORED OTC
The oTC is indicated in two ways according to the failure status.
If the PCM detects the problem at present, the gear position indicator will blink at all time , It is possible to readout the indicator
blink pattern as the current OTC.
If the PCM does not detect any problem at present but has a problem stored in its memory, the indicator will not blink. If it is
necessary to retrieve the past problem. readout the stored OTC by following the OTC readout procedure.
MCS INFORMATION
Refer to the "MCS INFORMATION" in "PGM-FI system" (page 4-6).
DTC READOUT
NOTE:
If the MIL blinks, readout the oTC (page 4-6) and troubleshoot the PGM- ~F-
A-'-m
-o-d-e-'-
'h
-O-W-"-.-----------
FI system first. Then recheck the OCT system after erasing the PGM-FI
OTC.
After performing diagnostic troubleshooting, erase the problem code{s) 1\ I
(page 13-14) and test-d rive the vehicle to be sure that the problem{s) [""iii]
have been removed ,
® @ re
If the gear position indicator [1] blinks "-", connect the MCS to the oLC
(page 4-6).
Read the OTC and stored data, and follow the troubleshooting index (page
®
- 11-
I
LI!
1./ .. ,...
@
13-15).
To read the OTG with the gear position indicator. use the following
procedure.
lOfu
/~
~_ 111
13-13
DUAL CLUTCH TRANSMISSION (FA1IFA2 models)
Reading oTC with the gear position indicator ~
Turn the ignition switch ON and read "-- blinks on the gear position
indicator. The number of blinks indicates the current oTC.
Refer to the troubleshooting index (page 13-15),
When retrieving the stored DTe, refer to the fonowing procedures.
Short the OLe [1) terminals using Ihe special 1001.
TOOL:
SCS Service Connector 12] 070PZ·ZY30100
CONNECTION : Brown/red - Green
Turn the ignition switch ON and read "-" blinks on the gear position
indicator. The number of blinks indicates the stored OTC.
Refer to the troubleshooting index (page 13-15).
ERASING DTC
Connect the MeS to the OLC (page 4-6).
Erase the OTC with the MeS while the engine is stopped .
To erase the OTC without MCS, refer to the following procedure.
How to erase the OTC without MCS
NOTE'
When Ihe OCT DIG is erased, the PGM-FI DIG would also be erased at Ihe same time. Check Ihe MIL blinks and troubleshoot
Ihe PGM-Ff system before erasing the OCT DTG.
1. Turn the ignition switch OFF. •
2. Remove the dummy connector (page 4-6),
3. Short the OLe 11] terminals using the special tool •
TOOL:
SCS Service Connec tor [2] 070PZ-ZY30100
Connection : Brown - Green

4. Turn the ignition switch ON.
5. Remove the special tool from the OLC.
6. The gear position indicator [1] will show "-" for approximately 5 seconds.
While the indicator shows "-", short the OLC terminals again with the FA1 model shown:
special tool. The self-diagnostic memory is erased if the indicator starts
blinking "-".
NOTE:
The OLe must be Jumped while the indicator shows "_". If not, the
indicator will not start blinking.
Note that the self-diagnostic memory cannot be erased if the ignition
"I ..,...
switch is turned OFF before the indicator starts blinking.
[11
CIRCUIT INSPECTION
Refer to the "INSPECTION AT PCM/ECM CONNECTOR" information in "PGM-FI system" (page 4-7).
13·14
DTCINDEX
When the gear position indicator shows "-" constantly , but no problem code is indicated and retrievable, refer to the symptom
troubleshooting (page 13-6).
OTC Function Faiture Symptom/Fail-safe Function

Refer to Mil
("- " blinks) page blinks
Dual clutc h PC solenoid valve Low input
Loose or poor contact of the dual clutch
· Gearshift function does nol
work (2nd, 4th or reverse
4-1 (4) PC solenoid valve connector gear only) 13-17
Dual clutch PC solenoid valve or its
circuit malfunction
--
4-2 (4)
Dual clutc h PC solenoid valve High input
• Dual clutch PC solenoid valve or its
· Gearshift function does not
work (2nd. 4th or reverse 13-18
-
circuit malfunction gear only)
4-3 (4)
Dual clutc h PC solenoid valve drive circuil
• Dual c lulch PC solenoid valve or its
work (2nd. 4th or reverse 13~17
circuit malfunction gear only)
TP sensar circuit Low voltage I · Poor engine acceleration
TP se nsor or its circuit malfunction · Fail-safe value: O'
8-1 (8) Loose or poor contact of the TP sensor
connector
4-15
gear only)
8
TP sensor circuit High voltage Poor engine acceleration
• TP sensor or its circuit malfunction Fail-safe value: O'
8-2 (8) Gearshift function does not 4-17
gear only)
-
Shift solenoid valve circuit · Gearshift function does not
15-1 (15)
· Loose or poor contact of the shift
solenoid valve connector
gear only) 13-19 -
· Shift solenoid valve or its circuit
malfunction
Shift spindle angle sensor circuit Low
· Gearshift function does not I
voltage work (2nd, 4th or reverse
21-1 (21) · Loose or poor contact of the shift spindle
angle sensor connector
gear only)
13-20 -
· Shift spindle angle sensor or its circuit
malfunction II
Shift spindle angle sensor circuit High
voltage
· work
Gearshift function does not
(2nd, 4th or reverse
21-2(21) 13-21 -
malfunction
gear only)
Shift spindle operation malfunction (while

operating gearshift mechanism)
22-1 (22) · Control motor or its circuit malfunction gear only) 13-22 -
malfunction
Shift spindle operation malfunction (after
23-1 (23) · Shift spindle angle sensor installation
problem
gear only)
13-23 -
malfunction
Shift control motor drive circuit
· Loose or poor contact of the shift control
24-1 (24) motor connector gear only) 13-24 -
· Control motor or its circuit malfunction
· Control motor drive circuit malfunction
32-1 (32)
Fail-safe relay circuit
· Fail-safe relay circuit malfunction
work (2nd, 4th or reverse 13-25
~
-
gear only)
Shift drum position switch circuit · Gearshift function does not
41·1 (41) · Shift drum position switch or its circuit
malfunction (Short)
gear only)
13-26 41
Gearshift switch circuit · Gearshift function does not

42-1 (42) · Gearshift switch or its circuit malfunction work (2nd, 4th or reverse
gear only)
13-27 -
13-15
OTC Refer to MIL
Function Failure Symptom/Fail-safe Function
r-" blinks) page blinks
EDT sensor circuit low vollage (less Ihan
0.08 V)
· work
44-1 (44 ) 13-28 l
· EOT sensor or its circui t malfunction gear only)
· Gearshift
Cooling fan turns on j
EDT sensor circuit high voltage (more Ihan · work (2nd,function does not 44
4.92 V) 4th or reverse ~
44-2 (44 )
· Loose or poor contact of the EDT sensor
connector
·
gear only)
Cooling fan turns on
13-29
, · EDT sensor or its circuit malfunction

Rear VS sensor no signal
66-1 (66) · sensor connector
Loose or poor contact of the Rear VS work (2nd, 4th or reverse
gear only)
13-30 66
· Rear VS sensor or its circuit malfunction
Front VS sensor no signal · work
67-1 (67) · lsensor
oose or poor contact of the Front VS
connector
gear only)
13-31 67
· Front VS sensor or its circuit malfunction
13-16
DTC TROUBLESHOOTING
NOTE :
Perform inspection wi th the ignition switch turned
OFF, unless otherwise specified .
After troubleshooting, erase the OTG (page 13-14)
and test-ride the vehicle to be sure that the system is
normal.
DTC 4-1 (DUAL CLUTCH PC

SOLENOID LOW INPUT), DTC 4-3
(DUAL CLUTCH PC SOLENOID DRIVE
CIRCUIT)
Before starting the troubleshooting, check the dual
dutch PC solenoid valve 2P (Black) connector for
loose or poor contacts, and recheck the OlG.
1. Recheck DTG
Recheck the current DIG with the MeS.
Is Dre 4-1 or 4-3 indicated ?
YES - GO TO STEP 2.
2. Dual Clutch PC Solenoid Inspection
Disconnect the dual clutch PC solenoid valve 2P PI
(Black) connector (page 13-6).
Measure the resistance between the solenoid valve
side 2P connector [1] terminals.
Standard : 5.1 - 5.7 n (20°C/68°F)
Is the resis tan ce within s tandard value ?
YES - GO TO STEP 3.
Q I--...J
3. Dual Clutch PC Solenoid Valve line Open

Circuit Inspection
Disconnect the PCM 33P (Black) connector (page
I
(21
4-35).
Check for continuity between the wire harness side A9
33P (Black) connector [1 ] and 2P (Black) connector
[2J terminals. ( Q WN
~Ef Ii
TOOL :
Pin Probe Male (2 pac k) 07ZAJ-RDJA110
Connection : A8 - Black/white
A9 - White/yellow
\ fQ
YES
NO
- GO TO STEP 4 .
Open circuit in the Black/white wire
• Open circuit in the While/yellow wire
l A\ BIIW
/
13·17
4. Recheck OTC
Connect the dual clutch PC solenoid valve 2P
(Black) connector and peM 33P (Black) connector.
Recheck the current DTG with the MeS.
Is DTe 4· 1 or 4·3 indicated?
YES - Replace Ihe peM with a known good one
(page 4-36), and recheck.
DTC 4-2 (DUAL CLUTCH PC

SOLENOID HIGH INPUT)
1. Recheck oTC
Recheck the current OTG with the MeS.
Is ore 4-2 indicated?
YES - GO TO STEP 2.
2. Dual Clutch PC Solenoid Valve Inspection
[1]
Disconnect the dual clu tch PC solenoid valve 2P
(Black) connector (page 13-6). •
side 2P connector [11 terminals.
Standard : 5.1 - 5.7 0 (20°CI68°F)
,
Is the resistance within 4.5 - 10.0 D?
•
YES - GO TO STEP 3.
L----{ Q }----'
3. Dual Clutch PC Solenoid Valve line Short

Ci rcuit Inspection
Disconnect the PCM 33P (Black) connector (page ' - - - - - - -[-,1- - -- - - - -- - ,
4·35).
Check the for continuity between the wire harness
side 2P (Black) connector [1] terminal and ground.
Connection : Black/white - ground
White/yellow - ground •
YES _ . Short circuit in the Black/white wire
• Short circuit in White/yellow wire
•
NO - GO TO STEP 4.
Q Q
13-18
4. Recheck DTG
Connect the dual clutch PC solenoid valve 2P
(Black) connector and peM 33P (Black) connector.
Is DTe 4-2 indicated?
YES - Replace the peM with a known good one
(page 4-36), and recheck .
DTC 15·1 (SHIFT SOLENOID VALVE

CIRCUIT)
Before starting the troubleshooting . check the shift
solenoid valve 2P (Brown) connector for loose or
poor contacts, and recheck the DIG.
1. Recheck OTG
Recheck the curren t DTG with the MeS .
YES - GO TO STEP 2.
2. Sh ift Solenoid Valve Inspection
[1]
side 2P connector {1] terminals .
Is the resistance within 14.6 - 16.2 D (20" C;
68"F)?
YES - GO TO STEP 3.
NO - Faulty shift solenoid valve
,----{Q
3. Shift Solenoid Val v e line Open Circuit

Inspection
Disconnect the PC M 33P (Gray) connector (page 4-
35).
11] [~]
Check for continuity between the wire harness side I
33P (Black) connector [1J and 2P (Brown) connector
[2J terminals, and between the 2P (Brown)
"P.J G
connector terminal and ground .
TOOL : I
J
Pin Probe Male (2 pack) 07ZAJ-RDJA 11 0
Connection: B7 - Brown/white , Q
Green - ground
-
Is there co ntinuity? B7 BerN
YES - GO TO STEP 4.
NO Open circuit in the Brown/white wire
• Open circuit in the Green wire
13-19
4. Shift Solenoid Valve Line Short Circuit
Inspection
2P (Brown) connector [1] terminal and ground.
11)
Connection : Brown/white - ground
YES - Short circuit in the Brown/white wire
NO - GO TO STEP 5.
5. Recheck oTC
Connect the shift solenoid valve 2P (Brown)
connector and PCM 33P (Gray) connector.
Is OTe 15-1 indicated?
YES - Replace the peM wi th a known good one
(page 4-36), and recheck. •
DTC 21-1 (SHIFT SPINDLE ANGLE

SENSOR LOW VOLTAGE)
Before starting the troubleshooting, check the shift
spindle angle sensor 3P (Gray) connector and
engine sub-wire harness 6P (Black) connector for
loose contacts or corroded terminals, and recheck
the DTe.
1. Shift Spindle Angle Sensor System Inspection
Check the shift spindle angle sensor wi th the MeS.
YES - GO TO STEP 2.
2. Shift Spindle
Inspection
Angle Sensor Input Voltage •
•
Disconnect the shift spindle angle sensor 3P (Gray) 111
\
3P (Gray) connector [1] terminals .
Connection: Brown/white (+) - Green/red (-)

YES - GO TO STEP 3.
NO - Replace the PCM with a known good one
BrfIN (+) GIR (-)
13·20
3. Shift Spindle Angle Sensor Output Line Short
Circuit Inspection
3P (Gray) connector [1] terminal and ground. 11J
Connection: Greenfyellow - ground
YES - Short circui t in the Green/yellow or Green!
blue wire
NO - GO TO STEP 4.
Q
4. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a known
good one (page 13-47).
Connect the shift spindle angle sensor 3P (Gray)
connector and peM 33P (Black) connector.
Check the shift spind le angle sensor with the MeS.
NO - Faulty original shift spindle angle sensor

SENSOR HIGH VOLTAGE)
Check the shift spindle angle sensor with the MCS.
YES - GO TO STEP 2_
ND - Intermittent failure
2. Shift Spindle Angle Sensor Input Voltage
Inspection
Disconnect the shift spindle angle sensor 3P (Gray)
[11
3P (Gray) connector {1] terminals_
Connection : Brown/white (+) - Green/red (-)
L
YES - GO TO STE P 3.
NO Open circuit in the Brown/white wire
Open circuit in the Green/red or Green!
white wire Brf'.N (+) G!R (- )
13·21
3. Shift Spindle Angle Sensor Output line Open
Circuit Inspection
Disconnect the PCM 33P (Black) connector (page 121
4-35).
33P (Black) connector [1) and 3P (Gray) connector
[21 terminals .
TOOL:
Connection : A23 - Green/yellow

YES - GO TO STEP 4. A23 GN
NO - Open circuil in the Green/yellow or Green!
blue wire
connector and PCM 33P (Black) connector.
Check the shift spindle angle sensor with the MCS. •
Is about 5 V Indicated? ,
YES - Replace the PCM wi th a known good one
•
DTC 22·1 (SHIFT SPINDLE ANGLE

SENSOR MALFUNCTION : While
operating gearshift mechanism) •
Is Low voltage (about 0 V) or High voltage (about
5 V) indicated?
YES - ' AboutOV: See DTC 21-1 (page 13-20)
• About 5 V: See DTC 21-2 (page 13-21)
NO - GO TO STEP 2.
2. Shift Control Motor/Reduction Gear Condition
Inspection
Check that the shift control motor and reduction
gears are installed properly and are not damaged
(page 13-47).
Are the shift control motor and reduction gears
In normal condition ?
YES - GO TO STEP 3.
NO - Inslalilhe shift control moior and reduction
gears properly or replace faul ty parts.
13-22
3. Shift Control Motor Inspection
Remove the shift control motor (page 13-47).
Connect a fully charged 12 V battery [1] to the
control molor 2P connector [2J terminals to check
the motor operation.
Change the battery connection to check the reverse
operation.
Does the shift control motor turn in both
direction ?
YES - GO TO STEP 4.
NO - Faulty shift control motor
12J I':...
J _ _--'
Remove the shift spindle angle sensor with the
connector connected.
While turning the shift spindle angle sensor shaft,
check the shift spindle angle sensor voltage with the
MeS.
When turning the sensor shaft clockwis e:
Voltage increase
When turning the sensor shaft
c ounterclockwise:
Voltage decrease
Does the voltag e vary properly?
YES - GO TO STEP 5.
NO - Faulty shift spindle angle sensor
5. Shift Spindle Angle Sensor Condition Inspection
Check that the shift spindle angle sensor is installed
properly.
Is the shift spindle angle sensor in normal
condition ?
YES - GO TO STEP 6.
NO - Install the shift spindle angle sensor
properly.
6. OTC Recheck
Recheck the DTC with the HDS pocket tester.

SENSOR MALFUNCTION : After
Refer to DTC 22-1 (page 13-22).
13-23
DUAL CLUTCH TRANSMISSION (FA1/FA2 models) I
DTC 24-1 (SHIFT CONTROL MOTOR ~
DRIVE CIRCUIT)
control motor 2P (Black) connector for loose
contacts or corroded terminals, and recheck the
OTe.
1. PCM Motor Power Input Line Open Circuit
Inspection
Disconnect the PCM 5P (Black) connector
(page 4-35), 111
SP (Black) connector [1]lerminal and ground.
Connection : C4 (+) - ground (-)
Is th ere battery voltage?
YES - GO TO STEP 2.
\
NO - ' Brown ES fuse (30 Al
Open circuit in the Red or Redlwhile
wire
C4 (+)
2. PCM Motor Power Ground Line Open Circuit

Inspection
Check for continuity between the wire harness side ' - - - - - -1-,1- - - - - - - - - - - - ,
5P (Black) connector [1] terminal and ground.
Connection : C5 - ground
YES - GO TO STEP 3.
NO - Open circuit in the Green wire
I
C5
3. Shift Control Motor Line Open Circuit Inspection

Disconnect the shift control motor 2P (Black) r[1~1----------------:12~1-'
5P (Black) connector [1] and 2P (Black) connector
[2] terminals.
Connection : C1 - Red
C2- Black
~\
NO Open circuit in the Red wire
C2 Q R 81
• Open circuit in the Black wire CI
13·24
4. Shift Control Motor Line Short Circuit Inspection
5P (Black) connector [1) terminals and ground . [1]
Connection : C1 - ground
C2 - ground
YES - ' Short circuit in the Red wire
• Short circuit in the Black wire
NO - GO TO STEP 5.
Q
C2 C1

Connect a fully charged 12 V battery [I] to the
control motor side 2P connector [2) terminals to
check the motor operation.
operation.
directions ?
YES - GO TO STEP 6.
[2] [1]
6. Rech eck OTC
Connect the PCM 5P (Black) connector and shift
control motor 2P (Black) connector.
Recheck the current DTC with the MCS .
Is OTC 24·1 indicated?
YES - Replace the PCM with a known good one
(page 4·36), and recheck. If DIG 24·1 is
indicated again, replace the control motor.
DTC 32·1 (FAIL SAFE RELAY CIRCUIT)

1. Rec heck OTC
Recheck the current DIG wi th the MCS.
Is DTC 32-1 indicated?
(page 4-36). and recheck. If DIG 32-1 is
indicated again, perform the following
troubleshooting ;
- DIG 21-1 (page 13-20)
- DIG 21-2 (page 13-21)
- DIG 22-1 (page 13-22)
- DIG 23-1 (page 13-23)
- DIG 24-1 (page 13-24)
13·25
DTC 41·1 (SHIFT DRUM POSITION
SWITCH CIRCUIT)
1. Recheck OTC
Is DTe 41-1 Indicated?
YES - GO TO STEP 2.
NO - Intermittent failure.
2. Shift Drum Position Switch Inspection at PCM
Connector
Check the shift drum position switch for short circuit
,
althe PCM 33P (Black) connector (page 13-50).
Are the test results normal?
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. Shift Drum POSition Switch Inspection at Switch
Connector
Check the shift drum position switch for short circuit
at the shift drum position switch 10P (Gray)
Are the test results normal? •
YES - Short
Short
Short
circuil
circuil
circuit
in
in
in
the
the
the
Gray wire
light green/red wire
Whi tefgreen wire
,
Short circuit in the Blue/black wire •
Short circuit in the Yellow wire
Short circuit in the Blue/red wire
Short circuit in the Blue/white wire
Short circuit in the Blue/green wire
Short circuit in the Blue wire
Short circuit in the light blue wire
NO - Faulty shift drum position switch
4. Recheck OTe
Connect the PCM 33P (Black) connector and shift
drum position switch 1QP (Gray) connector.
Erase the OTC (page 13-14).
Recheck the OTC with the MCS.
Is OTC 41-1 Indicated?
YES - Replace the PCM with a new one and
recheck,
13-26
DTC 42-1 (GEARSHIFT SWITCH
CIRCUIT)
Before starting the troubleshooting, check the
handlebar switch 14P (Green) connector for loose
contacts or corroded terminals, and recheck the
OIC.
1. Shift Switch Status Inspection
Check the shift switch status and voltage in the Data
list Menu of Mes as follows:
Is the shift switch status normal?

NO - GO TO STEP 2.
2. Shift Switch Ins pection at PCM connector
Disconnect the peM 33P connectors (page 4-35).
Check for continuity between the wire harness side 83
33P (Black) connector [1) and (Gray) connector (2] Q \---~
terminals while pushing each switch.
TOOL:
Connection:
With the upshift switch pushed :
AS-B3
With the downshift switch pushed:
A1S - B3
A16 121
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. Gearshift Switch Inspection at Handlebar Switch
Connector
Remove the left handlebar switch 14P (Green) , - - -- - - - - - - - - - - - - - ,
connector from the frame and disconnect it (page WIBu
23-10). WrY
~V
Check for continuity between Ihe switch side 14P
(Green) connector {1] terminals while pushing each
switch.
Connection :
With the upshift swit ch pushed
Brown/white - White/blue
111-~tiUJ]c
With the downshift switch pushed
Brown/white - Whitelyellow
Is there con tinuity?
YES - Open circuit in the following wire between L_ _ _ _ _ _ _ _ __ _ _ _ _ _ _ __
the PCM and handlebar switch
connectors :
Brown/white wire
• White/blue wire
• White/yellow wire
NO - Faulty gearshift switch (Replace the
handlebar switch.)
13-27
4. Recheck OTe
Connect the PCM 33P (Black) connector and
handlebar switch 14P (Green) connector.
Is DTe 42·1 indicated?
•
(page 4·36), and recheck. J
DTC 44-1 (EOT SENSOR LOW

VOLTAGE)
1. EDT Sensor System Inspection
Check the EOT sensor with the MeS.
,
Is about 0 V indica ted?
YES - GO TO STEP 2.
2. EOT Sensor Inspection
Disconnect the EOT sensor 2P (Black) connector
(page 13-53). •
Check the EOT sensor with the MCS.
Is about 0 V Indicated? •
YES - GO TO STEP 4. •
NO - GO TO STEP 3.
3. EOT Sensor Resistance Inspection
Turn the ignllion switch OFF.
Measure the resistance between the sensor side 2P 1'1
connector 11) terminals.
Standard: 2.3 _ 2.6 kQ (20°C/68°F)
/s the res/stance within standard value?

YES - Replace the PCM with a known good one ,
NO
(page 4-36). and recheck.
- Faulty EOT sensor
•
4. EDT Sensor Short CIrcuit Inspection

Disconnect the PCM 33P (Gray) connector (page 4- ' -- - --,-
1',-
1- - - - - -- -----,
35).
2P (Black) connector 111 terminal and ground.
Connection : Blue/yellow - Ground
YES - Short circuit in the Blue/yeUow wire
NO - Replace the PCM with a known good one
BoiY
13-28
DTC 44-2 (EOT SENSOR HIGH
VOLTAGE)
Before starting the troubleshooting , check the EDT
SWitch 2P (Black) connector for loose contacts or
corroded terminals, and recheck the DIG .
1. EDT Sensor System Inspection
Check the EDT sensor with the MeS.
YES - GO TO STEP 2.
2. EDT Sensor Inspection
Disconnect the EDT sensor 2P (Black) connector (11
(page 13-53),
Connect the wife harness side 2P connector [11
terminals with a jumper wire [2j.
Co nnectio n : Blue/yellow - Green
\
Check the EDT sensor with the MeS
B,IV G
YES - Faulty EDT sensor
NO - GO TO STEP 3.
121
3. EDT Sens or Line Open Circ uit In spection
(21 (I J
Remove the Jumper wire.
Disconnect the PCM 33P (Gray) connector B,IV
(page 4-35).
2P (Black) connector [1] and 33P (Gray) connector
(2) tenTunals, and between the 2P connector
TOOL:
Connection : B28 - Blue/y ellow

B28
Green - ground
j
NO - ' Open circuit in the Blue/yellow wire
• Open circuit in the Green wire
13·29
DTC 66-1 (REAR VS SENSOR NO
SIGNAL)
Before starting Ihe troubleshooting , check the reaf
vS sensor 3P (Black) connector and engine sub-
j
wire harness 6P (Black) connector for loose or poor
contacts, and recheck the o TC.
1. Rear VS Sensor Sy stem Check
j
Erase the OTC (page 13-14).
Test-drive the vehicle and stop the engine.
Check Ihe rear VS sensor signal with the MeS.
j
Is the VS sensor signal indicated normally?
YES - Intermittent failure.
NO - GO TO STEP 2.
2. Rear VS Sensor Power Input Voltage Inspec tion
Turn the ignition swllch OFF .
Disconnect the feaf VS sensor 3P (Black) connector 111
(page 13-53), I
Tum the ignition switch ON .
Measure the voltage between the wire harness side •
3P (Black) connector (1) terminal and ground.
Connection : Black/white (+1 - ground (-I
Is the voltage more than 10 V?
YES - GO TO STEP 4. 811W (+)
,
NO - GO TO STEP 3.
H ,
3. Rear VS Sensor Power Input Line Open Circuit
Inspection
Tum the ignItion switch OFF.
Disconnect the PCM 33P (Black) connector (page 121
4-35). A5
33P (Black) connector (1) and 3P (Black) connector
(2) terminals
TOOL:
Connection : AS - Black/white
Is there conti nui ty?
YES - Replace Ihe PCM with a known good one BWI
NO - Open circuit in the Black/red or Black/while L~~~~~~~~~~~~~~~~~-'
wire
13·30
4. Rear VS Sensor Ground Line Inspection
[1]
Connection : Black/white (+) - Green H
Is there battery ....oltagei'
YES - GO TO STEP 5.
BIIW (+)
'----,G (-)
r---'
'-------{V)-------'
5. Rear VS Sensor Output line Inspection

3P (Black) connector [1] terminals.
[1]
Connection: Pink (+) - Green H
Is the voltage about 5 Vi'
YES - GO TO STEP 6.
NO - Open or short circUit in the Pink or Pink! G (- )
green wire.
' --1 V r-----'

6. Rear VS Sensor Inspection
Replace the rear VS sensor with a new one (page
13-53).
Erase the DTG (page 13- 14).
Check the current OTG with the MeS.
Is DTe 66·1 indicated?
(page 4-36 ), and recheck.
NO - Faulty original rear VS sensor
OTC 67-1 (FRONT VS SENSOR NO

SIGNAL)
Before starting the troubleshooting , check the fron t
VS sensor 3P (Black) connector for loose or poor
contacts, and recheck the OTC.
1. Front VS Sensor System Check
Check the front VS sensor signal with the MeS .
Is the VS sensor signal indicated normally ?
YES - Intermittent failure .
NO - GO TO STEP 2.
13·31
1
2. Front VS Sensor Power Input Voltage Inspection
Turn the ignition switch OFF. , - - - - - - - - - - - - - - - -- - - ,
Disconnect the front VS
sensor 3P (Black) [1] •
<
Measure the \lollage between the wire harness side
3P (Black) connector [1] terminal and ground.
Connection : Black/red (+) - ground (- )
Is the voltage more than 10 V?
YES
NO
- GO TO STEP 4.
- GO TO STEP 3.
v SI/R (+) j
3. Front VS Sensor Power Input Une Open Circuit <

Inspection
Disconnect the peM 33P (Black) connector (page 11 ] 12]
4-35).
A5
33P (Black) connector [1) and 3P (Black) connector
[2) terminals
TOOL:
,
Connection: AS - Blackfred
Is there continuity? •
YES - Replace Ihe PCM with a known good one
(page 4-36), and recheck. ,•
4. Front VS Sensor Ground Line Inspection
•
3P (Black) connector [1] terminals, 11 ]
Connection: Black/red (+) - Green (-) •
YES - GO TO STEP 5.
NO - Open circuit in the Green wire BlfR (+) G(-)
13-32 •
5. Front VS Sensor Output Line Inspection
Measure the voltage between the wire harness side . - - - - - - -I-'-J- - -
3P (Black) connector (1] terminals.
Connection: Black/yellow (+) - Green {-I
Is the voltage about 5 V?
YES - GO TO STEP 6.
NO - Open or short circUli In the Black/yellow
allY ;..
1''-.
) _..J G 1-)
wire
6. Front VS Sensor Inspection

L_ j
Replace the front VS sensor with a new one (page
'3-54).
Erase the OTe (page 13-14),
Test-drive the vehicle and stop the engine .
Check the current OTe with the MeS .
Is DTC 67· 1 indicated?
NO - Faulty original front VS sensor
FRONT CRANKCASE COVER/SPACER

REMOVAL
- engine (page 16-4)
- shift valve body (page 13-56)
- shift control molor/reduction gears (page 13-47)
Loosen the bolt (1 ] of the front crankcase cover spacer.
Do not allow dust or Remove Ihe fOllowing :
dirt to enter the oil
sixteen bolts [2]
passages.
- front crankcase cover [3]
13-33
1
- O-ring [1J
- oil orifice [2) and O-rings [3)
- joint collar (4] and O-rings (5]
- two dowel pins 16]
- washer 17) j
l
j
j
1
- dipstick [1]
J,
- bolt [21
- front crankcase cover spacer {3]
••
J
J
•
•
,
- two dowel pins [1 J

- O-ring [2]
- joint collar [31 and O-ring [4] •,
- gasket (5]
•
•
- O-ring [1J
- output shaft oil 5eal[21
•
•
•
•
13-34
- sening cap (1 J and O-ring 12J
Do not allow the - feed pipe A (1]

dust or dirt to enter - selting collar [2] and O-rings [3]
the oil pipe.
Do not allow the - feed pipe BI1J and D-ring [2]

dust or dirt to enter
the oil pipe.
- gearshift spindle oil seal III
13-35
Il
FRONT CRANKCASE COVER j
CLEANING/I NSPECTION
Remove the oil filter (page 3-18).
I
Remove the setting bolt [I). sealing washer (2]. spring
and orifice relief valve.
Wash the crankcase cover with solvent and blow
through the oil passages and orifices with compressed
air to clean them thoroughly.
Check the orifice relief valve P] for wear or damage. J,

Check the spring (2] for fatigue or damage.
Clean the orifice relief valve thoroughly. I
Instatl the orifice relief valve, spring, new sealing
washer (3) and setting bolt [4] and tighten it.
TORQUE: 34 N'm (3.5 kgf'm, 25 IbHt)
•
Install the oil filter (page 3-18).
•
1
I
Remove the oil strainer [1].
1
Wash the strainer thoroughly in non-flammable or high
flash point solvent until all accumulated dirt has been •
removed .
Blow dry it with compressed air to clean completely. •
Before installing the strainer, the screen mesh should
be examined closely for damage.
Install the oil strainer with the wedge facing the front
side.
The feed pipes ere Check the feed pipe A and B for abnormal wear or
used 10 supply the damage.
engine oil to the
Check the crankshaft and mainshaft bearings for wear
dual clutch.
or damage.
BEARING REPLACEMENT
CRANKSHAFT BEARING
Remove the bearing [1J with the special tools.
TOOLS :
Bearing remover shaft 07936·KC1 01 00
Bearing remover head ,
15 mm (2] 07936·KC10200
Remover weight 07741-0010201
U.S.A . TOOLS :
,•
Remover weight 07936·371020A •,
13·36
Driye a new bearing squarely with the sealed side
facing down until it is fully seated.
TOOLS :
Driver (1) 07749.()010000
Attachment, 32 x 35 mm (2] 07746-0010100
Pilot, 15 mm [3] 07746-0040300
MAINSHAFT BEARING
Remove the snap ring 11J and washer [2]. and the
bearing {3].
Apply engine oil to a new bearing .
Inslallthe bearing until it is seated.
Install the washer and snap ring into the cover groove
properly.
INSTALLATION
Coat a new O-nn9 [I) with engine oil and install it onto r - - - - - -
the joint pipe.
Install the two dowel pins (I] and oil toint pin (2).
Coal new O-rings (3] with the engine oil, and install
them into the front crankcase groove and onto the oil
joinlpin.
Install a new gasket [4].
111
13-37
Install the front crankcase cover spacer [1] by aligning
the oil pump shaft [2J end with the balancer shaft (3]
groove.
,
j
1
J
•
Loosely inslalilhe bolt [lJ. •
Se car&ful not to Apply engine oil 10 a new output shaft oil seal [2] lip and
damage the oil seal install it into Ihe crankcase cover spacer until it is fully ,,
I;ps. sealed. •
Make sure that the oil seal is installed properly.
I
Install Ihe dipstick [3). ,
Install the centrifugal clutch (page 13-45).
Apply engine oil to the tips of new gearshift spindle 011

seal [1] and install it into the fronl crankcase cover.
Coat new O-rings [1] with Ihe engine oil.

Instalilhe D-ring into Ihe groove of the spacer.
Install the O-rings onlo the oil orifice [21 and install them
•
into the hote of the spacer.
13·38
Coal new O-rings 11 J with the engine oil and install the
O-rings onto the joint collar [2].
Instalilhe joint collar into the hole of the spacer.
Install the washer (1) and two dowel pins [2] .
Apply liquid sealant (TB1215 or equivalent) to the ~====~111~====="'=~'===

mating surface (shadowed area) of the fronl crankcase
cover as shown.
Be careful not to Install the front crankcase cover, aligning the water :=============.i;r;;;;;;;;;;;;;;;~
damage the oil seal pump shaft [I} end with the pin of the camshaft.
lips.
13-39
Install the sixteen bolts [1J.
Tighten the sixteen bolts and spacer bolt [21 in a
crisscross pattem in several steps. 1
I
1
J
Coal a new O-ring (1] with engine oil and install it onlo •
the flange of the feed pipe B [2].
Align the flange tabs Carefully insert the pipe B into the crankcase cover. •
with the grooves in
the cover
Coat new O-rings 11] with engine oil and install them • •
into the setting collar 12J grooves.
f~i~r==:J~~P;;:: •
Install the setting collar until it is seated .

Align the flange tabs Carefully insert the pipe A {3J into the setting collar.
with the grooves in
the collar.
•
13-40
Coat a new O-ring (1 ) with engine oil and Install it into
the setting cap [2] groove.
Inslalithe setting cap and tighten it.
TORQUE : 21 N-m (2.1 kgf-m , 15 tbHt)
Inslali the following:

- shift con trol molor/reduction gears (page 13-48)
- shift valve body (page 13-56)
CENTRIFUGAL CLUTCH
REMOVAL
Remove the fron t crankcase cover (page 13-33).
Be careful not to Unstake the clutch lock nut [1].
damage the
crankshaft threads.
Hold the clutch drive plate using the special 1001 and ,-----
loosen the lock nul.
TOOL:
Clutch holder set [1J 07ZMB-HN20001
U.S.A. TOOL:
Clutch holder 07ZMB-HN2A101
Remove the lock nut and washer.
Remove the centrifugal clutch assembly [1) using the ;;;;;;;======~:

special tool.
TOOL:
Clutch puller, 35 x 1.0 mm [2] 07933·HA80000 or
07933·HB3000A
(U .S.A. only)
13-41
Remove the pnmary drive gear [1] and washer [2).
1I
J
1
I
J
J
DISASSEMBLY
You should be able to turn the clutch weight assembly r - ---c-c- - - - - -- - - -- - ,
•
[11 counterclockwise smoothly, but the assembly should
not turn clockwise. I
Remove the clutch weight assembly from the clutch I
drum (2) while turning il counterclockwise.
;
Remove the E-clips (1] using a screwdriver while ~=====:::=::====::::'====::' •

compressing the clutch spring.
Remove the following: 1
- outer plale (2] •
- clutch spring 13)
- inner plale [4) •
,
•
••
•
14[ [2[
Remove the clutch weights 111 and springs [2) from the ~===============:--~
drive plate.
•
••
13-42
INSPECTION
Inspect the following parts for scratch, damage,
- clutch drum
- sprag clutch
- drive plate
- clutch weights
- clutch weight springs
Replace the clutch weight springs as a set.
• Replace the clutch weights as a set.
ASSEMBLY
CLUTCH WEIGHTS DRIVE PLATE
WEIGHT SPRINGS o
CLUTCH SPRING
@ '
OUTER PLATE
CLUTCH DRUM
@
©l
@ ,
/
E-CUPS
I INNER PLATE
~ SPRAG CLUTCH
Instal/with/he Install the clutch weights 111 and springs 121 onto the jr---------
spnng's open ends drive plale as shown.
faCIng in .
[2)
13-43
Install the inner plate [1) with flange side facing up.
Install the clutch spring [2) with concavity side facing
down.
I
1
J
i
111
,
86 careful nOllO
Install the ouler plate (1] with the pins [2] facing up.
Install the E-clips (3) into the spindle grooves with its
•
ciamage the clutch gap facing towards the pin by using the pliers while
weights while compressing th e clutch spring.
compressing.
Apply engine oil 10 the sprag clutch [1] whole surface

and the sprag clutch contacting surface of the clutch !
drum.
Install the sprag clutch into the clutch drum with the
1
·OUT SIDE- mark [2] facing up. 1
;
•
•
Apply engine oil to the sprag clutch contacting surface
of the drive plate boss.
Install the clutch weight assembly (1] while turning it
counterclockwise.
,
•
•l
13-44
INSTALLATION
Apply engine oil to the primary drive gear sliding
surface [1].
Install the washer [2] and primary drive gear [3] onto the
crankshaft.
Set the centrifugal dutch assembly [1] onto the ~~~IIIII~IiI!!~~~~=:~~

crankshaft by aligning the splines of the drive plate and
crankshaft, and the splines of the clutch drum and
primary drive gear.
Be careful not to Tap the drive plate to seat the clu tch assembly.
damage the
TOOL :
crankshaft threads.
Driver, 22 mm 1.0 . [2] 07746-0020100
Apply engine oil to the threads and seating suriace of a ~;;;;,;:;;;;;;;;;;;;;::~:::=::;:;;;~

new lock nut.
Instalilhe washer [1) and lock nul [2].
Hold the drive plate of the centrifugal clutch assembly

with the special tool and tighten the lock nut.
TOOL:
Clutch holder set 07ZMB·HN20001
U.S.A . TOOL :
Clutch holder 07ZMB·HN2A101
13-45
Be careful not /0
cran k S
ma,'
, dB..
8"
.'.he
t rea s.
Stake the lock nut into Ihe crankshaft groove.
Instalilhe front crankcase cover (page 13-37).
I
SHIFT SOLENOID VALVE

REPLACEMENT
Remove Ihe lank cover assembly (page 2~).
Clean around the shift solenoid valve [1] with

compressed air to remove dust. dirt and foreign
materia!.
Disconnect Ihe 2P (Brown) connector [2).
Remove Ihe bolt [3J and shift solenoid valve from the
valve body by pulling it.
Apply engine oil to the O-rings (1] of a new shift

solenoid valve (2].
,
Install the solenoid valve into Ihe valve body and lighten
the boll.
Connect the 2P (Brown) connector.
Inslalilhe lank cover assembly(page 2-4).
•
•
13-46
SHIFT SPINDLE ANGLE SENSOR
- right mudguard (page 2-5)
- air cleaner housing (page 7-17)
Disconnecllhe 3P (Gray) connector [1] from the shift
spindle angle sensor.
Remove the two socket bolts [2] and shift spindle angle
sensor [3] from the rear crankcase cover.
Coat a new O-ring (4) with engine oil and install it into
the shift spindle angle sensor groove.
Instali lhe shift spindle angle sensor by aligning the flat
surface of the sensor hole and gearshift spindle [5] end.
Apply locking agent to the socket bolt threads.
Install the socket bolts and tighten them.
TORQUE: 6 N'm (0.6 kgf-m , 4.4 IbHt)
Instalilhe removed part in Ihe reverse order of removal.
SHIFT CONTROL MOTOR/REDUCTION

GEARS
REMOVAL
Remove the right mudguard (page 2-5).
Disconnect the 2P (Slack) connector [1] from the shift
control motor.
Remove the three bolts [2]. wire clip stay and shift
control motor [3].
Remove the O-ring (4) from the shift control motor.
13-47
Remove the two bolls [IJ and reduction gear cover [2).
Remove the oil seal [3] from the gear cover.
1
Remove the two dowel pins II].

Remove the spindle gear [2] and reduction gears [3] .
Remove any grease from the gears, gear cover and
front crankcase cover.
,
,
INSTALLATION •
~ $I O-RING
•
SHIFT CONTROL MOTOR
\ \ REDUC TION GEARS
1
,
~l
•
j
•
•
WIRE CLIP STAY
DOWEL PINS
SPINDLE GEAR
REDUCTION
GEAR COVER
13-48
Clean the mating surfaces of the reduction gear cover
and fro nt crankcase cover thoroughly.
Apply 2 - 4 9 (0.07 - 0.14 oz) of specified grease to the
reduction gear [1] journals and gear teeth.
SPECIFIED GREASE: UNIREX N3 grease (EXXON)
Install the reduction gears into the fronl crankcase
cover.
Install the spindle gear [2] onto the gearshift spindle by
aligning the punch mark with the wide tooth.
Install the two dowel pins [1].
Apply grease to a new oil seal [1jlip and install it into

the reduction gear cover [21.
Apply sealant to the mating surface of the reduction
gear cover.
Install the cover with the two bolts [3] .
Coat a new D-ring [1] with engine oil and install it into
the control motor groove.
Install the shift control motor [2[ onto the front
crankcase cover.
13-49
Install the wire clip stay [1) and three bolts [21.
Tighten the five bolts in a crisscross pattern in two or
three steps.
Connect Ihe 2P (Black) connector [3) to the shift control
motor [4].
Install the fight mudguard (page 2~5).
SHIFT DRUM POSITION SWITCH

SYSTEM INSPECTION
Tum the ignition switch OFF and disconnect the PCM
33P (Black) connector (page 4-35). 11J 34 (A2) N2 (A1)
N (A17) 54 (A13)
Check for continuity between wire harness side 33P ;
(Black) connector [1) terminals and ground .
,
There should be continuity only at the terminal that
,
corresponds to the shift drum position (open circuit
inspection).
There should be no continuity at the other terminals .~
••
I
(short circuit inspection).
You must test at ten terminals in each shift drum
• ••••
position.
TOOL :
5N (A12) •
Pin Probe Male (2 pack) 07ZAJ-ROJA110 3N (A29) N4 (A24)
32 (A26)
12 (A27) 5R (A25)
,,
SWITCH INSPECTION
Remove the right mudguard (page 2-5) ,
Tum the ignition switch OFF and disconnect the gear
position switch 1QP (Gray) connector {1].
13·50
Check for continuity between switch side 1QP (Gray)
connector [1J terminals and ground. (1 ) I
There should be continuity only al the terminal that WjG
corresponds to the shift drum position (open circuil
inspection). G, LglR
B"~ ~~ ~/~
There should be no continuity at the other terminals
(short circuil inspection).
You must test at len terminals in each shift drum
position.
B"'R
Shift dwm;
~y
15R ,
,
12
I N2 I
=
132
Y B"
I
~ I
I
I
154 IBlue I
REPLACEMENT
Remove the two wire clamp bolts [1}.
Remove the wire grommet (2] from the rear crankcase
cover.
Remove the retaining bolt [3] and shift drum position
switch [4] from the rear crankcase cover.
Apply locking agent to all bolt threads .
Install the shift drum position switch onto the rear
crankcase cover and tighten the retaining bolt.
TORQUE : 12 N'm (1.2 kgf-m. 9lbHt)
Apply sealant to the grommet seating surface.
Route the wire as shown and install the grommet into
the crankcase cover groove properly.
Install the two clamp bolls and tighten them.
TORQUE: 12 N·m (1.2 kgf'm, 9 IbHt)
Install the rear crankcase cover (page 14-9).
13-51
1
REVERSE SWITCH
SYSTEM INSPECTION
1. Reverse Switch Inspection at PCM Connector
Disconnect Ihe PCM 33P (Black) connector (page 11J
4-35).
Check for con tinuity between Ihe wire harness side
\ 1
33P connector (1] terminal and ground in each ..l 1,
reverse selector lever position. ;
TOOL:
Pin Probe Male (2 pack) 07ZAJ·RDJA 110 l
j
Connection: A29 - ground
j
There should be continuity with Ihe selector lever rQ\
depressed and no continuity with the selector lever
released.
A2! I
1
YES - The system is normal.
1
NO - GO TO STEP 2.
2. Reverse Switch Inspection at Switch
Remove the engine guard (page 2-5).
Disconnect the Blue/red wire connector [11 from the
•
1
reverse switch (2).
Check for continuity between the switch terminal
and ground in each reverse selector lever position.
There should be continuity with the selector lever
depressed and no con tinuity with the selector lever
released.
•
YES - Open or short circuit in the Blue/red wire.
NO - Faulty reverse switch.
REMOVAUINSTALLATION 1
Remove the engine guard (page 2-5). 1
Disconnect the Blue/red wire connector [1] from the
•
reverse switch.
13-52
Remove the (everse switch [1 J and sealing washer [2).
Install the reverse switch with a new sealing washer
and tighten It.
TORQUE : 13 N'm (1.3 kgf'm, 10 IbHt)
Connect the Blue/red wire connector to Ihe reverse
switch .
Fill Ihe crankcase with Ihe recommended engine oil
(page 3· 17 ).
InsleUthe engine guard (page 2-5).
EOT SENSOR
Remove the right mudguard (page 2-5)
Drain Ihe engine oil (page 3-17 ).
Disconnect the 2P (Black) connector (1J from Ihe EOT
sensor [2] .
Remove the EOT sensor and sealing washer [3J from
Ihe front crankcase cover.
Install the EOT sensor with a new sealing washer and
tighten it.
TORQUE: 18 N'm (1 .8 kgf'm, 13 IbHt)
Connect the 2P (Black) connector.
Fill the crankcase with the recommended engine oil
(page 3-17).
Install the right mudguard (page 2-5).
REAR VS SENSOR
Disconnect the 3P (Btack) connector (1) from the rear
VS sensor (2) .
Remove the bolt (3) and rear VS sensor from the rear L.~~::
crankcase cover.
13-53
DUAL CLUTCH TRANSMISSION (FA1/FA2 models) j
Remove the C-ring (1] from the rear VS sensor (2).
Coat a new O-ring wilh engine oil and install it onto the
rear VS sensor.
Install the rear VS sensor into the rear crankcase cover
1
and tighten the bolt.
Connect the 3P (Black) connector to the rear VS
sensor.
Inslalithe tank cover assembly (page 2-4).
;
(
FRONT VS SENSOR 1
Remove the bolt [1] and guard plate [2].
•,
Disconnect the 3P (Black) connector [3) from the front
VS sensor [4] .
Remove the front VS sensor from the front final gear
case.
Remove the O-ring [1] from the front VS sensor [2J.

