- •Foreword
- •General Information Table of Contents
- •Inspection
- •Instrument
- •Model Identification
- •Technical Information - Cassette Type Transmission
- •Technical Information - Inlet Air Pressure Sensor
- •Inlet Solenoid Valve
- •Unit Conversion Table Prefixes for Units:
- •Units of Power:
- •Periodic Maintenance Table of Contents
- •Idle Speed Inspection ....................................................................................................... 2-18
- •Idle Speed Adjustment...................................................................................................... 2-18
- •Valve Clearance Inspection .............................................................................................. 2-21
- •Valve Clearance Adjustment............................................................................................. 2-23
- •Periodic Inspection
- •Basic Torque for General Fasteners
- •Specifications
- •Special Tools
- •Inside Circlip Pliers: 57001-143
- •Fuel System (dfi)
- •Idle Speed Inspection
- •Idle Speed
- •Idle Speed Adjustment
- •Evaporative Emission Control System (California Model)
- •Cooling System
- •Air Suction System
- •Engine Top End
- •Valve Clearance Inspection
- •Valve clearance adjustment chart inlet valve
- •Valve clearance adjustment chart exhaust valve
- •Wheels/Tires
- •(Over 130 km/h (80 mph))
- •Drive Train
- •Brake System
- •Suspensions
- •Steering System
- •Electrical System
- •Replacement Parts
- •Viscosity: sae 10w-40
- •1.9 L (2.0 us qt) (when filter is removed)
- •2.4 L (2.5 us qt) (when engine is completely dry) note
- •It does not reach to this tightening torque.
- •Fuel System (dfi) Table of Contents
- •Inquiries to Rider.................................................................................................................. 3-26
- •Inquiries to Rider............................................................................................................... 3-26
- •Terminal Names
- •Dfi Parts Location
- •Specifications
- •Special Tools and Sealant
- •Dfi Servicing Precautions
- •Dfi Servicing Precautions
- •Inquiries to Rider
- •Inquiries to Rider
- •Sample Diagnosis Sheet
- •Engine Doesn’t Start, Starting Difficulty
- •Self-diagnosis Procedures
- •Service Code Clearing Procedures
- •How to Erase Service Codes
- •Backups
- •Idle Speed Standard: 1 300 ±50 r/min (rpm)
- •Inlet Air Pressure Sensor Removal
- •Inlet Air Pressure Sensor Installation
- •Inlet Air Pressure Sensor Input Voltage Inspection note
- •Inlet Air Pressure Sensor Input Voltage Connections to ecu
- •Inlet Air Pressure Sensor Output Voltage Inspection note
- •Inlet Air Pressure Sensor Output Voltage Connections to ecu
- •Inlet Air Pressure Sensor Output Voltage Connection to Adapter
- •Inlet Air Pressure Sensor Circuit
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor Removal/Installation
- •Inlet Air Temperature Sensor Output Voltage Inspection note
- •Inlet Air Temperature Sensor Output Voltage Connections to ecu Connector
- •Inlet Air Temperature Sensor (Service Code 13)
- •Inlet Air Temperature Sensor Resistance Inspection
- •Inlet Air Temperature Sensor Circuit
- •Water Temperature Sensor (Service Code 14)
- •Water Temperature Sensor (Service Code 14)
- •Crankshaft Sensor (Service Code 21)
- •Speed Sensor (Service Code 24, 25)
- •Speed Sensor (Service Code 24, 25)
- •Vehicle-down Sensor (Service Code 31)
- •Vehicle-down Sensor Output Voltage Connections to Sensor
- •Vehicle-down Sensor Circuit
- •Oxygen Sensor-not activated (Service Code 33) (Europe Models)
- •Oxygen Sensor-not activated (Service Code 33) (Europe Models)
- •Stick Coils #1, #2: (Service Code 51, 52)
- •Stick Coil Removal/Installation
- •Input Voltage at ecu
- •Stick Coils #1, #2: (Service Code 51, 52)
- •Radiator Fan Relay (Service Code 56)
- •Subthrottle Valve Actuator (Service Code 62)
- •Subthrottle Valve Actuator (Service Code 62)
- •Input Voltage at Actuator
- •Air Switching Valve (Service Code 64)
- •Oxygen Sensor Heater (Service Code 67) (Europe Models)
- •Oxygen Sensor Heater (Service Code 67) (Europe Models)
- •Fi Indicator Light (led)
- •Inspection Flow Chart
- •Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)
- •Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models)
- •Ignition Switch off: Terminal 16 (br/w): 0 V
- •Needle Adapter Set: 57001-1457
- •Standard: Battery Voltage (12.8 V or more) for 3 seconds, and then 0 V.