Coal a new O-ring with engine oil and install it onto the
front VS sensor.
Install the front VS sensor into the front final gear case.
Connect the 3P (Black) connector to the front VS
sensor.
Install the guard plate and bolt, and tighten the bolt. •
l
13-54
DUAL CLUTCH TRANSMISSION (FA1IFA2 models)
SYSTEM INSPECTION
1. Drive Mode Select Switch Inspection
Raise the fronl fender (page 23-9).
Disconnect the drive mode select switch 2P (Black)
connector {1J.
Check for continuity between the switch side
connector terminals in each switch position.
There should be continuity with the switch t urned to
AUTO , and no continuity with the switch turned to
ESP.
Is the switch normal?
YES - GO TO STEP 2.
NO - Faulty drive mode select switch
2. Power Input Line Open Circuil Inspection

[11
2P (Black) connector [1]lerminal and ground.
Connection : Black/red (+) - ground (-)
Is there battery voltage ?
YES - GO TO STEP 3.
NO - Open circuil in the Black/red wire
BIIR (+)
3. Output Line Open Circuit Inspection

[11
Connect the drive mode select switch 2P (Black)
connector.
Disconnect the peM 33P (Black) connector (page
4-35).
Turn the drive mode selecl swilch 10 AUTO and the
ignition wilch ON.
Measure the vol tage between the wire harness side
33P connector [11 terminal and ground.
TOOL:
Pin Probe Male (2 pack) 07ZAJ·ROJA 110
A18 (+)
Connection : A18 (+) - ground (- )
YES - The system is normal.
NO - Open circuit in the Brown/black wire
13-55
SHIFT VALVE BODY
I NOTICE I
00 not drop or strike the solenoid valves when
setVicing. Excessive shock may damage the solenoid
valve.
EMERGENCY VALVE FUNCTION

,
NOTE
The emergency valve is used when the hydraulic
pressure is shut off by the faulty dual clutch PC
solenoid (stuck; mechanical lock). and the vehicle is
prevented from running. Open the bypass oil circuit
manually to supply hydraulic pressure.
The stopper boll [IJ that operates the emergency
valve Is secured with the lock plate [2]. When trouble
occurs, loosen the lock plate screw {3] and turn the
stopper bolt all the way in to activate the emergency ,
valve. •
!
•
REMOVAU INSTALLATION
Remove the left mudguard (page 2~5).
Clean around the valve body with compre ssed air to

remove dust, dirt and foreign maleriaL
Remove the wire clip [1] from the stay.
DIsconnect the shift solenoid valve 2P (Brown)
connector [2) and dual clutch PC solenoid valve 2P
(Black) connector [3).
Place a shop towel under the valve body [1].

- six bolts [2)
- valve body assembly
13·56
- gasket [1]
- three oil guide pin [2]
- six O-rings [3] from the guide pins
Cover the shift valve body housing of the front
crankcase cover with lape or clean cloth ,
Installation is essentially in the reverse order of

removal.
Replace the O-rings and gasket with new ones.
Coat the O-rings with engine oil.
VALVE BODY ASSEMBLY
2P (Brown)
CONNECTOR
....
~ GASKET
/
2P (Black)
CONNECTOR
DISASSEMBLY/ASSEMBL Y
NOTE :
Keep dust and dirt away from ailihe parts.
Take care not to damage the mating surfaces of the
valve body components.
Before assembly, clean all the parts with
compressed air. Make sure that there is no dust or
lint on any parts.
- bolt [1] and shift solenoid valve (2)
- three bolts [3], wire clip stay [4] and dual clutch PC
solenoid valve assembly [5[
111 (21
13-57
- rubber seal[ ' ]
- screw [1] and lock plale {2]

- valve stopper bolt [3]
- emergency valve [4]
- valve spring (5]
13J
- four boils [1)
- valve body [2]
•
I1J
- separator plate [1J
- two dowel pins [21
- three sealing bolts [3] and washers (4)
11J
13·58
~ spring seal [1]
~ valve spring [2J
- shift valve \31
Wash all the parts with a high flash point or non-
flammable solvent and blow through all oil passages
with compressed air to clean completely.
Assembly is essentially in the reverse order of

disassembly.
Replace the O-rings, rubber seal and sealing
washers with new ones.
Coal O-rings and rubber seal with engine oiL
Apply engine oil to the shift valve outer surface.
EMERGENCY VALVE
VALVE SPRING
\
~fk:3.;: : :;~~~e--~
.;"
WIRE CUP STAY
DUAL CLUTCH PC
. SOLENOID VALVE
"""11 g O-RING \
~~~
~~V- L
STOPPER BOLT --------~ J·~-<,::§]pf
LOCK PLATE
fII SEALING WASHERS
SEPARATOR PLATE SPRING SEAT
• o (
VALVE SPRING
SHIFT VALVE --"'1

13·59
INSPECTION
Use a hand- Connect a pressure pump to the input port (filter side) of
operated air pump the shift solen01d valve.
only, Do not use a
Connect a 12 V battery (1] to the shift solenoid valve
high pressure air
connector [21 terminals as shown and check for air flow
source. conditions.
~
~ ~ ~ I~ EB 8
[21 \ 1
Air should not flow (the pressure should be maintained) ,-----
while the battery is connected , and should now out of
. ~ ~
the output ports [1J that go to the shift valve when the
battery is disconnected.
Vi ,
DUAL CLUTCH PC SOLENOID VALVE •

Connect the 12 V battery [1J positive terminal to the
dual clutch PC solenoid valve connector (2] terminals
and check the spool valve through the oil passages for
•
operation ,
121
The valve [1] should move to away from the solenoid
side when the battery is connected, and should return
by spring force when the battery is disconnected .
.
-~-n .fLXi{J ,~,
-, \l'=-"< ,
[,.------>"
I
111
13-60
SHIFT VALVE AND VALVE BODY
Check the shift valve [1] and valve body [2J bore for r----------------~
scoring scratches or abnormal wear.
Check the valve spring [3J for fatigue or damage.
['I [3)
DUAL CLUTCH/PRIMARY DRIVEN

GEAR
REMOVAL
Remove the centrifugal clutch (page 13-41).
Be careful not to Unstake the lock nut (1].
damage the
main shaff threads
Loosen the lock nut [11 while holding the gear guide
boss with the special tool.
TOOL :
lock nut wre nch , 32.5 mm [2] 07AMA-HP7A100
Remove the following
- lock nut
- washer [1)
- 1sl clutch gear guide (2)
- thrust washer [3]
13·61
DUAL CLUTCH TRANSMISSION (FA1/FA2 models) j
- shift clutch/primary driven gear assembly [11
- four seal rings (2] from the mainshaft grooves
1
1
1
•
;
1ST SHIFT CLUTCH DISASSEMBLY

Remove the following :
- 1sl shift clutch assembly [1]
- needle bearing [2J
- seal rings [11
- snap ring [1)

- clutch end plate A [2]
13-62
- three clutch discs [1] and plates [2]
- wave spring [3]
[21
If either support Install the special tools onto the shift clutch. ~ _ _ [4[
block {II is set over
an area o( the TOOLS :
spnng seal {2J that Clutch compressor set 07LAE-PX40000
is unsupported by 0'
the return spring, Clutch compressor 07LAE-PX40100
the spring seat may attachment [3) (2 required) and
be damaged. Compressor bolt assembly [4) 07GAE-PG40200 or
07GAE-PG4020A
(U.S.A. only)
NOTE :
Be sure the special tool is adjusted to have full
contact the stepped areas with the spring seal.
[2[
To prevent loss o( Compress the return spring 11] by tightening the nut.
spring tension, do Remove the snap ring [2) from the boss.
not compress the
Loosen Ihe nut and remove the special lools, snap ring,
spring more than
spring seat [3] and return spring.
necessary.
Wrap a shop towel around the clutch drum.

Apply air pressure to the oil hole while closing the other
holes with your finger to remove the clutch piston.
Remove the O-rings from the piston.
Clean all the parts of the shift clutch in solvent
thoroughly and blow dry Ihem with compressed air.
13-63
DUAL CLUTCH TRANSMISSION (FA1fFA2 models)
!
2ND SHIFT CLUTCH DISASSEMBLY
- 2nd shift clutch assembly [1]
I
(11
- needle bearing [1 J
- seal rings [2)
,
,
- snap ring [1]

- clutch end plate B [2)
- clutch guide plale A [3J
131
- 2nd clutch gear guide [1)
- thrust washer [2)
Remove the following in the same procedures as the
1st shift clutch (page 13-63):
- three clutch discs and plates
- wave spring
- snap ring
- spring seat
- return spring
- clutch piston
,
13-64
INSPECTION
Inspect the following parts for scratch, damage ,
- clutch drum and piston
- clutch spring
- clutch discsJplates
- primary driven gear
Measure each part according to DUAL CLUTCH
TRANSMISSION SPECIFICATIONS (page 1-9).
• Replace the clutch discs and plates as a set.
CLUTCH DRUM AND PISTON
Check the clutch drum [1] for nicks, indentations or ,---- - - - - - - -- - - - - - ----,
abnormal wear made by the clutch plates.
Check the oil holes in the drum boss and check valve
[2J in the piston [3) for clogs.
1ST SHIFT CLUTCH ASSEMBLY

CLUTCH PLATES (3 pes)
---'71 CLUTCH DISCS (3 pes)
--""7It NEEDLE
iii BEARING
END PLATE
SNAP RING
~' O-RINGS
CLUTCH DRUM
WAVE SPRING
SNAP RING RETURN SPRING
SPRING SEAT
13-65
Clean the inner surface of Ihe clutch drum [1)
thoroughly and blow through Ihe oil holes in the drum
boss and check valve in Ihe piston 12).
I
Apply engine oil to new O-rings [3] and inslall them into
the piston groove.
Place the clutch piston into the clutch drum with Ihe flat
side facing in. I
1
Becarefulnot/o Install Ihe piston [1] while turning it to ensure proper ~===::;:;;============~
pinch the O-rings
with too much
sealing. ,
'orca.
Place the return spring [1), spring seat [2] and snap ring ~::::::::::::':~~::::::""111~===:;
(3J into the clutch drum.
Install the special tools [4] while adjusting their position
carefully (page 13-63).
To prevent /o$S of Compress Ihe return spring by lightening the nut.
spnng tension, do
not compr&ss the
spring more than
necessary.
•
111 [31
•
Align the end gap Instatl the snap ring [11 into the groove in the drum boss ~=================::;
with the groove (3 properly.
places) in the
Loosen the nut and remove the special tools.
spnng seat.
13-66
Install the wave spring (1J into the piston groove.
Coat the clutch discs [2] with engine oil.
Install the three clutch plates [31 and discs alternately,
starting with the plate.
Install end plate A [1] with the slepped side facing out.
Install the snap ring [2J into the drum grooves properly.
Check the clutch initial clearance (page 13-69).
Coal new seal rings {1] with engine oil and install them
into the primary driven gear grooves.
Apply engine oil to the needle bearing [1J and install it

into the primary driven gear.
Install the 1st shift clutch assembly [2] onto the primary
driven gear by aligning the splines.
[21
13-67
2ND SHIFT CLUTCH ASSEMBLY
RETURN SPRING SNAP RING
CLUTCH PISTON
J
CLUTCH DRUM
~./
PRIMARY DRIVEN GEAR
SPRING SEAT
•
SNAP RING
,
END PLATE
GUIDE PLATE
GEAR GUIDE
CLUTCH PLATES (3 pes) CLUTCH DISCS (3 pes) --"7!

Install the following in the same procedures as the 151 ,-------:c:---- - - - -- ---,
shift clutch (page 13-65):
clutch piston
- return spring
- spring seat
- snap ring •
- wave spring
- three clutch plates and discs
Inslallthe thrust washer (1) onto the clutch drum.
•
Inslalithe 2nd clutch gear guide (2) by aligning the gear
guide teeth with the clutch discs labs.
111
Inslall clutch guide plate A [1] and clutch end plate B [21. ~================:
Inslalithe snap ring (3) into the drum grooves properly.
Check the clutch initial clearance (page 13-69).
13-68
Coat new seal rings [1] with engine oil and instailihem
into the primary driven gear grooves.
Apply engine oil to the needle bearing [2J and install it
into the primary driven gear.
Inslallthe 2nd shift dutch assembly [1) onto the primary ~=lIIIl1iOl,;;oIIiIilllllllll~::::-:--::;"'.IIIIII:=:::;
driven gear by aligning the splines.
11 J
CLUTCH INITIAL CLEARANCE CHECK
Set a dial indicator on the end plate (lJ with the plate r---------
lowered.
lift the end plate up against the snap ring and read the
clearance, and record it.
Perform this inspection at the three points in 1200 apart.
STANDARD:
1st clutch : 0.70 - 0.90 mm (0 .028 - 0.035 in)
2nd clutch: 0.65 - 0.95 mm (0.026 - 0.037 in)
If the clearance is not within the standard value . select

the replacement end plate as follows:
Remove the snap ring and end plate.

Measure the flange thickness of the end plate at several
points and record it.
Calculate the new plate thickness using the equation
below. Choose a new plate as close to this dimension
as possible .
A = (B-0.8) + C
A: New plate thickness
B: Recorded clearance
C : Old plate thickness
13-69
1
I
~
If the calculated Selecllhe end plate from the lable below.
dimension is over
the thickest plate
1
thickness. rep/ace a c ness Mark Thickness
the clutch discs and 1.9mm 1.' 1.l;Imm
plates as a set. < ;'::.umm <.U <l.u mm
mm mm
mm 2.2 2.2mm
5 2.Jmm <.J L.Jmm
• ".4 mm
mm
<.• :t.4 mm
mm
mm mm
9 2.7mm <. 2. mm
Install the end plate into the drum.
Install the snap ring into the drum grooves properly.
INSTALLATION
Blow through the oil passages in the mainshaft with
compressed air.
Coat new seal rings (1] with engine oil and instalilhem
into the mainshaft grooves.
Apply engine oil to the needle bearings in the primary •

driven gear.
Install the shift clutch/primary driven gear assembly (1)
by aligning Ihe splines of the 2nd clutch gear guide and
mainshaft.
Inslallthe thrust washer [1 J onto the mainshaft.
13-70
Install the 1st dutch gear guide [1] by aligning the gear
guide teeth with the clutch disc tabs, and also aligning
the splines of the gear guide and mainshaft. until il is
fully seated.
Install the washer [2J .
Apply engine oil 10 new lock nut [1]lhreads and inslall it

onto the mainshaft.
Tighten the lock nut while holding the gear guide boss
wilh the special tool.
TOOL :
lock nut wrench , 32.5 mm (2) 07AMA-HP7A1QO
TORQUE : 108 N'm (11 .0 kgf'm , 80 tbHt)
Be careful not to Stake the lock nut into [1J the mainshaft groove.
damage the
Install the centrifugal dutch (page 13-45).
mamshaft threads.
GEARSHIFT LINKAGE
REMOVAL
- shift spindle angle sensor (page 13-47)
- front crankcase coverfspacer (page 13-33)
- shift dutch/primary driven gear assembly
(page 13-61)
- gearshift spindle assembly [1J and washer [2J
13-71
two bolts [1)
- guide plate [2] and drum shifter assembly (3]
,•
Shift the - two dowel pIns [1]

transmission into - shift drum center bolt [2J
reverse when - shift drum center [3)
loosening the - pivot bolt [4J. stopper arm [5]. return spring [6) and
center bolt. washer [7]
Check all parts for wear or damage.
INSTALLATION
Apply locking agent to the stopper arm pivot boll [1]
threads.
Install the stopper arm [21. return spring {3]. washer 14]
(between the arm and crankcase) and pivot bolt as
shown.
Tighten the pivot bolt.
TORQUE : 12 N'm (1.2 kgf'm , 9 IbHl)
•
Hold the stopper arm with a screwdriver and install the

shift drum center (1) by aligning the pin groove [2] with
the dowel pin Pl.
13-72
Apply locking agent to the shift drum cen ter bolt [1]
threads.
Install the bolt and tigh ten it.
TORQUE : 23 N' m (2.3 kgf 'm , 17 IbUt)
Install the two dowel pins [2].
Apply engine oil to the drum shifter [1), springs [2].

plungers (3] and ratchet pawls [4] . and assemble them
with the guide plate [5J.
14;-1
~
~ [2[ [3( 1
.
Install the guide plate [ 1) and drum shi fter assembly [2]
into the shift drum center and onto the dowel pins as
shown .
Apply locking agent to the guide plate bolt [3] threads.
Instailihe bolls and lighten them.
TORQUE : 12 N'm (1.2 k gf'm , 9 lbHt)
Install the washer [1] onto the gearshift spindle and

insert the spindle into the crankcase while aligning the
return spring ends [2] with the spring pin [3), and the
shifter collar [4] with the drum shifter pin [51.
Inslalilhe following:
- shift ctutch/primary driven gear assembly
(page 13-70)
- front crankcase cover/spacer (page 13-37)
- shift spindle angle sensor (page 13-47)
13-73
DUAL CLUTCH TRANSMISSION (FA1fFA2 models)
REVERSE STOPPER SHAFT
REMOVAL 1
Remove Ihe rear crankcase cover (page 14-6) .
Release the reverse stopper arm [1) from the shift drum
groove and remove the stopper shaft assembly [2] from
the crankcase.
1
1
,.
INSPECTION ,,
Check the reverse stopper shaft [1) for wear or damage. , - - - - - - - - - - - -- - - - - ,
Check the return spring [2) for fatigue or damage.
INSTALLATION
Apply engine oil to the reverse stopper shaft journal ;
surface.
Install the reverse stopper shaft assembly [11 into the ;
crankcase as shown.
13-74
14. ALTERNATORISTARTER CLUTCH
SERVICE INFORMATION ·· .... ·............ ·.... ··· 14-2 RECOIL STARTER (Canada FM1fFM2/FE1
models only) "" "" " " """"" " "" " """ " """' "14 -6
TROUBLESHOOTING······ ··························· 14-3
ALTERNATOR STATOR ·················· ······ ···· 14-6
SYSTEM COMPONENTS···························· 14-4
FLYWHEEUSTARTER CLUTCH ············· 14-11
14-1
AL TERNATORISTARTER CLUTCH
SERVICE INFORMATION
GENERAL
This section covers service of Ihe alternator stator, flywheel and starter clutch. The engine must be removed from the frame to
service these parts.
Transmission lubricating oil is fed through the oil passages in the rear crankcase cover. Clean the oil passages before installing
the cover.
Alternator stator inspection (page 22-7).
Starter molor servicing (page 6-4).
TOOLS
Flywheel holder Rotor puller Remover weight
07725-004000 1 07733-0020001 07741-0010201
,
or 07933-3950000 (U.SA only) or 07936-371020A (U.SA only)
Attachment, 52 x 55 mm Attachment, 24 x 26 mm Pilot, 10 mm
07746-0010400 07746-0010700 07746-0040100
= 8 •
•
Pilot, 25 mm Driver Bearing remover shaft, 10 mm
07746-0040600 07749-0010000 07936-GE00100 (nol available in
U.S.A.)
•,
14-2
Bearing remover head, 10 mm Bearing remover, 10 mm Remover handle
07936-GE00200 (nol available in 07936-GEOAOOO (U.S.A. only) 07936-3710100 (U.S.A. only)
U.S.A.)
Recoil puUey holder

07SMB-HM70100
TROUBLESHOOTING
Sta rter motor turns, but engine does not turn
Faulty starter clutch
• Damaged starter reduction gear and/or driven gear
14-3
SYSTEM COMPONENTS
U.S.A. all models and Canada FA2 model
TElIFE1 models shown:
108 N'm (11.0 ,80IbHt)
14-4
Canada FMlIFM2/FE1 models
FE1 model shown:
r
\\1 )!
~~~ ~~ 10BN-m (11 .0kgf-m,80Ibf-ft)
14-5
1
RECOIL STARTER (Canada FM1/FM21
FE1 models only)
Remove the mudguards (page 2-5).
~ four bolts [1] and clamp [2J
- recoil starter assembly [3]
Apply locking agent to the bolt threads.
Install the recoil starter assembly with the four bolts and
clamp, and tighten the bolts in a crisscross pattern in
several steps.
Secure the wire with the clamp properly.
Install the mudguards (page 2-5).
STARTER ROPE REPLACEMENT

\oVhen the rope has Pull the starter rope [1) fully to align the rope holes in ~---1-
4-1 ---I-
'-J --------~
broken or the pulley the drive pulley {2] and housing [3]. and secure the
has rewound. align pulley with a vise pliers or equivalent tool to prevent the
the rope holes by pulley from rewinding.
turning the pulley
Untie the starter rope and remove the rope.
6·112 turns
counterclockwise Insert a new starter rope through the pulley, housing
and hold it and grip [4J, and tie the rope ends in a square knot. Set
the pulley side rope end into the cavity as shown.
Carefully release the pulley and check the recoil starter
for smooth operation by pulling the grip.
I
Rope ends: •
ALTERNATOR STATOR
REMOVAL
air cleaner housing (page 7- 17)
- engine guard (page 2-5)
- swingarm (page 18-5)
- starter motor (page 6-4)
- TE1 /FE1fFA1 /FA2 only: shift spindle angle sensor
- FA1 /FA2 : page 13-47
- TE1 /FE1 : page 24·21
- Canada FMlIFM2/FE1 only: recoil starter
(page 14-6)
Canada FM1/fM2J Hold the recoil starter driven pulley using Ihe special
FEf only: 1001 and loosen the bolt.
TOOL:
Reco il pu lley ho lder (1) 07SMB·HM70100
14·6
AL TERNA TORISTARTER CLUTCH
Canada type only: Remove the following:
141 131
I
- bolt [1) and O-ring [2)
- driven pulley [3]
- oil seal [4)
111
The cover (stator) IS - Except FA1/FA2: thirteen bolts [IJ
magnetically - FA1/FA2: fourteen bolts [1)
attracted to the - rear crankcase cover (2]
flywheel, be careful
during removal.
- two dowel pins [1)

- oil joint pipe [2) and O-ring [3J
- thrust washer [4J from the countershaft
- Except FA1/FA2: thrust washer from the reverse
stopper shaft (51
- output shaft oil seal [1)

- reverse lock lever oil seal [2J
- TE1/FElIFA 1fFA2 only: gearshift spindle oil seal [3]
131
14-7
STATOR AND CKP SENSOR
REMOVAL
[5[ [3[
- two CKP sensor bolts (1J
- four stalor bolls (2)
- grommet [3J
- stator 14)JCKP sensor [5] assembly
['[
STATOR AND CKP SENSOR

[NSTALLAT[ON
Sel the stator [1 ]fCKP sensor [2J assembly onto the cc:[,c-[---------c:::c-- = ::-------,
alternator cover. (3) ...(€fru
Apply sealant to the grommet [3] seating surface and
install the grommet into the cover groove securely.
,
Apply locking agent to the threads of the stator bolts [4]
,•
and CKP sensor bolts (5] (page 1-16).
Inslall the stator and CKP sensor bolls, and lighten [11
them to the specified torque.
TORQUE :
Stator bolt : 10 N'm (1 .0 kgf'm , 7 IbHt)
CKP sensor bolt: 6 N'm (0.6 kgf'm, 4.4 IbHt)
1
BEAR[NG REPLACEMENT
OUTPUT SHAFT BEARING
Drive the bearing oul of the cover.
Apply engine oil 10 a new bearing.
Drive the bearing into the cover with the marked side
facing up.
TOOLS :
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 25 mm 07746-0040600
14·8
AL TERNA TOR/STARTER CLUTCH
CRANKSHAFT BEARING
Remove the crankshaft hole cap.
Remove the snap ring [1) and bearing [2].
Instalilhe bearing and snap ring.
• Make sure the snap ring is firmly seated in the
groove.
Inslalilhe crankshaft hole cap.

INSTALLATION
Clean the mating surfaces of the crankcase and rear r-~~~~~~
crankcase cover thoroughly. being careful not to
damage them.
Blow through the oil passage in the rear crankcase
Install new gearshift spindle oil seal (TE1IFE1/FA1/FA2
only) [1] and reverse lock lever oil seal [2) until they are
fully seated.
Install a new output shaft oil seal [3] until the depth from
the crankcase cover is 1.5 ± 0.2 mm (D.06 ± 0.01 in).
Apply engine oil to the oil seal lips.
13J
I.St 0.2
(0.06 mm
± 0.01 in)
Apply liquid sealant (T81215

or equivalent) to the ;::'=A='=
"=A2='=h=O='='===========~
=W
mating surface (shadowed area) of the rear crankcase ~~&~)~
cover as shown. ~
14-9
Inslallthe two dowel pins [1) and oil joint pipe (2J.
Coal a new O-ring [3J with engine oil and install it onto
the oil joint pipe.
Install the thrust washer [4J onto the countershaft.
Except FA1 /FA2: Install the thrust washer onto the
reverse stopper shaft [5].
Shift the transmission into neutral to align the groove in

LUG [2[
the shift drum [1J with the lug on the crankcase.
Align the long end (2) of the gear position switch pin
with the "N" mark (lug) on the rear crankcase cover.
The cover (stator) is Install the rear crankcase cover aligning the switch pin
magnetically with the shift drum groove, being careful not to damage
attracted to the the oil seal lips.
flywheel, be careful
not to get anything NOTE:
caught between TM1/FM11FM2 models only: Align the arm of
gearshift spindle A with the arm hole in the gearshift
lhese parts when
ins/a/ling. spindle when installing the cover. •
[1 [ LUG
,
Except FA1 fFA2: Install the thirteen bolts 11J.
FA1 /FA2: Install the fourteen bolts 11J. FA1fFA2 '"v,""'"-
Tighten the bolts in a crisscross pattern in 2 or 3 steps.
Canada FM1IFM2I Apply specified grease to the lips of a new oil seal [1J
FE1only; and install it into the crankcase cover until it is fully
seated.
I
....
Mobilith SHe 100 grease [1 J ~ [4[
SPECIFIED GREASE : Mobilith SHe 100 (EXXON)

Coat a new O-ring 12J with engine oil and install it onto
the pulley bolt flange.
Apply engine oil to the threads and seating surface of
the pulley bolt [3].
Install the driven pulley [4] with the bolt, aligning the
bosses with the grooves in the crankshaft.
14-10
Canada FM1IFM2IFEl only: Hold the driven pulley
using the special 1001 and lighten the bolt
TOOL:
Recoil pulley holder [1] 07SMB·HM70100
TORQUE : 108 N·m (11 .0 kgf'm , 80 IbHt)

- TElIFE1 /FA1 /FA2 only: shift spindle angle sensor
- FA lIFA2: page 13-47
- TEt /FE1 : page 24-21
- Canada FM1 /FM2/FEl only: recoil starter
(page 14-6)
- starter motor (page 6-4)
- swingarm (page 18-6)
- air cleaner housing (page 7-17)
FL YWHEELISTARTER CLUTCH
REMOVAL
Remove the starter reduction gear shaft [1] and gear
[2[ .
Excepr Canada Hold the flywheel using the special tool , and remove the
FMI/FM2JFE1 : nywheel bolt [1) and collar (2).
NOTE:
• Do not hold the CKP sensor magnet portion on the
flywheel.
TOOL:
Flywheel holder [3] 07725-0040001
14-11
Hold Ihe flywheel {11 and remove it from the crankshaft
using the special tools.
TOOL:
Rotor puller [2J 07733-0020001 or
07933·3950000
(U .S.A. only)
Be careful nor to Remove Ihe woodruff key [1] from the crankshaft.
damage/he
crankshaft and key
groove.
STARTER CLUTCH DISASSEMBLY

Make sure that the starter driven gear [1 J turns dock- , - - - - - - : - : - - - - - -- - - - - -,
wise smoothly and does not turn counterclockwise.
Remove the driven gear while turning it clockwise.
Hold the flywheel with the special tool and remove Ihe ;:::==============~~~~
starter clutch bolls (T40) {1].
NOTE'
• Do nol hold the CKP sensor magnet portion on the
flywheel.
TOOL:
Remove the starter clu tch assembly from Ihe flywheel.
14-12
INSPECTION
Inspect the following parts for scratch, damage.
- starter driven gear
- starter clutch outer
- sprag clutch
- starter reduction gear shaft
- starter reduction gear
Measure each part according to AL TERNATORI
STARTER CLUTCH SPECIFICATIONS (page 1-9).
Replace any part jf it is out of service limit.
STARTER CLUTCH ASSEMBLY

Lubricate the sprag clutch [1) with engine oil and install
it into the clutch outer [2) with the flange facing the
flywheel side.
Install the starter clutch onto the flywheel.
121
Apply locking agent to the starter clutch bolt [1] threads ~=================~
(page 1-16).
Align the bolt holes in the flywheel and starter clutch,
and instalilhe bolts.
Hold the flywheel with the special 1001 and lighten the
bolts.
NOTE :
• Do not hold the CKP sensor magnet portion on Ihe
flywheel.
TOOL:
TORQUE : 37 N'm (3.8 kgf'm, 27 lbHt) .ca

Install Ihe starter driven gear [1] while turning it C!ock- ~==:::'::==============~
wise .
14-13
1
INSTALLATION
Be careful not /0 Install the woodruff key [11 into the key groove.
damage/he
Apply molybdenum oil solution to the starter driven gear
crankshaft and key
sliding surface of the crankshaft.
groove.
Clean any oil from the tapered portions of the
crankshaft and flywheel.
Inslalithe flywheel [1] aligning Ihe key way with the key
on the crankshaft.
Except Canada Apply engine oil to the flywheel bolt [1] threads and
FM1/FM2/FE1: seating surface.
Install the collar [21 and flywheel bolt.
Hold the flywheel using the special 1001 and tighten the
flywheel boll.
NOTE :
• Do not hold the CKP sensor magnet portion on Ihe
flywheel.
TOOL:
TORQUE : 108 N'm (11 .0 kgf'm, 80 IbHt)
Apply molybdenum oil solution to the starter reduction

gear shaft (1]. and install the gear [2] and shaft.
14-14
STARTER MOTOR BEARING
REPLACEMENT
Remove the starter reduction gear shaft [1] and gear
121
Turn the inner race of the bearing [3) with your finge r.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fils tightly in the
rear crankcase cover.
Replace the bearing if the inner race does not turn
smoothly, quietly or if the outer race fits loosely in the
cover.
Remove the bearing using the special tools.
TOOLS :
Bearing remover shaft, 10 mm 07936-GE00100
Bearing remover head , 10 mm 07936·GE00200
Remover weight 07741-0010201
U.S.A . TOOLS:
Bearing remover, 10 mm 07936·GEOAOOO
Remover handle 07936-3710100
Remover weight 07936-371020A
Drive a new bearing into the crankcase with the marked
side facing out. using the special tools.
TOOLS :
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
Pilot, 10 mm 07746-0040100
Apply molybdenum oil solution to the starter reduction

gear shaft, and install the gear and shaft.
Install the (ear crankcase cover (page 14-9).
14-15
MEMO
15. CRANKCASEfTRANSMISSION/CRANKSHAFT/BALANCER
SERVICE INFORMATION ··························· 15-2 TRANSMISSION ····· ···································· 15-7
TROUBLESHOOTING································· 15-4 CRANKSHAFT/BALANCER·····················15-13
SYSTEM COMPONENTS ···························· 15-5 CRANKCASE BEARING

REPLACEMENT ·······································15-15
CRANKCASE SEPARATION······················15-6
CRANKCASE ASSEMBLY ······················· 15-19
15·1
j
CRANKCASEITRANSMISSION/CRANKSHAFT/BALANCER
SERVICE INFORMATION
GENERAL
The crankcase halves must be separated to service the transmission and crankshaft. To service Ihese parts, the engine must be
removed from the frame (page 16-4).
Be careful not to damage the crankcase mating surfaces when servicing.
Engine lubricating oil is fed through the oil passages in the crankcase. Clean the oil passages before assembling the crankcase
halves.
Figures in this section are mainly those of TM1fTE1 /FM1 1FM2/FE1 models.
TOOLS
Driver Attachment, 24 x 26 mm Attachment, 32 x 35 mm
07749-0010000 07746·0010700 07746-0010100
Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm

07746-0010200 07746·0010300 07746-0010400
= =

07746-0010500 07746-0010600 07GAD-SD40101
= =
Pilot, 15 mm Pilot, 17 mm Pilot, 20 mm

07746-0040300 07746-0040400 07746-0040500
15-2
Pilot, 22 mm Pilot, 25 mm Pilot, 32 mm
07746-004 1000 07746·0040600 07MAO-PR90200
Pilot. 35 mm Pilot, 40 mm Bearing remover shaft, 15 mm

07746-0040800 07746-0040900 07936-KC10100 (not available in
U.S.A.)
Bearing remover head , 15 mm Bearing remover, t 5 mm Bearing remover, 17 mrn

07936-KC10200 (not available in 07936·KC10500 (U,S.A. only) 07936-3710300
U.S.A.)
Bearing remover, 20 mm Remover handle Remover weight

07936-3710600 07936·3710100 07741-0010201
or 07936-371020A (U.S.A. only)
15-3
Assembly collar Assembly shaft Special nul
07965-VMOO100 07965·VMOO200 (1'101 available in 07931·HB3020A (U.S.A . only)
U.S.A.)
,,I
,
t
Puller shaft Universal bearing puller Threaded adapter

07931·ME4010B (U.SA only) 07631·00 10000 07965-VM00300 1
j
,
or equivalent commercially available in or 0793 1-KF00200 (U.S.A. only)

U.SA
TROUBLESHOOTING ,
Excessive engine noise
Worn, seized or chipped transmission gears
Worn transmission bearings
Worn connecting rod big end bearing •
Worn crankshaft main journal bearing
Worn balancer bearing
Improper balancer installation
,
Transmission jumps out of gear •
Worn gear dogs or dog holes
Worn shift drum guide groove
Worn shift fork guide pin
•
Worn gear shifter groove
Worn shift fork
Benl shift fork shaft
Faulty gearshift linkage (page 12-3)
Hard to shift
Damaged shift fork
Bent shift fork shaft
Damaged shift fork guide pin
Damaged shi ft drum guide groove
Bent gearshift spindle
Faulty gearshift linkage (page 12-3)
Abnormal vibration
• Improper balancer timing
15-4
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
SYSTEM COMPONENTS
15-5
1
CRANKCASE SEPARATION
cylinder head (page 10-10)
cylinder and piston (page 11-4)
camshaft (page 10-16)
Except FA1 /FA2: gearshift linkage (page 12-17)
Except FA1IFA2: change dutch (page 12-12)
FA 11FA2: gearshift linkage (page 13-71)
Except FA1IFA2: oil pump (page 9-6)
flywheel and starter clutch (page 14-11) •
1
reverse stopper shaft assembly [1]
FA1fFA2: See page 13-74
•
output shaft drive gear [2] , driven gear [3] and output
shaft [4]
- two front crankcase bolts [1]
Loosen the - fifteen rear crankcase bolts [1]

crankcase bolls in a
Place the crankcase assembly with the rear crankcase
crisscross pattern in down.
several steps.
Do not pry the Remove the front crankcase while tapping it at several
crankcase apart locations with a soft hammer.
with a screwdriver.
Remove the three dowel pins (1).
Remove any sealant material from the crankcase
mating surfaces .
15·6
OIL STRAINER CLEANING
Remove the oil strainer [1J and strainer plate [2].
Wash the strainer thoroughly in non~f1ammable or high
flash point solvent until all accumulated dirt has been
removed.
Blow dry the strainer with compressed air completely.
Before installing the strainer, the screen mesh should
be examined closely fo r damage.
Install the strainer and plate with the wedge facing the
crankcase.
TRANSMISSION
DISASSEMBLY
Separate the crankcase (page 15-6).
- TM1/FM1/FM2 models only: gearshift spindle
- shift fork shaft [1J
- shift forks [21
- shift drum [3]
- reverse idle shaft [11 and idle gear [2]
Position the crank - mainshaft [1] and countershaft [2J as an assembly

weights so that /hey
do nOf interfere wifh
the mainshaft
gears.
15-7
Do not expand the Disassemble the mainshaft (1) and coun tershaft [2}.
snap ring more than
Clean all disassembled parts in solvent thoroughly.
necessary for
removal. NOTE:
Keep track of the disassembled parts (gears,
bushings, washers and snap ring) by sliding them
onto a tool or slipping them onlo a piece of wire.
INSPECTION
- transmission gears
- transmission bushings
- transmission bearings
- shift drum
- shift forks
- shift fork shaft
Measure each part according to CRANKCASE!
TRANSMISSION/CRANKSHAFT/BALANCER
SPECIFICATIONS (page 1-10).
•
ASSEMBLY
NOTE :
•
Always install the thrust washers and snap ring [1) •
wi th the chamfered (rolled) edge facing away from Ends aHgned Ends aligned
the thrust load. with grooves with splines
Install the snap ring so its ends aligns with the
grooves in the splines.
Make sure the snap ring is fully seated in the shaft Correct Incorrect
,
groove after installing it. ~
Clean all parts in solven t and dry them thoroughly.

Apply molybdenum oil solution 10 the gear and bushing
sliding surfaces .
Assemble the mainshaft and counlershaft.
~ LQj(1 @
111
15-8
MAINSHAFT (Except FA1 1FA2 models)
M3 BUSHING
THRUST WASHER
M2fMR GEAR (17T)

SPECIAL WASHER
I
Ml GEAR (14T)
MAINSHAFT
\
M5 BUSHING
THRUST WASHER
M4 GEAR (28T)
SNAP RING
M5 GEAR (33T)
SPLINE WASHER M4 GEAR (2ST)
M3 GEAR (21T)
M3 GEAR (21T)
-:7J :
Gear and bushing sliding surfaces
SPLINE :',~;;-;;~i RING

Washer and snap ring direction:
15-9
j
COUNTERSHAFT (Except FA1 /FA2 models)
C1 GEAR (54T)
CR GEAR (46T)
C2/CR GEAR SHIFTER
C2 GEAR (38T)
THRUST WASHER C4 BUSHING
C4 GEAR (33T)
,
C3 GEAR (33T) --~-,\ •
SPLINE COLLAR
C1 GEAR (54T)
C4 GEAR (33T)
CR GEAR (46T) C3 GEAR (33T)
C5 GEAR (28T)
C2 GEAR (38T)
--'il-- - - - - - - -
~ : Gear and bushing sliding surfaces
THRUST WA:SHER
Washer direction:
15-10
MAINSHAFT (FA1 IFA2 models)
SPECIAL WASHER _ @ @
M 1 GEAR (17T)
~HRUI WASHE!
M5 GEAR (33T)
M3 GEAR (24T)
?@~ SNAP RING

M1 BUSHING I
~":."
, ~~ ~ , 1JBUSHING
, ~ SPLINE WASHER (:@@

MAINSHAFT
THRUST WASHER
~@~~
r i.' -"THRUST WASHERS
NEEDLE BEARING
M2IM4 GEAR (19Tf28T)
NEEDLE BEARINGS
Washer and snap ring direction :

, : Gear and bushing sliding surfaces
COUNTERSHAFT (FA1 /FA2 models)

CR GEAR (45T) C2/CR BUSHING
GEAR~28TI @~ 7 EAR
11
C5 " . SHIFTER
-aI::i/ (J)Y'i r: /
THRUST WASHER
~~
~( -
C4 GEAR (33TI
C5 BUSHING ( ~ C4 BUSHING \
~ THRUST WASHER
C3 GEAR (37T)
COUNTERSHAFT
Washer direction: ~ : Gear and bushing sliding surfaces
15-11
Check the gears for freedom of movement or rotation
on the shaft.
Apply engine oil to the mainshaft [1] and countershaft
[2] journals.
Engage the mainshaft and countershaft gears.
Position the crank weights so that they do nol interfere ~::;;;:::=============;;::=~

with the mainshaft [1].
Install the mainshaft and countershaft [2J assemblies as
a set into the rear crankcase.
Apply molybdenum oil solution to the reverse idle gear

[11 sliding surface.
Install the reverse idle gear and shaft (2).
Each shift fork has an identification mark; "FR" [1] for ~~~':;:::::::::::::..l~=-"'~:1.~..::J~~I11~
the front for\(, · C" (2) for the center fork and "RR" PI for
the rear fork.
15-12
CRANKCASEfTRANSMISSIONfCRANKSHAFTfBALANCER
Apply engine oil to the shift drum guide pin grooves and
install the shift drum [1].
Install each shift fork into the gear shifter grooves and
shift drum groove with their identification marks facing
up (front crankcase side).
Except FA1/FA2:
- rear shift fork {2] into the M4 gear
- center shift fork [3] into the C3 gear
- front shift fork [4] into the C2fCR gear shifter
FAlIFA2:
- rear shift fork [2] into the M5 gear
- center shift fork [3] into the C3 gear
- fronl shift fork {4] into the C2/C4 gear shifter
Apply engine oil to the fork shaft [5J.
Install the fork shaft through the shift forks and into the
crankcase.
TM1/FM1/fM2 models only: Install the gearshift
spindle.
Assemble the crankcase halves (page 15·19).
CRANKSHAFT/BALANCER
REMOVAL
Separate the crankcase halves (page 15-6).
Remove the transmission (page 15-7).
Be careful not to Remove the crankshaft 111 and balancer !2J from the
damage the crank- rear crankcase using a hydraulic press. Be sure to hold
case mating surface the crankshaft and balancer while pressing them out of
and crankshaft the crankcase.
assembly.
Remove the rear crankshaft bearing !1] using the , - -

bearing puUer wi th a suitable protector !2J. Discard the
bearing.
TOOL :
Universal bear ing puller [3] 07631-0010000 o r
equivalent
c ommercially
available in U.S .A.
NOTE :
Always replace the rear crankshaft bearing with a
new one when the crankshaft is removed .
INSPECTION
- balancer drive gear
- balancer driven gear
- crankshaft
Measure each part according to CRANKCASE/
TRANSMISSION/CRANKSHAFT/BALANCER
SPECIFICATIONS (page 1-10).
15-13
CRANKCASEITRANSMISSIONfCRANKSHAFTfBALANCER
CRANKSHAFT RUNOUT
Set the crankshaft in a stand or V-blocks and measure
the runout using a dial indicator.
SERVICE LIMIT: 0.15 mm (0.006 in) GAUGE GAUGE
Hold Hold
INSTALLATION
Apply engine oil to a new rear crankshaft bearing.
Drive the crankshaft bearing into the rear crankcase
with the marking side facing up.
TOOLS :
Driver (1) 07749-0010000
Attachment,72 x 75 mm [2J 07746·0010600
Pilot, 32 mm [3] 07MAD·PR90200
Other bearing replacement in the crankcase halves

(page 15-15)
Be careful not to Engage the balancer and crankshaft by aligning the

disengage the index lines [1J on the crank weight [2) and balancer
gears. driven gear [31. and install them together into the rear
crankcase.
Take care that the Install the special tool onto the rear crankshaft end.
crankshaft and
balancer do not fall TOOL:
out ofthe Threaded adapter [1] 07965·VM00300 or
crankcase when 07931·KF00200
installing the (U.S.A. only)
special/ools.
15-14
Install the special lools onto the crankshaft and
crankshaft bearing.
TOOLS :
Assembly collar [1] 0796S-VM00100
Assembly s haft (2) 07965·VM0020Q
U.S.A. TOOLS :
Assembly collar 0796S-VM00100
Assembly shaft 07931·ME4010B
Special nut 07931·HB3020A
Be careful not to leI Draw the crankshaft into the bearing inner race.
tha connecting rod
press against the
crankcase mating
surface.
A fter installing the crankshaft. make sure the index lines
(lion the crank weighl12] and balancer driven gear (31
are aligned.
Install\he transmission (page 15-8).
Assemble the crankcase halves (page 15·19).
CRANKCASE BEARING
REPLACEMENT
FRONT CRANKCASE (Except FA1fFA2
models)
Remove the coun\ershaft bearing [1] and balancer . - - - , . " . - - - - - - -T " " " - -Y - ,
bearing [21 with the special laols.
TOOLS :
Countershaft bearing :
Remover handle 07936·3710100
Remover shaft, 20 mm (3) 07936-3710600
Remover weight [4) 07741-0010201 or
07936-371020A
(U .S.A. only)
Balancer bearing :
Remover handle 07936·3710100
Bearing remover, 17 mm 07936-3710300
Remover weight 07741-0010201 or
07936·371020A
(U .S.A. only)
Drive the crankshaft bearing [5], output shaft bearing [6)
and shift drum bearing [7) out of the front crankcase.
15-15
Remove the two selling bolts [1] and drive the
mainshaft bearing [2] out of the fronl crankcase.
Apply engine oil 10 new bearings.

Orive the bearings in with the marked side facing up.
TOOLS :
Crankshaft bearing :
Driver [1) 07749-0010000
Attachment, 78 x 90 mm [2] 07GAD-SD40101
Pilot, 40 mm [3] 07746-0040900
Balancer bearing:
Driver [1] 07749-0010000
Attachment, 37 x 40 rnm [2] 07746'{)010200
Pilot, 17 mm [3] 07746-0040400
Mainshaft bearing :
Driver [1] 07749-0010000
Attachment, 52 x 55 mm [2] 07746-0010400
Pilot, 22 mm [3) 07746-0041000
Countershaft bearing:
Driver [1] 07749-0010000
Attachment, 42 x 47 mm [2] 07746-0010300
Pilot, 20 mm (3] 07746-0040500
Output shaft bearing:
Driver [1] 07749-0010000
Attachment, 42 x 47 mm [2] 07746-0010300
Pilot, 22 mm (3] 07746-0041000
Shift drum bearing :
Driver [1] 07749·0010000
Attachment, 52 x 55 mm [2] 07746-0010400
Pilot, 35 mm (3] 07746-0040800
Apply locking agent to the mainshaft bearing setting
bolt [1) threads (page 1-16),
Install the selling bolts and tighten them to the specified
torque.
TORQUE : 12 N'm (1.2 kgf'm, 9Ibf·ft)
15-16
FRONT CRANKCASE (FA1fFA2
models)
Remove the counlershaft bearing [1 J with the special III~~"--
tools.
TOOLS:
Remover shaft, 20 mm (2J 07936·3710600
Remover weight [3] 07741·0010201 or
07936·371020A
(U.S.A. only)
Drive the crankshaft bearing [4J, mainshaft bearing {5],

balancer bearing [6] and output shaft bearing 17] out of
the front crankcase.
Remove the two setting bolts [8] and drive the shift
drum bearing [9} out of the front crankcase.
Apply engine oil to new bearings .

Drive the bearings in with the marked side facing up.
TOOLS :
Crankshaft bearing:
Driver 07749-0010000
Attachment, 78 x 90 mm 07GAD-SD40101
Pilot, 40 mm 07746-0040900
Balancer bearing:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 17 mm 07746-0040400
Malnshaft bearing :
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot, 35 mm 07746-0040BOO
Driver [1] 07749-0010000
Attachment, 42 x 47 mm [2] 07746-0010300
Pilot, 20 mm [3] 07746-0040500
Output shaft bearing :
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 25 mm 07746-0040600
Shift drum bearing;
Driver 07749-0010000
Attachment. 42 x 47 mm 07746-0010300
Pilot, 25 mm 07746-0040600
15-17
Apply locking agent to the shift drum bearing setting
bolt [1] threads (page 1-16).
Inslallthe setting bolts and lighten them to the specified
torque.
TORQUE : 12 N'm (1.2 kgf'm , 9lbHt)
REAR CRANKCASE
Remove the mainshaft bearing PJ and camshaft
bearing (2] with the special tools.
TOOLS :
Malnshaft bearing :
Bearing remover, 17 mm [3] 07936·3710300
Remover weight [4] 07741-0010201 or
07936-371020A
(U.S.A. only)
Camshaft bearing:
Bearing remover shaft, 15 mm 07936·KC1 01 00
Bearing remover head, 15 mm 07936·KC10200
(U.S.A. only)
Remover weight 07741..(}010201or
07936·371020A
(U.S.A. only)
Drive the countershaft bearing [5] and balancer bearing
(6) out of the rear crankcase.
FA1 /FA2 only: Heat the crankcase around the shift
drum bearing [7] to 80°C (176°F) and remove the shift
drum bearing.
Apply engine 0 11 to new bearings.

Drive the bearings in with the marked side facing up.
TOOLS:
Balancer and mainshaft bearings:
Driver (1] 07749-0010000
Attachment, 37 x 40 mm (2] 07746·0010200
Pilot, 17 mm [3] 07746-0040400
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot, 25 mm 07746-0040600
Camshaft bearing :
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 15 mm 07746-0040300
15-18
CRANKCASEITRANSMISSIONICRANKSHAFTIBALANCER
FA 1/FA] only: Freeze the shift drum bearing.
['[
Press the shift drum bearing [1) in with the marking
fa cing up until the depth from the crankcase mating
surface Is 70.8 - 71.4 mm (2.79 - 2.81 in).
70.8 ~ 71.4 mm
TOOLS : (2.79 ~ 2.81 in)
Driver 07749·0010000
Attachment, 24 x 26 mm 07746-tl010700
Pilot, 20 mm 07746'{)040500
CRANKCASE ASSEMBLY
Clean the front and fear crankcase mating surfaces
thoroughly, being careful not to damage them .
Blow through the oil passages in the crankcases with
compressed air.
Apply liquid sealant (TB1215 or equivalent) to the
mallng surface (shadowed area) of the front crankcase
as shown.
Install the three dowel pins [1].

Make sure all the parts are installed in the rear
crankcase.
Install the front crankcase over the rear crankcase.
Install the fifteen rear crankcase bolts [1] .
15·19
,
Install the two front crankcase bolts 111.
Tighten all the bolls in a crisscross pattern in several
sleps.
Insert the output shaft [11 into the crankcase until it :;;;;:i;~~
seats against the bearing in the front crankcase.
Inslall the output shaft drive gear [2J and output shaft
driven gear [3}.
Except FA1 /FA2: Apply engine oil to the reverse
stopper shaft journal surface and install the reverse
stopper shaft assembly [4) into the crankcase as
shown.
Inslallths following:
~ FAlIFA2 : reverse stopper shaft assembly See page
13-74
-
-
flywheel and starter clutch (page 14-14)
Except FA1 /FA2 : oil pump (page 9-7)
,
- FA1!FA2 : gearshift linkage (page 13-72)
- Except FA1 /FA2: change clutch (page 12-15)
- Except FA1/FA2: gearshift linkage (page 12·18)
- camshaft (page 10-18)
- piston and cylinder (page 11-6)
- cylinder head (page 10-15)
15-20
16. ENGINE REMOVAUINSTALLATION
SERVICE INFORMATION ···························16-2 ENGINE REMOVAL ····· ···························· .. · 16-4
SYSTEM COMPONENTS····························16-3 ENGINE INSTALLATION ······· ····················· 16-9
16·1
SERVICE INFORMATION
GENERAL
When removing and installing the engine, tape the frame around the engine and front gear case beforehand for frame
protection .
The transmission/crankshaft/balancer require engine removal for service (page 15-6).
16·2
ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS
44 N m (4 5 kgfm 32lbfft)
44 N-m (4.5 kgf-m. 321bHI)
rl}-o...------:- 63 N'm (6.4 kgf-m, 46 IbH! )
_--7 63 N'm (6.4 kgf·m . 46 Jbf-ftj
U§l)~~J ~ A
. -""
32 N 'm (3.3 kgf-m. 24 IbHt) ~==----:g:=--

- ~52
l~~ 2J~r::x
Ql-----
~~\~~~
~-~;
16-3
ENGINE REMOVAL
Remove the fonowing:
- exhaust system (page 2-10)
battery (-) cable (page 22-5)
- tueltank (page 7-16)
Drain the engine oil
- Except FAlIFA2 : page 3-15
- FA1 /FA2: page 3-17
Drain the coolant (page 8-8),
TM1 /FM1 /FM2 only: Remove the pinch bolt [1] and the [2]
gearshift pedal [2]. "--'---_ _ _ _ _ _ _ _ _ _ _ _ _ _'--'-1
Disconnect the alternator 3P (Gray) connector (1] from

the regulator/rectifier and release the alternator wire
from the wire damps (2].
Remove the trim clips [1].

Remove the heat protector [2J from the left frame pipe, 11)
,
slide it rearward to release the retaining tabs (3J as
shown .
,
Remove the heat protector while releasing the water
hose [4J from the guides [5).
16-4
- CKP sensor 2P (Gray) connector [ 1J
- Except FA1/FA2: gear position switch BP (Gray)
connector [2J
- FA1/FA2: shift drum position switch 10P (Gray)
connector [2]
Remove the rubber cap [1], nut [21 and starter motor
cable [3] from the starter motor terminal.
Remove the bolt [4] and battery ground cable [5].
Remove the bolt [6} and engine-to-frame ground cable
[71·
Remove the wire band [Sj.
Remove the crankcase breather hose (1].

Disconnect the rear VS sensor 3P (Black) connector
121
Except TM1/FM1IFM2: Disconnect the shift angle

sensor 3P (Gray) connector [1J.
FA1/FA2 only: Disconnect the reverse switch connector
121·
Remove the boll [3] and reverse selector arm [4].
Disconnect the selector cable [51 from the arm and
remove it from the holder [6)
16·5
j
- Except TM 1{FM1 /FM2: shift control motor 2P (Black)
connector [1 J
- FA1/FA2 only: EDT sensor 2P (Black) connector 12]
FA1IFA2 only: Remove the wire dip (1J from the slay.
connector (2) and dual clutch PC solenoid valve 2P
(Black) connector [31.
Loosen the band screws [1) and disconnect the water

hoses [2] from the engine.
Except TM1fTE1 : Remove the bolts [1] and 2WD/4WD selector lever
assembly [2] from the frame.
16·6
Excepf TMlfTE1 : Remove the following:
- front fi nal gear case mounting nuts [1) and bolts [2)
- two bolts [3) and mounting bracket [4]
Move the front final gear case assembly forward for
maximum clearance between the propeller shaft joint
and engine.
Turn the handlebar to the right side fully to gel the
clearance between the gear case and tie-rod.
Excepr TMlfTE1 : Pull the shaft jOint [1) out of the output shaft (2) of the ~iiiiiiiiiiiioi:iiiii~;:::;:;:::;;:=:;::;::~~"'''';
engine .
Remove the O-ring (3) from the output shaft.
Except TM1ITE1 : Remove the boot band [1] and release the propeller ~;;::;iiiiiiii~
shaft boot {2] off the pinion joint [3] of the gear case
assembly.
Puilihe propeller shaft [4] to force the stopper ring past
the groove in the pinion joint to remove the propeller
shaft.
Remove the stopper ring 151 from the propeller shaft.
16-7
Place a jack or other adjustable support under the
engine.
NOTE:
• The jack height must be con tinually adjusted to
relieve stress for ease of bolt removal.
Remove the following from the engine upper mount:
- two 8 mm engine hanger bolts [1]
- 10 mm engine hanger nut 121 and boll 131
- hanger bracket 141
mounting rubbers (51
Remove the following from each engine lower mount:

- engine hanger nul [11 and bolt [21
- spacer [3]
- mounting rubbers [4]
Move the engine forward and disconnect the output

shaft [1] from the universal joint [2].
Hold the engine Remove the engine ou t of the frame to the left side.
securely and lake
Remove the O-ring {31 from the output shaft.
care not to damage
the frame and
engiflfJ,
16-8
Remove the dust seals [11 and engine mounting
bushings [2J.
Check the mounting rubber, bushings and dust seals
for deterioration, wear or damage.
ENGINE INSTALLATION
NOTE:
• Roule the wires, cables and hoses properly
(page 1-23).
Insl~1I the lower engine mounting bushings [1] into the
engine.
Install the dust seals with Ihe lip side {2) facing out.
During engine Using a jack or other adjustable support, carefully place ~;;;;;;;;;=;;;n;;;;~;:;;;;:;;:;;:;;:;;:;;::;;;;;;~
installation, hold the the engine in Ihe frame from the left side and maneuver
engine securely it into place.
and be careful not
Coat a new O-ring [1 J with molybdenum disulfide
to damage the
frame and engine.
grease and install it into the groove in the output shaft
121·
Apply molybdenum disulfide grease to the splines in the
universal joint [3].
Carefully move the engine and engage the output shaft
with the universal joint.
16-9
1
Be sure the Install the mounting rubbers [1] onto the lower mounting
universa/joint is not bushing with the large I.D. side facing in.
disengaged. Install the spacer [2J and the hanger boll [3) (from the
fronl side) while aligning the bolt holes carefully.
Loosely instalilhe hanger nul [4J.
Install the other side mounting fasteners in the same
manner as above.
Install the mounting rubbers [11 onto the upper ;;;;;;;;;;;;;;;;;;~=::::;~=~~~~~~~~~

mounting bushing in the hanger bracket [2] with the
large 1.0. side facing in.
Install the hanger bracket with the 10 mm hanger bolt
[3] (from the front side) and nut (4).
Install the two 8 mm hanger bolts {5].
After installing aU the mounting fasteners and seat
them, lighten the fasteners in order as follows:
- left and right lower engine hanger nut
TORQUE: 63 N'm (6.4 kgf'm , 46 IbHt)
- engine side upper engine hanger bolts

TORQUE: 32 N'm (3.3 kgfm , 24 IbHt)
- frame side upper engine hanger nut
TORQUE : 63 N'm (6.4 kgf'm , 46 IbHt)
Install a new stopper ring [1] into the groove in the
,
~r · ' .
.~ - ;
Excepr TM1flE1 :
propeller shaft [2] end.
Apply 5 - 8 g of molybdenum disulfide grease to the
propeller shaft splines.
Apply molybdenum disulfide grease to the front end of
the propeller shaft.
Place the boot band [3J over the pinion joint [4]
... ~\ '~~7'.: ~~
-. '
temporarily.
Install the propeller shaft into the pinion joint. aligning
the splines until the stopper ring seats in the groove.
Make sure the stopper ring is seated properly by pulling :"---1'" ,. , .~
the propeller shaft lightly. / .,' . ~ \
Install the boot [5] over the pinion joint groove securely [=-~
and the boot band into the boot groove.
___---':~~'J!~_~&~~~
16-10
Except TMfITEf . Move Ihe gear case assembly forward for maximum
clearance between Ihe shaft joint and output shaft
Tum the handlebar to the right side fully to get the
clearance between the gear case and he-rod
Coal a new O-ring (1) with molybdenum dlsulrlde
grease and Install it inlo the output shaft (2) groove.
Apply molybdenum disulfide grease to the propeller
shaft jOint (3] splines.
Engage the shaft joint over the outpul shaft and move
the gear case assembly rearward.
Except TM1ITEf : Install the 2WD/4WD selector lever assembly [11 onlo ~;;. .;;;;;;~;;;;;:::-=;~;;~~~~
the frame and lighten the two bolt [21 .
Except TMI /TEI Align the lower mounting bott holes in Ihe gear case
and frame, insert the mounting bolt [11 from the right 'I~~~:)~~~~m~=ij~iiiiii
side and install a new mounting nut 121_
Install the mounting bracket (3) and lighten the two boll s
141·
Install the upper mounting bolt lSI from the nght side
and a new mounting nut [61.
Tighten the gear case mounting nuts.
TORQUE : 10 mm: 44 N'm (4.S kgf'm , 32 IbHt)
removal.
TORQUE:
Gearshift pedal pinch bolt (TM1 /FM1 IFM2 only):
20 N'm (2 .0 kgf-m, 15Ibf·ft)
InslaUthe following:
- fuel tank (page 7-16)
throttle body (page 7-20)
battery H cable (page 22-S)
exhaust system (page 2-10)
engine guard (page 2-5)
mudguards (page 2-5)
Check the following and adjust if necessary:
- Except TM1fTE1: 2WD/4WO selector cable
(page 3-23)
- reverse selector cable (page 3-26)
Fill the engine with recommended oiL
- Except FA1 /FA2: page 3-1S
- FAlIFA2 : page 3- 17
Fill and bleed the cooling system (page 8-8).
16-11
<
MEMO j
j
1
1•
•
17. FRONT WHEELJSUSPENSION/STEERING
SERVICE INFORMATION ··························· 17-2 WHEEL HUB AND KNUCKLE ·················· 17-13
TROUBLESHOOTING· ································ 17-3 SUSPENSION ARM .. ·· ······························ 17-20
SYSTEM COMPONENTS ···························· 17-4 FRONT SHOCK ABSORBER ···················17-23
HANDLEBAR ·············································· 17-6 STEERING SHAFT

(Except FM2/FA2 models) ·······················17-24
THROTTLE HOUSING ·············· ·· ····· ··········· 17-9
STEERING SHAFT/EPS UNIT
FRONT WHEEL· ········································ 17-10 (FM2/FA2 models) ···································· 17-27
TIRES························································· 17-10 TIE-ROD ························· ··························· 17 -32
17-1
FRONT WHEEUSUSPENSION/STEERING 1
SERVICE INFORMATION
GENERAL
This section covers service of the front wheel, suspension and steering (including EPS unit; FM2/FA2 models). For electrical
system service of the EPS , see Electric Power Steering (EPS) section (page 25-2).
A contaminated brake disc or pad reduces stopping power, Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
A jack or other support is required to support the vehicle.
Adjust toe whenever the tie-rod , knuckle or steering shaft are replaced or removed (page 3-29).
Do not twist or bend the brake hose when servicing.
Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
For brake system service. see Brake System section (page 19-4).
For each switch inspection , see lights/Meters/Switches section.
- handlebar switch (page 23-10)
- front brake switch (page 23-1 1)
- rear brake light switch (page 23-11)
FM2IFA2 model only: Perform the torque sensor initialization when you service the fOllowing components (page 25-9).
TOOLS
07746-0010300 07746-0010400 07746-0010900
Attachment, 20 mm 1.0. Pilot, 20 mm Driver

07746-0020400 07746-0040500 07749-0010000
17-2
FRONT WHEEL/SUSPENSION/STEERING
Attachment, 28 x 30 mm Bat! joint remover, 28 mm Remover/installer, 42.5 x 43 mm
07946· 1870100 07MAC-SL00201 07WMF-H N00100
07MAC-SL00202 only)
TROUBLESHOOTING
Hard steering
Steering shaft holder too tight
Damaged steering shaft bearing/bushing
• Insufficient tire pressure
• Faulty EPS (FM2/FA2 models) (page 25-5)
Steers one side or does not track straight
Incorrect wheel alignment
Unequal tire pressure
Bent tie-rod , suspension arm or frame
Worn or damaged knuckle bearing
Weak shock absorber
Front wheel wobbling
Benl rim
Worn Of damaged knuckle bearing
• Faulty tire
• loose wheel hub nut
Soft suspension
• Weak shock absorber spring
• Oil leakage from damper unit
Stiff suspension
Damaged shock absorber damper
Faulty shock absorber pivot bushings
• Improperly installed suspension arms
• Faulty suspension arm bushings
Front s uspension noise
Faulty front shock absorber
Loose front suspension fas teners
Worn fron t suspension pivot bushings
Damaged suspension components
17-3
SYSTEM COMPONENTS
Except FM21FA2 models
FAt model shown:
32 N'm (3.3 kg f-m, 24 IbHt)
\-
33.5 N 'm (3.4 kgf-m,

251bHt)
, 9 Ibf-ft)
<-.: 54 N'm (5.5 kgf-m, 40 Ibf-ftj
~.
r; ~-
, ~ 29 N' m (3.0 kgf-m, 21 Ibf·ft)
~ t08N-m(tl .0kgf-m,
~80Ib,.ft)
11 N-m(l ,1 kgf-m. -~_ ... Fir~'fj"

8Ibf·ft) e:~§:\if~'--l ..
30 N-m (3.1 kgf' m,
221bHt)
11 N-m(1 .1 kgf-m,8IbHt)
29 N-m (3.0 kgf-m, 21 IbHI)
137 N'm (14.0 kgf-m, lOt Ibf·ft)
64 N'm (6.5 kgf- m, 4 7 IbUt)
17-4
FM2/FA2 mod eIs (equi
FA2 model shown'. pped with electric power s t eenng)
.
241bUt)
60 N'm (6. 1
33.5 N'm (3 .4 kgf-m. 25 Ibf-ft)
54 N'm (55
, kgf-m , 40 IbHt) ,9Ibf-ft )
29N·m(30
. kgf·m. 21 IbHt)
--
l1N' m(11 kgf m, 8 Ibf tt) - - --
. kgf-m.21IbHt)
29N 'm(30
137 N'm (1 4.0 kgf-m, 101 Ibf-ft)
\
64 N 'm (6 .5 kgf-m , 47 Ibf-ft)
17-5
HANDLEBAR
REMOVAL
Remove the handlebar cover/slay assembly from Ihe '£~~~;;:--~~~
handlebar (page 23-5), ~
- two wire bands [11
Keep the master - two screws [lJ

cylinder upright to - throttle housing holder [2)
prevent air from - throttle housing (3)
entering the - connectors (4)
hydraulic system. - two bolts [5J
- master cylinder holder [6]
- brake master cylinder [7J
- two screws (1)

- bracket holder [2)
- rear brake lever bracket [3J
- two screws (TM1fFM 1/FM2 models)
three screws (TE 1/FE1 /FA1 IFA2 models)
- handlebar switch 14]
- grip ends (1) (turn the grip end to release the setting ~================:!1111~
tabs [2) and pry it using a screwdriver)
- handlebar grips [3]
17-6
- four bolts [1)
- upper holders [2J
- handlebar [3J
INSTALLATION
NOTE :
• Route the wires and cables properly (page 1-23).
Align the punch Inslallthe handlebar and upper holders with the punch
mark on the mark [4) facing forward. Tighten the front bolts first, then
handlebar with the tighten the rear bolts.
top edge of the
lower holder.
Apply Honda Bond A or Pro Honda Handgrip Cement

(U.S.A. only) 10 the inside surface of each handlebar
grip [1J and to the clean surfaces of the handlebar.
Allow (he adhesive Wait 3 - 5 minutes and install the grips. Rotate the grip
to dry for an hour for even application of the adhesive.
before using.
Install new grip ends [2) by aligning the tabs (3) with the
holes in the handlebar.
TM1IFMIIFM2 Install the handlebar switch [1]. Tighten the upper screw
TM1/FM1/FM2 models: (21
models: first, then tighten the lower screw.
Align the locating
pin on the SWitch
housing with file
hole in the
handlebar.
Align the edge of Install the brake lever bracket 121 and holder [3J with Ihe Align
the bracket with the punch mark [4) facing up. Tighten the upper screw first.
~
punch mark on the then tighten the lower screw.
handlebar.
(11 (41 131

TE1 /FE1/FA1IFA2 Install the handlebar switch [1]. Tighten the inside
TE1/FE1/FA1IFA2 models :
models: screw [2] first, then tighten the outside screws PJ.
Align the seam of
the switch with the
punch mark on the
handlebar.
17-7
FRONT WHEEUSUSPENSION /STEERING
TE1IFEflFA1IFA2 Install the brake lever bracket [1] and holder [2] wi th the
models: punch mark. (3] facing up. Tighten the upper screw {4]
Align the locating first, then tighten the lower screw [5].
pin on the bracket
with the hole in the
switch housing.
Align the edge of Install the brake master cylinder (2] and holder [3) with
/hemastercylinder the ·UP" mark. [4J facing up. Tighten the upper bolt [5J
with the punch first, then lighten the lower bolt 16} to the specified
marl! (1J on the torque.
handlebar.
TORQUE : 12 N-m (1.2 kgf'm, 9 IbHt)
Connect the connectors [7).
Align the lug {ljon Install the throttle housing [2] and holder (3] against the ~~1111':':=~============:;
the throttle housing master cylinder [4]. Tighten the front screw first [5J. then
with lhe mating /ina tighten the rear screw 16J,
of the master
cylinder and holdar.
Secure the wires with the wire bands [1J.

Install the handlebar cover/stay assembly (page 23-5),
FM2IFA2 only: Perform the torque sensor initialization
(page 25-9).
17-8
THROTTLE HOUSING
OISASSEMBLY
- three screws [1]
- throttle housing cover [2]
- gasket (3]
Slide the boot [4J off the throttle cable adjuster.
Loosen the lock nut [1] and cable adjuster [2J.

Bend down the lock washer tab and remove the
following :
- pivot nul [3]
- lock washer 14J
throttle lever and plastic washer [5J
return spring [6J
- throttle arm [7] (by disconnecting the cable [8])
- dust seal (from the housing)
ASSEMBLY
Coat a new dust seal [1] lip with grease and install it into r----~
the housing until it is fully seated.
Apply grease to the throttle cable end [2) and connect it
to the throttle arm .
Insert the throttle lever [31 with the plastic washer [4]
into the housing.
Inslall the throttle arm [5] with the spring [6J over the
throttle lever pivot by aligning the flat surfaces.
Install a new lock washer [7] and the nut [8], and tighten
the it.
Bend up the lock washer tab against the nul.
17-9
Install the housing cover [1] with a new gasket [21 and
tighten the three screws [3J,
TORQUE : 1,5 N'm (O.2 kgf'm , 1.1IbHt)

Adjust the throttle lever freeplay (page 3-5).
FRONT WHEEL
REMOVAL
Loosen the wheel nuts [11.
Support the vehicle using a hoist or equivalent and
raise the front wheels off the ground.
Remove the wheel nuts and wheel.
INSTALLATION
Do not interchange Install the front wheel with the tire valve facing out and
the left and right the arrow mark [2] facing in the normal rotating
wheels direction.
Install the wheel nuts with the tapered side (31 facing
inward and tighten them.
TORQUE: 64 N'm (6.S kgf-m, 47 tbHt)
TIRES
REMOVAL
NOTE :
This service requires the A TV Bead Buster
(KLS379024 ).
Remove and install the tire from the rim side
opposite the valve stem,
Remove the core from the valve stem.
Use a pneumatic tire changer or equivalent to remove
the tire from the rim. If a tire changer is not available,
rim protectors and tire irons may be used.
Adjust the bottom rim supports [1] to the proper rim ' - - - - - - - - [ - ' 1 - - - - - -- - - '
size. Align the flat side of the support wi th the
corresponding rim size indicator.
Use only water as a Lube the bead area of the tire with water, pressing
lubricant when down on the tire sidewallfbead area in several places to
removing or allow the water to run into and around the bead.
mounting tires. 00
Soap or some
mounting lubricants
may leave a
slippery 00
residue which can
cause the tire to
shiff on the rim and
lose tire pressure
during riding.
17-10
Place the wheel assembly over the center shaft (1] and
use the correct size cone [2J to keep the wheel centered 111
during operation.
Install the bottom hold down nut [3J, bearing side down, 131
and finger lighten il so the wheel can rotate freely
during operation.
Install the breaker arm assembly [1) over the center ~=================::,
shaft and adjust the upper rim supports [2J to fit the
outside rim diameter.
Install the top hold down nut (3] and lighten it finger
tight.
Failure to back oul Pull the leverage bar [1] down so the breaker shoe is ~=====---===========~
the breaker shoe just below the rim lip. Turn the crank [2J to fully push the [1)
two tums wi/I cause breaker shoe 13] between the tire bead and rim. Once
the shoe /0 scratch the shoe contacts the rim, back the crank out two tums
the bead lock, to allow the shoe to clear the nm's bead lock.
which may cause
the tire 10 leak.
121 f;
13] (C i , '>, ,,
~ \..\. \-\ \ , ~ .......-
"
Push down on the leverage bar [1) to push the tire bead
over the bead lock. Use only short strokes on the ]1 I
handle. While the shoe (2) is still engaged, turn the [
wheel as far as it will go between strokes as you break
the bead around the rim.
Remove the breaker arm assembly and flip the wheel
over. Install the breaker arm assembly, adjust the shoe
1
properly and break the other bead by fallowing the
above procedures.
Remove the tire from the rim using a tire changing
J
machine or tire irons and rim protectors.
12~( C ' lc '" ,,
r-- \..l.\-\ \; '- , ." ~.;
17·11
TIRE REPAIR
NOTE'
Use the manufacturer's instructions for the tire repair
kit you are using. If your kit does not have
instructions, use the procedures provided here.
Check the tire for puncturing objects.
Chalk mark the punctured area and remove the
puncturing object.
Inspect and measure the injury.
Tire repairs for injuries larger than 15 mm (5J8 in)
should be a section repair.
Section repairs should be done by a professional tire
repair shop.
If the injury is smalter than 15 mm (518 in), proceed with
the repair as described here.
Install a rubber plug into the injury as follows:

Apply a cement to a plug inserting needle and work the
needle into the injury to clean and lubricate it.
Do this three times.
Do not let the cement dry.
Be careful not /0 Insert and center a rubber plug through the eye of the
push the plug aNthe inserting needle.
way into the /IIW/O
Apply cement to the rubber plug.
prevent it from
Push the inserting needle with plug into the injury until
falling inside.
L
the plug is slightly above the tire.
Twist the needle and remove it from the tire; the plug
wm stay;, Ihe I;,e.
Trim the plug 6 mm (1 /4 in) above the tire surface. :=--=================~

Repeat the above procedure if the puncture is large.
Do not use more than two plugs per Injury.
Allow the repair to dry. Drying time will vary with air
temperature. Refer to the tire repair kit manufacturer's
recommendations.
Inflate the tire and test the seal by dabbing a small
amount of cement around the plug. Escaping air will
cause a bubble in the cement. If there is leakage ,
remove the tire (page 17-10) and apply a cold patch to
the inside of the tire as described below.
If a plug has been inserted , trim it even with the inner

tire surface. I~=====~~===~======l
Temporarily place a rubber patch that is atleasl twice
the size of the puncture over the injury. Make a mark
around the patch, slightly larger than the patch itself.
Rough the area marked inside the tire with a tire buffer
or a wire brush. Clean the rubber dust from the buffed
area.
Apply cement over the area marked and allow it to dry
until tacky.
Do not touch the cement with dirty or greasy hands.
Remove the lining from the patch and center it over the
injury.
17-12
Press the patch against the injury using a special roller. '
:;:
~
-
=..- -
:::=--
ASSEMBLY
Install the tire onto the rim, where the rim shoulder
width is the narrowest, to simplify inslallation,
Clean the rim bead seat and flanges.
Use only water as a Apply clean wa ter to the rim flanges , bead seal and
lubricant when base .
removmg or
mounting tires.
Instalilhe valve core in the valve slem. ,,
Inslall Ihe lire with the arrow mark facing in the normal
Soap or some
rotating direction.
mounting lubn'canls
Inflale Ihe tire 10 seal the tire bead.
may leave a
slippery residue Deflate Ihe lire. Wait 1 hour and inflate the lire 10 the
which can cause the specified pressure.
tire to shift on the
RECOMMENDED TIRE PRESSURE
rim and lose air
pressure during
Front: Standard : 30 kPa (0.30 kgflcm 2 , 4.4 psi)
n'ding. With cargo : 30 kPa (0.30 kgf/cm 2 , 4.4 psi)
Rear: Standard : 30 kPa (0.30 kgf/cm2, 4.4 psi)
With cargo : 30 kPa (0.30 kgf/cm 2 , 4.4 psi )
Check for air leaks and install the valve cap.
WHEEL HUB AND KNUCKLE

REMOVAL
Remove the wheel center cap [1] and cotter pin [2].
Apply front brake and loosen the hub nul [3] .
17-13
Remove the front wheel (page 17-10),
Remove the two hose clamp bolls [1) from the upper
arm.
Except TM1fTE1: Remove the two setting bolts [1] and

outboard guard [21 .
::====1111"""~~
Support the caliper Remove the following:
so thai it does not - two mounting bolls [3]
hang from the brake
- brake caliper [4]
hose. Do not twist or
bend the brake
hose.
- hub nut [1J

- wheel hub [2]
- TM1fTE1 only: fronl axle shaft
- three socket bolts (1)

- splash guard [2]
12J
17-14
- coller pin [1) (from the lie-rod ball joint stud)
- ball joint nul [2] (by holding the joint stud fla t
surfaces [3))
- tie-rod [4]
- cotter pins [1]

loosen the ball joint nuts [2J, but do nol remove them
yet.
1111121
Release the ball joints, using the special tool according :=========7;;!""':::;;;;;;;~
to the following instructions.
TOOL:
Ball joint remover, 28 mm {I] 07MAC-SL00201 or
07MAC ·SL00202
(U.S.A. only)
111
Apply grease to the ball joint remover al the point :=========-=====-====~
shown .
This will ease installation of the 1001 and prevent
damage to the pressure bolt (IJ threads.
Insert the jaws carefully, making sure Ihal you do not
damage the ball joint boot.
,,
/( necessary. apply Adjust the jaw spacing by turning the pressure bolt. ,
penetratmg type
lubn"cant to loosen
the ball join/.
17-15
FRONT WHEEUSUSPENSIONfSTEERING
To prevenllhe tool from dropping, tie the strap [1] on a
neighboring solid part such as the lower arm, tie-rod, I1J
etc. before operation .
NOTE :
Do not tie Ihe strap on the brake hose, brake pipe.
rubber boot, and other parts that can be damaged
easily.
Once the tool is in place. turn the adjusting bolt [1) as

necessary to make Ihe jaws parallel.
Then hand-tighten Ihe pressure bolt [2) and recheck the
jaws to make sure they are still parallel.
Tighten Ihe pressure boll with a wrench until Ihe bal'
joint stud pops loose.
Remove Ihe ball joinl nuls and the knuckle from the
upper and lower arms.
[1J
•
INSPECTION
Turn Ihe inner race of each bearing in the knuckle with
your finger. The bearing should turn smoothly and
quielly. Also check Ihat the bearing outer race fils tightly
in the knuckle.
Inspect the knuckle for damage or cracks.
Inspect the ball joint boot for tears or other damage by
moving the ball joint stud.
It should move freely and smoothly.
BRAKE DISC REPLACEMENT

Remove the four disc bolts [1J and brake disc [2J from
the wheel hub [31. -'"
~
Do no/gel grease Instan a new brake disc with the stepped surface facing
on the brake disc or up (knuckle side).
Slopping power will Install new disc bolts and tighten them.
be reduced.
TORQUE: 42 N'm (4.3 kgf 'm , 31 IbHt)
17·16
BEARING REPLACEMENT
Remove the snap ring [1] and drive the bearing [2J out
of the knuckle.
TOOLS :
Driver 07749·0010000
Attachment, 40 x 42 mm 07746-0010900
Drive in a new bearing squarely with the marked side

facing up until they are fully seated.
~~::;.=i~~;;"~~===~
TOOLS :
Driver (1) 07749"()010000
Attachment, 52 x 55 mm [2] 07746'()010400
Install the snap ring into the knuckle groove with the
chamfered side facing in .
BALL JOINT REPLACEMENT

Remove the snap ring [1] from the ball jOint [2].
121
Set the knuckle [1] and special lools with "A" mark (21 ~===~~"::'IIIIIIIIIIII':":="=~IIIIIIII~
side of the remover/installer [3) facing to the ball jOint in
the vise as shown .
Press the ball joint [4] out of the knuckle.
TOOLS :
Remover/Installer 42.5 x 43 mm 07WMF·HN00100
Attachment, 28 x 30 mm [5J 07946-1870100
17-17
Set the knuckle [1] and special lools with "6" mark [2]
side of the removerfinstaller [3] facing to the ball joint in
the vise as shown.
Press the ball joint [4] into the knuckle until it is fully
seated.
TOOLS :
AHachment, 20 mm 1.0 . [5J 07746-0020400
I NOTICE I
If you feel strong resistance when compressing the
vise, stop. Reset the attachment of the tool so that the
ball joint head can go into the hollow of the attachment
and If}' again.
Install the snap ring [1J with the chamfered edge facing , - - - - - - - - - - - - - - - - - - ,
in.
INSTALLATION
Install the knuckle onto the drive shaft (Except TM1f
TE1 models), and lower and upper arms with the ball
joint nuts [1).
Tighten each joint nul to the specified torque and further
tighten untit its grooves align with the cotter pin hole.
TORQUE : 29 N'm (3.0 kgf-m , 21 IbUt)
Install new cotter pins (2].
Install the tie-rod [1 J into the knuckle with a new joint nut
12].
Tighten the nut by holding the joint stud flat surfaces [3J.
Install a new cotter pin (4).
17·18
Install the splash guard [1J with new bolls [2) and
lighten them,
TORQUE: 11 N'm (1.1 kgf'm , 8Ibf·ft)
Except TM1fTE1: Apply molybdenum disulfide grease

to the drive shaft splines [3].
TM1fTE1 only: Install the front axle shaft into the
knuckle.
Apply sealant to the hub nut [1] threads.

Instal! the wheel hub [2] and hub nut, and temporarily
lighten the nut.
Install the brake caliper [1) with new mounting bolts [2]
and tigh ten them.
TORQUE : 30 N-m (3.1 kgf-m, 22Ibf·ft)

Except TM1rrE1 : Install the drive shaft guard [3J and
lighten the bolls [4].
TORQUE : 11 N-m (1 .1 kgf-m , 81bHtj
Install the hose clamps with new clamp bons [1] and
lighten them.
Install the fronl wheel (page 17-10).
17-19
Apply front brake. tighten the hub nut [1)10 the specified
torque and further lighten until its grooves align with the
cotter pin hole.
TORQUE : 137 N'm (14.0 kgf'm, 1011bHt)

Install a new colter pin [21 .
Install the wheel center cap [3).
SUSPENSION ARM
REMOVAL
Remove the wheel hub and knuckle (page 17-13).
- pivot nuts [1] and bolls [2J
- lower arm /31
- shock absorber lower mounting nut [1) and bolt [2]

- pivot nuts [3]. and bolts [4] and plale [5]
- upper arm [6)
17-20
INSPECTION
Check the pivot bushings [lJ for wear or damage.
111
Inspect the ball joint boot [2] on the upper arm for lears
or other damage by moving the ball joint stud.
It should move freely and smoothly.
Replace the bolt Except TMlfrEl: Remove the bolt [3J and inboard
with a new one guard [4] from the lower arm if necessary.
when mstalling.
BALL JOINT REPLACEMENT

Remove the snap ring [1] from the ball joint [2 ] .
Set the upper arm [1] and special tools wi th "A" mark [2]
side of the removerlinstaller PI facing to the ball joint in
the hydraulic press as shown.
Press the ball joint out of the upper arm.
TOOLS:
Remover/Installer 42.5 x 43 mm 07WMF·HN001QO
Attachment, 28 x 30 mm (4J 07946-1870100
17-21
1
Sellhe upper arm [1J and special tools with "8" mark [2]
side of the remover/installer [3] facing to the ball joint as
shown.
Press the ball joint into the upper arm until it is fully
seated.
TOOLS :
AHachment, 20 mm 1.0. [4] 07746-0020400
I NOTICE I
If you feel strong resistance when lowen'ng the press,
stop. Reset the attachment of the tool so that the ball
joint head can go into the hollow of the attachment and I~!.l~iiiiiiiiii.~
try again.
Install the snap fing (1) with the chamfered edge facing r-----------------~
in.
•
INSTALLATION
Insert the boilS from Instailihe upper arm [1] into the frame with the plate [2],
the outside of the bolts [3] (10 x 65 mm) and new nuts [4] .
upper arm.
Insert the bolt from Connect the shock absorber to the upper arm with the
the rear side. bolt (5] (10 x 45 mm) and a new nut (6].
Loosely tighten the nuts.
17-22
Insert the bolts from InslaUthe lower arm [1 J with the pivot bolls [2] and new
the front side. nuts 13). and loosely tighten nuts.
Install the knuckle and wheel hub (page 17-18)
Install the front wheel (page 17-10).
Place the vehicle on level ground, and tighten the
suspension arm and shock absorber mounting nuls.
FRONT SHOCK ABSORBER

Support the vehicle using a hOist or equivalent and
raise th e front wheels off the ground .
Support the lower arm. Remove the mounting nuls [1].
bolts (upper: 10 x40 mm [2), lower: 10 x 45 rnm [3 ]) and
front shock absorber [4].
Insert the bolts from Instatlation is in the reverse order of removal.
the rear side ,
INSPECTION
Check the pivot bushings [1) for wear or damage.
Check the damper unit for leakage or other damage.
Replace the shock absorber assembly if necessary.
111
17-23
,
FRONT WHEEUSUSPENSION fSTEERING
STEERING SHAFT (Except FM2/FA2
models)
REMOVAL
121 111
- front fenderfcarrier (page 2-6)
handlebar cover/stay assembly (page 23·5) J
coner pins 11] (from the tie·rods)
joint nuts (2] (by holding the joint stud flat surfaces)
tie-rods [3) (from the steering arm)
cotter pin (4] (from the steering shaft)
shaft end nut and washer IS]
steering arm (6] 16J
14J [31
Support the - hose clamp bolt (1)
handlebar securely - hose damp (2]
While keeping the - handlebar holder bolts (3]
mas/ercyllnder - slay (4]
r&S6fV01f upright - handlebar holders [5)
- handlebar assembly 16) (from the steering shaft)
Release the brake hose (1) from the clamp 121.