- •Injector Output Voltage Connections to Injector #1
- •Injector Wiring Inspection
- •Injector Signal Test
- •Injector Resistance Inspection
- •Injector Resistance Connections to Injector
- •#1: W/r ←→ bl/r Terminal #2: w/r ←→ bl/g Terminal
- •Injector Unit Test
- •Injector Fuel Line Inspection
- •Injector Fuel Line Maximum Pressure Standard: 333 kPa (3.4 kgf/cm², 48 psi)
- •Idle Speed Inspection
- •Throttle Body Assy
- •Throttle Body Assy
- •Air Cleaner
- •Air Cleaner
- •Evaporative Emission Control System (California Model)
- •Evaporative Emission Control System (California Model)
- •Cooling System Table of Contents
- •Exploded View
- •Coolant Flow Chart
- •Specifications
- •Coolant
- •Coolant
- •Water Pump
- •Impeller Assembly
- •Thermostat
- •Thermostat
- •Hose and Pipes
- •Water Temperature Sensor
- •Engine Top End Table of Contents
- •Exhaust System
- •Exhaust System
- •Specifications
- •Special Tools and Sealant
- •Clean Air System
- •Clean Air System
- •Cylinder Head Cover
- •Cylinder Head Cover
- •Camshaft Chain Tensioner
- •Inlet 36.44 mm (1.4346 in.)
- •Valve Guide Removal
- •Valve Guide Installation
- •Valve-to-Guide Clearance Measurement (Wobble Method)
- •Throttle Body Holder
- •Muffler
- •Muffler
- •Clutch Table of Contents
- •Exploded View
- •Specifications
- •Clutch Lever and Cable
- •Clutch Lever and Cable
- •Clutch Cover
- •Engine Lubrication System Table of Contents
- •Exploded View
- •Engine Oil Flow Chart
- •Engine Oil and Oil Filter
- •Oil Pressure Relief Valve
- •Oil Pump
- •Oil Pump
- •Oil Pressure Measurement
- •Oil Pressure Switch
- •Engine Removal/Installation Table of Contents
- •Exploded View
- •Crankshaft/Transmission Table of Contents
- •Balancer
- •Balancer
- •Balancer Shaft Bearing Insert Selection
- •Ball Bearing, Needle Bearing, and Oil Seal
- •Wheels/Tires Table of Contents
- •Exploded View
- •Specifications
- •Service Limit:
- •Hub Bearing
- •Hub Bearing
- •Final Drive Table of Contents
- •Exploded View
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Brakes Table of Contents
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Brake Lever, Brake Pedal
- •Brake Disc
- •Brake Fluid
- •Inquiries to Rider
- •Sample Diagnosis Sheet
- •Service Code Table
- •Suspension Table of Contents
- •Specifications
- •Inside Circlip Pliers: 57001-143
- •Special Tools
- •Viscosity: kayaba khl34-g10 or equivalent
- •Inner Tube Inspection
- •Rear Shock Absorber
- •Special Tools - Jack: 57001-1238
- •Rear Shock Absorber
- •Jack Attachment: 57001-1608
- •Steering Table of Contents
- •Exploded View
- •Special Tools
- •Steering
- •Handlebar
- •Handlebar
- •Frame Table of Contents
- •Inner Fairing Removal
- •Inner Fairing Installation
- •Side Covers
- •Seat Covers
- •Fenders
- •Fenders
- •Sidestand
- •Frame Cover
- •Electrical System Table of Contents
- •Specifications
- •Parts Location
- •Parts Location
- •Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)
- •Precautions
- •Electrical Wiring