- bolls [3]
- steering shaft holder (4)
- shaft bushing (5)
- steering shaft (6)
-
-
three trim clips ]1]
radiator mounting bolls [2J
•
Release the fan motor breather hose (3J and front final
gear case breather hose [4] from the radiator grille
covers.
Remove the radiator mounting bosses from the
grommets and move the radiator assembly forward.
17-24
Remove the nuts [1], bolt [2] and bearing holder [31.
11}
13} 12}
BEARING REPLACEMENT
Turn the inner race of Ihe steering shaft bearing wi th
your finger.
13} {2}
The bearing should turn smoothly and quietly. Also
check that Ihe bearing outer race fits lightly In the
bearing holder.
Remove the following from Ihe bearing holder [1):
- dust seals [2]
- snap ring [3J
- bearing [4]
12}
Pack the cavities of a new bearing (1J with 2 - 3 9 (0.07

- 0 .11 02) of molybdenum disulfide grease.
Drive the bearing into the bearing holder [2J with the
marked side facing up. {3}
TOOLS:
Driver [3] 07749-0010000
Attachment, 42 x 47 mm (4] 07746-0010300 14}
Pilot 20 mm [5] 07746-0040500
~
e 11}
~gl'~12} IS}
Make sure the snap Install the snap ring [1] into the groove properly with the
nng IS firmly seated chamfered edge facing down . P} 12}
in the groove
Coat the lips of new dust seals (2J with molybdenum
disulfide grease.
Install each dust seal with the flat side facing oul so that
I
it is flush with the bearing holder edge.
L ~e I2}
17-25
INSTALLATION
Temporarily install the following :
- lower steering bearing holder {1 J
- bolt 121
- new nuts [3}
Apply 2 - 3 9 (0.07 - 0.11 oz) of grease to the shaft ~========:==i~~;:;;iiiiiiiiiiiiiiiiii;:::;~

bushing [1) sliding surface. ~
Install the shaft bushing onlo the steering shaft (2) with
the arrow mark [3] facing up.
Inslall the steering shaft into the bearing in the bearing
holder.
Install the steering shaft holder [4] and tighten the bolts
[5J alternately in several sleps to the specified torque.
TORQUE : 32 N'm (3.3 kgf-m , 24 Ibf-ft)
Inslalithe brake hose [6] into the clamp [7].
(31
Tighten the bearing holder nut to the specified torque in

the following sequence:
1. front left nut [11
2. front right nul [2J
3. rear nut [3J
TORQUE : 33.5 N'm (3.4 kgf-m, 25 IbHt)
Install the radialor assembly in place by inserting the

bosses into the grommets.
- radiator mounting bolts [1J
- three trim clips (2)
- fan motor breather hose (3)
- front final gear case breather hose {4J
17-26
Install the handlebar [1] and upper holders [2] with the
punch mark (3] facing forward.
Install the stay [4J and bolls [5].
Ahgn the punch mark [6J on the handlebar with the top
edge of the lower holder and tighten the front bolts first.
then tighten the rear bolts.
Inslall the hose damp [7] with a new damp bolt [8J and
tighten it to the specified torque.
TORQUE : 12 N'm (1.2 kgf'm , 9 lbHt)
Apply molybdenum disulfide grease to the steering , - - -- - - - -- - - -- - - - - - - ,

shaft spline [lJ.
Install the steering arm [2J over the steering shaft with
the marked side facing down by aligning the wide
groove with the wide tooth.
Install the washer and a new end nut [3], and lighten the
nut to the speciflE!d torque.
Install a new cotter pin [41.
InstaUthe tie-rods [5J inlo the steering arm.
Install new joinl nuts [6] and tighten them to the
specified torque by holding the joint stud flat surfaces. Align [2[
Inslall new cotter pins [7] into the ball jOint studs.
fI ['1 [7J fI
I -:--0 ['J
Inslalilhe following:
-
-
front fender/carrier (page 2-6)
handlebar cover/stay assembly (page 23-5) "
....!:!'P
12J
151
-----"
STEERING SHAFT/EPS UNIT (FM2/FA2
models)
REMOVAL
- front fender/carrier (page 2-6)
handlebar cover/stay assembly (page 23-5)
colter pins [1] (from Ihe lie-rods)
joint nuls (2] (by holding the joint slud nat surfaces)
tie-rods [3] (from the steering arm)
cotter pin [4] (from the steering shaft)
shaft end nut [5] and washer [6]
steering arm f7J
17-27
•
Support the - hose clamp bolt (1)
i
•
handlebar securely - hose clamp [2)
while keeping the - handlebar holder boils (3)
mas/ercy/inder - stay [4]
reservoir upright. handlebar holders [5]
- handlebar assembly [6] (from the steering shaft)
Release the brake hose (1) from the clamp [2].

- bolts [3]
- steering shaft holder [4]
- shaft bushing [5)
Remove the bolt [1] and steering shaft (2).

- EPS motor 2P (Gray) connector [1J
- torque sensor 3P (Gray) connector [2J
•,
17-28
- three trim clips [1J
- radiator mounting bolts (2]
Remove the radiator mounting bosses from the
grommets and move the radialor assembly forward.
HOld the EPS unit Remove the nuts [11. bolt [2] and EPS unit [3).
securely and
maneuver it out of
the frame to the /eft
side, being careful
not to damage the
shaft splines.
INSPECTION
Inspect the fonowing parts for damage. abnormal wear,
bend, distortion.
- steering shaft
- shaft bushing
- EPS unit
INSTALLATION
Hold the EPS unit lnslalilhe EPS unit 11J into the frame.
securely and
Install the mounting bolt [2] from the left side and new
carefully maneuver
nuts (3) . but do nollighten them yet.
it into place, being
careful not to
damage the shaft
splines.
17·29
Connect the following :
- EPS motor 2P (Gray) connector [1J
- torque sensor 3P (Gray) connector [2)
Inslall the steering shaft [1] over the EPS unit input r---------,
shaft [2] by aligning the wide groove with the wide tooth.
Inslall a new steering shaft pinch bolt (3] by aligning the
bolt holes and groove, and lighten it to the specified
torque.
Apply 2 - 3 9 (0.07 - 0.11 oz) of grease to the shaft ;===:;==:::====:~~:

bushing [1] sliding surface .
Instalilhe shaft bushing onto the steering shaft [2) with
the arrow mark [3] faCing up.
Install the steering shaft holder [4J and loosely install
the bolls [5}.
Tighten the steering shaft holder bolls a!lernalely in
several steps to the specified torque .
TORQUE: 32 N 'm (3.3 kgf'm , 24 IbHt)
Install the brake hose [6] into the clamp [7].
Tighten the bearing holder nut to the specified torque in

the following sequence:
1. front left nut 111
2. front right nut [21
3. rear nut 13]
TORQUE : 33.5 N'm (3.4 kgf'm , 25 IbHt)
17-30
Install the radiator assembly in place by inserting the
bosses into the grommets.
- radiator mounting bolts [1J
- three trim clips 121
Install the handlebar [1) and upper holders [2] with the -~--=
punch mark PI facing forward .
Installthe stay [4) and bolts [5].
Align the punch mark 16J on the handlebar with the lop
edge of the lower holder and tighten the front bolts first,
then tighten the rear bolts.
Install the hose clamp [7] with a new damp bolt [8J and
lighten it to the specified torque.
Apply molybdenum disulfide grease to the splines of the

EPS unit output shaft [1 1·
1[5~~i~i;
L
Install the steering Install the steering arm (2] onto the output shaft by
ann with the "HR3" aligning the wide groove with the wide tooth .
marl<. facing the
Install the washer [3] and a new nut [4]. and tighten the
EPSunit.
nut to the specified torque.
TORQUE: 108 N·m (11.0 kgf·m , 80 Ibf-ft)
!nstall a new cotter pin [5}.
Inslallthe tie-rods [I} into the steering arm [2] .

Install new joint nuts [31 and tighten them to the
specified torque by holding the joint stud flat surfaces.
TORQUE : 54 N·m (5.5 kgf-m, 40 Ibl-fl)
Install new cotter pins [4] into the ball joint studs.
Install the following :
- fronl fender/carrier (page 2-6)
- handlebar cover/stay assembly (page 23-5)
Perform the torque sensor initialization (page 25-9).
17-31
TIE·ROD
REMOVAL
- mudguard (page 2-5)
- front wheel (page 17-10)
Remove the cotter pins [ 1].
Remove the joint nuts [2] by holding the jOint stud flat
surfaces with an open end wrench.
Remove the tie-rod [3] from the steering arm and
knuckle.
INSPECTION
Inspect the tie-rod [1) for distortion or damage.
Inspect the ball jOint boots (2J for lears or other damage
and the ball joints for looseness by moving the ball jOint
studs [31.
They should move freely and smoothly without binding.
[3] [21
OISASSEMBLY/ASSEMBL Y
Loosen the lock nuls (1], and remove the ball joints and ,--- - -- - - - - - - - - - - - - - ,
lock nuts from the tie-rod. [1]
Install the righi-hand threads nul and unmarked ball
jOint on the flat (2] (wrench holding area for toe
adjustment) side of the lie-rod , and the left-hand
threads nul and "L~ marked [3] ball joint on the opposite
side.
[2[ 131
17-32
Note the reference distances (between the lock nul and
thread end).
REFERENCE DISTANCES : A : 6.8 mm (O.27 in)

B : 6.8 mm (O.27 in)
A difference between distances A and B should be 3
mm(O.12 in) max.
Tighten Ihese nuts Temporarily tigh ten the lock nuts while the ball joint
0
after ins/ailing the positions are approximately 180 from each other.
tie-rod and B A
adjusting the toe.
INSTALLATION
Inslallthe tie-rod with the flats [1] of the rod toward the
knuckle,
Install new jOint nuts (2] and tighten them by holding the
jOint stud flat surfaces.
TORQUE : 54 N-m (5.5 kgf-m, 40 IbHt)
Inslall new cotter pins [3].

Install the fronl wheel (page 17-10),
Adjust the toe (page 3-29).
Install the mudguard (page 2-5)
17-33
MEMO
•
18. REAR WHEEUSUSPENSION
SERVICE INFORMATION .... · ...... ·.. ·· .. ·········16-2 REAR WHEEL· ··································· .... · .. ·· 18-4
TROUBLESHOOTING································· 18-2 REAR SHOCK ABSORBER ...................... · 18-4
SYSTEM COMPONENTS······················· ····· 18-3 SWINGARM · .... · .. ·· .. ·.... ·· .... · .... .... · .. · ...... · .... · 18-5
18-1
SERVICE INFORMATION
GENERAL
This section covers service of the rear wheel. reaf shock. absorber and swingarm.
A jack or other support is required to support the vehicle.
Use genuine Honda replacement bolls and nuts for all suspension pivots and mounting points.
For lire information, see Front WheeUSuspensioniSteering section (page 17-10).
For brake system service, see Brake System section (page 19-2).
For driving mechanism service, see Rear Driving Mechanism section (page 20-2).
TROUBLESHOOTING
Rear wheel wobbling
Benl rim
Worn or damaged rear axle bearings
Faulty lire
Axle fastener nOllighlened properly
Loose wheel hub nul
Faulty swingarm pivot bushings
Rear wheel hard to turn
Faulty rear 8)(le bearings
• Bent fear axle
• Rear brake drag
Soft suspension
• Weak shock absorber spring
• Oil leakage from damper unit
Stiff suspension
Damaged shock absorber damper
• Faulty shock absorber pivot bushings
• Damaged swingarm pivot bushings
Rear suspension noise
Faulty rear shock absorber
loose rea r suspension fasteners
• Worn rear suspension pivot bushings
•
18·2 •
REAR WHEEL/SUSPENSION
SYSTEM COMPONENTS
64 N'm (6.5 kgf-m . 471bHtJ
113 N'm (11 .5 kgf-m, 831bHt)
961bHt)
34 N'm (3.5 kgf·m, 25Ibf-ft)
18-3
•
REAR WHEEL
REMOVAL
loosen the wheel nuts.
Support Ihe vehicle using a hoist or equivalent and
raise the rear wheels off Ihe ground.
Remove Ihe wheel nuts [11 and rear wheel.
For tire removal/installa tion and repair, see Front
Wheel/Suspension/S teering section (page 17.10).
INSTALLATION
00 not interchange Install the rear wheel with the tire valve facing out and
the leI! and right the arrow mark. (2) facing in the normal rotating
wheels direction.
Install the wheel nuts with the tapered side 13] facing
inward and lighten them.
REAR SHOCK ABSORBER

Remove Ihe seat (page 2-3).
Support the vehide using a hoist or equivalent and
raise Ihe rear wheels off the ground.
Loosen the shock absorber mounting nuts [1] and
remove them.
Support the swingarm, and remove the mounting bolts
[2] and shock absorber (3].
Insert the boilS from Install the shock absorber [1] with the mounting bolts [2 ]
the right side. and new nuts [3].
Tighten the upper mounting nut.
Tighten the lower mounting bolt to the specified torque.
TORQUE : 113 N·m (11 .5 kgf·m , 831bHt)
Install the seat (page 2-3).
18-4
INSPECTION
Check the pivot bushing (1 J for wear or damage.
Check the damper unit [2] for leakage or other damage.
I
Replace the shock absorber assembly if necessary.
It]
SWINGARM
REMOVAL
- final gear assembly (page 21~9)
- final gear case breather hose [1] (from the clamps)
- shock absorber lower mounting nut (2] and bolt [31
- two nuts [11, bolts [2] and trailer hitch [3)

- two pivot nuts [4), bolls [5] and swingarm (6)
Check the pivot bushings [I] for wear or damage

If the universal jOint guard (2) is removed , install it with
new bolts [3) and lighten the bolts to the specified
torque.
(1(
18-5
•
INSTALLATION
Insert the bolts from Inslalithe swingarm (lJ with the pivot bolts 12] and new
the outside. nuts (3]. and lighten the nuts to the specified torque.
TORQUE: 130 N'm (13.3 kgf'm, 961bHt)

Install the trailer hitch (4J with the bolts (5) and new nuts
[6]. and tighten the nuts to the specified torque.
TORQUE: 34 N'm (3.5 kgf'm, 25 IbHl)
Instal! the shock absorber [1 ). tower mounting bolt (2] ~iiii~;:;=iilliiiiili;;~:;2:::===~

and new nul [3J, and tighten the nut to the specified
torque.
TORQUE: 113 N'm (11.5 kgf'm, 831bHt)

Install the final gear case breather hose [4] into the
clamps.
Install the final gear assembly (page 21-22).
18-6
19. BRAKE SYSTEM
SERVICE INFORMATION ···························19·2 BRAKE PAD/DISC································ .. ·· .. 19-7
TROUBLESHOOTING ································· 19-3 FRONT MASTER CYLINDER ········ ············· 19-8
SYSTEM COMPONENTS .... ·· .. · .. · .. · ...... · ...... 19-4 FRONT BRAKE CALIPER ........................ 19-10
BRAKE FLUID REPLACEMENT/AIR REAR BRAKE DRUM/SHOES .... ·............ 19-12

BLEEDING .... ··........ ··........ · .. · ...... · .. ·· .. · .. · ...... 19-6
REAR BRAKE PEDAL .................... · ........ · 19-16
19-1
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Frequent inhalation of brake pad or lining dust, regardless of malerial composition could be hazardous to your health.
Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA. approved vacuum cleaner.
NOTICE I
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
A contaminated brake disc, pad , drum or shoe reduces stopping power. Discard contaminated pads or shoes, and clean a
contaminated disc or drum with a high quality brake degreasing agent
Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
Once the hydraulic system has been opened. or if the brake feels spongy, the system must be bled.
Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as
they may not be compatible.
Always check brake operation before riding the vehicle.
TOOLS
Base assembly. 56 x 66 mm Attachment. 62 x 68 mm Driver
070MF-MEC0300 07746-0010500 07749-0010000
19-2
BRAKE SYSTEM
TROUBLESHOOTING
FRONT DISC BRAKE
Brake lever soft or spongy
Air in hvdraulic system
leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake padldisc
Contaminated caliper
Contaminated master cylinder
Caliper not sliding properly
Low brake fluid level
Clogged fl uid passage
Warped/deformed brake disc
Slickinglworn caliper piston
Stickinglworn master cylinder piston
Bent brake lever
Brake lever hard
Cloggedlreslricted brake system
Slicking/worn caliper piston
Stickinglworn master cylinder piston
Caliper not sliding properly
Bent brake lever
Brake drags
Contaminated brake pad/disc
Badly worn brake pad/disc
Warpedfdeformed brake disc
Cahper nol sliding properly
Clogged/restricted fluid passage
Sticking caliper piston
REAR DRUM BRAKE

Poor brake performance
Brake not adjusted properly
Worn or contamina ted brake shoes
Worn or contamina ted brake drum
Water in brake drum
Incorrectly installed rear brake arm
Worn rear brake cam
19·3
j
BRAKE SYSTEM
SYSTEM COMPONENTS
2 N-ffi (0.2 kgf-m, 1.5Ibf-ft)
,/
~
~
34 N'm (3.5 kgf-m . 25Ibf-ft )
@~/
~
f1fj, o 0
30 N'm (3.1 kgf-m, 22Ibf·ft)

17.2 N'm (1.8 kgf-m. 131bHI)
34 N'm (3.5 kgf-m, 25Ibf-ft)
2.4 N'm (0.2 kgf'm, 1.8IbHt )

11 N'm (1. 1 kgf'm, 8 Ibf-ft)
19-4
BRAKE SYSTEM
20 N'm (2.0 kgf·m, 151bHt)
137 N'm (14.0 kgf-m, 1011bHt)
19-5
BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
Turn the handlebar to the left untillhe reservoir is level
before removing the reservoir cap [1J.
Remove the screws (2]. reservoir cap, set plale and
diaphragm.
Connect a bleed hose (1] to the fronl brake caliper

bleed valve (2).
Loosen the bleed valve and pump the front brake lever
until no more fluid flows out of the bleed valve.
Perform above procedure for the other side bleed valve.
BRAKE FLUID FILLING/BLEEDING

Close each brake caliper bleed valve.
Fill the master cylinder reservoir to the casting ledge [1)
with DOT 4 brake fluid from a sealed container.
Follow the Connect a commercially available brake bleeder to the

manufacturer's bleed valve.
operating
Operate the brake bleeder and loosen the bleed valve.
ins/ructions.
Check the fluid level If an automatic refill system is not used, add fluid when
often while bleeding the fluid level in the reservoir is low.
the brake to prevent
air from being
pumped into the
system.
Ifairentersthe Perform the bleeding procedure until the system is
bleeder from completely flushedfbled.
around the bleed
Perform air bleeding for the other side bleed valve.
valve threads, seal
the threads with After bleeding air, operate the front brake lever. If it still
teflon tape. feels spongy, bleed the system again.
19-6
BRAKE SYSTEM
If the brake bleeder is not available, perform the
following procedure:
Pump up the system pressure with the front brake lever
until the lever resistance is fell.
Connect a bleed hose [1) to the front brake caliper
bleed valve [2J and bleed the system as follows:
Do not release the 1. Squeeze the brake lever all the way and loosen the
brake lever untH the bleed valve 114 of a tum. Wait several seconds and
bleed valve has then close the bleed valve.
been closed
2. Release the brake lever slowly and wait several
seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
Tighten the bleed valve.
TORQUE: 5.4 N' m (0.6 kgf-m , 4.0 IbUt)
Perform air bleeding for the other side bleed valve .
After bleeding air, operate the front brake lever. If it still
feels spongy, bleed the system again.
Fill the master cylinder reservoir to the casting ledge
With DOT 4 brake nuid from a sealed container.
Install the diaphragm, set plate and reservoir cap, and
lighten the screws.
TORQUE : 2 N'm (0.2 kgf'm, 1.5IbHt)
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Remove the front wheel (page 17-10).
Remove the pad pin plugs [1).
Loosen the pad pins (2).
Remove the two mounting bolts [3J and brake caliper
[4[ ,
Check the nuid level Push the caliper piston all the way in by prying the
in the master brake pads to allow installation of new pads.
cylmder reservoir es
this operatIOn
causes the nuid
level to rise.
Pull the pad pins PJ out of the caliper while pushmg the
brake pads [2J in against the pad spring [3J, and remove
the pads.
Make sure the pad Install new brake pads into the caliper body.
spnng is installed Align the pad pin holes in the caliper body and pads by
correctly pushing the pads in against the pad spring, and install
Always replace the the pad pins.
brake pads in pairs
/0 ensure even dIsc
pressure
19-7
BRAKE SYSTEM
,
Install the brake caliper [11 so the disc is positioned
between the pads, being careful not to damage the
,
I
pads.
Install new mounting bolts (21 and tighten them to the
specified torque.
TORQUE: 30 N·m (3.1 kgf'm , 22 IbHtl
Tighten the pad pins (3) to the specified torque.
TORQUE : 17.2 N'm (1 .8 kgf'm, 13 IbHtl
Install the pad pin plugs (4} and tighten them to the
specified torque.
TORQUE : 2.4 N'm (0.2 kgf'm , 1.8IbHt)
Squeeze the front brake lever to seat the caliper piston
against the pad.
Install the front wheel (page 17-10).
BRAKE DISC INSPECTION

Visually inspect the brake disc for damage or cracks.
Measure the brake disc according to BRAKE SYSTEM
SPECIFICATIONS (page 1-11) and replace if
necessary.
FRONT MASTER CYLINDER

Drain the brake fluid (page 19-6).
When removing the Remove the following:
oil bolt, DOver the
- brake light switch connectors [1]
end o( the hose to
- oil bolt (21
p""en'
contamination. -- sealing washers 131
brake hose (4)
loosen the screw 11 1 and rotate the throttle housing [2)

forward.
~===========~~"""'111111~
19·8
BRAKE SYSTEM
Remove the bolts [1), holder 121 and master cylinder [3] .
Disassemble and assemble the remaining parts as

shown in the illustration.
Replace the master piston , spring, piston cups and
snap ring as a set.
Do not allow the piston cup lips to turn inside out.
Be certain the snap ring is firml y seated in the groove.
1.0N·m (O. 1 . O.7lbf ft)

SEPARATOR
A MASTER I
CUP
PISTON
SPRING
• PISTON
(lever contacting
;::..-::c:---- 5.9 N'm (0.6 kg! m,
4.4 IbHt)
~
area)
SNAP RING ---,~
PISTON
(lever pivot )
BRAKE LEVER 1.2 N m (O. 1 kgf-m . 0.9 Ibf-ft)
Install the master cylinder (1] . holder 121with the · UP·

mark [3J ladng up, and bolts [4) .
Align the edge of the master cylinder with the punch
mark on the handlebar and lighten the upper boll first,
then tighten the lower bolito the specified torque.
TORQUE : 12 N·m (1.2 kgf·m, 9 IbHtl
19-9
BRAKE SYSTEM
Align the lug on the throttle housing [1) with Ihe mating
line of Ihe master cylinder and holder, and lighten Ihe FA1 /FA2 shown:
screw (2).
Install the brake hose [1 1 with the new sealing washers ~===::""===========~
(2) and oil boll [3} by setting the brake hose jOint
between Ihe stopper groove in the master cylinder.
Tighten the oil bolt to the specified torque.
TORQUE: 34 N'm (3.5 kgf'm , 25 tbH t)
Connect the brake light switch connectors [4]
FiU and bleed Ihe hydraulic system (page 19-6 ).
INSPECTION
Check the following parts for scoring , scratches,
deterioration or damage.
- Master cylinder
- Master piston
- Piston cups
- Spring
- Boot
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-11 ) and replace if
necessary.
FRONT BRAKE CALIPER

OISASSEMBLY/ASSEMBL Y
Remove the front wheel (page 17· 10).
Drain the brake fluid (page 19-6).
Except TM1fTE1: Remove the two bolts [1] and
outboard guard [21.
19-10
BRAKE SYSTEM
When removing /he Remove the following:
oil boll, cover the
- oil bolt (1]
end of the hose to
- sealing washers [21
prevent
- brake hose [3]
conlaminal/O(J.
- slide pin plug [4]
loosen the slide pin (5].
Remove the brake pads (page 19-7).
Disassemble and assemble the remaining parts as

shown in the illustration.
.cu ,....riSi.( O.~ ~ (0.014 oz)

CALIPER BODY
SLIDE PIN
minimum
22 N'm (2.2 kgf-m, 16 Ibf-ft)

PISTON SEAL I
So
•~
= . 0.29 (0.007 0'1
mlnlmum
SLIDE PIN PLUG --~.t&
PISTON BOOT
PAD SPRING /"""'_ _ '~

CALIPER PISTON I
~ ~ _--!-1--I---
~ ,....riSi.(
SLIDE PIN BOOT
BRACKET PIN BOOT
,....riSi.( O.~ ~ (0.014 oz)
minimum
~ . . BRACKET
CALIPER BRACKET
SPRING WASHER
Tighten the slide pin [1J to the specified torque.
TORQUE : 22 N' m (2.2 kgf 'm , 16 IbHt)
Inslalilhe slide pin plug [2).

Rest the brake hose joint [3] onto the stopper on the
caliper body.
Connect the brake hose [4] with the oil bolt [5) and new
sealing washers [6). and lighten the oil bolt) to the
specified torque.
19-11
BRAKE SYSTEM
Except TM1fTE1: Inslall the outboard guard [1] and
lighten the bolts (2) to the specified torque.
TORQUE : 11 N'm (1.1 kgf-m, 8lbHt)

Fill and bleed the hydraulic sys tem (page 19-6).
Instalilhe front wheel (page 17-10).
INSPECTION
Check the caliper cylinder and piston for scoring ,
scratches or damage.
- Caliper cylinder
- Caliper piston
Measure the brake disc according to BRAKE SYSTEM
SPECIFICATIONS (page 1.11) and replace if
necessary.
REAR BRAKE DRUM/SHOES

BRAKE DRUM REMOVAL
Remove the right rear wheel (page 18-4).
- cotter pin III
- hub nut [2J
- wheel hub [3]
- six bolts [1]

- drum cover [2]
- dust seal (3)
19·12
I -
O-ring [1J
brake drum [2]
BRAKE SYSTEM
INSPECTION
Check the dust sea! in the brake panel for wear or
damage.
Measure the brake drum according to BRAKE SYSTEM
SPECIFICATIONS (page 1-11) and replace jf
necessary.
For dust seal replacement, see Rear Driving
Mechanism section (page 21-8).
DISASSEMBLY
A,wa ys r&pJace the Remove the following:
brake shoes In
- cotter pins [1]
pailS
- setting plate [2)
- brake shoes [3)
- springs [4)
- adjusting nuts (1)

- brake cables [2J
- joint pins [3]
- springs [4)
- Brake panel drain bolt [5) and washer [6)
19-13
BRAKE SYSTEM
- nut (1) and bolt 12]
- brake arm 13)
- wear indicator 14]
- return spring (5)
- brake cam [6)
- felt seal
- dust seal
ASSEMBLY
Apply grease to the lips of a new dust seal [1) and
install it with the flat side facing toward the brake arm
until it is fully sealed.
Apply 0.2 - 0.3 g (0.007 - 0.011 oz) of grease to the
brake cam (2) spindle and install it.
Apply engine oil to a new fel t seal [1) and install It over
the brake cam.
~iiii~~~~;;~iiiiiiiii~;:;O~::T:::::::::~
install the return spring [2) by aligning its end with the
hole (3).
Instailihe wear indicator 14] by aligning the wide teeth
with the wide groove.
Install the brake arm [1) by aligning the punch marks.

Install the pinch boll [2] from the punch mark side and
the nut (3), and tighten it.
TORQUE : 20 N'm (2 .0 kgf'm, 151bHt)
19-14
BRAKE SYSTEM
Install the brake cables [1] into the cable holders on the
brake panel (upper holder for lever brake cable and
lower holder for pedal brake cable).
Install the cable springs [2] onto the cables and the joint
pins [3] inlo the brake arm. Connect the brake cables to
the brake arm with the adjusting nuts [4].
Install the brake panel drain bolt wi th a new sealing
washer (5] and tighten Ihe boll (6].
TORQUE : 12 N'm (1.2 kgf'm , 9 Ibf-ft)
Apply 0.20 - 0.30 g (0.007 - 0.Q11 oz) of grease to ~""~:::~::;;;;;::::;~;;::;;;;;;~;;;;;;;;;

each anchor pin groove and brake cam sliding
surfaces.
Do not get grease Assemble the brake shoes [1] and springs [2] so that
onto the shoo the spring ends are facing outside as shown and install
linings. the assembly onto the brake panel.
The COffer pins are Install the setting plate [3] with the cham fered side
installed from the (rolled edge side) facing in and secure it with new cotter
front side. pins (4] .
BRAKE DRUM [NSTALLAT[ON

Do not gel grease Inslallthe brake drum [1J onlo the axle unlil it is fully
10 the brake drum seated.
and shoos.
Coal a new O-ring (2] wilh grease and Install It Into the
groove 10 the brake panel (3].
[l[ ~
Pack the seal lips of a new dust seal [1] with 3 - 4 g of

grease.
1~i:=~i~::i~~r=~;====J3i-':':'~
~
Install the dust seal into the drum cover so that It is Hush
with Ihe cover surface.
TOOLS :
Oriver [2J 07749-0010000
Attachment, 62 x 68 mm (3J 07746-0010500
Base Assembly 56 x 66 mm [4] 070MF-MEC0300
L -'-.
[4[' -----_
19-15
1
BRAKE SYSTEM
Inslallthe drum cover (1J. aligning the boll holes.
Instalilhe six bolts 12] and lighten them.
Do not get grease Apply molybdenum disulfide grease to Ihe axle spline ~====~~~
on tM 8¥ie threads. (1] and install the wheel hub [2] onlo the axle.
Apply sealant to the hub nut threads.

Install the hub nul (1) and tighten it to the specified
torque and further lighten until its grooves align with the
cotter pin hole.
TORQU E: 137 N-m (1 4.0 kgf'm , 1011bHt)
Install a new cotter pin 121.

Install the right rear wheel (page 18-4).
Adjus t the rear brake (page 3-25).
S!J 121 [1] . (lm!
REAR BRAKE PEDAL

REMOVAUINSTALLATION
Remove the right mudguard (page 2-5).
Disconnect Ihe pedal brake cable from the brake arm
(page 19-13),
- switch spring [1J
- return spring [2]
- brake cable (3] (from the cable holder [4) and pedal)
131 141
19·16 •
BRAKE SYSTEM
- coller pm (1 J
- washer 121
- brake pedal [1]

- dust seals [2]
Replace the dust seals and colter pin with new ones.
Apply grease 10 the brake pedal pivot sliding surface
and dust seal lips.
Install the dust seals with the flat side facing out so
that they are flush with the pedal
Install the return spring [3) and SWitch spring [4J in
the direction as shown.
Adjust the brake pedal freeplay (page 3-26).
19-17
MEMO
20. FRONT DRIVING MECHANISM (Except TM1fTE1 models)
SERVICE INFORMATION ···························20·2 FRONT FINAL CLUTCH ··························· 20·15
TROUBLESHOOTING ································· 204 FRONT FINAL GEAR DlSASSEMBLYI

INSPECTION ................... .......................... 20·21
SYSTEM COMPONENTS··············· ·············20·5
GEAR CASE AND COVER BEARING
FRONT DRIVE SHAFT ································ 20·6 REPLACEMENT ········· ···· ·························· 20·28
FRONT FINAL DRIVE REMOVAL ············ 20·11 FRONT FINAL GEAR ASSEMBLY ·········· 20·31
FRONT PROPELLER SHAFT ···················20·13 FRONT FINAL DRIVE INSTALLATION···· 20·35
20·1
,
FRONT DRIVING MECHANISM (Except TM1ITE1 models) •
SERVICE INFORMATION
GENERAL
Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The
extension lines from the gear engagement surfaces should intersect at one point.
Protect the gear case with a shop lowel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage the gear
case.
When using the lock nul wrench, use a deflecting beam type torque wrench 20 inches long. The lock nul wrench increases the
torque wrench's leverage , so the torque wrench reading will be less than the torque actually applied to the lock nut. The
specifICation given is the aclualtorque applied to the lock nul, not the reading on the torque wrench. Do not overtighten the lock
nul. The specification later in the text gives both actual and indicated.
Replace the ring and pinion gears as a set.
Replace the cam followers (12 pieces) as a set, and the cam followers , face cams and differential housing as an assembly if the
face cam or differential housing is faulty.
TOOLS
Bearing dip compressor, 26 mm Threaded adaptor Remover weight
070ME-HP50100 070MF-HP50100 07741-0010201
or 070ME-HP5A100 (U.S.A. only) Of 070MF-HP5A100 (U.S.A. only4 07936-371020A (U.S.A. only)

07746-0010400 07746-0010700 07746-0010800
Attachment, 20 mm 1.0 . Attachment, 35 mm 1.0. Pilot, 12 mm

07746-0020400 07746-0030400 07746-0040200
•
20-2
FRONT DRIVING MECHANISM (Except TM1ITEI models)
Pilot, 15 mm Pilol. 30 mm Fork Seal Driver Weight
07746-0040300 07746-0040700 07747-0010100
Fork Seal Driver Attachment, Driver Locknut Wrench, 34 x 44 mm

33 mm 1.0. 07749-0010000 Ol916-MES0001
07747-0010501
)
l
Remover head, 12 mm Remover shaft. 12 mm Remover shaft. 15 mm
07936-1660110 07936·1660120 07936-KC10100 (not available in
U.S.A.)
I or 07936-166010A (U.S,A. only)

h - .~,-----t---o===~~----I~
Remover head, 15 mm Bearing remover, 15 mm Driver
07936-KCl 0200 (not available in 07936·KC10500 (U.S.A. only) 07949-3710001
U.S.A.)
20-3
J
FRONT DRIVING MECHANISM (Except TM1ITEl models) 1
Puller shaft and nut Attachment, 40 mm 1.0. Pinion Puller Base j
07965-VM00200 07GAF-SE00200 07HMC-MM80110
(J
Of 07931-ME4010B and or 07HMC-MM8011A (U.S.A. only)
07931-HB3020A (U .S.A. only)
Differential inspection tool Pilol32
07KMK-HC50101 07MAD-PR90200
~.
.:J~
or 07KMK-HC5010A (U.S.A. only)
TROUBLESHOOTING
Consistent noise during cruising
Oil level too low
Foreign mailer contaminating gear oil
Worn or damaged bearing
Worn or damaged ring gear and pinion gear
Deformed ring gear or gear case
Improper tooth contact between ring gear and pinion gear
Gear noises while running
Oil level 100 low
Foreign matter contaminating gear oil
• Chipped or damaged gears
• Improper tooth contact between ring gear and pinion gear
Gear noises while coasting
• Chipped or damaged gears
Abnormal noises when turning
Worn or damaged ring gear bearing
Worn or damaged face cams and cam followers
• Worn or damaged differential housing grooves
• Worn cone spring or shim
Abnormal noises at start or during acceleration
Excessive backlash between ring gear and pinion gear
Worn differential splines
• Loose fasteners
• Worn cone spring or shim
Oil leak
Oil level too high
Clogged breather
• Damaged seals
• Loose case cover bolt
Overheating
• Oil level too low
• Insufficient backlash between ring gear and pinion gear
20-4
FRONT DRIVING MECHANISM (Except TMl/TEl models)
SYSTEM COMPONENTS
44 N-m (4.5 kgf-m. 32 IbHt)
10 N'm (1.0 kgf-m . 7Ibf-ft)
10 N-m (1.0 kgf.m . 7 Ibf.tt)
44 N-m (4.5 kgf-m, 32 Ibt-tt)
20-5
FRONT DRIVING MECHANISM (Except TM1ITE1 models)
FRONT DRIVE SHAFT
REMOVAL
Remove the knuckle (page 17-13)
To prevent damage Hold the inboard joinl11j of the drive shaft and tug firmly
to the differential oil to force the stopper ring on the inboard joint end past
seal, hold the the groove while prying with a screwdriver.
inboard joint
horizontal until the
drive shaff is clfJar
of the differential.
Remove the stopper ring [1 ) from the inboard joint.
DISASSEMBL YIINSPECTION
Check the boots [1 J for cuts or other damage.
Check the drive shaft joints [21 for excessive play or
noise by moving the joints in a circular direction.
Outboard
If the outboard joint seems to be worn or damaged, the
drive shaft must be replaced.
NOTE:
To replace the outboard boot. first remove the
inboard boot as described in following steps.
Then remove bands and the outboard boot off the
inboard end of the shaft.
The outboard joint can not be disassembled.
Inboard
121
Cut off and remove the boot bands [11 from inboard ~==================
boot [2].
Remove the boot from the inboard joint.
20-6
- stopper ring [1J
- inboard jOint (2)
121
- snap ring (1)
- bearing (2)
- inboard boots [3]
Rep/ace these Check the following for wear or damage.

components as an
- bearing cage [1)
assembly
- race (2)
- steel balls (3)
- inboard joint (4J
[11 121
Cut off and remove the boot bands [1) from outboard
boot [2J.
Remove the outboard boot.
20-7
ASSEMBLY
DRIVE SHAFT
SHAFT BOOT BAND ~
INa<)AR:O JOINT
OUTBOARD BOOT
OU1raO.'RO JOINT
$I OUTBOARO BOOT BAND
$I INBOARD BOOT BAND
INBOARD BOOT
g SHAFT BOOT BAND
The outboard boot (1] is large and the inboard boot [2)
is small. Do not interchange them.
121 111
I~ Q
Each boot band has following identification number [1].

111
INBOARD BOOT BAND : 77
SHAFT BOOT BAND : 78
OUTBOARD BOOT BAND : 79
, ""
20-8
FRONT DRIVING MECHANISM (Except TM1fTE1 models)
Pack the outboard joint with 35 - 55 9 (1 .2 - 1.9 oz) of
specified grease.
SPECIFIED GREASE: NKG708 (KYODO VUSHI)

- outboard boot [1)
- inboard boot (2]
,,
NKG70a [21
Install the bearing (1 J with the small 0.0. facing the ~;:==============~
drive shaft,
Install the snap ring 121 with the cham fered side facing
the bearing.
Pack the inboard joint with 50 - 70 9 (1.8 - 2.5 oz) of

specified grease.
~=;~~~=ti ••iiir==;;;===l
SPECIFIED GREASE : NKG708 (KYOOO YUSHI)
Install the Inboard joint [1} over the bearing.

Install the stopper ring [2] into the groove in the inboard
joint properly.
Inslallthe boot over the inboard joint.
Adjust the length of the drive shaft to the figure given ~=======""'=======~
below.
DRIVE SHAFT LENGTH :

Left: 335.9 mm (13.22 in)
Right : 357.5 mm (14.07 in)
20-9
o
Note the InS18/1811Of1Install new shaft boot band (1] and inboard boot band
direction 01 the (2J onto the inboard boot 131.
[41
band. lock the boot bands using the following tool.
TOOL:
CV boot band pliers [4] OET14100134 Lock
(U.S.A . only)
[lJ j
j
j
I
Note the /nstaliallOfl
dlf"fJ(;tion o f/h e
Install new shaft boot band (1] and outboard boot band
[2] onto the outboard booI13]. \
==~~=~iir===T=~~~:=l
{4J
band. Lock the boot bands using the following tool.
TOOL:
CV boot band pliers [4] OET14100134
(U .S.A . only) [3[
_ _ [lJ
g
INSTALLATION
Install a new stopper ring [1] into the groove in the
inboard joint.
Be careful nolto Inslall the drive shaft by holding the inboard joint 11}
damage the of! seal until the stopper ring seats in the groove of the
In the gear case. differential .
Make sure thai the stopper ring is sealed properly by
pulling on the inboard joint lightly.
Install the knuckle (page 17-18).
20-10
FRONT FINAL DRIVE REMOVAL
Drain the front final gear oil (page 3-22).
- tank cover assembly (page 2-4)
- FAlIFA2 only: front VS sensor (page 13-54)
- left drive shaft (page 20-6)
Disconnect the breather hose [1J and select switch
connector [2J from the final gear case.

- cover bolt [1]
- clutch arm cover [2) (by releasing the two tabs [3])
- adjusting nut [1]

- cable retaining plate [2]
- selector cable [31 (remove from the cable holder (4)
and joint pin 15])
- cable spring (6]
- jOint pin
- base bolts [1]

- arm cover base [2]
- holder bracket [3J
20·11
FRONT DRIVING MECHANISM (Except TM1ITEl models)
- final gear case mounting nuts (1] and bolls (21
- two bolts (3J and mounting bracket [4)
Move the gear case assembly forward for maximum

clearance between the propeller shaft joint [1] and
engine.
Pull, the shaft joint out of the output shaft 12J of the
engine.
Remove the boot band [3) and release the propeller
shaft boot (4) off the pinion joint [5] of the gear case
assembly.
pun the propeller shaft [61 to force the stopper ring 171
past the groove in the pinion joint to remove the
propeller shaft.
Remove the stopper ring from the propeller shaft.
Remove the O-ring [81 from the output shaft.
20·12
Separate the right drive shaft (1] from the final gear
case assembly [2) by tapping the right drive shaft end
lightly through the gear case, using a screwdriver or
equivalent.
Remove the gear case assembly from the frame.
OPERATION CHECK
Turn the pinion jOint [1 ) while the clutch arm [2J is set to
the rear (4WD position). and check thallhe gear turns
smoothly and quietly without binding .
If the gear does not turn smoothly or quietly, the pinion
gear, ring gear, bearing and/or dutch components may
be damaged or faulty. They must be checked after
disassembly; replace them If necessary.
Operate the change-over mechanism while turning the
pinion jOint. check for smooth engagementl
disengagement.
12J
FRONT PROPELLER SHAFT

DISASSEMBLY/INSPECTION
Remove the outer boot band (1] and the shaft boot [2]
from the propeller shaft joint (3]. and remove the joint
from the shaft [4].
121
131
- joint spring [1)
- shaft seal [2]
- inner boot bands (3]
- shaft boots [4)
Check the splines [5] of the propeller shaft and joint for
wear or damage.
If they are damaged , check the splines of the output
shaft and pinion joint.
Check the boots for cuts, deterioration or damage.
Check the seal lips of the pinion joint side boot and
shaft seal for damage.
141 111
20-13
ASSEMBLY
~
Seal lip area on shaft SEAL LIP
~(J--e--
i,~~'_,
~~~--I
----I =rI ~
I \ j
SPLINES
PROPELLER
PROPELLER ~ SHAFT JOINT
SHAFT
Place the inner boot bands [1) on the propeller shaft.

Do not allow the Apply molybdenum disulfide grease to the seal lips of
sea/lip 10 tum pinion joint side boot and shaft seal.
outside in Inslall Ihe boots [2J onto the shaft grooves. being
careful nollo damage the seal lip.
Instalilhe boot bands into the each boot groove.
Instalilhe shaft seal (3) into the shaft groove.
Install the jOint spring [4) into the propeller shaft
securely.
[4}
Apply 5.0 - 5.3 9 (0.18 - 0.19 oz) of molybdenum :================~
disulfide grease to the propeller shaft joint [1] splines.
Set the shaft joint onto the propeller shaft [2] while
compressing the spring, then install the boot [3) over
the shaft joint groove and the outer boot band 14] into
the boot groove to secure it.
20-14
FRONT FINAL CLUTCH
DISASSEMBLY/INSPECTION
The housing is Remove the foUewing:
under spring
- select switch and sealing washer [1]
pressure; hold the
- three bolts [2J
housing when
- final dutch housing [3J (by releasing the shift fork [4)
loosening the bolt.
from the clutch sleeve (5])
- clutch sleeve
- O·ring [6]
- dowel pins [7]
Check the splines of the pinion joint [8J. clutch sleeve
and pinion gear shaft [9] for wear or damage.
Check the needle bearing (10j in the pinion gear shaft
for wear or damage.
Release the dutch spring end [1J from the stopper plate ;:::===::::'::':::=~~==~~~==~
[2) by pulling the arm shaft [3].
Remove the fork bolt [1J,

Pry the clutch arm lab [2J to release it from the coliar [3]
and slide the shaft 14] outward.
20-15
- clu tch spring [lJ
stopper plale (2)
shift fork [3]
clutch arm shaft [4]
lock spring (5]
collar 16)
O-ring (7)
oil seal/B]
[21 [81 141

Check the shift fork craws [1] for wear or damage.
Check the arm shaft [21 and stopper plate [3] for
deformation or damage.
Check the springs (4) for fatigue or damage.
PINION JOINT BALL BEARING

REPLACEMENT
Remove the snap ring I1J and drive the pinion joint [2J
Qui of the bearing.
Remove the oil seal [1] and the snap ring [2].
Drive the bearing [3) out of the housing .
20·16
Drive a new bearing into the housing.
TOOLS:
Driver (1J 07749-0010000
Attachment, 52 II 55 mm [2] 07746-0010400
Pilot, 32 mm [3) 07MAD·PR90200
Instal! the snap ring {1] into the housing groove securely :======~IIIIIIIIIIIIIIIIIIII~===--==~
with the chamfered edge facing the bearing.
Pack the seal lips of a new oil seal [2] with grease.
Install the oil seal so that it is fl ush with the housing end .
Be careful nol to Hold the bearing inner race and press the pinion joint ~~~IIIIII~:
damage the 011 s9a/ [1] into the bearing until it is fully sealed .
I,p'
TOOLS :
Fork seal driver weight [2] 07747-0010100
Fork seal driver attachment,
33 mm 1.0 . [3] 07747-0010501
Install the snap ring (1J into the pinion Joint groove
securely with the chamfered edge facing the bearing.
20-17
FRONT DRIVING MECHANISM (Except TM1/TE1 models)
ASSEMBLY
SNAP RING
PINION JOINT
OIL SEAL $!I _v;;;;..

$!I ~
r
Oil SEAL
CD
LOCK \ \ ~ - '{.~--~~~;~H ARM
SPRING COLLAR \
D-RING
Coat a new D-ring (1] with grease and install it into the
arm shaft groove.
Apply grease to the arm shaft Quter surface.
Install the collar (2] and the lock spring (3] with the short
end toward the collar, and set the spring end into the
hole [4) in the collar.
131
Coliar side
----.. Collar
side
Fork side
Apply grease to the lips of a new oil seal [1] and install it
into the clutch housing until it is fully seated.
;====::;;;;;::============:;
~ ..
Take care not to let Install the arm shaft assembly [2], being careful not to
the lock spring damage the oil seal.
S!I
come off the collar
Install the shift fori< [3] and align the groove with the lock
dun"ng assembly.
spring end.
20-18
FRONT DRIVING MECHANISM (Except TM1ITE l models)
Install the stopper plate [1] onto the arm shaft by
aligning the flat surfaces, so Ihal the plate rests on the
fork lug [2).
Install the clutch spring [3) with the bended end (41
toward the shift fork.
While holding the shift fork, push the arm shaft inward
and insert its end into the pivot hole in the housing .
Align the bolt hole in the fork with the groove in the shaft ~:::::'::"~::"~~=~=~:.;;;;;~==~
and install a new fork bolt [1].
Tighten the fork bolt.
TORQUE : 10 N'm (1.0 kgf'm, 7lbHt)
Turn the arm shaft [21 clockwise by holding the collar [3]
with a open end wrench and align the arm tab with the
collar groove , then tap the shaft to fit them securely.
111
.....
!!I>"
[2[
Turn the arm shaft 111 and set the clu tch spring [2) ends ~.c..."=====''=:''~~'''''''~~~~~~~
onto the housing ledge (3] and the reverse side of the
stopper plate (4] as shown.
Check the arm shaft for smooth operation.
20-19
Install the clutch sleeve [1] with the large 0 .0 . side
facing down.
Coat a new O-ring [2] with grease and install it into the
case groove .
Inslalilhe two dowel pins [3].
Aligning the fork claws [1) with the sleeve groove [2] . ~:;;o;;;;;;;:o;:;;;;;;;;;!::~~~~~::::::~~
install the final clutch housing PI while turning Ihe
clutch arm (4), then secure it with the bolls (5] . ,-''''-
Tighten the three bolls.
TORQUE: 25 N'm (2. 5 kgf'm , 18 IbHt)
Inslall Ihe select switch (61 with a new sealing washer 1--.,
[7) and tighten it.
TORQUE : 12 N'm (1 .2 kgf'm, 9Ibf-ft)
....e"
16}
20·20
FRONT FINAL GEAR OISASSEMBLVI
INSPECTION
BACKLASH INSPECTION
Remove the final clutch housing (page 20-15).
Set the final gear case into a jig or vise with soft jaws,
Remove the oil filler cap.
Cover/he clutch Hold the pinion gear [1] with the special tools.
housing mating
surface with
TOOLS :
protective tape or Pinion puller base [1) 07HMC·MM80110
an equivalent 10 Puller shaft and nut [2) 07965-VM00200
prevent damaging Threaded adaptor [3] 070MF·HP50100
it. U.S.A. TOOLS :
Pinion puller base 07HMC-MM8011A
Puller shaft 07931·ME4010B
Threaded adaptor 070MF·HP5A100
Instailihe differential inspection tool into the left side of
the gear case.
TOOL:
Differential inspection tool [5) 07KMK·HC50101 or
07KMK·HC5010A
(U.S.A. only)
Set a horizontal type dial indicator on the ring gear

through the filler hole.
Turn the ring gear back and forth to read backlash.
STANDARD : 0.05 - 0.25 mm (0.002 - 0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in)
Remove the dial indicator. Turn the ring gear 120 ~ and
measure backlash. Repeat this procedure once more.
Compare the difference of the three measurements.
If the difference in measurements exceeds the service
limit. it indicates that the bearing is not installed
squarely, or the case is deformed.
Inspect the bearings and case.
If the backlash is excessive, replace the ring gear left
side shim [1] with a thinner one.
If the backlash is too small. replace the ring gear left
side shim with a thicker one.
The backlash is changed by about 0.06 mm (0.002 in) [2]
when the thickness of the shim is changed by 0.10 mm
(0.004 in).
NOTE , 111-"'::D='1
Twenty-three different thickness shims are available
from the thinnest (0.50 mm thickness: A) shim to the
thickest (1.60 mm thickness: W) in intervals of 0.05
mm.
Ring gear shims :

A: (thinnest): 0.50 mm (0.020 in)
K : (standard): 1.00 mm (0.039 in)
W : (thickest): 1.60 mm (0.063 in)
Change the right side shim [2] as follows: If the left shim
was replaced with a 0.10 mm (0.004 in) thicker shim,
replace the right shim wi th one that is 0. 10 mm (0.004
in) thinner.
20-21
DIFFERENTIAL REMOVAL
Loosen the six cover bolts [1] in a crisscross pattern in
several steps and remove them.
Pry the final gear case cover [2) at the points [3] as
shown by using a screwdriver and remove it.
[3] [1]
Remove the O-ring 11].
Remove the differential assembly (2] and shims [3).
Turn the inner race of each bearing in the gear case
and case cover with your finger. The bearings should
turn smoothly and quietly. Also check thai the bearing
outer race fils tightly in the case or cover.
[3[
GEAR TOOTH CONTACT PATTERN
CHECK
Keep dust and dirt Apply thin coat of Pruss ian Blue to the pinion gear teeth , - - - - - - - - - ----c-:-c-:--,--,
out of/he case and for a looth contact pattern check. [1] Shim)
cover.
Install the ring gear shims [1J onto the differential
assembly [2].
Inslallthe differential assembly into the gear case.
Apply Prussian Blue
[1J (Right Shim)
20-22
ills important to Install the case cover and tighten the bolls [1J in several
tum the pinion gear steps until the cover (2] evenly touches the gear case.
while tightening the Then, while rolaling the pinion gear, lighten the bolts to
bolts. If the ring the specified torque in a crisscross pattern in several
gear shim is too steps.
thick, the gears will
lOCk after only light
TORQUE : 10 mm bolt : 46.5 N'm (4.7 kgf'm, 341bHt)
lightening. 8 mm bolt : 25 N'm (2.5 kgf'm, 18 IbHt)
[1J (8 mm)
Rotate the ring gear several times in both directions of

NORMAL-
rotation.
HEEL ~
Check the gear tooth contact pattern through the oil
filler hole.
The pattern is indicated by the Prussian Blue applied to
TOE
the pinion.
Contact is normal if the Prussian Blue is transferred to
the approximate center of each tooth. but slightly to the
,rh, FACE :9 ~ fACE
~- '
heel side and to the flank side.
1
If the patterns are not correct. remove and change the I! '" FLANK FLANK
pinion shim with one of an alternate thickness_ I' \ - Drive side Coast side
~
----~..::::- --~ -
~
Replace the pinion shim [1\ with a thicker one if the
con tact pattern is too high . toward the face.
=O=H='G=H='=============~
:=T=O
FACE FACE
Drive side Coast side
Replace the pinion shim [1) with a thinner one if the

TOO LOW:
contact pattern is too low. toward the flank.
The pattern will shift about 0.5 -1.0 mm (0.02 - 0.04 in)
(0.005 in).
NOTE :
Fifteen different thickness shims are available from
the thinnest (1.64 mm thickness: A) shim to the
thickest (2.48 mm thickness: 0) in intervals of 0.06
mm.
Pinion shims: A (thinnest): 1.64 mm (0.OG5 in)

G (standard): 2.00 mm (0.079 in)
Drive side IV ~ j Coast side
o (thickest) : 2.48 mm (0.098 in) FLANK FLANK
Pinion shim replacement (page 20-27).
20-23
DIFFERENTIAL INSPECTION
Install the inspection tools into both sides of the , - - - - - - - - - - - - - - - - - - - ,
differential .
TOOL:
Differential Inspection tool (1] 07KMK-HC50101 or
(2 required) 07KMK·HC5010A
(U.S.A . only)
Hold the flat surface of the 1001 with a bench vise [21. 111
Attach a torque wrench to the other tool and measure
the limited slip torque.
STANDARD:
14 -17 N'm (1.45 - 1.75 kgf-m, 10 - 13Ibf-ft) ~
SERVICE LIMIT: 12 N'm (1 .2 kgf-m , 9Ibf-ft) ~_..#-~ --.. . . . . . [2J
If the slip torque is oul of specification. disassemble the L _ _ _ _ _ _ _ _ _ _ _'--'-_ _ _----'
differential and perform the components inspection
(page 20-25) since the differential may be faulty.
DIFFERENTIAL DISASSEMBLY
Remove the len bolts [1 1. then place the differential , - - - - - - : - , , - - - - - - - - - - - - - - - - ,
assembly with the ring gear side {2J up.
Remove the fol lowing :

- ring gear [1]
- side cone spring (2)
- shim (3)
131 111
- face cam (1)
20-24
- six cam followers A and six cam followers B 111
- face cam [2)
DIFFERENTIAL COMPONENTS
INSPECTION
RING GEAR
Check the sliding surface of the ring gear for damage or ;----------------~
discoloration.
Measure the depth of the ring gear from the mating
surface as shown.
DIFFERENTIAL HOUSING/FACE CAM/CAM

FOLLOWER
If/he differential Check the sliding surface and grooves of the housing
housing and/or cam [1] for damage or discoloration .
face are faulty,
rep/ace the
differential as an
assembly.
Check the shim, face cams (1) and followers [2] for ~===ll=I============~
damage.
20-25
Temporarily assemble the differential housing, face
cams and cam followers (page 20-32). 1.47 kN (150 kgf)
•
Measure the height of face cam from the housing
mating surface as shown while applying a load of
1.47 kN (150 kgf) to the face cam boss using a
hydraulic press. •
If the height is less than the limit, repla ce the differential

as an assembly.
SIDE CONE SPRING

Check the cone spring for damage.
Measure the height of the spring.
PINION GEAR REMOVAL

Be careful/hal Unstake the bearing lock nul [1} with a drill or grinder.
melal partICles do Unslake
not enter the
beanng and the
threads of the case
are not damaged.
Remove the lock nut and discard it.
TOOL :
Lock nut wrench, 34 x 44 mm [1] 07916-ME50001
20-26
Cover the clutch Install the special tools with a washer onto the pinion
housing mating gear shaft and gear case.
surface with
aluminum shims or TOOLS:
an equivalent to Pinion puller base (1) 07HMC·MM80110
prevent damaging Puller shaft and nut [2] 0796S·VM00200
it. Threaded adaptor [3] 070MF·HPS0100
U.S.A. TOOLS :
Pinion puller base 07HMC·MM8011A
Puller shaft 07931 ·ME4010B
Threaded adaptor 070MF· HPSA100
Pull the pinion assembly {4] out from the gear case.
PINION BALL BEARING AND SHIM

REPLACEMENT
Take care not to Press the pinion gear out of the bearing.
contact the support
Remove the bearing and shim.
blocks against the
gear teeth. Replace the pinion joint needle bearing in the shaft end
if necessary (page 20-28).
Install a new shim {1] and a new bearing [2] onto the
pinion gear [3].
NOTE :
When the gear set, differential bearing, differential
housing andlor gear case has been replaced, use a
2.00 mm (0.079 in) thick shim for initial reference.
[21
Press the pinion gear into the bearing until it is fully ~==jiljl:;==='iiiiiiiiir==:::;;iiii~;:::=~
seated by supporting the bearing inner race.
TOOL:
Attachment, 35 mm 1.0 . [1] 07746-0030400
20-27
PINION JOINT NEEDLE BEARING
REPLACEMENT
Remove the pinion ball bearing (page 20-27).
Be sure to wear Heat the pinion gear (1] to about BO"C (176°F) and
heavy gloves to remove the needle bearing [2), using the special tools.
avoid bums when
TOOLS :
handling the heated
gear. Remover head, 12 mm 07936·1660110
,,,1
Using a torch to Remover shaft, 12 mm 07936·1660120 or
07936·166010A
heal the gear may
cause warpage.
Remover weight
(U.S.A. only)
07741-0010201 or
I II!I
07936-371020A
(U .S.A. only)
....... .
Press a new bearing into the pinion gear with the
marking facing up so thai it is flush with the shaft end.
=====;•••iiii"••;:====
111
TOOLS :
Driver (1) 07749-0010000
Attachment, 22 x 24 mm (2) 07746-0010800
Pilot, 12 mm (3) 07746-0040200 121
Install the pinion ball bearing (page 20-27).
- - -131

REPLACEMENT
DIFFERENTIAL BEARING
Remove the oil seals 111 from the gear case and cover.
Drive the bearings [2J out of the case and cover.
20·28
Drive the bearings into the gear case and cover.
TOOLS :
Drive r [1J 07749-0010000
Attachment, 52 x 55 mm [2] 07746-0010400
Pilot 30 mm [3] 07746-0040700
Apply grease to the seal lips of new dust seals [1].

Install each dust seal into the case and cover with the
metal side facing oul.
TOOL:
Attachment, 20 mm 1.0 . [2J 07746-0020400
PINION NEEDLE BEARING

Rotate the stopper ring (1] until its end appears in the
access hole (2].
Strike gently near the end of the ring with a punch to
bend the end upward.
Grasp the end of the ring with needle-nose pliers and
pull the stopper ring out through the access hole.
Be sure to wear Heat the gear case to about ao·c (176°F) and remove
heavy glolles 10 the needle bearing [31. using the special tools.
alloid bums when
handling Ihe heated
TOOLS :
gear case. Remover head, 15 mm 07936-KC10200
Usmg a torch to Remover shaft, 15 mm 07936-KC1 01 00
heal the gear case Remover weight 07741-0010201
may ceuse U.S.A. TOOLS :
werpage Bearing remover, 15 mm 07936-KC10500
Install a new stopper ring [1) into the groove in a new
bearing.
Make sure the Install Ihe bearing Inlo the compressor until the stopper
stopper nng steys in nng is flush with the end of the tool.
the groove
TOOL:
Bearing clip compressor, 070ME·HP50100 or
26 mm [2J 070ME·HP5A100
(U.S.A . only)
(2(
20-29
Place the driver, attachment and pilot on the top of the
bearing and tape the driver to the compressor [1].
TOOLS :
Driver 12] 07949·3710001
Attachment, 24 x 26 mm [3] 07746-0010700
Pilot, 15 mm [4] 07746-0040300
Place the bearing and tool assembly into a freezer for at
least 30 minutes.
Heat th e gear case to 80·C (1 76°F).
Remove the bearing and tool assembly from the freezer
and drive the bearing into the gear case using the
special tools.
Only strike the driver once. If you strike it more than
once, the ring may slip out of the groove. If this
happens, remove the ring and bearing , and install a
new ring.
Make sure the stopper ring [5] is securely set in the
groove of the gear case.
20-30
FRONT FINAL GEAR ASSEMBLY
PINION BALL
PINION JOINT BEARING (6206)
NEEDLE BEARING
(12)( 18x 12)
SIDE CONE SPRING 98 N'm
PINION (10.0 kgf·m,
PINION GEAR
72lbHt)
DIFFERENTIAL SHIM
PI NION NEEDLE
BEARING (16 x 26 x 23)
10 mm BOLTS I FINAL CLUTCH
,
46.5 N'm (4.7 kgf·m, 34 IbHt) STOPPER HOUSING
\ RING
RING
II!
I
(32)(58)( 13)
Q-;L
GY ....
\ ' '''''''.• c~
'WO SELECT SWITCH
12 N ·m (1.2 kgf·m . 9lbHt)
RING GEAR SHIM
_ _- - LEFT FACE CAM
8 rnm BOLTS
tF~
25 N'm (2.5 kgf'm,
1a Ibf ttl
GEAR COVER
CAM FOILLOWEIRS
DIFFERENTIAL BEARING
(29)(52x12)
49 N'm kgf·m, RIGHT CAM

361bHt)
HOUSING
20-31
PINION GEAR INSTALLATION
Drive the pinion gear assembly into the gear case.
TOOLS :
Driver (1) 07749-0010000
Attachment, 40 mm 1.0 . (2) 07GAF-SE00200
Install a new lock nul [1] and tighten it.
TOOL :
Locknut Wrench, 34 x 44 mm (2] 07916-ME50001
Refano ·Service TORQUE: Actual : 98 N'm (10.0 kgf'm, 72 IbUt)

Information" for Indicated : 89 N'm (9.1 kgf-m, 661bHt)
torque wrench
reading information
(page 20-2).
Be careful not to Slake the lock nut [1} into the case groove.
damage the threads
of/he case.
DIFFERENTIAL ASSEMBLY
Keep dust and dirt Instalilhe face cam into the differential housing .
out of/he [2[ [1[
Install six cam followers A (rib) [1] and six followers B
differential housing. (flat) (2] into the specified grooves in the housing [3] by
two and two as shown.
NOTE :
The housing grooves are sized differently to
accommodate the differently sized cam followers A
o o
and B. Make sure to install the followers correctly.
o o
13[
20·32
Inslalilhe face cam [1] onlo the cam followers .
Measure the depth of the ring gear (page 20-25) and
the height of the housing-to-cam (page 20-26), and
record them.
Calculate the shim thickness using the equation below.
The correct shim is nearly this dimension.
A = B - C - 1.6 mm
A: New shim thickness
B: Recorded ring gear depth
C : Recorded cam height
[2[
Select the shim (1 ) and install it onto the face cam .
Differential shims:
A: 1.3 mm (0 .051 in) E: 1.7 mm (0 .067 in)
B: 1.4 mm (0.055 in) F: 1.8 mm (0.071 In)
c: 1.5
0 : 1.6
mm (0.059 in)
mm (0.063 in)
G: 1.9 mrn (0 .075 in)
o
Install the cone spring [2] with the concave side facing
up (ring gear side).
Install the ring gear [3). r
[11 [31
Inslall new ring gear bolts 111 and screw them until the
seating surfaces of all the bolts touches the hOUSing, ~
but do not tighten them yet.
Temporarily install the drive shafts [1] Into the

differential assembly without the stopper rings until they
I (11
are fully seated to align the face cams [2) with the
differential housing [3J.
Tighten the ring gear bolts [4J to the specified torque in
a crisscross pattern in several steps.
TORQUE : 49 N·m (5.0 kgf·m , 36 tbf-ft)
Remove the drive shafts.

Inspect the slip torque (page 20-24).
If the slip torque is out of specification, perform the shim
adjustment. Replace the differential assembly when the
replacement shim ;s changed by 0.3 mm or more from
L [41
the selected shim.
20·33
FRONT DRIVING MECHANISM (Except TMl/TEl models)
FINAL GEAR CASE ASSEMBLY
NOTE:
When the gear set, bearing , differential housing andl
or gear case has been replaced, check the tooth
contact pattern (page 20-22) and gear backlash
(page 20-21).
Keep dust and dirt Blow compressed air through the breather hole in the , - - - - - - - - - - - - - - - - - - - ,
out of the case and case cover.
cover.
Install the proper ring gear shims [1 J onto the differential ~==~~::::::::~~~~~'====~
assembly.
r' A~/
\
,.
,
, 1,
',/ .
Install the differential assembly [1) into the gear case ~=================~
121 ..--.
Coat a new D-ring (3) with grease and install it into the ~
case cover groove. "'IiIII'
Install the cover over the gear case.
It;s important to Apply locking agent to the threads of the two 10 mm

tum the pinion gear bolts.
while tightening the Install the six bolts [1] and tighten them several steps
bolts. If Ihe ring until the cover evenly touches the case. Then, while
gear shim is too rotating the pinion gear, tighten the bolts to the
thick, the gear.> will specified torque in a crisscross pattern in several steps.
lock after only light
tightening.
TORQUE : 10 mm bolt: 46.5 N·m (4.7 kgf·m, 34 IbHt)
8 mm bolt: 25 N·m (2.5 kgf-m, 18 IbHt)
Make sure that the gear assembly rotates smoothly
without binding.
Install the final dutch housing (page 20·20).
[1] mm)
20-34
FRONT FINAL DRIVE INSTALLATION
Place the final gear case assembly [1] into the frame.
If both drive shafts Instalilhe right drive shaft (2) into the gear case (page
are removed, install 20-10).
them after mounting
the gear case
assembly
comple/ely.
Install a new stopper ring [1J into the groove in the

propeller shaft [2].
Apply 5.0 - 5.3 9 (0. 18 - 0.19 oz) of molybdenum
disulfide grease 10 the propeller shaft splines.
.!It!'.. ' 111 [3) ~
Apply molybdenum disulfide grease to the seal lip [3] of

the front side boot [4].
Make sure the seal lip is not turned outside in.
Apply molybdenum disulfide grease to the front end of
the propeller shaft
Place the boot band [1] over the pinion joint temporarily.
Install the propeller shaft [2) into the pinion joint,
aligning the splines until the stopper ring seats in the
groove.
Make sure the stopper ring is seated properly by pulling
the propeller shaft lightly.
Install the boot [3) over the pinion joint groove securely
and the boot band [4) into the boot groove.
Coat a new O-ring {1) with molybdenum disulfide

grease and install it into the output shaft groove.
Apply molybdenum disulfide grease to the propeller
shaft joint [21 splines.
Move the gear case assembly forward for maximum
clearance between the shaft joint and output shaft [3].
Engage the shaft joint over Ihe output shaft and move
the gear case assembly rearward .
20-35
Align the lower mounting bolt holes in the gear case
and frame , then install the mounting boll [1J and a new
nut [2).
Inslall the mounting bracket [3] with the two bolls [4].
Install the fronl mounting bolt (5] and a new mounting
nul (6).
Tighten the lower mounting nut.
TORQUE : 44 N'm (4.5 kgf-m , 32 IbHt)
Tighten the mounting bracket bolts.

Tighten the front mounting nut.
Connect the switch connector (1] and breather hose [2] .
Install the holder bracket [1] and cover base (2) with the
two bolts [3}, and tighten bolts.
TORQUE : 10 N'm (1 .0 kgf'm, 7 IbHt)
20-36
FRONT DRIVING MECHANISM (Except TM1 /TE 1 models)
Insert the selector cable (1) into the cable holder (2] and
spring [3), and connect it to the clutch arm with the joint
pin [4J and adjusting nul {5].
Set the groov8 in the cable grommet [61 onto the cover
base end properly.
Install the retaining plate [71 between the cable and
holder to secure the cable.
Adjust the selector cable (page 3-23).
- left drive shaft (page 20-10)
- FA1 fFA2 only: front VS sensor (page 13-54)
- lank cover assembly (page 2-4)
Fill the front final gear case with the recommended oil
(page 3-22).
20-37
MEMO
21. REAR DRIVING MECHANISM
SERVICE INFORMATION ·· .. ····· .. ······ ··········21-2 REAR FINAL GEAR DISASSEMBLYI

INSPECTION ............................................. 21-11
TROUBLESHOOTING· ........................ · ...... ·21-4
SYSTEM COMPONENTS .................... · .... · .. 21-5 REPLACEMENT .. · .. · .. · ...... · .... ·· ................ · 21-16
REAR AXLE REMOVAL ............................ ·21-6 REAR FINAL GEAR ASSEMBLy ............ · 21-19
REAR FINAL DRIVE REMOVAL ................ 21-9 REAR FINAL DRIVE INSTALLATION ...... 21·22
REAR AXLE INSTALLATION .................. ·21-24
21-1
SERVICE INFORMATION
GENERAL
Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The
extension lines from Ihe gear engagement surfaces should intersect at one point.
Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp iliaD tight as it could damage Ihe gear
case.
When using the lock nut wrench and torque wrench adaptor, use a deflecting beam type torque wrench 20 inches long. The tool
increases Ihe torque wrench's leverage, so the torque wrench reading will be less Ihan Ihe torque actually applied to Ihe nut.
The specification given is the actuallorque applied to Ihe nut, not Ihe reading on the torque wrench. Do not overtighten Ihe nut.
The specification later in the text gives both actual and indicated .
Replace the ring and pinion gears as a set.
TOOLS
Bearing clip compressor, 26 mm Remover weight Attachment, 42 x 47 mm
070ME-HP50100 07741-0010201 07746-0010300
or 070ME-HP5A100 (U.S.A. only) or 07936-371020A (U.S.A. only)

07746-0010400 07746-0010500 07746-0010700
= =
Attachment, 35 mm 1.0. Pilot, 15 mm Pilot, 35 mm

07746-0030400 07746-0040300 07746-0040800
21·2
Pilot, 28 mm Fork seal driver weight Driver
07746·0041100 07747-0010100 07749-0010000
./
lock nut wrench, 30 x 64 mm - - -'S"peo
;;-;O;,;;;'-;C
ou' - -- - -- - t -'Puller shaft and nut
07916-MBoo002 07931·HB3020A (U.S.A. only) 07931-ME400oo
"
Puller sha"'ft- ----'---
07931-ME4010B (U.S.A. only)
Remover shaft. 15 mm
07936-KC10100 (not available in
Remover head, 15 mm
07936·KC10200 (not available in
U.S.A.)
U.S.A.)
Bearing remover, 15 mm Driver Oil seal driver attachment

07936-KC10500 (U.S.A. only) 07949-3710001 07GAD-PG40100
21-3
Pinion puller base Pilot, 32 mm
07HMC·M M80110 07MAD-PR90200
Cf
or Q7HMC·MM8011A (U.S.A. only)
TROUBLESHOOTING
Excessive noise
Wom or scored ring gear and axle splines
Wom or scored pinion gear and propeller shaft splines
Worn or damaged bearing
Worn pinion and ring gears
Excessive backlash between pinion and ring gears
Oil Iev81 100 low
Wobble or vibration in vehicle
• Axle not lightened properly
• Bent axle
Oil leak
Oille'o'81 too high
Clogged breather
Damaged seals
Loose case cover bolt
21-4
SYSTEM COMPONENTS
74 N'm (7.5 kgf-m, 551bHt)
137 N'm (14,0 kgf-m. 1011bHI)
'l;n~~~
- - ®~ r
46.5 N'm (4.7 kgf'm, 34 IbHt) ~
g 8 . \)I$1i))f
21-5
REAR AXLE REMOVAL
Remove the left rear wheel (page 18-4),
Remove the cotter pin (1) and loosen the hub nul [2]
while applying the rear brake.
Remove the hub nut and rear wheel hub [3].
Remove the brake drum (page 19·12).
Do nor ger grease Remove the following :

onto rhe brake shoe
- breather hose (1)
linings.
adjusting nuts (2)
jOint pins [3)
springs [4J
brake cables [5)
four panel nuts (6J
brake panel assembly (7]
O-ring [8] (from the brake panel)
Remove the four bolts (1), turn the left axle housing [2]
90 degrees and remove it.
Remove the side collar 11).

Remove the O-ring 12) from the left axle housing .
21-6
Remove the rear axle [1) by driving it from the left side
using a rubber mallet.
11]
INSPECTION
AXLE
Set the axle in V-blocks and measure the axle runout
with a dial indicator.
Axle runout is 1/2 the total indicator reading . Indicator
~I
SERVICE LIMIT: 3.0 mm (0. 12 in)
20mm
jr
(0.8 in)
AXLE BEARING
Turn the inner race of the bearing with your finger.
t
•t
The bearing should turn smoothly and quietly . 20mm
Hold (0.8 in) Hold
Also check that the bearing outer race fils tightly in Ihe
axle housing or brake panel.
Indicator
AXLE BEARING REPLACEMENT

AXLE HOUSING
Remove the oil seal [1] and drive Ihe axle bearing (2)
out of the axle housing.
Drive a new bearing (1) into the axle housing until the
depth from the axle housing end is 11.0 - 11 .5 mm
(0.43 - 0.45 in). 11.0-11 .5mm
TOOLS : (0.43 - 0.45 in)
Driver (2J 07749-0010000
Attachment, 52 x 55 mm [3] 07746·0010400
Pilot, 32 mm [4] 07MAO-PR90200
13] [4] 11]
21-7
REAR DRIVING MECHANISM 1
Apply grease to the lip of a new oil seal [1).
Install the oil seal with the metal plate side facing up so
that it is flush with the axle housing end.
TOOLS :
Driver [2] 07749-0010000
Attachment, 62 x 68 mm (3) 07746·0010500
BRAKE PANEL
Remove the dust seal [1] and snap ring [2].
Drive the axle bearing [3] out of the brake paneL
Pack the cavities of a new bearing [1] with 4 - 5 9 (0.14

- 0.18 oz) of grease ,
~~~:;;:~~ir==:::~~===~
Support the bearing Drive the bearing squarely with Ihe sealed side facing
housing section of up until it is fully seated.
1M brake panel
when installing.
TOOLS:
Driver [2] 07749-0010000
Attachment, 62 x 68 mm [31 07746-0010500
Pilot, 28 mm [4] 07746·0041100
Install the snap ring PI with the chamfered edge facing

the bearing securely.
~:;~~!~~~~;;;~;;;;~~~~
Apply grease to the lip of a new dust seal [2].
Install the dust seal with the nat side facing up so thai it
is flush with the panel.
21·8
REAR BRAKE PANEL STUD BOLT
REPLACEMENT
Thread two nuts onto the stud bolt and lighten them ~----------------,
together, and use a wrench on them to turn the stud boll

out.
Inslall new stud bolls
After installation, check that the length from the bolt
head to the steering bearing holder surface is within
specification.
16-18mm
(0.6 - 0.7 in)
REAR FINAL DRIVE REMOVAL

Drain the gear case oil (page 3-22).
- skid plate (page 2-7)
- rear axle (page 21-6)
Disconnect the breather hose [1J from the final gear
case.

- four bolts [1] (while supporting the gear case
securely)
- gear case assembly [2J
- O-ring [3]
- joint spring [1]

- propeller shaft {2]
- universal joint [3]
- O-rings (4] (from the propeller shaft and output shaft)
21-9
INSPECTION
PROPELLER SHAFT
Check the splines (1] of the drive shaft [2] for wear or ' - - - - - - - - -[2-[- - - - - -[-3]- - ,
damage .
If the they are damaged , check the pinion and universal
joint splines also.
Check the joint spring [3J for fatigue or damage.
[1]
UNIVERSAL JOINT
Check the boot [1) for cuts or other damage.
Check thai the jOint moves smoothly without binding or
noise.
OPERATION CHECK
Temporarily install the propeller shaft [1] .
Turn the propeller shaft and check that the gears turn
smoothly and quietly without binding.
If the gears do not turn smoothly or quietly, the gears
and/or bearing may be damaged or faulty.
They must be checked after disassembly: replace them
if necessary.
JOINT BOOT REPLACEMENT

Bend up the lock tabs [11 and raise each band end [2]10 , - - - - - - - - - - - - - - - - - ,
loosen the boot bands.
Remove the boot bands and joint boot [3] .
Install a new boot and sel it onto the universal joint
property.
[31
21-10
Install new boot bands (1] so the band ends (2) are
facing opposite the forward direction.
Viewed from the rear side:
Bend down each band end and secure it with the lock
tabs [3]. Tap the lock tabs with a plastiC hammer.
[3J
"-
fi l'l / [2J
REAR FINAL GEAR OISASSEMBLVI

INSPECTION
BACKLASH INSPECTION
Set the gear case assembly in a vise.
Hold the pinion gear with the special tools.
TOOLS :
Puller shaft and nut [1 ] 07931-ME40000
Pinion puller base [2] 07HMC-MM80110
U.S.A. TOOL :
Puller shaft 07931-ME4010B
Special nut 07931-HB3020A
Pinion puller base 07HMC-MM8011A
Install the rear axle [3] into the gear case assembly.
Set a horizontal type dial indicator [1J on the ring gear

[2) through the oil filler hole.
Turn the ring gear back and forth with the axle to read
backlash .
STANDARD : 0.05 - 0.25 mm (0.002 - 0.010 in)
Remove the dial indicator. Turn the ring gear 1200 and
measure backlash. Repeat this procedure once more.
Compare the difference of the three measurements.
SERVICE LIMIT : 0.2 mm (0.01 in)
If the difference in measurements exceeds the service

limit, it indicates that the bearing is not installed 111
squarely , or the case is deformed .
Inspect the bearings and case.
21-11
If the backlash is excessive, replace the ring gear right
side shim [1 J with a thinner one. 121
If the backlash is 100 small. replace the ring gear right
side shim with a thicker one.
Backlash changed by about 0 .06 mm (0.002 in) when
thickness of the shim is changed by 0.12 mm (0.005 in). i
Ring gear shim s:
i
A: 1.26 mm (0.050 in) G: 1.62 mm (0.064 in» I
B: 1.32 mm (0.052 in)
c: 1.38 mm (0.054 in))
0 : 1.44 mm (0.057 in)
H: 1.68 mm (0.066 in)
I: 1.74 mm (0.069 in)
J : 1.80 mm (0.071 in)
-'-*-'! .-
E: 1.50 mm (0.059 in) K: 1.86 mm (0.073 in)
F: 1.56 mm (0.061 in)
111
Change the left side shim [2] as follows: If the right shim '---------'-'-----------~
was replaced with a 0.12 mm (O,OOS in) thicker shim,
replace the left shim with one that is 0.12 mm (0.005 in)
thinner.
REAR FINAL GEAR CASE

DISASSEMBLY
Loosen the eight cover bolls 11] in a crisscross pattern r - - - - c - , - - - - - - - - - - - - -,
in several steps and remove them.
Be careful not to Remove the case cover [2] by lightly tapping it.
damage the mating
surfaces.
Remove the ring gear [1) and shims (2) .
121
21-12
BEARING INSPECTION
Turn the inner race of the bearing {1] with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fils tightly in the
gear case or cover.
Ring gear bearing replacement (page 21-16).
GEAR TOOTH CONTACT PATTERN

CHECK
Keep dust and dirt Clean sealing malerial off the mating surfaces of the
out of the case and gear case and cover, being careful not to damage them. Apply Blue
cover.
Apply thin coal of Prussian Blue to the pinion gear teeth
for a tooth contact pattern check.
Install the right shim [1] onto the ring gear {21 .
Install the ring gear [11 with the shim into the gear case.
Install the left shim [2] onto the ring gear.
{21
It is important 10 Install the case cover [1], 10 mm bolts [2} and 8 mm ~=================~
tum the pinion gear bolts {3]. and lighten the bolts in several steps until the
while tightening the cover evenly touches the gear case.
bolts. If the ring Then , while rotating the pinion gear, lighten the bolts to
gear shim is too the specified torque in a crisscross pattern in several
thick. the gears wjfJ steps.
lock after only light
tightening. TORQUE: 10 mm bolt: 46.5 N·m (4.7 kgf·m, 34 1bHt)
8 mm bolt : 25 N·m (2.5 kgf-m, 18 IbHt)
{11
21-13
Normal:
Rotate the ring gear several limes in both directions of
rotation.
Check the gear looth contact pattern through the oil
Heel ~
filler hole.
The pattern is indicated by the Prussian Blue applied to Too
the pinion gear.
Contact is normal if the Prussian Blue is transferred to Face-- _ Face
the approximate center of each tooth, but slightly to the
heel side and to the flank side. IcP """ I
Flank Flank
If the patterns are not correct, remove and change the
pinion shim wi th one of an alternate thickness. Drive side Coast side
Replace the pinion shim [1) with a thicker one if the ;=============
Too High:
11=1====~
contact pattern is too high, toward the face .
Drive side
je? ~j Coast side
Replace the pinion shim [1] wi th a thinner one if the

Too Low: [11
contact pattern is too low, toward the flank.
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in)
(0.005 in).
Pinion shims:
A: 1.82 mm (0.072 in) F: 2.12 mm (0.083 in)
B: 1.88 mm (0.074 in) G: 2.18 mm (0.086 in)
I~ ~ I
c : 1.94 mm (0.076 in) H: 2.24 mm (0.088 in)
D: 2.00 mm (0.079 in) I: 2.30 mm (0.091 in)
E: 2.06 mm (0.081 in) Drive side Coast side
Pinion shim replacement (page 21-15).
Flank Flank
PINION GEAR REMOVAL
Remove the oil seal [11 from the gear case.
21·14
Be careful that Unstake the bearing lock nut [1] wi th a drill or grinder.
melal parricles do
nor enter the
bearing and the
threads of the case
are not damaged.
Remove the lock nut and discard it.
TOOL:
lock nut wrench , 30 x 64 mm [1] 07916·MB00002
Install the special lools onto the pinion gear and gear
case.
~.~~~;;~~~IIII~~~I11I111~==l
TOOLS :
Puller shaft and nut [1] 07931-ME40000
Pinion puller base (2) 07HMC-MM80110
U.S.A. TOOL:
Puller shaft 07931-ME40108
Special nut 07931-HB3020A
Pinion puller base 07HMC·MM8011A
Pull the pinion gear assembly [3] out from the gear
case.
[2[
PINION BEARING AND SHIM
REPLACEMENT
Pull the bearing [1] from the pinion gear [2] with a ...------:..,-------=----~-.,
commercially available bearing puller.
Remove the bearing and shim.
21-15
Install the shim [1 1 and a new bearing (2] onto the pinion
gear 13].
NOTE :
When the gear set, ring gear bearing, and/or gear
case has been replaced , use a 2.00 mm (0 .079 in )
thick shim for initial reference.
111
Press the pinion gear [1] into the bearing [2] until it is ~=====::::;;;;::======~
fully sealed by supporting the bearing inner race.
TOOL
Attachment, 35 mm 1.0 . [3] 07746-0030400

REPLACEMENT
RING GEAR BEARING
Remove the oil seals [1] from the gear case and cover.
Drive the bearings [2] out of the gear case and cover.
21-16
Drive new bearings into the gear case and cover.
TOOLS :
Cover side :
Driver (1) 07749-0010000
Attachment, 62 x 68 mm [2] 07746-0010500
Pilot, 35 mm [3] 07746·0040800
Case side :
Driver [11 07749-0010000
Oil seal driver attachment [4] 07GAD·PG40100
Pilot, 35 mm [3] 07746-0040800
131
121
Case side:
Apply grease to the seal lips of new oil seals. liiiiiiiiii~i~ir==J~===l

Inslall each oil seal (1] with the flat side facing out so ~
thai it is flush with the case or cover.
TOOLS:
Driver [2] 07749-0010000
Attachment, 52 x 55 mm (3) 07746-0010400
PINION NEEDLE BEARING

Rotate the stopper ring [1] unlil ils end appears in the ,--~
access hole (2).
Strike genlly near Ihe end of the ring wllh a punch to
bend the end upward.
Grasp the end of the ring with needle-nose pliers and
pull the stopper ring out through the access hole.
Be sure to wear Heat the gear case to about 80~C (176 ~ F ) and remove
heavy gloves to the needle bearing [3], using the special lools.
aVOId bums when
handling the healed
TOOLS :
gearcasB. Remover head , 1S mm 07936·KC10200
Using a torch 10 Remover shaft, 1S mm 07936·KC10100
heat Ihe gear case Remover weight 07741-0010201
may cause U.S .A. TOOLS :
warpage. Bearing remover, 1S mm 07936·KC10500
21·17
Install a new stopper ring [1] into the groove in a new
Make sure the

bearing.
Install the bearing into the compressor until the stopper
....
[11 ¢>"
stopper ring stays in ring is flush with the end of the tool.
the groove.
TOOL:
Bearing clip compressor, 070ME·HN80100 or
26 mm [2] 070ME·HN8A100
(U.S.A. only)
Place the driver, attachment and pilot on the top of the

bearing and tape the driver to the compressor 111 .
TOOLS :
Driver [2] 07949·3710001
Attachment, 24 x 26 mm [3] 07746-0010700
Pilot, 15 mm [4] 07746-0040300
Place the bearing and 1001 assembly into a freezer for at
least 30 minutes.
Heat the gear case to ao°c (176°F).
Remove the bearing and tool assembly from the freezer
and drive the bearing into the gear case using the
special tools.
Only strike the driver once. If you strike it more than
once, the stopper ring [51 may slip out of the groove. If
this happens, remove the ring and bearing, and install a
new ring.
Make sure the stopper ring is securely set in the groove
of the gear case.
21-18
REAR FINAL GEAR ASSEMBLY REAR DRIVING MECHANISM
C/b'" GEAR CASE ~ 12 N'm (1.2 kgf.m, 9lbHt)
.... - - . , ~O-RING C/b'" -

OIL SEAL "f ..... - -
C/b'" ~ BALL BEARING
....... (ffg(I/ (35x60x14)
STOPPER RING RING GEAR
SHIM
BALL BEARING
NEEDLE
(6007)
BEARING
(15x26x17)
8 mm BOLT
25 N'm (2.5 kgf'm,
181bHt)
111--.,
Oil SEAL
SHIM
GEAR CASE COVER

BALL BEARING
(6007)
~ 98N ·m(10.0kgf-m, 10 mm BOLT

12N·m(1,2kgf-m.
"'.... 72 IbN!) 46.5 N'm (4.7 kgf-m.
91bHI)
34 IbHt)
21-19
PINION GEAR INSTALLATION
Blow compressed air through the breather hole [11 in , - - - - - -- - --,,-
the gear case,
Drive the pinion gear assembly into the gear case.
TOOLS:
Driver [1] 07749-0010000
Attachment, 42 x 47 mm (2] 07746-0010300
Fork seal driver weight [3J 07747'()010100
Inslall a new lock nul [11 and tighten it.
TOOL:
Lock nut wrenc h , 30 x 64 mm (2) 07916· MB00002
Refer to ·Service TORQUE : Actual : 98 N"m (10.a kgf'm, 72lbHt)

Information " for Indicated : 89 N'm (9.1 kgf'm, 661bHt)
torque wrench
reading information
(page 21-2).
Be careful not 10 Stake the lock nut into the case groove.
damage the threads
of/he csse.
21-20
Apply grease to the lips of a new oil seal [1] and install it
so thaI it is flush with the gear case.
RING GEAR CLEARANCE

INSPECTION
Instalilhe ring gear [1J with the left shim into the case , - - - - - - - - - - - - - - - - -,
cover [2J.
Measure the clearance between the ring gear and stop
pin [3) with a feeler gauge.
CLEARANCE: 0.3 - 0.6 mm (O.01 - 0.02 in)
Remove the ring gear.
Be sure fa wear If the clearance exceeds Ihe standard value, heat the
heal'}' gloves to case cover to approximately Boac (176"F) and remove
avoid bums when the stop pin by tapping the cover.
handling fhe healed
Install a stop pin shim [4] to obtain the corfect
case cover.
clearance.
Using a torch /0
heal the cover may Stop pi n s hims:
cause warpage. A: 0. 10 m m (0.004 in)
B: 0. 15 mm (C.006 in)
Install Ihe shim and drive the stop pin into the case
cover.
FINAL GEAR CASE ASSEMBLY

NOTE :
When the gear set, bearing, andlor gear case has
been replaced, check the tooth contact pattern
(page 21-13) and gear backlash (page 21-11).
Keep dust and dirt Clean the mating surface of the gear case and cover,
oul of the case and being careful not to damage them.
cover.
Install the proper ring gear shims [1] onto the ring gear
[2) and install them into the gear case.
111
21-21
I
I
I
REAR DRIVING MECHANISM ~
Apply liquid sealant (TB1215 or equivalent) to the ~
mating surface of the case cover [1].
Inslallthe cover onto the gear case [2J .
Itisimportanl/o
/Urn the pinion while
Apply locking 8genllo the threads of the two 10 mm
bolts [1].
;::=================c;
tightening the bolts. Inslall the two 10 mm bolts and six 8 mm bolts 12]. and
I'the ring gear shim tighten them several sleps until the cover [3J evenly
is too thick. the touches the case. Then, while rotating the pinion gear,
gears will Jock after tighten the bolts to the specified torque in a crisscross
only light tightening. pattern in several steps.
TORQUE: 10 mm bolt: 46.5 N'm (4.7 kgf'm, 341bHt)

8 mm bolt: 25 N'm (2.5 kgf'm , 18Ibf-ft)
Make sure that Ihe gear assembly rotates smoothly
without binding.
REAR FINAL DRIVE INSTALLATION

Coat a new O-ring (1) with molybdenum disulfide
grease and install it into the groove in the output shaft.
Apply molybdenum disulfide grease to the splines of
both sides in the universal joint [2].
Install with the small Instalilhe universal joint onto the output shaft until it is
0 .0 . side facing the fully seated .
engine.
Coat a new O-ring {1] with molybdenum disulfide

grease and install it into the groove in the propeller
shaft [2}.
Install the propeller shaft into the universal joint until it is
fully seated.
21-22
Coat a new O-ring [11 with grease and install it into the
gear case groove.
Apply molybdenum disulfide grease to the splines of the

propeller shaft [1] .
Install the joint spring (2) into the propeller shaft firmly.
Install the gear case assembly [3] onto the propeller
shaft by aligning the splines, and onto the swingarm.
Install the four mounting bolls [1] and tighten them to

the specified torque.
TORQUE : 74 N·m (7.5 kgf·m, 55 IbHt)
Connect the breather hose [1)to the final gear case.

- rear axle (page 21-24)
- skid plate (page 2-7)
21-23
REAR AXLE INSTALLATION
=>::.
Apply molybdenum disulfide grease to the center spline , - - - - - -- -,-, - - - - - - - - -'
(ring gear contacting area) of the axle (1]. ~
Inslall the axle into the final gear case from the right \
side until it is fully sealed.
Gear case side -+-
(1)
Coat a new O-ring [1J with grease and install it into the ~======::;;;;;;;=========~
groove in the left axle housing.
Install the side collar [2] onto the rear axle with the
tapered side facing inward.
Install the left axle housing [1 ' and turn it 90 degrees.

Install the four mounting bolts [2] and tighten them to
the specified torque.
TORQUE : 74 Nom (7 .5 kgf-m, 55Ibf-ft)
Do nol gel grease Coat a new O-ring [1] with grease and install it into the ~======~:=::'"~""''======;
onlo the brake shoe panel groove.
linings.
21-24
Inslalilhe brake panel assembly PI onto the axle.
Install new brake panel nuts (2] and tighten them to the
specified torque.
TORQUE: 46.5 N-m (4.7 kgf-m, 34Ibf·ft)
Install the brake cables [3} into the cable holders of the
brake panel (upper holder for lever brake cable and
lower holder for pedal brake cable).
Instalilhe cable springs (4) onto the cables.
Connect the brake cables to the brake arm wi th the joint
pins [S} and adjusting nuts [6J.
Connect the breather hose [7] to the hose joint on the
brake panel.
Wheneverbofh hub InstaJi the brake drum, drum cover and right wheel hub,
nuts are removed. and tighten the right wheel hub nut (page 19- t 5).
lighten the n"ghl side
first, then tighten the
left Side .
Do no/ gel grease Apply molybdenum disulfide grease to the axle spline
on the axle threads. [1] and install the wheel hub [2] onto the axle .
Apply sealant to the hub nut threads and install it.

Apply rear brake and tighten hub nut [1] to the specified
torque and further tighten it until its grooves align with
the cotter pin hole.
TORQUE : 137 N·m (14.0 kgf·m , 1011bHt)
Install a new co tter pin [2].
Install the left rear wheel (page 18-4).
Fill the gear case with the recommended oil if the gear
case was disassembled (page 3-21).
~ 12J
21-25
MEMO
22. SATTERY/CHARGING SYSTEM
SERVICE INFORMATION ···························22-2 CHARGING SYSTEM INSPECTION ··········22-6
TROUBLESHOOTlNG ·································22-3 ALTERNATOR CHARGING COIL··· ·········· ·22-7
COMPONENT LOCATION ··························22-3 REGULATOR/RECTIFIER .......................... 22-7
SYSTEM DIAGRAM ···································· 22-4 MAIN POWER RELAY········ ··················· .. ·.. 22-8
BATTERY ···················································· 22-5
22·1
BATTERY/CHARGING SYSTEM
!
j
SERVICE INFORMATION
GENERAL
1
AWARNING
The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately.
NOTICE
Always tum OFF the ignition switch before disconnecting any electrical component.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space.
For a battery remaining in a stored vehicle, disconnect the negative battery cable from the battery.
The maintenance free battery must be replaced when it reaches the end of its service life.
The battery can be damaged if overcharged or undercharged, or if left 10 discharge fo r long period. These same conditions
contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after
2 ~ 3 years.
Battery voltage may recover after battery charging, but under heavy load, the battery vol tage will drop quickly and eventually die
out. For this reason, Ihe charging system is often suspected as the problem. Battery overcharge often results from problems in
the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage
does not increase, the regulatorfrectifier 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
frequenlly under heavy load, such as having the headlight and taillight on fo r long periods of time withou t riding the vehicle.
The battery will self-discharge when the vehicle is not in use. For this reason, charge the battery every two weeks to prevent
sulfation from occurring.
When checking the charging system, always follow the steps in the troubleshooting (page 22-3).
For alternator removalfinstallation, refer to Alternator/Starter Clutch section (page 14-6).
BATIERY CHARGING
Turn power ON/OFF at the charger, nol at the battery terminal.
For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending
the charging time may damage the battery.
Quick charging should only be done in an emergency; slow charging is preferred.
BATIERY TESTING
Refer to the instructions in the Operation Manual for the recommended battery tester for details about battery testing . The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
Recommended battery tester: Micro 404XL (U.S.A. only)
22·2
TOOLS
~
I
Motorcycle battery analyzer Christie battery charger
Micro 404Xl (U.S.A. only) MC1012/2T (U.S.A. only) I
or OptiMate Pro-4 battery charger
Model: TMNTS53 (U .S.A. only)
.... ,.---, "

~ ....
-=
c:.-:.-.
lJ
."
._ il..-J'
,...,
~,~.
='='''- _
00 (JJ(f,
0- utN-;..'7:' l1
TROUBLESHOOTING
Unusual condition Probable cause_(Check in numerical order)
Battery Battery is damaged or weak 1, Faulty battery
2. Current leakage higher than specified value
- Faulty ign ition switch
- Shorted wire harness
3. Faulty alternator charging coil
4. Faulty regula torireclifier
5 . Faulty main power relay or its circuit
s _ _~
6. Open circuit or loose connection in the wire harne" ,,,
COMPONENT LOCATION
FA2 model shown:
IGNITION SWITCH
FUSE BOX: RELAY BOX

- MAIN FUSE 1 (30 A) - MAIN POWER RELAY
-IGN FUSE (20 A) -:;~",,~~~~:c.-----~
- DIODE r 'I.""fJ1iil
eKP SENSOR
ALTERNATOR
RECTIFIER
22-3
SYSTEM DIAGRAM
DIODE MAIN FUSE 2
(10 A)
~Rf'(
~ MAIN FUSE 1
(30 A)
-
IGNITION SWITCH
0- 81 -vvv ~
IGNFUSE
MAIN
(20 A)
y
I BlfR
RELAY
VIW
eKP
tL
Y Y R G
SENSOR
REGULATOR!
RECTIFIER
PCMIECM
o~ Pe~e""
L-_ _ _ _- ' BufY G BATIERY
ALTERNATOR
* L-_ _----'
22-4
BATTERY
Turn the ignition switch OFF and disconnect the
negative (-) cable [IJ first, then disconnect the positive
(+) cable [2) by removing the terminal bolts.
Remove the battery holder band [3].
Remove the battery [4].
NOTE :
Connect the positive (+) cable first and then the
negative (-) cable.
If the battery is being replaced, the battery boot
(50334-HRO-F00 1) should be taken off the battery
that is being removed and applied to the new
battery.
VOLTAGE INSPECTION
--- f;F
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (20°C/68°F):
Fully charged: 13.0 -13.2 V
Under charged : Below 12.3 V 0"
. (
.
,
e.
:o ~
''\
,
'\1
"j,
~
."
/
• -
.".. .......
" '7
\ ~
~
BATTERY TESTING
Remove the battery (page 22-5).
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Motorcycle battery Micro 404XL (U .S.A. only)
analyzer
BATTERY CHARGING (U,S,A, only)

Remove the battery (page 22-5).
Refer to the instructions that are appropriate to the
battery charging equipment available to you .
TOOL:
Christie battery charger MC101212T (U.S.A. only) or
OptiMate Pro-4 battery Model : TMNTS53 (U.S.A.
charger only)
22-5
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Turn the ignition switch OFF and disconnect Ihe
negative H cable (1] from the battery.
Connect the ammeter (+) probe [2J to the negative H
cable and the ammeter H probe [3) to the battery H
terminal [4].
With the ignition switch turned OFF , check for current
leakage.
NOTE :
When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the range
selected may blowout the fuse in the tester.
While measuring current, do not turn the ignition
switch ON . A sudden surge of current may blowout
the fuse in the tester.
SPECIFIED CURRENT LEAKAGE:

TM1 : 0.012 rnA maximum
TE1 /FM1 /FM2JFE1 : 0.27 rnA maximum
FAlIFA2 : 0.3 rnA maximum
If current leakage exceeds the specified value, a

shorted circuit is likely.
locate the short by disconnecting connections one by
one and measuring the current.
CHARGING VOLTAGE INSPECTION

NOTE :
• Be sure the battery is in good condition before
performing this test.
Warm up the engine to normal operating temperature.
Connect the multimeter between the battery positive (+)
and negative (- ) terminals.
NOTE:
To prevent a short, make absolutely certain which
are the positive (+) and negalive (-) terminals or
cables.
Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tester or electrical components.
Restart the engine and turn the headlight on.
Measure the voltage on the multimeter when the engine
runs at 5,000 rpm.
Standard :
Measured BV <: Measured CV <: 15.5 V
BV =- Battery voltage (page 22-5)
• CV =- Charging vo ttage
22-6
ALTERNATOR CHARGING COIL
INSPECTION
Disconnect the altemator 3P (Gray) connector [1].
Check the connector for loose contacts or corroded
terminals.
Measure the resistance between the Yellow wire
terminals of the alternator side connector.
Standard : 0.1 - 1.0 Q (20 ~CI68° F)
Check for continuity between each Yellow wire terminal

of the alternator side connector and ground.
Replace the alternator stator if resistance is out of
specification, or jf any wire has continui ty to ground.
For alternator stator replacement (page 14-6).
REGULATOR/RECTIFIER
Remove the two mounting bolts [1] and regulatorl
rectifier [2].
Disconnect the stator 3P (Gray) connector [3) and
regulator/rectifier 3P (Black) connector [4].
WIRE HARNESS INSPECTION

Remove the rea r fender cover (page 2-8).
Disconnect the regulator/rectifier 3P (Black) [1]
connector.
Check the connectors for loose contacts or corroded
terminals.
Check the following at the wire harness side
connectors.
Battery Line (B lack connector):
Measure the voltage between the Red wire terminal
and ground.
There should be battery voltage at all times.
Ground Line (Black connector):
Check for continuity between the Green wire terminal
and ground.
There should be continuity at all times.
22-7
MAIN POWER RELAY
RELAY INSPECTION
Remove the relay box lid (page 6-8),
Remove the main power relay [11.
Connect an ohmmeter to the main power relay [1] ,-- - - - - - - - -- - - - - - - - - - ,

terminals. [1J
Connect a 12 V battery to the relay terminals as shown. \
There should be continuity when the 12 V battery is
connected and no continuity when the battery is
disconnected.
DIODE INSPECTION
Remove the fuse box cover and diode [1].
Check for continuity between the diode [1) terminals.

When there is continuity, a small resistance value will
register.
If there is con tinuity in one direction, the diode is
normal.
.III< I' A
B
A
C B
22·8
23. LIGHTS/METERS/SWITCHES
SERVICE INFORMATION ·· .. ·······················23-2 GEAR POSITION SWITCH

(Excep1 FA1/FA2 models) ...................... · 23-10
COMPONENT LOCATION .......................... 23-2
FRONT BRAKE SWITCH · ...... · ................ · 23-11
HEADLIGHT .......... · .. · ........ · .. · ...... · .. · ...... · .... ·23-3
REAR BRAKE LIGHT SWITCH .......... · .... · 23-11
BRAKE/TAILLlGHT .. · ...... · .. · ................ · .. · .... 23-4
COOLING FAN .......................................... 23-13
COMBINATION METERIINDICATOR ........ ·23-4
FUEL GAUGE/FUEL INDICATORIFUEL
IGNITION SWITCH .... ·· .. · .... · ...... · .. ··· .. · .. ·.. ·· .. 23-9 LEVEL SENSOR ....................................... 23-14
HANDLEBAR SWITCH .... ·· .................. ·· .. ·23-10 4WD SELECT SWITCH/4WD INDICATOR

(Except TM1/TE1 models) · .... · ................ ·23-17
23-1
SERVICE INFORMATION
GENERAL
I NOTICE
Note the following when replacing the halogen headlight bulb.
- Wear clean gloves while replacing the bulb. 00 not put fingerprints on the headlight bulb, as they may create hot spots on the
bulb and cause it to fail.
- If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.
All plastic connectors have locking tabs that must be released before disconnecting. and must be aligned when reconnecting .
To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be
made without removing the part from the vehicle. Simply disconnect the connectors and connect a continuity tester to the
terminals or connections.
BI: Black Bu : Blue Gr: Gray Lg: Ught green P: Pink V : Violet Y: Yellow
Br: Brown G: Green Lb: Ught blue 0: Orange R: Red W:White
TOOL
Pin Probe Male (2 pack)
07ZAJ-RDJA 110
COMPONENT LOCATION
FA2 model shown: REAR BRAKE LIGHT COMBINAliON METER
SWITCH (LEVER SIDE) - - _ - , _
=1".1i~".----- FRONT BRAKE SWITCH
HANDLEBAR SWITCH
IGNITION SWITCH ---7~~1~~~~
COOLING MOTOR
4WD '<LEGl SWITCH

REAR BRAKE LIGHT
SWITCH (PEDAL SIDE)
GEAR SWITCH
23·2
LIGHTS/METERS/SWiTCHES
HEADLIGHT
BULB REPLACEMENT
Remove the headlight cover cap [1).
Disconnect the headlight 3P connector [2J .
Remove the headlight bulb [3] by turning it
counterclockwise.
NOTICE
Avoid touching halogen headlight bulb. Finger prints
can create hot spots that cause a bulb to break.
Align the bulb tabs lnslall a new bulb in the reverse order of removal.
with the headlight
grooves properly.
[1J
REMOVAL/iNSTALLATiON
Remove the headlight cover cap [1].
Disconnect the headlight3P connector [2] .
- screws 13]
- mounting bolt [4)
- headlight assembly [5]
i5J i4J
Release the screw [1 ] from the headlight cover [2J.
Remove the headlight [3] by unhooking its bosses (4]
from the headlight cover holes [5] .
Route the headlight Install the headlight unit in the reverse order of removal.
wire info the groove
After installing the headlight to the cover, align the
in the headlight
headlight lens snap fit with the headlight cover lug
cover properly.
by turning the adjusting screw as shown .
23-3
After inslalling the headlight assembly, adjust Ihe
headlight aim by turning the adjusting screw [11 if
necessary.
BRAKE/TAILLIGHT
REPLACEMENT
Open the tool box lid.
{5) {1 {
Remove the clip [11.
Remove the brake/taillight [2] from the tool box lid by
releasing the bosses [3J from the grommets (4).
Disconnect the brake/taillight 3P connector [51.
Route the wire Install a new brake/taillight in the reverse order of
properly (page f- removal.
23).
{4)
{2)
COMBINATION METER/INDICATOR
{NITIAL OPERATION CHECK (Except
TM1 model)
When the ignition switch is turned ON, the combination r-------------------,
meter turns aU the indicators on and shows alilhe LCD
digital segments for a few seconds.
If the combination meter does nol shows the initial
operation. check its power/ground lines (page 23-6).
If the power/ground lines are OK, replace the
combination meter assembly (page 23-5).
23-4
Remove the three bolts [1] and handlebar cover/slay , --,---,..
assembly [2).
Except TM1 model: Slide the boot [lJ and disconnect r - - - - - - - - - - - - - - -, .

the 16P connector [2) from the combination meter.
TM1 model: Raise the rear of the front fender/carrier
(page 23-9) , remove the indicator socket lOP (Gray)
connector from the clip and disconnect it.
Remove the three cover screws [3) and handlebar
cover [41from the meter cover stay [5] .
Except TM1 model: Remove the three combina tion ,--------------:-,.~
meter mounting screws (1) and meier [2) from the meter
cover slay.
TM1 model: Remove the three screws (1] and indicator
slay from the meter cover stay.
TORQUE:
Combination meter mounting s c rew:
0.8 N'm (0.1 kgf'm, O.6lbHtj
CLOCK ADJUSTMENT
Turn the ignition switch ON and select the digital clock , - - - - -- - - - - - - -- - - - - - ,
mode with the mode select button [1].
To enter the adjustment mode , press and hold mode
select button until the clock display start blinking .
To advance the clock display, press and hold the mode
select button.
First 5.5 seconds, the clock display wilt advance one
unit at a time.
After 5.5 seconds, the clock display will advance five
unit at a time.
After 10.5 seconds, the clock display will advance
ten unit at a time.
After completing the adjustment, press the mode select L~[l~I_ _ _ _ _ _ __ _ _ _ _ __ __ ___"
button or turn the ignition switch OFF.
23-5
POWER/GROUND LINE INSPECTION
(Except TM1 model)
Remove the handlebar coverfs tay assembly
(page 23-5).
Slide the boot [I] and disconnect the 16P connector [2]
from the combination meter.
Check the power and ground lines at the wire harness
side 16P connector.
POWER INPUT LINE

Measure the voltage between the 16P connector [1]
terminal and ground. [1 J BI/R
Connection: Black/red (+) - Ground H

There should be battery voltage with the ignition switch
turned ON.
If there is no voltage, check the following:
- faulty circuit between the battery and IGN fuse
(20 A) (page 4-36)
EfJ
- Black/red wire between the combination meter and
fuse box for an open circuil V
BACK·UP VOLTAGE LINE

Measure the voltage between the 16P connector [11 C:-11~1-------------------'
Connection : Red/yellow (+) - Ground (-)

There should be battery voltage with the ignition switch
turned ON. 00000 0 0
If there is no voltage, check the following:
- MAIN fuse 2 (10 A)
EfJ
- Red/yellow wire between the combination meter and
fuse box for an open circuil
V
GROUND LINE
Check for continuity between the combination meier r-
[1-
J ----------------~
16P connector [11 terminal and ground.
There should be continuity all times.
If there is no continuity, check for an open circuit in the
Green wire.
G
23-6
SERIAL COMMUNICATION LINE
(Except TM1 model)
Gear position indicator continuously blinks
MIL, engine coolant temperature, neutral and
reverse indicators stay on
1. PCM /ECM Power Input Inspection
Check that the engine can be started normally.
Can the engine start?
NO - Check the PCM/ECM power/ground line
(page 4-35).
2. Connector Inspection
Check the combination meter 16P connector and
PCM/ECM 33P (Black) connector for loose contacts
or corroded terminals.
Are the connectors in good condition ?
YES - GO TO STEP 3.
NO - Loose or poor contacts at the combination
meter 16P connector or PCM/ECM 33P
(Black) connector
3. Serial Communication Line Short Circuit
Inspection
Disconnecllhe PCM/ECM 33P (Black) connector 11}
111
(page 4-35) and combination meter 16P connector
(page 23-5).
PCM/ECM 33P (Black) connector terminal and
ground .
TOOL: . 1
Connection: Pink (A21) - ground

P (A21)
YES - Short circuit in the Pink wire
NO - GO TO STEP 4.
4. Serial Communication Line Open Circuit
Inspection
Check for continuity between the 33P (Black)
connector [1} and 16P connector [2} terminals. v
TOOL:
Connection: Pink (A21) - Violet

YES - GO TO STEP 5.
NO - Open circuit in the Pink or Violet wire P(A21)
121 111
23-7
5. PCMfECM Circuit Inspection
Connect the PCM/ECM 33P (Black) connector.
Turn the ignition switch ON and wail 5 seconds or 11]
more. Measure resistance at the 16P connector (1]
terminals.
Connection: Violet - Green
Is the resistance 0.1 kD - 100 kO ?
YES - Replace the combination meter wi th a
known good one, and recheck.
NO - Replace the PCM/ECM with a known good G
one, and recheck.
SPEEDOMETER (Except TM1 model)

Speedometer does not operate
1. Combination Meter Inspection
Check the combination meier initial operation (page
234).
Does the combination meter operate properly?
YES - ' Except FA1fFA2 : GO TO STEP 2 .
• FA1/FA2: GO TO STEP 3.
NO - Check the combination meter powerl
ground lines (page 23-6).
2. ESP System DTG Inspection
Check the ESP system OTG (page 24-7).
Is OTe 11· 1 indicated?
YES - Perform the DTG 11-1 troubleshooting
(page 24-10).
NO - GO TO STEP 4.
3. OCT System OTC Inspection
Check the OCT system OTC (page 13-13).
Is OTe 66-1 indicate d?
YES - Perform the DrC 66-1 troubleshooting
(page 13-30).
NO - GO TO STEP 4.
4. Speedometer line Open Circuit Inspection
Disconnect the VS sensor 3P (Black) connector
(page 24-20) and combination meter 16P connector 12] 11]
(page 23-5) .
Check for continuity between the 16P connector [1)
and 3P (Black) connector [21 terminals.
Connection : Pin k/green - Pink
YES - Replace the combination meter
(page 23-5).
p PIG
NO Open circuit in the Pink/green or Pink
wire
loose Of poorly connected related
connectors
23·8
IGNITION SWITCH
INSPECTION
Remove the tank cover assembly (page 2-4),
[3)
Loosen the lower bolts [1 J on both sides of the front
fender/carrier.
Remove the trim clips (2) and bolls (3] from both sides
of the front fender/carrie.
[1)
Remove the eight trim clips [1] from both right and left
mudguards.
~=;;~====;;;:==~[;21~=====l
[1)~ ~ ...
Remove the fuel lank cap [2] and raise the rear of the ~
front fender/carrier slightly.
Install the fuel tank cap.
Remove the ignition switch 4P connector [1J from the .iiiiiiiiiiiiiiiiiiiiiiiii;;;;~"iiiiiiiiiiiiiiil

clip and disconnect it.
Check for continuity between the switch side connector
terminals in each switch position according to the chart.
- TM1: page 26-2
- TE1 : page 26-3
- FM1: page 26-4
- FM2: page 26-5
- FE1 : page26-6
- FA1:page26-7
- FA2: page 26-8
REPLACEMENT
Disconnect the ignition switch 4P connector
(page 23-9).
[21
Remove the handlebar cover/stay assembly
(page 23-5).
Release the ignition switch wire from the wire band and
wire guides.
Remove the ignition switch P] from the handlebar caver
by pushing in the two stoppers 12J.
Install a new ignition switch by aligning the locating tab
[3] with the cover groove.
Insta ll the removed parts in the reverse order of
removal. [3) [11
23-9
HANDLEBAR SWITCH
INSPECTION
Raise the rear of the front fender/carrier (page 23-9).
Remove the 14P (TM1 model: BP) (Green) connector
[11 and disconnect it
Check for con tinuity between the switch side connector
terminals in each switch position according to the chart.
- TM1: page 26-2
- TE1: page 26-3
- FM1: page 26-4
- FM2: page 26-5
- FE 1: page 26-6
- FA1: page 26-7
- FA2: page 26-8
GEAR POSITION SWITCH (Except FA1!

FA2 models)
NOTE:
• Shift drum position switch service for FA 1/FA2
models (page 13-50).
INSPECTION
Remove the gear position switch BP (Gray) connector
[11 from the frame and disconnect it.
If the transmission Check for continuity at the switch side connector
terminals.
will not shift with the
gearshift switches, There should be continuity in each gear position as
use the gear follows:
included with the

tool kit (TE1/FE1
change/col
models).
~~~~~~~~i~~~i~:~~~~~
REPLACEMENT
Remove the two wire clamp bolts (1].
Remove the wire grommet (2) from the rear crankcase
cover.
Remove the retaining bolt (3J and gear position switch
(4) from the rear crankcase cover.
Apply locking agent to all the bolt threads.
Install a new gear position switch onto the rear
crankcase cover and tighten the retaining bolt.
Apply liquid sealant to the grommet seating surface.
Route the wire as shown and install the grommet into
the crankcase cover groove property.
Install the two clamp bolts and tighten them to the
specified torque _
TORQUE : 12 N-m (1.2 kgf·m , 9lbHt)
Inslallthe rear crankcase cover (page 14-9).
23-10
FRONT BRAKE SWITCH
INSPECTION
Disconnect the front brake switch connectors [1 J.
Check for continuity between the switch terminals.
There should be continuity with the front brake lever
squeezed and no continuity with the lever released.
REPLACEMENT
Slide the dust cover [1] and disconnect the front brake
switch connectors [21.
Squeeze the front brake lever and secure it.
Remove the screw [3J and front brake switch [4).
Install the front brake switch onto the master cylinder by
aligning Ihe boss with Ihe hole.
Install the screw and lighten it to the specified torque.
TORQUE : 1.2 N'm (0.1 kgf'm , 0.9 tbfoft)
Connect the switch connectors and install the dust

cover properly.
REAR BRAKE LIGHT SWITCH

LEVER SWITCH INSPECTION
Remove the dust cover [1] from the rear brake lever , - , - , - - - -- -- - - - - -------,
switch.
Disconnect the rear brake lever switch connectors (2]
and check for continui ty between the switch terminals .
There should be continuity with the rear brake lever
squeezed and no continuity with the lever released .
23-11
LEVER SWITCH REPLACEMENT
Apply parking brake.
Remove Ihe dust cover [1] from the rear brake lever
switch [2].
Disconnect the rear brake lever switch connectors [3).
Remove the screw (4] and switch from the brake lever
bracket.
Install the screw (1) and spacer [2J onto the rear brake r<-,....,..-" .
lever switch [3]
Install the switch onlo the brake lever bracket by
aligning the boss with the hole.
Tighten the screw to the specified torque.
TORQUE : 1.2 N-m (O.1 kgf-m , O.9IbHt)
Connect the connectors to Ihe switch.

Install the dust cover onto the switch properly.
PEDAL SWITCH INSPECTION

Remove the air deaner housing (page 7-17).
Disconnect the rear brake pedal switch 2P (Black)
connector [1] and check for continuity between the
switch side conneclor terminals.
There should be continuity with the rear brake pedal
depressed and no continuity with the pedal released.
23-12
COOLING FAN
Cooling fan does not start
1. Fuse Inspection
Check the fonowing:
- TMlIFM 1/FM2: FAN fuse (20 A)
- TElIFElIFA1fFA2:ESfuse(30A)
Is the (use blown ?
YES - Replace the fuse.
NO - GO TO STEP 2.
2. PGM-FI System DTC Inspection
Check the PGM-FI system OlG (page 4-6),
Is DTe 7-1 and/or 7-2 indicated?
YES - Perlorm the OTG 7-1 troubleshooting
(page 4-13).
Perform the OTG 7-2 troubleshooting
(page 4-14).
NO - GO TO STEP 3.
3. Ground line Inspection
Disconnect the PCM/ECM 5P (Black) connector [1]
(page 4-35).
Check for continuity between the PCM/ECM 5P
(Black) connector [1] terminal and ground.
Connection : Green - ground
Is ther e c ontinuity?
YES - GO TO STEP 4.
4. Cooling Fan Operation Inspection

Connect the PCMfECM 5P (Black) connector [1]
terminals with Jumper wire [2]. 11 J
Connection : Green/b lack - green G/SI
Check the cooling fan when connecting the jumper
wire. 121
Does the cooling fan start?
YES - Replace the PCM/ECM wi th a known good
one, and recheck.
NO - GO TO STEP 5.
23·13
5. Cooling Fan Ground Line Inspecti on
Remove the cooling fan 2P connector [1] from the , -- - - - - - - - - - - - - -- ,
frame and disconnect it (page 8-7).
With the jumper wire connected to the PCM/ECM
5P connector, check for continuity between the fan
molor 2P connector [2] terminal and ground.
Connection: Green/black - ground
YES - GO TO STEP 6.
NO - Open circuit in the Greenfblack wire
11)
6. Cooling Fan Power Input Line Inspection

Measure the voltage between the fan motor 2P [1] , - - - - - - - -- - - - - - - - ,
terminal (+) and ground (-).
Connection : Red/white (+) - ground (-)
YES - Replace the cooling fan with a new one
(page 8-8).
NO - Open circuit in the Red /while wire between
the cooling fan and fuse box
[1)
FUEL GAUGE/FUEL INDICATOR/FUEL

LEVEL SENSOR
SYSTEM INSPECTION (Except TM1
model)
Check that the combination meter shows the initial , - - -- - - - - - - - - - - - - ,
operation (page 234).
If the fuel mark and fuel gauge afe blinking with the
ignition switch ON, check for open or short circuit in the
GreenfyeUow andlor Yellowfwhite wire between the fuel
pump unit and combination meter.
If the wires are normal, replace the combination meter
(page 23-5).
23-14
Remove the fuel pump unit (page 7-12).
Connect the fuel pump unit 4P (Gray) connector.
With Ihe fuel level sensor noat [1) al the top (FULL)
position [2) . turn the ignition switch ON and check the
fuel gauge.
All segments up to segment "F" should come on .
(11
i'JE ••••• F
Move Ihe noat to the bottom (EMPlY) position . turn Ihe ~=================:::;
ignition switch ON and check Ihe fuel gauge.
The fuel mark and fuel gauge should blink three times,
Ihen Ihe fuel mark and "lOW FUEL" message should
blink three times. This indication is repeated.
If the fuel gauge does not function properly, check the
fuel level sensor (page 23-16 ).
If the fuel level sensor is OK, replace the combination
meter.
If all segments blink during inspection , replace the
combination meter.
Tum the ignition switch OFF .
Instalilhe fuel pump unit (page 7-13).
SYSTEM INSPECTION (TM1 model)

Turn the ignition switch ON and check thai the fuel ' - - - -- - - -- - - - - -[-,[- ---,
indicator (11 comes on for about 2 seconds and goes
off.
If the fuel indicator does not operate property and the
other indicator operate properly, check as follows:
23-15
111
Disconnect the ECM 33P (Black) connector
(page 4-35),
Ground the wire harness side 33P (Black) connector {1]
terminal with a jumper wire.
TOOL:
Connection : A33 - ground

Turn the ignition switch ON and check the fuel indicator.
A33
If the fuel indicator comes on, replace the ECM with a
known good one (page 4-36).
If the fuel indicator does not come on, check the
following:
- Open circuil in the Green/yellow wire between the
ECM and
- Faulty fuel indicator bulb
- Open circuit in the Blacklred wire between the fuel
indicator and joint connector
'.,"
Connect the fuel pump unil4P (Gray) connector.
131 ,---
The fuel indicator should come on with the fuel level
-,'
f
sensor float {1] at the bottom (EMPTY) position [2], and
should go off when the float is moved to the top (FULL) "
"
position [3]. ,,,"
If the fuel indicator does not operate properly, check the
fuel level sensor (page 23-16). [21
'';-:::'''1
111
FUEL LEVEL SENSOR INSPECTION
Measure the fuel level sensor resistance with the float
[1] at the top (FULL ) [2] and bottom (EMPTY) [31
positions.
Connection : Green - Yellow/white
FLOAT POSITION
TOP [FULLI 19.0 - 21 .00
BOnOM (EMPTY) 772.0 - 788.0 0
111
YIW
b G
23-16
4WD SELECT SWITCHI4WD
INDICATOR (Except TM11TE1 models)
SYSTEM INSPECTION
!f the gear position indicator continuously blinks "-",
MIL. engine coolant temperature, neutral and reverse
indicators stay on , check the serial communication line
(page 23-7 ),
Disconnect the 4WD select switch connector [11 .
Ground the switch connector terminal with a Jumper
wire .
Turn the ignition switch to ON and check the 4WD
indicator [2].
The indicator should light when the connector terminal
is grounded.
The indicator should not light when the jumper wire is
removed .
FM2IFA2 models : If the 4WD indicator operation is abnormal, check the
Brown/white wire between the 4WD select switch and
Except FM2JFA2
models:
EP$ ECU . and the Blue wire between the EPS ECU
and PCM/ECM .
If the 4WD indicator operation is abnormal, check the
Brown/white wire between the 4WD select switch and
®
@ 4WD
,-.-
LI.
PCM/ECM , fi_
Sii'--"":? .,~
[21
SWITCH INSPECTION
Disconnect the 4WD select switch connector [1] .
Check for continuity between the switch terminal and
ground.
There should be continuity when the 2WDI4WD select
lever is 4WD position, and no continuity when the lever
is 2WD position .
REPLACEMENT
Disconnect the 4WD select switch connector [1].
Remove the 4WD select switch [2] and sealing washer
131·
Install the 4WD select switch with a new sealing washer
and tighten it.
Connect the 4WD select switch connector.
23-17
MEMO
24. ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)
SERVICE INFORMATION ···················· .. ·····24-2 TROUBLESHOOTING INFORMATION ...... 24-7
COMPONENT LOCATION ············ ·········· ····24-3 DTC INDEX ·.. ··············································24-9
SYSTEM OIAGRAM ····································24-4 DTC TROUBLESHOOTING ...................... 24-10
BEFORE TROUBLESHOOTING·················24-5 VS SENSOR .............................................. 24-20
SYMPTOM TROUBLESHOOTING ·············24-5 SHIFT SPINDLE ANGLE SENSOR .......... 24-21
ELECTRIC SHIFT DOES NOT SHIFT CONTROL MOTOR!

OPERATE .................................................... 24-6 REDUCTION GEARS········ ··· ····················· 24-22
24-1
ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)
SERVICE INFORMATION
GENERAL
Refer to "Before Troubleshooting" first and begin the troubleshooting (page 24-5).
When performing the OIC troubleshooting , read "Troubleshooting Information" carefully, and inspect and troubleshoot
according to the DIG. Observe each step of the procedures one by one. Note the oTC and probable faulty part before starting
diagnosis and troubleshooting.
A faulty ESP system is often related to poorly connected or corroded connectors. Check those connections before proceeding.
The PCM may be damaged if dropped. Also, if the connector is disconnected when current is flowing , the excessive voltage may
damage the PCM. Always tum off the ignition switch before disconnecting or connecting the connectors.
Use a digital tester for ESP system inspection.
BI: Black Su: Blue Gr: Gray Lg: Light green P: Pink V: Violet Y: Yellow
Sr: Brown G: Green Lb: Light blue 0: Orange R: Red W:White
For ESP Troubleshootin g

The PCM controls the PGM-FI and ESP systems. Therefore some detection items are shared by the PGM-FI and ESP and they
may affect the operation of both systems.
Before starting any troubleshooting , check the items as follows and refer to the appropriate troubleshooting.
1. MIL blinks or OTC for the PGM-FI system (page 4-6).
2. Gear position indicator blinks or OTC for the ESP (page 24-7).
3. Symptom of the ESP operation (page 24-5).
Refer to PGM-FI System section for "General Troubleshooting" information (page 4-5).
TOOLS
SCS service connector Pin Probe Male (2 pack)
070PZ-ZY30100 07ZAJ-RDJA 110
24-2
COMPONENT LOCATION
FE1 mode! shown:
UPSHIFT SWITCH
COMBINATION METER
DOWNSHIFT SWITCH - GEAR POSITION INDICATOR
IGNITION SWITCH
OLC
FUSE BOX:
- MAIN FUSE 1 (30 A) RELAY BOX
- ES FUSE (30 A) - MAIN POWER RELAY
-IGN FUSE (10 A)
- ACe FUSE (20 A)
- DIODE
BATTERY
SHIFT MOTOR
(TP SENSOR)
VS SENSOR
GEAR POSITION SWITCH
24-3
ELECTRIC SHIFT PROGRAM (ESP : TE1/FE1 models)
SYSTEM DIAGRAM
ES FUSE (lOA)
.~- --------------------------~
IGNITION SW!TCH IGN FUSE (20A)
BATTERY MAIN FUSE 1 (30 AI .~.~-

r--F:::J;;;f- '~ ~ R'f!O~P~WI6I -r_--------1-+-----r__,
ACC FUSE (2OA)
-~ m IBl .-1---------'
MAIN FUSE 2 (HlA) DIODE L--------+-----f---+--,
~i::===~-_-.J
~ •• -----------t--t
==::====:1(-M) ""ORSHIFT CONTROl.

El(22)
peM
~ ~ fI
~,Ol ~~
~G Ole SCSSERVICECONNECTOR
" A.-12 1'1 -22

A 11
I
B-1
8·12 B-n
dl Sh<wI_for
-.oDTC
r~1
5P 1_) CONNECTOR nP(Gtay) CONNECTOR
24-4
BEFORE TROUBLESHOOTING
NOTE
If the ATV has any ESP trouble, the gear position indicator blinks to indicate the OTe (Diagnostic Trouble Code) (page 24-7).
Check the DIG and refer to the OTG index and begin the appropriate troubleshooting procedure (page 24-9).
• If there are no OTG stored in the PCM memory, do the troubleshooting as · Symptom Troubleshooting- (page 24-5).
VERIFY THE COMPLAINT

Check the accuracy of the cus tomer complaint by lest riding the A TV.
Nole the symptoms .
Do not begin disassembly or lesting until you have determined if the prOblem is electrical or mechanical by shifting the gear
manually (page 24-6).
Temporarily failures can occur. Under certain conditions , the ESP system can -miss a shift." When this happens. the PCM may
record a OTC . Be sure to note and erase any stored DTC(s) when verifying the customer's complaint. If the cus tomer's
complaint is duplicated during the test-ride, and the blinking gear position indicator displays a DTC . proceed with
troubleshooting .
PRELIMINARY ESP SYSTEM INSPECTION

Inspect the fOllowing before diagnosing the system:
- Make sure the battery is fully charged and in good condition (page 22-5).
- Make sure the clutch is adjusted properly (page 3-27).
- Check the main fuse 1 (30 A), ES fuse 2 (30 A) and IGN fuse (20 A) for blown .
sympt~o~
m ::;;:;;;::;==::::::::;~~DiagnoSIS Also check for
Shift control failure but no DTC set Troubleshoot the wElectric Shift Does Clutch adjustment (page 3-27)
,~~~~+-~N~o~tOperate~ (page 24-6)
Gear position indicator blinks" .. Inspect the serial communication line
constantly (No DTC sel) (page 23-7)
Gear position indicator is no indication Check for short circuit in the Brown! Short circuit in the DLC related wire
and MIL stays on . but no DTC is sel red wire of Ihe OLe .
24-5
ELECTRIC SHIFT PROGRAM (ESP: TE11FE1 models)
ELECTRIC SHIFT DOES NOT OPERATE
1. Shifting Operation Check
ore 23-1 will Remove the left mudguard (page 2-5).
be indicated Turn the ignition switch OFF . 121
with the ignition ManuaUy shift the transmission by rotating the
switch tumed gearshift spindle [IJ with the emergency gear
ON. change tool [2].
Can the gears be changed manually?
YES - GO TO STEP 2.
ND - Check the gearshift linkage (page 12-17) Dow"
and the transmission (page 15-7).
2. Gearshift Switch Inspection at PCM Connector

Disconnect the PCM 33P connectors [1)
(page 4-35). A6
111
Check for continuity between the wire harness side 83
PCM 33P (Black) connector [1) and 33P (Gray)
connector {2] terminals white pushing the gearshift
switch.
TOOL:
Pin Probe Male (2 pack) 07ZAJ-ROJA110
\ Q
Connection :
With the upshift switch pushed:
B3-A6 Q
A16
B3 - A16 \1
YES - Loose or poor contact of the PCM 33P
connectors
NO - GO TO STEP 3.
3. Gearshift Switch Inspection
Check the gearshift switch (page 24-19).
Is the gearshift switch normal?
YES - ' Open circuit in the following wire
between the handlebar switch 14P
(Green) connector and PCM 33P
connectors
- 8rownlwhite or White/blue
- Brownlwhite or White/yellow
NO - Faulty gearshift switch
24-6
ELECTRIC SHIFT PROGRAM (ESP: TE1 /FE1 models)
• Refer to PGM·FI System section for "General Troubleshooting"
information (page 4-5).
SYSTEM DESCRIPTION
SELF·DIAGNOSIS SYST EM
The peM controls the PGM-FI and ESP systems. Therefore some detection
items are shared by Ihe PGM-FI and ESP and they may affect the opera tion
of both systems.
The ESP system is equipped with Ihe self-diagnostic system. When any
abnormality occurs in Ihe ESP system, the peM slops system function ,
have the gear position indicator [11 blinking and stores a DTe in its erasable ,- - @
memory for Ihe relevant system failure.
IN DICATOR BLINKING PATIERN
Lt, @
The number of indicator blinks is the equivalent of the main code of Ihe
DTC (the sub code cannot be displayed by the indicator blinking).
The indicator has two types of blinks, a long blink and short blink. The
long blink lasls for 1.2 seconds, the short blink lasts for 0.4 seconds.
One long blink is the equivalent of ten short blinks. For example, when [1]
two long blinks are followed by three short blinks, the OTG is 23 (two L _ _-'--'-_ _ _ __ _ _ __ _ __
long blink = 20 blinks, plus three short btinks).
When the PCM stores more than one OTC, the indicator displays in the
order from the lowest number to highest number.
CURRENT OTC/STOREO OTC
The oTC is indicated In two ways according to the fa ifure status.
If the PCM detects the problem at present, the gear posillon indicator Will
blmk at all times. It is possible to readout the indicator blink pattern as
the current OTC.
If the PCM does not detect any problem at present but has a problem
stored in ils memory, the indicator will not blink. If II IS necessary to
retrieve the past problem, readout the stored OTC by following the OTC
readout procedure.
MCS INFORMATION
DTC READOUT
NOTE :
If the Mil blinks, readout the OTG (page 4-6) and troubleshoot the PGM- r - - - - - - - - - - -- -- - - - ,
FI system first. Then recheck the ESP system after erasing the PGM-FI
OTC.
After performing diagnostic troubleshooting, erase the problem OTC(s)
(page 24-8) and test-ride the vehicle to be sure that the problem(s) have
been removed.
If the gear position indicator 11] blinks, connect the MCS to the OLC (page
® ,-,;::.
4-6). @ Lt,
Read the OTC and stored data, and follow the troubleshooting index (page
I '"I "'LI!
24-9)
To read the OTC with the gear position indicator, use the following
procedure.
24-7
ELECTRIC SHIFT PROGRAM (ESP: TE1fFE1 models)
Reading DTC with the gear position indicator
Turn the ignition switch ON and read the gear position indicator blinking.
The number of blinks indicates the current OTC.
When retrieving the stored OTC , refer to the following procedures.
Remove the dummy connector (page 4-6),
Short the Ole [1] terminals using the special 1001.
TOOL:
SCS Service Connector (2) 070PZ·ZY30100
Turn the ignition switch ON and read the gear position indicator blinking .
The number of blinks indicates the stored OTC .
ERASING OTC
NOTE :
When erasing the ESP OTC, the PGM-FI OTC would also be erased al
the same time . Check the MIL blinks and troubleshoot the PGM-FI
system before erasing the ESP OTG.
Connect the MGS to the OLC (page 4·6).
Erase the OTG with the MGS while the engine is stopped .
To erase the OTG without MGS , refer to the following procedure.
How to erase the DTC without MCS
1. Remove the dummy connector (page 4·6).
2. Tum the ignition switch OFF.
3. Short the OLC (1j terminals using the special tool.
TOOL:
SCS Service Connector [2] 070PZ·ZY30100
Connection : Brown/red - Green
4. Tum the ignition switch ON.

5. Remove the special tool from the OLC.
6. The gear poSition indicator [1J will display for approximately 5 seconds.
While the indicator displays, short the OLG terminals again wi th the
special tool. The self-diagnoslic memory is erased if the indicator starts
blinking.
NOTE:
The DLe must be jumped while the indicator displays. If not, the ®
indicator will not start blinking. @
Note that the self-diagnostic memory cannot be erased if the ignition
switch is turned OFF before the indicator starts blinking.
CIRCUIT INSPECTION
Refer 10 the "INSPECTION AT PCMIECM CONNECTOR" information in
"PGM-FI system" (page 4-7).
24-8
ELECTRIC SHIFT PROGRAM (ESP : TE1 /FE1 models)
DTCINDEX
NOTE :
When the gear position indicator "-" is blinking constantly (and the MIL and coolant temperature, neutral and reverse indicators
stay on), but no DlG is indicated or retrievable, check the serial communication line (page 23-7).
OTC Function Failu re Sym ptom /Fail.safe f uncti on

Refer
("-" bli nks) to
TP sensor circuit low voltage - - - - 1 -.,..-.,
Poor engine acceleration
8·1 (8) • TP sensor or its circuit malfunction Fail·safe value: O~ 4-15
ESP does not work
---+-TP sensor circuil High voltage Poor engine acceleration
8·2 (8) • loose or poor contact of the TP sensor connector Fail-safe value: O· 4·17
I -_ _ _ _ _-r-,.~TP sensor or its circuit malfunction ESP does not work
VS sensor no signal Engine operates normally
• loose or poor contact of the Rear VS sensor ESP does not work
11-1 (11) 24·10
connector
• Rear VS sensor or its circuit malfunction
Shift spindle angle sensor circuil Low voltage • ESP does not work
• Loose or poor contact of the shift spindle angle
21-1 (21) 24·12
sensor connector
• Shift spindle angle sensor or its circuit malfunction
Shift spindle angle sensor circuit High \/oltage (more • ESP does not work
21·2 (21) than 4.62 V) 24·13
• Shift spindle angle sensor or its Circuit malfunction
Shift spindle operation malfunction (while operating • ESP does not work
gearshift mechanism)
22·1 (22) 24-14
o Control motor or its circuit malfunction
o Shift spindle angle sensor or its circuit malfunctl.,o~ _""",,,,=c===c--
"_......
Shift spindle operation malfunction (after operating 0 ESP does not work.
gearshift mechanism)
23-1 (23) 24·15
o Shift spindle angle sensor installation problem
___h o Shift spindle angle sensor or its circuit malfunction
Shift control motor drive circuit • ESPdoesnoCtw~o~~----------------
24-1 (24) o Control molar or its circuit malfunction 24-16
,-__. ---t-.o Control motor drive circuit malfunction
Fail-safe relay circuit ESP does not work
32·1 (32) 24·17
• Fail-safe relay circuil malfunction
Gear position switch circuit
• Gear position switch circuit malfunction (Short)
-+-:--;=====----+
Engine does not start
ESP does not work 24·18
Gear position indicator blink~'~·_
-·_I-___
42-1 (42)
Gear position switch circuit
• Gear position switch circuit malfunction (Open)
Gearshift (UP/DOWN) switch circuit
Gearshift (UP/DOWN) switch circuit malfunction
(Short)
- 1 ESP does not work
ESP does not work
24·18
24·19
24-9
DTe TROUBLESHOOTING
NOTE-
After troubleshooting, erase the OTG (page 24-8)
and test-ride the vehide to be sure that the system is
normal.
OTC 11-1 (VS SENSOR NO SIGNAL)

NOTE
Before starting the troubleshooting, check the VS
sensor 3P (Black), engine sub-wire harness 6P
(Black), and PCM 33P connectors for loose or poor
contact, and recheck the DIG.
Make sure the battery is fully charged.
1. VS Sensor System Inspection
Erase the OTG (page 24-8).
Test-ride the vehicle and check the VS sensor
signal with the MeS.
Is the VS sensor signal indicated normally?
NO - GO TO STEP 2.
2. YS Sensor Input Voltage Inspection
Disconnect the VS sensor 3P (Black) connector
(page 24-20).
Tum the ignition switch ON .
VS sensor 3P (Black) connector 11] terminal and
ground
Connection: Black/white (+) - Ground H
Is th e voltage more than 10 V? BIIW
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. VS Sensor Input Line Open Circuit Inspection

121
J'
Disconnecllhe PCM 33P (Black) connector
(page 4-35).
1'\
(1\
PCM 33P (Black) connector 11] and VS sensor 3P
(Black) connector (2] terminals. j
TOOL:
Pi n Probe Male (2 pack) 07ZAJ-ROJA 110
Connection : AS - Blacklwhite
Q
YES
NO
- Replace the PCM with a known good one
- Open circuit in the Blacklwhile wire
L
24-10
4. VS Sensor Ground Une Open Circuit Inspection
Measure Ihe voltage between the wire harness side
VS sensor 3P (Black) connector [1) terminals. 111
Connection: Black/white (+) - Green (-)
Is the voltage more tha n 10 V?
YES - GO TO STEP 5.
NO - Open circuit in Ihe Green wire
BIIW
5. VS Sensor Signal Line Open Circuit Inspection

Disconnect the peM 33P (Gray) connector 121 111
\
(page 4-35).
PCM 33P (Gray) connector (1) and VS sensor 3P
(Black) connector [2) terminals.
TOOL:
Connection: 816 - Pink
p B16
YES - GO TO STEP 6.
NO - Open circuil in the Pink or Pink/green wire
6. VS Sensor Signal Line Short Ci rcuit Inspection
Check for continuity between the wire harness side , - - - -- - - - - - - - - -- - - - ,
VS sensor 3P (Black) connector [1J and ground. [1\1f=-t'C1'9
Connection : Pink - Ground
YES - Short circuit in Ihe Pink or Pink/green wire
NO - GO TO STEP 7.
7. VS Sensor Inspection
Replace the VS sensor with a new one
(page 24-20).
Erase the Ole (page 24-8).
Test-ride Ihe vehicle and recheck Ihe Ole .
Is the OTC 11·1 indicated?
NO - Faulty original VS sensor
24-11
SENSOR LOW VOLTAGE)
spindle angle sensor 3P (Gray), engine sub-wire
harness 6P (Black), and PCM 33P connectors for
loose contacts or corroded terminals, and recheck
the OTe.
1. Shift Spi ndle Angle Sensor System Inspection
Check the shift spindle angle sensor with the Mes.
YES - GO TO STEP 2.
Inspection
11]
Disconnect the shift spindle angle sensor 3P (Gray)
3P (Gray) connector [1] terminals.
Connection : Brown/white (+) - Green/red (-)
Is the voltage within 4. 75 - 5.25 V?
YES - GO TO STEP 3.
NO - Replace the PCM wi th a known good one
BrllAl (-t)
v GIR(-)
3. Shift Spindle Angle Sensor Output Line Short

Circuit Inspection
3P (Gray) connector [11 terminal and ground. 11)
Connection : Green/yellow - ground
YES - Short circuit in the Green/yellow or Green/
blue wire
NO - GO TO STEP 4.
Q
GN

connector and PCM 33P (Black) connector.
24-12
SENSOR HIGH VOLTAGE)
Check the shift spindle angle sensor with the MeS .
15 about 5 V indicated?
YES - GO TO STEP 2.
Inspection
Oisconnecllhe shift spindle angle sensor 3P (Gray) 11)
3P (Gray) connector [1] terminals.
Connection: Brownlwhite (+) - Green/red (-)
Is the voltage within 4.75 - 5.25 V 7
YES - GO TO STEP 4.
NO - GO TO STEP 3.
BrNJ (+) G/R(-)
3. Shift Spindle Angle Sensor Input line Open

Circuit Inspection
Disconnect the PCM 33P (Gray) connector [11 63 (2)
(page 4-35).
PCM 33P (Gray) connector [lJ and shift spindle
angle sensor 3P (Gray) connector [2]lerminals.
TOOL:
Connection : B3 - Brownlwhite
YES - Open circuit in the Green/red or Green!
white wire
NO - Open circuit in the Brownlwhite wire
4. Shift Spindle Angle Sensor Output line Open
Circuit Inspection
Disconnect the PCM 33P (Black) connector 121
(page 4-35).
33P (Black) connector [1] and 3P (Gray) connector
[2J terminals.
TOOL:
Connection: A23 - Green/blue

YES - GO TO STEP 5. A23 G/Bu
NO - Open circuit in the Green/yellow or Green! L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ ~
blue wire
24-13
Replace the shift spindle angle sensor wi th a known
connector and peM 33P (Black) connector.
Check the shift spindle angle sensor with the MeS .
(page 4· 36), and recheck.
DTC 22·1 (SHIFT SPINDLE ANGLE

SENSOR MALFUNCTION : While
Check the shift spindle angle sensor wi th the MeS.
Is Low voltage (about 0 V) or High voltage (about
5 II) indicated?
YES - ' AbDUl 0 V: See Ol G 21-1 (page 24- 12)
• Aboul5 V: See o TC 21-2 (page 24-13)
NO - GO TO STEP 2.
2. Shift Control Motor/Reduction Gear Condition
Inspection
Check that the shift control motor and reduction
gears are installed properly and are not damaged
(page 24~22).
Are the s hift control motor and reduction gears
in normal condition ?
YES - GO TO STEP 3.
NO - Install the shift control motor and reduction
gears properly or replace faulty parts.
Remove the shift control motor (page 24~22) .
Connect a fuJly charged 12 V battery [1] to the
control motor 2P connector [2] terminals to check
the motor operation.
operation.
Does the shih control motor turn in both
direction?
YES - GO TO STEP 4.
[2[ [1[
24-14
Remove the shift spindle angle sensor with the
connector connected.
While turning the shift spindle angle sensor shaft,
check the shift spindle angle sensor voltage with the
MeS .
When turning the sensor shaft clockwise;
Voltage increase
When turning the sensor shaft
counterclockwise:
Voltage decrease
Does the voltage vary properly?

YES - GO TO STEP 5.
NO - Faulty shift spindle angle sensor
5. Shift Spindle Angle Sensor Condition Inspection
Check tha t the shift spindle angle sensor is installed
properly.
Is the shift spindle angle sensor in normal
condition?
YES - GO TO STEP 6.
NO - Install the shift spind le angle sensor
properly.
6. eTC Recheck
Recheck the OTC with the HOS pocket tester.
Is DTC 22·1 indicated?

SENSOR MALFUNCTION: After
Refer to ore 22-1 (page 24-14)
24-15
DTC 24·1 (SHIFT CONTROL MOTOR
DRIVE CIRCUIT)
NOTE:
Before starting the troubleshooting, check for loose
or poor contact of the control motor 2P (Black) and
PCM 5P (Black) connectors. and recheck the Dre.
1. PCM Motor Power Input Line Inspection
Disconnect the PCM 5P (Black) connector
(page 4-35). 111
PCM 5P (Black) connector [1 ) lerminal and ground .
Connection: C4 (+) - Ground (-)
Is there battery voltage? ffi
YES
NO
- GO TO STEP 2.
Blown ES fuse (30 A) C4 V
Open circuit in the Red/white or Red
wire 8
2. PCM Motor Power Ground Line Inspection
SP (Black) connector [11lerminal and ground . 111
Connection: C5 - Ground
YES - GO TO STEP 3.
3. Control Motor Line Open Circuit Inspection

Disconnect the control motor 2P (Black) connector , - - - - - - - - - - - - - - - - - - ,
(page 24-22).
{1 J
5P (Black) connector [1] and 2P (Black) connector C2
~
[2] terminals. R
Connection: C1 - Red
C2 - Black
NO Open circuit in the Red wire C1
• Open circuit in the Black wire
{21
24·16
4. Control Motor Line Short Circuit Inspection
Check for continuity between the wire harness side '---~11~
1 ---------
5P (Black) connector [1) terminals and ground. C2
Connection : C1 - Ground
C2 - Ground
YES - ' Short circuit in the Black wire
• Short circuit in the Red wire
NO - GO TO STEP 5.
5. Control Motor Inspection

Connect a fully charged 12 V battery [1] to the
control motor 2P connector [2) terminals to check
the motor operation .
operation.
directions ?
YES - GO TO STEP 6.
NO - Faulty control motor
121 11 J
6. Electric Shift Failure Checking

Connect the peM 5P (Black) and control motor 2P
(Black) connectors.
Erase the DTC (page 24-8) .
Recheck the oTC with the MCS.
Is the DrC 24-1 indicated?
(page 4-36), and recheck. If the DTC
indicated again. replace the control motor.
OTC 32-1 (FAIL-SAFE RELAY CIRCUIT)

1. Recheck DTC
Erase the DTG (page 24-8) .
Recheck the curren t DTC with the MCS.
Is the DrC 32·1 indicated ?
24-17
DTC 41 ·1, 41·2 (GEAR POSITION
SWITCH CIRCUIT)
NO TE :
or poor contact of the gear position switch 8P (Gray)
and peM 33P (Black) connectors, and recheck the
OTC.
1. Gear Position Switch Inspection with MeS
Check the gear position switch status with the MCS
data list menu .
Is the gear position status normal?
NO - GO TO STEP 2.
2. Gear Pos ition Switch Inspection
Disconnect the gear position switch BP (Gray)
connector (page 23-10). Lb/W G, WIG 19/R
11~
Check for continuity between the switch side BP
(Gray) connector [1J terminals and ground .
There should be continuity in each gear position ,
11J
~li
and should be NO continuity in the other position.
y So WIR
Is the gear position switc h normal?

YES - GO TO STEP 3.
NO - Faulty gear position switch
3. Gear Position Switch Inspection at PCM
Connector
Connect the gear position switch 8P (Gray) , - - - - - - - - - - - - - - - - - - - ,
connector and disconnect the peM 33P (Black) [1]
connector (page 4-35). A17 \ A2
Check for continuity between the wire harness side ),
peM 33P (Black) connector [1] terminals and ~
ground.
There should be continuity in each gear position . •
and should be NO continuity in the other position.
TOOL: A13
Pin Probe Male (2 pack) 07ZAJ· RDJA 11 0
A25 A24
Is the continuity normal condition ?

YES - GO TO STEP 4 ,
NO - Open or short circuit in the wire harness
between the PCM and gear position switch
24-18
4. Recheck OTe
Connect Ihe peM 33P (Black) connector.
Erase the DIG (page 24-8).
Shift the transmission into each gear and check the
OTG with the MeS.
Is the DTe 41-1 or 41-2 indicated?
DTC 42-1 (GEARSHIFT SWITCH

CIRCUIT)
NOTE '
Before starting the troubleshooting , check. for loose
or poor contact of the handlebar switch 14P (Green)
and peM 33P connectors , and recheck the DTC.
1. Gearshift Switch Inspection
Check the gearshift switch status with the MeS data
IIsl menu .
Is the gearshift switch s tatus normal?

YES - Intermittent failu re
NO - GO TO STEP 2.
2. Gearshift Switch Inspection at Handlebar Switch
Connector
Disconnect the handlebar switch 14P (Green)
Check for continuity between the handlebar switch
side 14P (Green) connector \11 terminals while
pushing the gearshift switch .
Connection:
With the upshift switch pushed:
Brown/white - White(blue
With the downshift switch pushed :
Brown/white - White/yellow
B,M/
(s there continuity?
YES - GO TO STEP 3. I 111
NO - Faulty handlebar switch
24-19
3. Gearshift Switch Inspection at PCM Connector
Connect the handlebar switch 14P (Green)
connector and disconnect the peM 33P (Black)
connectors (page 4-35).
33P (Black) connector (1] and (Gray) connector [2]
Q
A6 B3
terminals while pushing each switch. -10;--
TOOL :
Pin Probe Male (2 pack) 07ZAJ -ROJA110
Connection : A16 B3
With the upshift switch pushed :
A6 - B3 Q
A16 - 83 11] 12]
YES - GO TO STEP 4.
NO - Open circuil in the White/blue, Whitel
yellow or Brown/while wire between the
switch and peM .
4. Rec heck OTe
Connect the peM 33P connectors.
Erase the DTe (page 24-8) ,
Check the DTe with the MeS.
Is the DTC 42· 1 indicated?
VS SENSOR
REMOVAl/INSTALLATION
Disconnect the VS sensor 3P (Black) connector [1].
Remove the bolt {2] and VS sensor {3] from the rear
crankcase cover.
24-20
ELECTRIC SHIFT PROGRAM (ESP: TEl fFEl models)
Coat a new 0·r1n9 [1] with engine oil and install it onto
the VS sensor [2] .
Install the VS sensor to the rear crankcase cover and
tigh ten the bolt.
Connect the VS sensor 3P (Black) connector.
Install tank cover assembly (page 2-4).

REMOVAL
Disconnect the shift spind le angle sensor 3P (Gray)
connector [1].
Remove the two socket bolts [2] and shift spindle angle
sensor [3}.
Remove the O-ring [4) from the shift spindle angle
sensor.
Check the shift spindle angle sensor for wear or
damage.
INSTALLATION
Coal a new O-ring [1] with engine oil and install it into
the shift spindle angle sensor [2) groove.
Carefully install the shift spindle angle sensor by
aligning the flat surfaces of the sensor shaft hole and
gearshift spindle end.
Apply locking agent to the shift spindle angle sensor

socket bolt [1] threads.
Install the two socket bolts and tighten them to the
specified torque.
TORQUE : 6 N·m (0.6 kgf'm , 4.4 IbHt)
connector [2].
Install the left mudguard (page 2-5).
24·21
SHIFT CONTROL MOTOR/REDUCTION
GEARS
REMOVAL
CONTROL MOTOR
- right mudguard (page 2-5)
- right front wheel (page 17-10)
Disconnect the control motor 2P (Black) connector [1].
Remove the three bolts [2] and the control motor [31.
Remove the O-ring from the motor.
REDUCTION GEARS
Remove the three bolls [1J and the gear cover [2].

- reduction gear [11
- spindle gear (2)
- two dowel pins [3]
Check the gear teeth and splines for wear or damage.
24·22
INSTALLATION
SPINDLE GEAR
GEAR COVER
fI"7I O-RING
/ REDUCTION GEAR
CONTROL MOTOR DUST SEAL ~,

Remove any grease from the gears, gear cover and . ----U-N-'R-E-X-N
-3-G-R-EA-S-E
- - - - - - -'
crankcase cover. 121
Clean the mating surfaces of the covers thoroughly,
being careful not to damage them.
Install the spindle gear (1) by aligning with the reference
marks (2) on the crankcase cover.
Apply 2 - 4 9 (0.07 - 0.14 oz) of specified grease to the
reduction gear (3) journals (both sides) and teeth as
shown.
SPECIFIED GREASE : UNIREX N3 grease (E XXO N)
Install the reduction gear.

Inslalilhe dowel pins [4] into the crankcase cover.
24-23
Apply engine oil to the seal lips of a new dust seal [1].
Install the dust seal into the gear cover [2] with the nat
side facing out until it is fully seated.
Apply liquid sealant (ThreeBond 1215 or equivalent) to
the mating surface of the gear cover as shown.
Tighten the bolts Instalilhe gear cover with the three bolts (3].
after installing the
oontrol motor.
Coat a new O-ring [1] with engine oil and install it into ~_:;;;:;;::;;;:::;;iiiiiiiiiiiiiiiiiia;;;;;;;.iiiiiiiiiiiiiiiiii~
the control motor [2] groove.
Inslallthe control motor [IJ with the three bolts [2J.

Tighten the six bolts in a crisscross pattern in several
sleps.
Connect the control motor 2P (Black) connector [3].
- right fronl wheel (page 17-10)
- right mudguard (page 2·5)
24·24
25. ELECTRIC POWER STEERING (EPS: FM2IFA2 models)
SERVICE INFORMATION ·············· .. ····· ...... 25·2 DTC INDEX ·········· ·····································25·11
COMPONENT LOCATION .... · .................. ··· 25·3 DTC TROUBLESHOOTING ...................... 25·13
SYSTEM DIAGRAM ···· .... ·.. ····· .. ··················25-4 EPS INDICATOR CIRCUIT INSPECTION 25·26
SYMPTOM TROUBLESHOOTING ·············25·5 EPS ECU ................................................... 25·29
TROUBLESHOOTING INFORMATION ·· .... 25·5
25-1
ELECTRIC POWER STEERING (EPS : FM2/FA2 models)
SERVICE INFORMATION
GENERAL
This section covers electrical system service of the EPS (FM2JFA2 models). For other service of the steering system, see Front
WheeVSuspensioniSteering section (page 17-27).
When performing the DIG troubleshooting, (ead "Troubleshooting Information" carefully (page 25-5), and inspect and
troubleshoot according to the OTG . Observe each step of the procedures one by one. Note the DTG and probable faulty part
before starting diagnosis and troubleshooting .
A faulty EPS system is often related to poorly connected or corroded connectors. Check Ihose connections before proceeding .
The EPS ECU may be damaged if dropped. Also, if the connector is disconnected when current is flowing , the excessive voltage
may damage the EPS ECU. Always tum off the ignition switch before disconnecting or connecting the connectors.
BI: Black Bu : Blue Gr: Gray Lg: Light green P: Pink V: Violet Y: Yellow
TOOLS
SCS service connector Pin Probe Male (2 pack)
070PZ-ZY30100 07ZAJ-ROJA 110
25-2
ELECTRIC POWER STEERING (EPS: FM21FA2 models)
COMPONENT LOCATION
COMBINATION METER
- EPS INDICATOR
- 4WD INDICATOR
IGNITION SWITCH
DlC
EPS FUSE BOX

ECU
- EPS FUSE (40 A)
RELAY BOX
EPS UNIT (Including EPS

Motor and Torque Sensor)
BATIERY
FUSE BOX: 4WD

- MAIN FUSE 1 (30 A) SWITCH
-IGN FUSE (20 A)
- ACe FUSE {20 A)
VS SENSOR
25-3
SYSTEM DIAGRAM
IG~ FUSE (
BATIERV
,,
...
8frJ) (1tl
(17)(111
."
~~{b
r D!.C SCS SERVICE CO/ffl€CTOfl
EPSECU
.. -
C-I4
BI BIa""
o 0,.,,,
lb; Ughl blue
Br Brown
Bu 811M
G: Grwn
Gr G<ay
, "".
R: Red
19 LigIl! 11'...... y- Yellow
@( ): EPS illdicalOr tljjlllo.
d)
1\·2 A·' B-2 B-1 C-2' C-15
2P(~)CO NN ECTOR 2? (Gmy) CONNECTOI'l 21P (Grny) CONNECTOR
25-4
Symptom Diagnosis Also check for
EPS indicator does not come Inspe~'''It~h~e~E;;:PS indicator circuit Short ~';~"~""';I~b~e~Iw'Ceen the combination meter and
00 (page 25-26) EPS ECU
~-
Faulty combination meter
EPS indicator does not go Inspect the EPS indicator circuit Open circuil between the combination meter and
off, and no OTCs are stored (page 25-27) EPS EeU
Short circuit in the OLe related wire
Open circuit in the EPS ECU line
Open circuit in the motor power input line
Open circuit in the power ground line
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The EPS system is equipped with the self-.diagnostic system. If the EPS , - - -
ECU detects a system failure , it functions as follows: 1=~::=====r=~
1. Turns on the EPS indicator [1) to notify the rider of the problem. rI
2. Stores a oTC (Diagnostic Trouble Code) in its erasable memory.
3. Stops power assist (manual steering operation begins or reduces the
assist power).
Self-diagnosis can be classified into three categories :
®
ICLUt!
[\1 ,-r
L" ~ "IOU
~ Initial diagnosis: performed right after the engine starts and until the EPS
indicator goes off.
~ Regular diagnosis: performed right after the initial diagnosis until the
ignition switch is turned OFF.
~ Revest: The EPS indicator turns on when the oTC is set. The EPS
indicator will turn off after the vehicle has recovered from the fail-safe
11]
condition, but the oTC will be stored in the EPS ECU . There was a
temporary problem. butthe system is now fuJly operational.
DTC (Diagnostic Trouble Code)
The DTC(s) is memorized in the EEPROM (nonvolatile memory) therefore the memorized DTC(s) cannot be erased by
disconnecting the bat1ery. Perform the specified procedures to erase the DTe(s) (page 25-7).
EPS INDICATOR
Under normal conditions, the EPS indicator comes on when the ignition switch is turned ON, then goes off after starting the engine.
This indicates that the LED and its circuit are operating correctly.
If there is any trouble in the system after the engine is started , the EPS indicator will stay on and the EPS ECU memorizes the OTC.
(When the OTC 22 is stored; No initializing the torque sensor neutral position , the EPS indicator will blink.)
When a problem is detected and the EPS indicator comes on , there are cases that the indicator stays on until the ignition switch is
turned OFF, and the indicator goes off automatically when the system returns to normal.
If a problem is continuing atter restarting the engine, the EPS indicator stays on and the EPS ECU stops the EPS function .
When the OTC 23 (torque sensor problem) is stored in the EPS ECU, the EPS indicator will stay on until the OTC is erased.
RESTRICTION ON POWER ASSIST OPERATION

Repeated extreme steering force, such as turning the handlebar continuously back-and-forth with the vehicle stopped, causes an
increase of power consumption in the EPS motor. The increase of electric current causes the motor to heat up. Because this heat
adversely affects the system , the EPS ECU monitors the electric current of the motor. When the EPS ECU detects heat build-up in
the motor, it reduces the electric current to the motor gradually to protect the system (motor and EPS ECU), this restricts the power
assist operation. The EPS indicator does not come on during this function. When steering torque is not applied to the handlebar, or
when the ignition is turned off, and the system cools. the EPS ECU will gradually restore the power assist.
25-5
TORQUE SENSOR NEUTRAL POSITION (Torque Sensor Initialization)
The EPS ECU stores the torque sensor neutral position in the EEPROM. The torque sensor must be initialized whenever the EP$
unit. the EPS ECU, elc is serviced (page 25-9).
Perlorm the Torque Sensor Initialization when you service the following components.
REMOVAU
MAINTENANCE LOCATION REPLACEMENT INSTALLATION
Cables and harness around handlebar INITIALIZE INITIALIZE
Handlebar INITIALIZE INITIALIZE
Steering shaft and sleering shaft bushing INITIALIZE INITIALIZE
Steering arm and end nul INITIALIZE INlTIAUZE
EPS unit INITIALIZE INITIALIZE
EPS EeU INITIALIZE NO NEED
NOTE :
• The torque sensor neutral position is not effected when erasing the OTC.
HOW TO TROUBLESHOOT EPS DTC

1. Question the customer about the conditions when the problem occurred, and try to reproduce the same conditions for
troubleshooting. Find oul when the EPS indicator came on , such as during EPS control , after EPS control, when the vehicle was
at a certain speed , etc.
2. When the EPS indicator does not come on during the test-ride, but troubleshooting is done based on the OTC , check for loose
connectors , poor terminal contact, etc., in the affected circuit before you start troubleshooting.
3. After troubleshooting , erase the OTC(s) (page 25-7) and test-ride the vehicle to be sure that the EPS indicator does not come
00.
MCS INFORMATION
DTC READOUT
NOTE :
If the MCS is not available, OTC can be read from the EPS ECU memory by the EPS indicator blinking pattern (page 25-7).
• After performing diagnostic troubleshooting. erase the DTC(s) (page 25-7) and test-ride the vehicle to be sure that the
problem(s) have been removed .
Start the engine and check the EPS indicator [1] .
NOTE :
,--
Under normal conditions, the EPS indicator stays on with the ignition
switch is turned ON until the engine starts, and it goes off after starting
the engine.
®
If the EPS indicator stays on or blinks with the engine running , connect the
MCS to the OLC (page 4-6).
Read the DTC, stored data and follow the troubleshooting index
® L"'-I ..,.....
(page 25-11 ).
To read the OTC without the MCS, refer to the following procedure.
(11
25-6
Reading DlG with the EPS indicator
Short the DLe [1] terminals using the special tool.
TOOL:
SCS Service Connector 12] 070PZ-ZY30100
CONNECTION: Brownfred - Green
Turn Ihe ignition switch ON , then read and nallhe EPS indicator blinks and
refer to the troubleshooting index (page 25-11 ).
EPS Indicator Blinking Pattern

The number of EPS indicator blinks is the equivalent to the main code of
the DTG (the sub-code cannot be displayed by Ihe indicator blinking).
The indicator has two types of blinks, a long blink and short blink. The L _ _~_ _ _";;.:;;:'
long blink lasts far 1.3 seconds, the short blink lasts for 0.3 seconds.
One long blink is the equivalent of ten short blinks. For example , when two long blinks are followed by one short blink, the DTC
is 21 (two long blink = 20 blinks. plus one short blink).
When the EPS ECU stores more than one DTC , the ind icator blinks in the order from the lowest number to highest number.
ERASING DTC
NOTE '
• Perform this procedure using fully charged battery. The EPS indicator will stay lit and the EPS ECU will abort the process if you
use a low or dead battery.
Connect the MCS to the OLC (page 4-6).
Erase the DTC with the MCS while the engine is stopped.
To erase the OTC without MCS , refer to the following procedure.
How to erase the OTC without MCS
1. Raise the front wheels off the ground and support the vehicle securely.
2. Remove the dummy connector (page 4·6).
3. Short the OLC [1] terminals using the special tool.
TOOL:
SCS Service Connector [2] 070PZ·ZY30100
4. Place a 6 mm width screwdriver [1] between the right side of the steering ~:'::""::::::::";;~=~~~~~~~~II
stopper [2] and steering arm (3] as shown .
111
25-7
25·8
TORQUE SENSOR INITIALIZATION
NOTE :
Perform this procedure using a fully charged battery. The EPS indicator
will stay lit and the EPS ECU will abort the process if you use a low or
dead battery.
The DIG will be erased when initializing the torque sensor.
How to Initialize the Torque Sensor with MeS
1. Raise the front wheels off the ground and support the vehide securely.
Straight
2. Connect the MeS to the OLe (page 4-6).
3. Turn the ignition switch ON and engine stop switch "0 ".
Turn the handlebar [1] straight ahead.
Initialize the torque sensor with the MeS while the engine is stopped.
Follow the instructions of the MeS.
III
How to Initialize the Torque Sensor without MeS
1. Raise the fron t wheels off the ground and support the vehicle securely .
2. Remove the OLC from the dummy connector (page 4-6),
3. Short the OLC [1] terminals using Ihe special 1001.
TOOL:
SCS service connector (2) 070PZ-ZY30100
Connection: Brown/red - Green
4. Place a 6 mm width screwdriver (11 between the right side of the steering
stopper (21 and steering arm [3] as shown.
25-9
ELECTRIC POWER STEERING (EPS : FM2fFA2 models)
5. Make sure the engine slop switch is turned ·0·,
[3[
Fully tum the handlebar [1J to the left to apply a load and hold it firmly . Len
6. Turn the ignition switch [2] ON.
The EPS indicator [3] comes on and it goes off after 4 seconds.
•
®
4 seconds
7 . Within 4 seconds after the EP$ indicator PI goes off. turn the handlebar
Straight [lJ
[2) in the straight ahead position and release it immediately.
The EP$ indicator comes on again for 4 seconds.
®
•
4 seconds
8. Within 4 seconds after Ihe EPS indicator (1) comes on, fully turn Ihe :==================~
handlebar (2] to the left and hold it immediately.
Len
The EPS indicator goes off for 4 seconds.
®
•
4 seconds
[2J
9. Turn the handlebar (1) in Ihe straight ahead position (fully ~=================~
turn- to-straight ahead time; within 1 second) and release it immediately Straight [1]
after the EPS indicator (2] goes off. Do not touch the handlebar after
releasing the handlebar.
The EPS indicator blinks twice . Wait for 5 seconds and the EPS indicator ®
blinks 3 times.
Turn the ignition switch [3] OFF after the EPS indicator blinks 3 times
(torque sensor initialization is completed at this time).
NOTE:
•
If the EPS indicator does not blink 3 times, an error was made in the
procedure and the torque sensor was not initialized. Turn the ignition
switch OFF . and repeat the operation from step 4 . Blinks
10.Remove the special tool from the DLC , install the dummy connector to
the DLC and the radiator cap lid (page 2· 3).
Remove the screwdriver inserted in Step 4.
CIRCUIT INSPECT[ON
Refer to the "INSPECTION AT PCM CONNECTOR" information in "PGM·FI
system" (page 4-7).
25·10
DTCINDEX
DEFINITIONS
latc h : The E?$ indicator turns on and slays on whenever the ignition switch is ON , or untillhe DTG is erased,
Reset : The EPS indicator turns on when the olC is set. The EPS indicator will nol turn on after the ignition switch is cycled from
ON to OFF, but the DlG will be stored in the EP$ ECU ,
Revest : The EPS indicator turns on when the DIG is set . The EPS indicator will turn off after vehicle has recovered from Ihe fail-
safe condition, but the DIe will be stored in the EPS ECU . There was a temporary problem, but the system is now fully operational.
Initial diagnosis: Performed nght after Ihe engine starts and until the EPS indicator goes off.
Regular d iagnosis : Performed right after the initial diagnOSIs until the ignition switch is turned OFF.
Ole
(EPS
indicator
F r F 'I
unc Ion al ure
Symptom/Fail-safe Detection
Type
Refer
function timing 10
blink~
1
11-01 (11)
E.xcessive change of vehicle speed Indicator ON/Substitution Regular Revest 25-13
Signal control of the engine rpm
11-02 (11) Compari.son betwee,n vehicle speed Indicator ON/Substitution Regular Revest 25-13
1
and engme speed Signal control of the engine rpm
13-01 (13) EPS ECU internal circuit Indicator ON/Disables Initial Reset 25-14
_~_ (Lower FET stuck ON)'c._ _ steering assist immediately
EPS ECU internal Circuit Indicator ON/Disables
13-02 (13) (Upper FET stuck ON) steering assist immediately Initial Reset 25-15
- - - ---lE'>PS ECU internal circuit Indicator ONlDisables '---+ - -- -- ' -
>-_'3_-O_3_I'_3_1~--lI~F~Eil~stuck ON <over current» _ _---t~steering assist immediately Regular Reset 25-15
EPS ECU internal circuit
'3_-_04_ I'_3_1---t----):{FET stuck ON (VM<Voltage Motor>))
t-_
Indicator ONlDisables
steering assist immediately
Regular Reset ~25-'5
EPS ECU internal circuit Indicator ON/Disables
13-05 (13) (FET stuck ON (over steering assist immediately Regular Reset 25·15
t-_ _ __+~'~u~rrent<accu~m~u~la;l~e~d~'~II~---
14-01 (14) Regular Reset 25-15
(Power relay stuck ON) steering assist immediately _ f -_ __ _ + -+
14-02 (1 4) Initial Reset 25-16
(Fail-safe relay 1 stuck ON) steering assist immediately
14-03 (14) 'r EPS ECU internal circuit Indicator ON/Disables
Initial Reset 25-16
-l-- (Fail-safe relay 2 stuck ON) steering assist immediately
14-04 (1 4) EPS ECU internal circuit Indicator ON/Disables
Regular Reset 25-16
_--t--!i(power relay stuck open)
15-01 (15)
2WD/4WD select Signal blinking 4WD i
Indicator will not come ON)I
2WD assist power stabilized
Regular Reve,,+;;
I 2WD/4WD select signal inpulline Indicator ON/2WD assist
15-02 (15) power stabilized or EPS Regular Revest 25-17
>-_ __ __ , operation is normally
,. EPS ECU internal circuit Indicator ON/Disables
16-01 (16) Regular Reset 25-17
_ _ _ _ _ _ (Direction steering assist immediately
,. EPS i Indicator ON/Disables
16-02 (16) Initial Reset 25-17
(I NH output CircUit) _ _+_;steering assist immediately
EPS ECU internal circuit - Indicator ON/Disables
(Voltage i circuit)' _+-T.,,:;eerin g
25~
EPS ECU i i - Indicator i
17-02 (17) (Voltage raise transformation circuit) steering assist under the Regular Reset
Specified condition
i - - -- - +-'EPS ECU internal circuit Indicator ON/Disables
_ __ ---'---J~C~u;';rrent sensor) steering assist immediately _
_18-02
__ _ (18)
_ __:(Current sensor off set) Regular
steering assist immediately _i---__
Reset 25-17
1
(Current sensor stuck low steering assist immediately
~PS ECU internal circuit Indicator ONlDisables R I 25-19
'8-04 1'81 Reset
Current sensor stuck low) "eerlng assl" Immediately egu ar
EPS ECU internal circuit Indicator ON/Disables R I
18-05 (18) Reset 25-17
(Motor current deflection) _ --i'.teering assist immediately egu ar
EPS ECU internal circuit Indicator ON/Disables R I Reset 25·17
18-06 (18) steering assist immediately egu ar
IIM21 I
25-11
Ole
(EPS Symptom/Fail.safe Detection Refer
Function Failure Type
indicator function timing 10
bl inks), -+===~==;;;;;;;;-;;;;;;;C;;;;-----+--,;;
- Abnormal motor terminal voltage Indicatc rON/Disables
21-01 (21) steerin g assist immediately initial Reset 25-t9
21-02 (21) Abnormal motor terminal voltage IndicatorON/Disables Regular Reset 25-19
21-03 (21)
Open in the motor harness
steerin g assist immediately
Indicato rON/Disables
steerin g assist immediately Regular Reset I25-19
Failure to initialize the torque sensor Indicator bhnkIDlsables I I
steering aSSiS~I~"~nl*iili~'h~e;z.,"-_t-R
_eg
="_la~r_1_L_a_'ch
_'_~=2=5-_1=9_
22-01 (22)
23-01 (23)
lowlhigh voltage for the torque
sensor ---0:fi.~~assist until the DTC Regular Latch 25-20
(VT1 and VT2)
Torque sensor ---f_I'
- ~I;:;;~ ClNJNs;a;);es---r---
indicator
23-02 (23) (VT3 Differential-amplification steering assist until the OTC Regular Latch 25-22
----------1~I~'~.~rasedC)NIOI"ables_===--r_=_~----_r __~--_r~
Function)
Torque sensor Indicator
23-03 (23) (VT1, VT2 rapid change) steering assist until the DTC Regular Latch 25-23
is erased
Torque sensor ------~-iClndicator ON/Disables - - - f - - - - - + -R-e-'-e-) -+---
25-23
23-04 (23) steering assist i i Regular
(Temperature sensor)
23-05 (23)
Torque sensor
(Sensor Coil)
-----r~~~~'assist
ON/Disables
until the DTC Regular Latch 25-23
Engine speed signal ON/Disables

24-01 (24) i under the Regular Revest 25-23
condition
Lowlhigh lGHerminal vol tage ONlOisables
31-01 (31) )he Initial Revest 25-24
Low/high IG1-lerminal
31-02 (31) steering i under the Regular Revest 25-24
,
_ _ _ ____~S~pec:iE."'ified cond"tion
lowlhigh VBU voltage Indicator 0 N/Disables
32-01 (32) steering assist under the Regular Reset 25-25
Specified condition
EPS ECU internal circuit - - +-c.'ndicator 0 N/Disables
(EEPROM) steering assls! immediately _
EPS ECU internal circuil Indicator 0 N/Disables t- Inilial and
35-01 (35) Reset 25-17
(CPU) steering assisl immediately Regular
EP-S ECU internal circui t Indicator 0 N/Disables
(CPU communication) _ _-1~steering a ssisl immediately .
EPS- eCUinlernal circuit Indicator 0 N/Oisables
35-04 (35) (CPU communication) steering assist under the Regular Reset 25-17
~
_ _ _ __ --'---"Specified co."nd"i"tio"n' -_ _~'___
'The stored OTC is erased by performing the torque sensor initialization"
25·12
DTC TROUBLESHOOTING
NOTE'
After troubleshooting. erase the DTC{s) (page 25-7)
and test-ride the vehicle to be sure that the EPS
indicator does not come on.
DTC 11-01: EXCESSIVE CHANGE OF

VEHICLE SPEED SIGNAL (REGULAR
DIAGNOSIS)
NOTE:
or poor con tact of the following connectors, and
recheck the EPS indicator (page 25-6).
- FM2: engine sub-wire harness 3P (Black)
- FA2: engine sub-wire harness 6P (Black)
- EPS ECU 21 P (Gray)
- VS sensor 3P (Black)
The system is reducing the assist power, the EPS
indicator will come on when the EPS ECU detects
conditions of DTC 11-01 and DIC 1 '-02.
1. VS Sens or Signal line Open Circuit Inspection
Disconnect the EPS ECU 21P (Gray) connector [21 p
(page 25-29) and VS sensor 3P (Black) connector
(page 24-20).
21 P (Gray) connector (1] and 3P (Black) connector
(2J terminals .
TOOL:
Pin Probe Male (2 pack) 07ZAJ-ROJA110
Connection : e17 - Pink

YES - GO TO STEP 2. [1 [ C17
NO - Open circuil in the Pink or Pink/green wire
2. VS Sensor Signal line Short Circuit Inspection
Check for continuity between the wire harness side r-
[1-
1---------------~
21P (Gray) connector (1J terminal and ground.
TOOL:

YES - Short circuit in the Pink/green or Pink wire
NO - Replace the EPS ECU with a known good C17
one (page 25-29), and recheck .
DTC 11-02: COMPARISON BETWEEN

VEHICLE SPEED AND ENGINE SPEED
SIGNAL
(REGULAR DIAGNOSIS)
25-13
DTC 13·01 : EPS ECU INTERNAL
CIRCUIT (LOWER FET STUCK ON)
(INITIAL DIAGNOSIS)
NOTE:
or poor contact of the following connectors. and
- EP$ ECU 21 P (Gray)
- EPS motor 2P (Gray)
1. EPS ECU System Inspection
1. Erase the DTC (page 25-7).
2. Start the engine.
3. Fully turn the handlebar to the left or right and
hold it 10 seconds.
4. Check the EPS indicator.
Does the EPS indicator come on?
YES - GO TO STEP 2.
2. Motor Line Ground Short Circuit Inspection
Disconnect the EPS ECU 2P (Gray) connector
(page 25-29).
2P (Gray) connector [1]lerminals and ground.
Connection : Black - Ground
Red - Ground
YES - GO TO STEP 3. 111
NO - GO TO STEP 4.
3. Motor Short Circuit Ins pection

Remove the righ t mudguard (page 2-5)
Disconnect the EPS motor 2P (Gray) connector [1).
25-14
Check for continuity between the motor side 2P
111~_~_
connector [1j lerminals and ground . BI
Connection : Red - Ground
Blac k - Ground
Is there c ontinuity?
YES - Replace the EPS unit with a new one
NO - Short circuil in the Red or Black wire
4. Motor Line Short Circuit Ins pec tion

Disconnect the EPS motor 2P (Gray) connector , - - - - - - - - - - - - -- - - ,
(page 25-14).
EPS ECU 2P (Gray) connector [1] terminals.
Connection : Black - Red
YES - Short circui t in the Red and Black wires
/
NO - Recheck for loose or poor contact of the
EPS ECU 2P (Gray) connector and EPS
motor 2P (Gray) connector. If they are OK,
replace the EPS EeU with a new one
(page 25-29).
111
DTC 13-02: EPS ECU INTERNAL
CIRCUIT (UPPER FET STUCK ON)
(INITIAL DIAGNOSIS)
Refer to DTG 13-01 (page 25-14).

CIRCUIT (FET STUCK ON <OVER
CURRENT» (REGULAR DIAGNOSIS)
Refer to DIG 13-01 (page 25-14).

CIRCUIT (FET STUCK ON
(VM<VOLTAGE MOTOR»
(REGULAR DIAGNOSIS)

CIRCUIT (FET STUCK ON (OVER
CURRENT<ACCUMULATED»
(REGULAR DIAGNOSIS)

CIRCUIT (POWER RELAY STUCK ON)
(REGULAR DIAGNOSIS)
25-15
CIRCUIT (FAIL-SAFE RELAY 1 STUCK
ON) (INITIAL DIAGNOSIS)
Refer to DIG 13-01 (page 25-14),

CIRCUIT (FAIL-SAFE RELAY 2 STUCK
ON) (INITIAL DIAGNOSIS)

CIRCUIT (POWER RELAY STUCK
OPEN) (REGULAR DIAGNOSIS)
Refer to OTe 13-01 (page 25-14).
DTC 15-01: 2WD/4WD SELECT SIGNAL

BLINKING (REGULAR DIAGNOSIS)
NOTE :
Before starting the troubleshooting, check for 10Dse
or poor contact of the following connectors. and
recheck the 4WD indicator.
- 4WD select switch
- combination meter 21P (Black)
When this problem occurs, there are some of
problem of 2WDf4WD select system.
Question the customer about the conditions when
the problem occurred. and try to reproduce the same
conditions for troubleshooting. Find oul when the
4WD indicator blinked , such as during 4WO-lo-2WO
selecting, 2WD-to-4WD, al what speed, etc.
1. EPS ECU System Inspecti on
Test-ride the vehicle and check the 4WD indicator
111
Does the 4WD indicator blinking?
YES - Check the 4WD select switch
(page 23-17). If it is OK, inspect the 2WDI
®
4WD select system (page 20-15). @
• Loose or poor contact of the connector
11J
25-16
DTC 15·02: 2WD/4WD SELECT SIGNAL
INPUT LINE (REGULAR DIAGNOSIS)
NOTE:
Question the customer about the conditions when
the problem occurred , and try to reproduce the same
condllions for troubleshooting . Find oul when the
4WD indicator blinked , such as during 4W D-lo-2WD
selecting . 2WD-to-4WD selecting , at what speed ,
etc.
1. EPS ECU Sys tem Inspection
Erase the DTG (page 25-7).
Start the engine and check the EPS indicator.
Does the indicator stay o n ?
YES - GO TO STEP 2.
2. 4WD Indicator Inspection
Stop the engine.
Operate the 2WD/4WD select lever several times
and check the 4WD indicator [1] .
Is the 4WD indicator operated normally?
YES - Replace the EPS ECU wi th a known good
one (page 25-29), and recheck .
NO - Check the 4WD select switch
(page 23-17).
[11
DTC 16·01, 16·02, 17·01, 17·02, 18·01,
18·02, 18·05, 18·06,33·02,35·01 , 35·03,
or 35·04: EPS ECU INTERNAL CIRCUIT
16-01 EPS ECU internal circuit (Direction determine logic circuit)
(Regular diagnosis)
16-02 EPS ECU Internal circuit (INH output circuit)
(Initial diagnosis)
17-01 EPS ECU internal circuit (Voltage raise transformation circuit)
(Initial diagnosis )
17-02 EPS ECU internal circuit (Voltage raise transformation circuit)
(Regular diagnosis)
18-011 EPS ECU internal c ircuit (Current sensor)
(Initial diagnosis)
18-02 EPS ECU internal circuit (Current sensor off set)
-
(Regular diagnosis)
18-05 EPS ECU internal circuit (Motor current deflection)
(Regular diagnos is)
18-06 EPS ECU internal circuit (1M2)
(Regular diagnosis)
33-02 EPS ECU internal circuit (EEPROM)
(Regular diagnosis)
35-01 EPS ECU internal circuit (CPU)
-
(Initial and regular diagnosis)
35-03 EPS ECU internal circuit (CPU communication)
(Initial diagnosis)
I 35-04
I
I EPS ECU internal circuit (CPU communication)
I (Regular diagnos is)
25-17
1. Erase Ihe DI G (page 25-7).
2. Start Ihe engine,
3. Fully turn the handlebar to Ihe left or right and
hold it 10 seconds.
YES - GO TO STEP 2.
2. OTe Inspection
1. Check Ihe DTG (page 25-6).
Is OTe 16.01, 16-02, 17-01, 17-02, 18-01, 18-02,
18.05, 18-06, 33-02, 35-01, 35-03 or 35-04
indicated?
YES - Replace the EPS ECU with a known good
NO - Perform Ihe troubleshooting for the
indicated DIG (page 25-11),
DTC 18·03: EPS ECU INTERNAL

CIRCUIT (CURRENT SENSOR STUCK
LOW) (INITIAL DIAGNOSIS)
NOTE:
Before starting Ihe troubleshooting, check for loose
or poor contact of the following connectors, and
- EPS ECU 2P (Gray)
- EPS motor 2P (Gray)
1. Erase the DTC (page 25-7).
hold it 10 seconds.
YES - GO TO STEP 2.
2. Motor Line Open Circuit Inspection
(page 25-29).
EPS ECU 2P (Gray) connector 111 terminals.
Connection : Black - Red
NO - GO TO STEP 3.
[11
25·18
3. Mot or Open Ci rcuit Inspect ion
Disconnect the EPS motor 2P (Gray) connector , - - -(1-1- - - - - - - - - - -----,
(page 25-14), R 81
Check for continuity between the motor side 2P
connector 11] terminals.
Conn ectio n : Red - Black
YES - Open circuit in the Red or Black w ire
NO - Replace the EPS unit with a new one

CIRCUIT (CURRENT SENSOR STUCK
LOW) (REGULAR DIAGNOSIS)
DTC 21-01 : ABNORMAL MOTOR

TERMINAL VOLTAGE (INITIAL
DIAGNOSIS)
DTC 21 -02 : ABNORMAL MOTOR

TERMINAL VOLTAGE (REGULAR
DIAGNOSIS)
DTC 21-03: OPEN IN THE MOTOR

HARNESS (REGULAR DIAGNOSIS)
Refer to OTe 18-03 (page 25-18).
DTC 22-01 : FAILURE TO INITIALIZE

THE TORQUE SENSOR (INITIAL
DIAGNOSIS)
NOTE:
The EPS ECU stores the torque sensor neutral
position. The torque sensor must be initialized
whenever the EPS unit, the EPS ECU , etc is
serviced (page 25-9).
Refer to torque sensor neutral position information
for del ai! of the initialization parts (page 25-6).
1. Initializing To rqu e Sensor
Perform the torque sensor initialization (page 25-9)
and check the EPS indicator.
Does the EPS indicator come on ?
YES - Check the DIC (page 25-6) and perform
the troubleshooting for the indicated DTe
(page 25-11).
25-19
DTC 23·01: LOW/HIGH VOLTAGE FOR
THE TORQUE SENSOR (VT1 AND VT2)
(REGULAR DIAGNOSIS)
NOTE:
or poor contact of the fonowing connectors.
- torque sensor 3P (Gray)
1. Erase the OTe (page 25-7).
hold it 10 seconds.
YES - GO TO STEP 2.
2. Torque Sensor Line Short Circuit Inspection
Disconnect Ihe EPS ECU 21P (Gray) connector
(page 25-29).
Measure the resistance between the wire harness
side EPS ECU 21P (Gray) connector [1 1 terminals.
TOOL:
Connection: C1 - C2
C1-C3
C2-C3
C3
Is the resistance less than 10 n (at 20°CI68°F)?
YES - GO TO STEP 3.
NO - GO TO STEP 4.
3. Torque Sensor Coil Short Circuit Inspection
Disconnect the torque sensor 3P (Gray) connector
111.
25-20
Measure the resistance between the torque sensor
side connector [1J terminals in the EPS unit. Q }-------,
Connection : A - B
A- C
B
B- C
Is the resis tance les s than 10 {J (at 20°C/ 68"F) ?
(page 17-27), and recheck (short circuit in
the torque sensor coit) .
C A
NO Short circuit in the Yellow/red and
Green/orange wires
Short circuit in the Yellow/red and
White/blue wires [1 [
Short circui t in the Green/orange and
While/blue wires
4. Torque Sensor Line Ground Short Circuit
Inspection
EPS ECU 21P (Gray) connector [1] terminals and C1 C3 [11
ground.
TOOL:
•
C3 - Ground
YES - GO TO STEP 5. Q Q
NO - GO TO STEP 6.
5. Torque Sensor Coil Ground Short Circuit

Inspection
Check for continuity between the torque sensor side , - - - -- -- - - - - - -- --
connector !1 ) terminals in the EPS unit and ground. C A
Connection : A - Ground
C - Ground
1
(page 17-27), and recheck (short circuit in
the torque sensor coil).
NO Short circuit in the Yellow/red wire
• Short circuit in the White/blue wire
[1J
25-21
6. Torque Sensor Une Open Circuit Inspection
Check for continuity between the wire harness side ,-----------:;
G~/O
::------,
EPS ECU 21P (Gray) connector [1) and torque Y/R
sensor 3P (Gray) connector (2] terminals.
W/Bu
TOOL:
Connection : C1 - Yellow/red 121

C2 - Green/orange
C3 - White/blue
C3
Is there continuity? C1
YES - GO TO STEP 7.
NO Open circuit in the Yellow/red wire PI
• Open circuil in the Greenforange wire
• Open circui t in the While/blue wire
7. Torque Sensor Open Circuit Inspection
Measure the resistance between the torque sensor , -- - - - - - - - - - - - - - -- ,
side connector [1]lerminals in the EPS unit.
Connection : A - B 111
8-C
Is the resistance within 10 - 40 {} (20°Cl68°F) ? A
NO - Replace the EPS unit with a new one
(page 17-27). and recheck (open circuit in
the torque sensor coil).
C
DTC 23·02: TORQUE SENSOR (VT3

DIFFERENTIAL AMPLIFICATION
FUNCTION) (REGULAR DIAGNOSIS)
NOTE:
Before starting the troubleshooting. check for loose
or poor contact of the following connectors.
- EPS ECU 21P (Gray)
- torque sensor 3P (Gray)
1. Erase the OTC (page 25-7).
hold it 10 seconds.
Does the EPS indicator come on ?
YES - GO TO STEP 2.
2. Recheck OTC
Check the OTC (page 25-6).
NO - Perform the troubleshooting for the
indicated OTC (page 25-11).
25·22
DTC 23·03: TORQUE SENSOR
(VT1, VT2 RAPID CHANGE) (REGULAR
DIAGNOSIS)

(TEMPERATURE SENSOR) (REGULAR
DIAGNOSIS)

(SENSOR COIL) (REGULAR
DIAGNOSIS)
DTC 24·01: ENGINE SPEED SIGNAL

(REGULAR DIAGNOSIS)
NOTE :
Before starting the troubleshooting , check for loose
or poor contact of the following connectors, and
recheck the EPS indicator (page 25-6 ).
- PCM/ECM 33P (Black)
1. CKP Sensor Signal line Open Circuit Inspection
(page 25-29) and PCMIECM 33P (Black ) connector
rl----------------'
!1]
R
(page 4-35 ).
(r 1 M M
EPS ECU 21 P (Gray) connector [1] and PCM/ECM
33P (Black) connector [2]lerminals.
TOOL:
A20 C20 Q
Connection : C19 (EPS ECU ) - A20 (PCM/ECM)

Is there c ontinuity? j I I...L I I I
YES - GO TO STEP 2.
NO - Open circuit in the Blue/black wire
2. CKP Sensor Signal Une Short Circuit Inspection
Check for continuity between the wire harness side ~
'1
EPS ECU 21P (Gray) connector [11 terminal and
ground .
TOOL,
Pin Probe Male (2 pack) 07ZAJ-RDJA110 '1l~
Q
YES - Short circuit in the Blue/black wire C19
NO - Replace the EPS ECU with a known good
one (page 25-29 ). and recheck.
25-23
DTC 31-01: LOW/HIGH IG1-TERMINAL
VOLTAGE (INITIAL DIAGNOSIS)
NOTE :
Before starting the troubleshooting, check the fonowing
items:
- Check for loose or poor contact of the EP$ ECU 21 P
(Gray) connector, and recheck the EPS indicator
(page 25-6).
- Check for blown IGN fuse (20 A),
- Check the battery condition (page 22-5). (A fully
charged battery must be used.)
1. IG1 Line Open Circuit Inspection
Disconnect Ihe EPS ECU 21P (Gray) connector C7
(page 25-29).
EPS ECU 21P (Gray) connector [1] terminal and
ground.
TOOL:
Pin Probe Male (2 pack) 07ZAJ· ROJA 110
Connection : C7 (+) - Ground (- )

Is rhere battery voltage?
YES - GO TO STEP 2.
2. Battery Inspection
Perform the Battery/Charging System
Is the battery and charging system in good
condition?
NO - Repair the battery/charging system.
DTC 31-02: LOW/HIGH IG1-TERMINAL

VOLTAGE (REGULAR DIAGNOSIS)
Refer to DTC 31-01 (page 25-24)
25-24
DTC 32-01: LOW/HIGH VBU VOLTAGE
(REGULAR DIAGNOSIS)
NOTE:
Before starting the troubleshooting, check the following
items:
- Check for loose or poor contact of the EPS ECU 2P
(Brown) connector, and recheck the EPS indicator
(page 25-6).
- Check for blown EPS fuse (30 A)
- Check the battery condition (page 22-5). (A fully
charged battery must be used.)
1. EP$ ECU +B Une Open Circuit Inspection
Disconnect the EPS ECU 2P (Brown) connector , - - - -- -- - - - - - - - - - -,
(page 25-29). FM2: BI 1'1
Measure the voltage between the wire harness side FA2: W/R
EPS ECU 2P (Brown) connector [1] terminal and
ground.
Connection : FM2: Black (+) - Ground (-)
FA2 : White/red (+) - Ground (-)
YES - GO TO STEP 2.
NO FM2: Open circuit in the Black wire
• FA2: Open circuil in the White/red wire
condition ?
25-25
EPS INDICATOR CIRCUIT INSPECTION
EPS INDICATOR DOES NOT COME ON
NOTE :
Under normal conditions, the EPS indicator comes
on when the ignition switch is turned ON, then goes
off after starting the engine.
Before starting the troubleshooting. check for loose
or poor contact of Ihe following connectors, and
recheck the EPS indicator.
- combination meter t6P
- front sub-wire harness 8P (Gray)
1. Combination Meter Inspection
Check the combination meter initial operation (page
23-4).
Does th e combination meter operate properly?
YES - GO TO STEP 2.
NO - Check the combination meier powerl
ground lines (page 23-6).
2. EPS ECU Inspection (Short Ci rcuit inspection)
(page 25-29),
Check the EPS indicator.
Does the indicator come on?
NO - GO TO STEP 3.
3. Indicator Line Short Circuit inspection
Disconnect the combination meter 16P connector {1 J Y/G
(page 23-5).
Check the for continuity between the wire harness
side 16P (Black) connector (1) terminal and ground.
Connection : Yellow/green - Ground
00000 00
Is there continuity? DOODDD D
YES - Short circuit in the Yellow/green wire
NO - Replace the combination meter with a
known good one (page 23-5). Q
25·26
EPS INDICATOR DOES NOT GO OFF,
AND NO DTCs ARE STORED
NOTE:
Under normal conditions, the EPS indicator comes
on when the ignition switch is turned ON, then goes
off after starting the engine.
Before starting the troubleshooting check the
following items, and recheck the EPS indicator.
- Check for loose or poor contact of the following
connectors:
- EPS ECU 2P (Brown)
- combination meter 16P
- front sub-wire harness 8P (Gray)
- Check the battery condi tion (page 22-5). (A fully
charged battery must be used .)
1. Fuse Inspection
Check the EPS fuse (30 A) and IGN fuse (20 AJ.
Are the fuses OK?
YES - GO TO STEP 2.
NO - Replace the fuse and recheck. If the fuse
is blown, check for short to ground in this
fuse circuit.
2. Recheck OTe
Check the DTG (page 25-6).
Are there any DTCs ?
YES - Perform the troubleshooting for the
indicated DTC (page 25-11).
NO - GO TO STEP 3.
3. Indicator Operation Check (Indicator Line Open
Circuit Inspection)
Disconnect the EPS ECU 21P (Gray) connector 111
(page 25-29).
Ground the wire harness side 21 P (Gray) connector
C5
[1] terminal with a jumper wire.
TOOL:

Check the EPS indicator.
Does the Indicator go off?
YES - Recheck for loose or poor contact of the
21 P (Gray) connector. If it is OK, replace
the EPS ECU with a known good one
(page 25-29). and recheck.
NO - GO TO STEP 4.
25-27
4. Indicator Line Open Circuit Inspection
Disconnect the combination meier 16P connector C5
ytG
(page 23-5).
16P (Black) connector [1) and 21P (Gray) connector
[2] lerminals.
TOOL:
Connection : Yellow/green - CS 00000000
YES
NO
- GO TO STEP 5.
- Open circuit in the Yellowfgreen wire 11I
\ [21
5. SCS Line Short Circuit Inspection

Disconnect the PCM/ECM 33P (Gray) connector ~------------------,
(page 4-35). C9
21P (Gray) connector [1 ) terminal and ground.
TOOL :
YES - Short circuil in the Brown/red wire.
NO - GO TO STEP 6.
111
6. IG1 Une Open Circuit Inspection
Measure the voltage between the wire harness side 11 I C7
EPS ECU 21P (Gray) connector [1) terminal and
ground.
TOOL:
Pin Probe Male (2 pack) 07ZAJ·ROJA 110
Connection: C7 (+) - Ground H

YES - GO TO STEP 7.
7. EPS ECU +B Une Open Circuit Inspection

Disconnect the EPS ECU 2P (Brown) connector FM2 : BI 11 I
(page 25-29). FA2: W/R
2P (Brown) connector [11 terminal and ground.
Connection : FM2: Black (+) - Ground H
FA2: Whitelred (+) - Ground H
YES - GO TO STEP 8.
NO FM2: Open circuit in the Black wire
• FA2: Open circuit in the White/red wire
25-28
8. EPS Eeu PG Line Open Circuit Inspection
Check for continuity between the wire harness side ' - - -- -[-, [- - -- - - - - - - ----,
EPS ECU 2P (Brown) connector [1J terminal and Green
ground.
YES - GO TO STEP 9.
NO - Open circuil in the Green wire
condition?
YES - Recheck for loose or poor contact of the
combination meier 16P connector, fron t
sub-wire harness 8P (Gray) connector,
EPS ECU 21 P (Gray) connector and EPS
ECU 2P (Brown). If they are OK, replace
the EPS ECU with a known good one
EPS ECU
Remove the right following:
- trim clips [1]
- bolts [2]
- EPS ECU holder [3]
Remove the EPS ECU [1J from the stays on the EPS
ECU holder [2].
Disconnect the following connectors:
- EPS ECU 21 P (Gray) (3)
- EPS ECU 2P (Gray) [4]
- EPS ECU 2P (Brown) [5J
Perlorm the torque sensor initialization if the EPS ECU
replaced (page 25-9).
25-29
MEMO
26. WIRING DIAGRAMS
TM1 model ················· ·································26-2 FE1 model ··········· ········································ 26-6
TE1 model ................................................. "26-3 FA1 model ·················································' 26-7
FM1 model ·········· ········································26-4 FA2 model ................................... ............... 26-8
FM2 model ···································· ··············26-5
26-1
INDEX
2WD/4WD SELECT SYSTEM ELECTRIC SHIFT DOES NOT OPERATE·· ····· ·· 24-6
(Except TMlfTEl models) ................... ··· .. · .... · .. ·,, 3-24 EMISSION CONTROL SYSTEMS ······ ·· ,-35
4WD SELECT SWITCH/4WD INDICATOR ENGINE GUARD ............................... . ·············· 2-5
(Except TM1fTE1 models )' ······ 23-17 ENGINE IDLE SPEED·· ······· ················ 3-19
AIR CLEANER .. .......... .. ............ .. ... "' 3-7 ENGINE INSTALLATION .... .............................. 16-9
AIR CLEANER HOUSING · " '7-17 ENGINE OIL
AIR CLEANER HOUSING DRAIN TUBE ·····3-9 Except FA1/FA2 models .. ... .. ...... ... .............. 3-15
ALTERNATOR CHARGING COIL ..... "' 22-7 FAlIFA2 models .... ... ... . ······· 3-17
ALTERNATOR STATOR ................... .............. "' 14-6 ENGINE OIL FILTER
BANK ANGLE SENSOR .................................. " "' 4·34 Except FA1/FA2 models .. .... ..... ...... ... ····· 3-18
BATTERY··· ................... . .............. ' 22-5 FA1 /FA2 models '.. ······· 3-19
BODY PANEL LOCATIONS ......... .... ........ .. .. ················· 2-2 ENGINE REMOVAL · ... ... ... .................. 16-4
BRAKE FLUID ..... .. .... ... .. .. ... ' 3-24 EOT SENSOR .. ... .. .... ....... .. .. ... ..... .... .. ... 13-53
BRAKE FLUID REPLACEMENT/AIR BLEEDING ... ... ' 19-6 EPS ECU ..... .................. ...... .. ....... .... ..... .. ... ·· ·· 25-29
BRAKE LIGHT SWITCH ............. .................. ' 3-26 EPS INDICATOR CIRCUIT INSPECTION ·· .. ............ 25-26
BRAKE PAD WEAR ········ .................................. " 3-25 ESP BEFORE TROUBLESHOOTING· ······· ············· 24-5
BRAKE PAD/DISC ···························· " 19-7 EXHAUST SySTEM ···· ····· ··· .. ................. ·········· 2-10
BRAKE SHOE WEAR ........................................ ·········· 3-25 FLYWHEEUSTARTER CLUTCH ...................... ..... 14-11
BRAKE SYSTEM ..... ............... ..... ········· 3-26 FRONT AND REAR FINAL GEAR OIL' ·········· 3-22
BRAKEfTAILLIGHT ... ... ... .. .......... ····· 23-4 FRONT BRAKE CALIPER ··· ·· · 19-10
CABLE & HARNESS ROUTING ··· ····· 1-23 FRONT BRAKE SWiTCH ······················· ······· 23-11
CAMSHAFT .... .......... .. ..... . .............. ··· ·· 10- 16 FRONT CRANKCASE COVER .... .. ... . ..... .. .. .. ... ........... 12-5
CENTRIFUGAL CLUTCH FRONT CRANKCASE COVERISPACER ······ 13-33
Except FAlFPA models .................. ········ 12·8 FRONT DRIVE SHAFT· ............. ····· 20-6
FAlFPA models .......... .................. ·· ····· 13-41 FRONT FENDER/CARRIER ............................... ·········· 2-6
CHANGE CLUTCH ......... ............. ···· 12-12 FRONT FINAL CLUTCH ............... .................. 20-15
CHARGING SYSTEM INSPECTION .. ........ ......... ·· ····· 22-6 FRONT FINAL DRIVE INSTALLATION ·· ······ 20-35
CLUTCH SYSTEM (Except FA1 /FA2 models ) ······· 3-28 FRONT FINAL DRIVE REMOVAL····· ······ ···· 20-11
COMBINATION METERIINDICATOR ····· ····· 23-4 FRONT FINAL GEAR ASSEMBLy· ····· ······ 20·31
COMPONENT LOCATION FRONT FINAL GEAR DISASSEMBLY/
BATTERY/CHARGING SYSTEM "' 22-3 INSPECTION ······ ............. . ······ 20-21
DUAL CLUTCH TRANSMISSION FRONT MASTER CYLINDER ········ ,9-8
(FAlFPAmodels) .............. 13-11 FRONT PROPELLER SHAFT ... ······ 20-13
ELECTRIC POWER STEERING (EPS) ·················· 25-3 FRONT SHOCK ABSORBER ··· ···· 17-23
ELECTRIC SHIFT PROGRAM (ESP)" ····· ·············· 24-3 FRONT VS SENSOR ........ ..... .. ... ······ 13-54
ELECTRIC STARTER .. ..... ........ ·· ···· ··· 6-3 FRONT WHEEL·· ..................... 17-10
IGNITION SySTEM ·········· ............. ··· ······ 5-4 FUEL GAUGE/FUEL INDICATORI
LlG HTS/METERS/SWITCH ES '" ... .. .......... ..... 23-2 FUEL LEVEL SENSOR .............. ... 23-14
PGM-FI SYSTEM ............. ............. ········ -4-2 FUEL INJECTOR ·········· ................. .. ... 7-22
CONDENSER (Canada FM1 /FM2IFE1 models only) ····· 5-8 FUEl LINE .. .................... ····· 3-6
COOLANT REPLACEMENT ...... ............... ................... 8-5 FUEL LINE INSPECTION ·········· 7-5
COOLING FAN ................. ·23-1 3 FUEL PUMP UNIT ······· ··· ····· ········ 7·11
COOLING SySTEM ···························· "' 3-20 FUEL TANK ·· ··············· ..... ... ...................... ····· 7-16
COOLING SYSTEM FLOW PATTERN ··········· ····· 8-4 GEAR CASE AND COVER BEARING REPLACEMENT
COOLING SYSTEM TESTING ........... .............. ···· ·8-5 FRONT DRIVING MECHANISM
CRANKCASE ASSEMBLy ·· ············ ··· ............. ' 15-19 (Except TMfTE models) ..................... . ···· 20-28
CRANKCASE BEARING REPLACEMENT ·· ' 15-15 REAR DRIVING MECHANISM ······ 21-16
CRANKCASE SEPARATION ............... ............. "' 15-6 GEAR POSITION SWITCH
CRANKSHAFT/BALANCER .... ········· 15-13 (Except FA1 /FA2 models).. ············ ···· 23·10
CYLINDER COMPRESSION ..... ............. ··········· , 0-6 GEARSHIFT LINKAGE
CYLINDER HEAD ......... .. ........... ' 10-10 Except FAlFPA models ···· ··· ····················· ,2-17
CYLINDER HEAD COVER .. ..... ......... "' 10-6 FAlFPA models ·················· ............... ······ 13-71
CYLINDER/PISTON· · .. ... ... .. .... ... ..... ... " ' 11 -4 GUARDS .. ..... ... ................ ................ ... ..... ...... 3-28
DRIVE MODE SELECT SWITCH ... ' 13-55 HANDLEBAR ·· .. ············ ······ 17-6
DRIVE TRAIN BOOTS ", .... .... ..... ········ 3-22 HANDLEBAR SWITCH ···· 23·10
DTC1NDEX HEADLIGHT ......... .. ..... ······ ······ 23-3
DUAL CLUTCH TRANSMISSION IACV·· ··· ····· ·· ··· ····· ··· ··· ··················· 7-21
(FAlFPA models)" ... .. .............. .... .... ...... ... ····· ······ 13-15 IGNITION COIL .................. ····································· 5-7
ELECTRIC POWER STEERING (EPS ) ······ 25·11 IGNITION SWITCH ··· .................. ································ 23·9
ELECTRIC SHIFT PROGRAM (ESP) .. ········ " 24-9 IGNITION SYSTEM INSPECTION ..................... ··········· 5-5
PGM-FI SYSTEM , .......... .. ............. ·············· ·4-8 IGNITION TIMING ..................................... ······ ·5-7
DTC TROUBLESHOOTING LUBRICATION & SEAL POINTS "' 1-20
DUAL CLUTCH TRANSMISSION LUBRICATION SYSTEM DIAGRAM
(FNFPA models) ............................. ·················· 13-17 Except FAlIFA2 models .................... ········ 9-4
ELECTRIC POWER STEERING (EPS)' ··· ·· 25- 13 FA 1/FA2 models .................................. ···· 9-5
ELECTRIC SHIFT PROGRAM (ESP) .... ·· ·· ·· 24-10 MAIN POWER RELAY ·· .... ..................... .. 22-8
PGM-FI SYSTEM .. ........ ........................... ....... ······· 4-10 MAINTENANCE MINDER INDiCATOR .. ·· ········ ············· 3-3
DUAL CLUTCH/PRIMARY DRIVEN GEAR ········· ··· ··· 13-61 MAINTENANCE SCHEDULE ........ .................. ·········· 3-4
ECT SENSOR ......................................... ···· ·· ···· 4-34 MIL CIRCUIT INSPECTION .... ··········· 4-30
INDEX
MODEL IDENTIFICATION ....................... 1-3 SHIFT CONTROL MOTOR/REDUCTION GEARS
MUDGUARD ..... .. . .. .... ... ... ... ······ .... ·· .... ·· .. ··· .... ·· 2-5 DUAL CLUTCH TRANSMISSION
NUTS, BOLTS, FASTENERS .... .................................. 3-29 (FAlFPA models) ······ ·············,· ··,·········· ····· ····· ·.. ·· ··· 13-47
0 2 SENSOR ...... ................. ···· ········· · 4-37 ELECTRIC SHIFT PROGRAM (TE/FE models).. ··· 24·22
OIL CHECK LID···.. · ...... ··· .... · .... ···· .... ·· ··· · ·· ··2-3 SHIFT DRUM POSITION SWITCH ·· .. · .. ······ ·.. ··· .. ······ ·13-50
OIL PRESSURE CHECK SHIFT SOLENOID VALVE .... .... .. ....... ...... .... ·· ······ ···· 13-46
AUTOMATIC TRANSMISSION ... .. ... .. 13·8 SHIFT SPINDLE ANGLE SENSOR
OIL PRESSURE CHECK (FA l /FA2 models) DUAL CLUTCH TRANSMISSION
LUBRICATION SYSTEM .......................... ... . 9-8 (FAlFPA models)" " " """" " """ '''' '''''''''''''' '''''''''''' 13-47
OIL PUMP (Except FA1 /FA2 models) .................. . 9-6 ELECTRIC SHIFT PROGRAM (TEIFE models) .. ··· 24-21
OIL PUMP/RELIEF VALVE (FAlIFA2 models) '" ... ...... . 9-9 SHIFT VALVE BODy ·· .. ···· .. ·.. ···· .... ···· .. · .......... 13-56
PCMfECM ··· ············ .... · .. ·· .. · .... ·· . ................ ····· 4-35 SKID PLATE ...... ·........ ·...... · .. ·· .. ··.. ...... .. .. .. ... ·· .. ···· ·· ···2-7
RADIATOR CAP LID ··· .... ·· ...... ·.. ····· ······· .. · ··· ··· ··2-3 SPARK ARRESTER ..................... . 3-29
RADIATOR COOLANT .. ···· .. · .. · . .. ......... ········ ······· 3-20 SPARK PLUG ........ ... ....... .. .. ...... .. ... .. .... .. .. ... ···· ···· ··· ···3-10
RADIATOR RESERVE TANK .......... .... ... ....... ... ............. 8·9 SPECIFICATIONS ·· ·· ···· ···· · 1-5
RADIATOR/COOLING FAN ····· ····· ·· ····· ··················· .. ····· 8-7 STARTER MOTOR ··· ··· ···· ···· ··· ·6-4
REAR AXLE INSTALLATION ··· ··············· ···············,··· 21-24 STARTER RELAY SWITCH ····· ···· .. ·· 6·6
REAR AXLE REMOVAL · .. ..... ... .. ............ ,........... .. ...... 21-6 STARTER RELAY SWITCH DIODE···· ················,·········· 6-8
REAR BRAKE DRUMfSHOES ............... ..... .. .. 19-12 STEERING SHAFT (Except FM2JFA2 models) ··· ······· 17-24
REAR BRAKE LIGHT SWITCH· ······· ····· .. .... .. .... .. ... .. 23-11 STEERING SHAFT HOLDER BEARING .... · .. ·,· .... ·· .. ···· 3-30
REAR BRAKE PEDAL.. ·· ···· ··· ·· ..... .... .... .. . ,................ 19-16 STEERING SHAFT/EPS UNIT (FM2/FA2 models) ··· ·17-27
REAR FENDER COVER .. ··· ·········· ··· ·· .... ............. .. , 2·8 STEERING SYSTEM .. ... ... .. .. . ······ ······ 3-30
REAR FENDER/CARRIER·· ··· .... .. ................ ,.... 2·8 STEP BRACKET· ···· .... .... ..... .. .. ·· ··· ·· ······· ·2-7
REAR FINAL DRIVE INSTALLATION .. ···· ... 21-22 SUSPENSION · ...... ..... 3·28
REAR FINAL DRIVE REMOVAL ........ ··.. · ······21-9 SUSPENSION ARM ·· ···· · .. ·.. ·· 17-20
REAR FINAL GEAR ASSEMBLy ··· .. ··· .. . 21-19 SWINGARM ... .. ... .. .. ··· · 18-5
REAR FINAL GEAR DISASSEMBLYf SYMPTOM TROUBLESHOOTING
INSPECTION·· ···· ······ .. ·· 21·11 DUAL CLUTCH TRANSMISSION
REAR SHOCK ABSORBER ···· ···· ··· ·· ··18-4 (FAlFPA models) ··· .. ·.. .... .... 13-6
REAR VS SENSOR·······,····· .. ····· ,············· ,······,······· ... 13-53 ELECTRIC POWER STEERING (EPS) .......... . ·· .. 25-5
REAR WHEEL ········ .. ·,········· .. ·····,······························· ··18-4 ELECTRIC SHIFT PROGRAM (ESP) " ···· · 24-5
RECOIL STARTER (Canada FM1 /FM2JFE1 PGM-FI SYSTEM ....... . ... .. ... .. ........ .. ... .. ··· ·· ·4-8
models only) .... .. ..... .... .. .... ... .. ... ... . 14-6 SYSTEM COMPONENTS
REGULATOR/RECTIFIER · ... 22-7 AL TERNATORJSTARTER CLUTCH· · ··· ··· ···· 14-4
RELIEF VALVE (Except FA1/FA2 models) " ····· · 9-7 BRAKE SYSTEM .......... ......... .. .. .... ... ................... .... 19-4
REVERSE LOCK SYSTEM' " .. ... .............. ................. 3-27 CLUTCH/GEARSHIFT LINKAGE " ' "''''''''''''''''' ' '''''' 12-4
REVERSE STOPPER SHAFT .. ··· .... · ...... · .. ····· .. ·.... ·.. · 13-74 CRANKCASEITRANSMISSION/CRANKSHAFT/
REVERSE SWITCH .. ,........... ,.... ,........ ,.... ,.... ....... ,..... 13-52 BALANCER ................ .... ,.......... ,.... ,..................... "' 15-5
SEAT ···· .. ·· .......... ................................... ······· 2-3 CYLINDER HEADNALVE · ........ .. ... ···· · 10-4
SENSOR UNIT (MAPITP SENSOR) ... ... .. 4-32 CYLINDER/PISTON ....... .... .. .. .. .. ..... .. ..... . ·· ·· · 11-3
SERVICE INFORMATION DUAL CLUTCH TRANSMISSION
ALTERNATOR/STARTER CLUTCH .. ............ .. 14-2 (FAlFPA models)· ········ ·· · ....... .... ..... ..... ····· 13-4
BATTERY/CHARGING SYSTEM .......... 22-2 ENGINE REMOVAUINSTALLATION ..... ······· 16-3
BRAKE SySTEM ·········· ····,················ .. ,·· .. ·,······ ·· ··"' 19·2 FRONT DRIVING MECHANISM ... ............ ............... 20-5
CLUTCH/GEARSHIFT LINKAGE .... ·· .... ·, .. ····· .. ·.. · .. · 12·2 FRONT WHEEUSUSPENSION/STEERING .... · ...... 17-4
COOLING SySTEM ·,,······· ········ .. ····· .. ······· ······· ··· ·· ····· 8-2 FUEL SYSTEM .. ....... .. ................... ··· .. ·.... ·.... ·.. ··7-3
CRANKCASEfTRANSMISSIONfCRANKSHAFT/ REAR DRIVING MECHANiSM ······ ····· 21-5
BALANCER .... .. .... ... ... ... ....... .... ... ... .. .. 15-2 REAR WHEEUSUSPENSION .. ... .. ··· ····18-3
CYLINDER HEADNALVE ... ···· .... ·· .. ········ .... · 10·2 SYSTEM DIAGRAM
CYLINDER/PISTON ....................... .. ............. 11·2 BATTERY/CHARGING SYSTEM ... .. .... .. ... .. ... ·· ··· 22-4
DUAL CLUTCH TRANSMISSION DUAL CLUTCH TRANSMISSION
(FAlFPA models) ........ .... ...... ........ ···· 13·2 (FAlFPA models) ···········, .... ·· .... · .. ··· ........ · .. ···· .. · ''' 13-12
ELECTRIC POWER STEERING (EPS)··· ··· .. 25-2 ELECTRIC POWER STEERING (EPS) ···,·········,· ···· 25-4
ElECTRIC SHIFT PROGRAM (ESP) .. ······ .. 24-2 ELECTRIC SHIFT PROGRAM (ESP) ·· ····· ·········· ····· 24-4
ELECTRIC STARTER ...... ,.... ,........ ,.... ,..... ,..... ,........ , 6·2 ELECTRIC STARTER ,.. ··· .... ... .. ...... ······· .... ·· 6-3
ENGINE REMOVAUINSTALLATION ·· ···· ·· ···· ······ ··· · 16-2 FUEL SYSTEM (PGM-FI) ··· ··· ·········,··················,······· 4-3
FRAME/BODY PANELS/EXHAUST SYSTEM ...... .... 2-2 IGNITION SySTEM ······· ········ ··· ···· ·· ······ ··· ··· ·· ·············· 5-4
FRONT DRIVING MECHANiSM ·.. ,........ · ...... ·, .. ·.. · .. · 20·2 TANK COVER ASSEMBLY ········· ·· ·· .. ··· ··· ·· ····· ··· .. ···· ······ ·2-4
FRONT WHEEUSUSPENSION/STEERING· ·· ·· ······ 17-2 THERMOSTAT .................. .. .................. ,... ............. ···,···· 8·6
FUEL SYSTEM'" .. ... .... ..... .... .. .... ······ ···· ·7-2 THROTTLE BODy··· ··· ·· ··· ·· · ·······,······· 7-18
IGNITION SYSTEM " ... ... ..... ....... .. ............... ... 5·2 THROTTLE HOUSING .. .... ... .... ... .. ..... ... .... .. ..... .. ... ··· ·· 17-9
LIGHTS/METERS/SWITCHES ·· ... ......................... 23·2 THROTTLE OPERATION .. ,.. ·.. ··· .. ·· ···· ·· ···· ···· ··· .. ··· .. ········ 3-6
LUBRICATION SySTEM· ··· ··.. ···· .. ··· 9-2 TIE-ROD ·· ·.... ·· ·· .. ·.......... · .... ·· .. · .... ·.... ·· .. ·· ······ .. ····· ······ 17-32
MAINTENANCE ·· ... .......... ... .. ......... .. ... .. .... ... 3-3 TIE-ROD AND JOINT BOOTS ·.. ········· ·························· 3·30
PGM-FI SySTEM .. ······ .. ······,··········· ,····,················,···· 4-2 TIRES ..... ...... ... .. .... .. .. ··· ···.... ·· ·.. · 17- 10
REAR DRIVING MECHANISM ................................ 21·2 TOOLBOX LID ..... .... .... ... .. .. .. ..... ...... 2-8
REAR WHEEUSUSPENSION ··· ·· ··· ....... ..... .. .. .. ..... 18-2 TORQUE VALUES .. ............. , ·· .. · 1· 13
SERVICE RULES ····,·····,,···········,,········· ·,················ .. ·· ·· · 1-2 TRANSMiSSiON··· ·· ·· ·· ... .. ......... "' 15·7
INDEX
TROUBLESHOOT!NG TROUBLESHOOTING INFORMATION
AL TERNATORISTARTER CLUTCH .. ····· 14-3 DUAL CLUTCH TRANSMISSION
BATTERY/CHARGING SYSTEM ............. "." ""' 22-3 {FNFPA models)······················· ............... "' 13-13
BRAKE SySTEM·· ·· ·· ·· .. ...... ..................... "''' 19-3 ELECTRIC POWER STEERING (EPS)········ ······· ··· 25-5
CLUTCH/GEARSHIFT LINKAGE ·········· 12-3 ELECTRIC SHIFT PROGRAM (ESP)" ············ 24-7
COOLING SYSTEM .. .. ......... ·········· 8-3 PGM-FI SYSTEM .... ... .. ......... .. ···· 4-5
CRANKCASEITRANSMISSION/CRANKSHAFTI VALVE CLEARANCE ....... ······ 3-11
BALANCER .................... . .............. " 15-4 VS SENSOR ........................... ............. ········ 24-20
CYLINDER HEADNALVE ···· .. ···.. "' 10-3 WATER PUMP ···· 8-9
CYLINDER/PISTON .............................................. ' 11~2 WHEEL HUB AND KNUCKLE · .......... .. ....... ······ 17-13
ELECTRIC STARTER ·· .. · .... ··.. ············ 6-2 WHEELS{TIRES ··· ··· ... 3-29
FRAME/BODY PANELS/EXHAUST SySTEM ·· .. · .. "' 2-2 WIRING DIAGRAM
FRONT DRIVING MECHANISM ........... ·········· 20-4 FA1 model ······ ............. ······ 26-7
FRONT WHEEUSUSPENSION/STEERING "' 17-3 FA2 model ", ···· 26-8
FUEL LINE .................... ....... .. ... ........ ··· ··7-4 FE1 model ··· ········· ··· 26-6
IGNITION SySTEM ················· ········ ····· 5-3 FM1 model " ···· ·· 26-4
LUBRICATION SYSTEM " . 9-3 FM2 model , ······ 26-5
REAR DRIVING MECHANISM ............... ················ 21-4 TEl model ··· ................................... ········ 26-3
REAR WHEEUSUSPENSION .. ·················· 18-2 TMl model ·" .... ....... ·········· 26-2

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HOW TO USE THIS MANUAL

A Few Words About Safety

For Your Safety

Follow the procedures and precautions in this

Important Safety Precautions

Replace the part{s) with new one(s) before assembly.

Use the recommended engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use silicone grease.

Use fork or suspension fluid.

SPECIFICATIONS ·········································1-5 EMISSION CONTROL SYSTEMS ·············· 1-35

TORQUE VALUES ······································ 1-13

Model name TM1 TE1 F~ '--- FM2 FE1 FA1 FA2

111 I \ '---" --'

Trail length 5 mm (3116 in_

- 51h 0.848 (28/33 )

IGNITION SYSTEM SPECIFICATIONS

FUEL SYSTEM SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

Recommended antifr;;;e;;;e;;,eC:-~==-- Pro Honda HP Coolant or an equivalent high quality ethylene

CYLINDER HEADNALVE SPECIFICATIONS

DUAL CLUTCH TRANSMISSION (FA1/FA2 models)

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Shaft 0.0. 12.966 ~ 12. . ~

; Gear 1.0. M3 25.000 ~ 25.021 ~

, ;dle 12.966 ~ 12. ~51,* ~

Transmission 20.000 20.021 (0.7874 0.7882)

25.000 25.021 (0.9843 0.9851) ,

_~2 , C4,CR 28.020 28.041 (1.1031 1.1040) ~

C5 31.000 31.025 (1.2205 1.2215) ~

_ ~everse idle 13.000 13.018 (0.5118 0.5125)

Too Toe-out: 1S± 15(9/16 ±9/16)

REAR WHEEL/SUSPENSION SPECIFICATIONS

BRAKE SYSTEM SPECIFICATIONS

FRONT DRIVING MECHANISM SPECIFICATIONS (Except TM1/TE1 models)

REAR DRIVING MECHANISM SPECIFICATIONS

Except TM1 model

I Coolant temperature indicator

ENGINE & FRAME TORQUE VALUES

Step bracket mounting boll 4 8 32 (3.3, 24)

CYLINDER HEADN ALVE

DUAL CLUTCH TRANSMISSION (FA1/FA2 models)

Apply engine oil to the threads.

(0.12 - 0.16 in) from tip

ITEM C'TY REMARKS

Swingarm pivot nut 2 12 130(13.3,96) U-nul: replace with a new one.

FRONT DRIVING MECHANISM (Exc eptTM1fTE1 models)

ITEM Q'TY REMARKS

REAR DRIVING MECHANISM

ITEM Q'TV THREAD TORQUE REMARKS

Except FA1 fFA2

Front propeller shaft splines

NKG70B (Kyodo Yushi)

Front drive shaft inboard joint inside

Inside of front fender:

REAR (PARKING) BRAKE CABLE

IGNITION SWITCH WIRE

H-~'---HANOlEBAR SWITCH WIRE

BANK ANGLE SENSOR

FRONT FINAL GEAR CASE