- •Initial Charge
- •Interchange
- •Rotor Holder: 57001-1658
- •Interlock Operation Inspection
- •1St Check
- •2Nd Check
- •3Rd Check
- •Ic Igniter Inspection
- •Ignition System Circuit
- •Air Switching Valve
- •Air Switching Valve
- •Radiator Fan System
- •Indicator Lights Inspection
- •12 V 3.4 w Bulb (Other Side) → bl Lead Terminal Battery (–) → bk Lead Terminal
- •30 A Main Fuse Removal
- •15 A ecu Fuse Removal
- •Appendix Table of Contents
- •Engine Doesn’t Start, Starting Difficulty:
- •Poor Running at Low Speed:
- •Poor Running or No Power at High Speed:
- •Overheating:
- •Over Cooling:
- •Clutch Operation Faulty:
- •Gear Shifting Faulty:
- •Abnormal Engine Noise:
- •Valve noise:
- •Abnormal Drive Train Noise:
- •Battery Trouble:
- •Model application
Exhaust System
Exhaust System EX650A6F/EX650B6F
Full: Full Power
H: Honeycomb Type Catalyst
Silencer
[A] with Hole [B] for Oxygen Sensor [C]
Exhaust System
Manifold Mark Position [A]
Silencer
Mark Position [A]
Specifications
Item |
Standard |
Service Limit |
Camshafts Cam Height: Exhaust Inlet Camshaft Journal, Camshaft Cap Clearance Camshaft Journal Diameter
Camshaft Bearing Inside Diameter Camshaft Runout |
35.843 35.957 mm (1.4111 1.4156 in.) |
35.74 mm (1.4071 in.) |
36.543 36.657 mm (1.4387 1.4432 in.) |
36.44 mm (1.4346 in.) |
|
0.028 0.071 mm (0.0011 0.0028 in.) |
0.16 mm (0.0063 in.) |
|
23.950 23.972 mm |
23.92 mm (0.942 in.) |
|
(0.9429 0.9438 in.) |
|
|
24.000 24.021 mm |
24.08 mm (0.948 in.) |
|
(0.9449 0.9457 in.) |
|
|
TIR 0.02 mm (0.0008 in.) or less |
TIR 0.1 mm (0.004 in.) |
|
Cylinder Head |
|
|
Cylinder Compression |
(Usable Range) |
|
|
961 1 471 kPa (9.8 15.0 kgf/cm², 139 |
– – – |
|
213 psi) at 400 r/min (rpm) |
|
Cylinder Head Warp |
– – – |
0.05 mm (0.002 in.) |
Valves Valve Clearance: Exhaust Inlet Valve Head Thickness: Exhaust Inlet Valve Stem Bend
Valve Stem Diameter: Exhaust Inlet Valve Guide Inside Diameter: Exhaust Inlet Valve/Valve Guide Clearance (Wobble Method): Exhaust Inlet Valve Seat Cutting Angle Valve Seating Surface: Width: Exhaust Inlet Outside Diameter: Exhaust Inlet |
0.22 0.31 mm (0.0087 0.0122 in.) |
– – – |
0.15 0.21 mm (0.0059 0.0083 in.) |
– – – |
|
0.8 mm (0.031 in.) |
0.5 mm (0.020 in.) |
|
0.5 mm (0.020 in.) |
0.25 mm (0.0098 in.) |
|
TIR 0.01 mm (0.0004 in.) or less |
TIR 0.05 mm |
|
|
(0.002 in.) |
|
4.455 4.470 mm (0.1754 0.1760 in.) |
4.44 mm (0.175 in.) |
|
4.475 4.490 mm (0.1762 0.1768 in.) |
4.46 mm (0.176 in.) |
|
4.500 4.512 mm (0.1772 0.1776 in.) |
4.58 mm (0.180 in.) |
|
4.500 4.512 mm (0.1772 0.1776 in.) |
4.58 mm (0.180 in.) |
|
0.07 0.14 mm (0.0028 0.0055 in.) |
0.27 mm (0.0106 in.) |
|
0.02 0.08 mm (0.0008 0.0032 in.) |
0.22 mm (0.0087 in.) |
|
32°, 45°, 55°, 60° |
– – – |
|
0.5 1.0 mm (0.020 0.039 in.) |
– – – |
|
0.5 1.0 mm (0.020 0.039 in.) |
– – – |
|
27.6 27.8 mm (1.087 1.094 in.) |
– – – |
|
32.6 32.8 mm (1.283 1.291 in.) |
– – – |
Specifications
Item |
Standard |
Service Limit |
Valve Spring Free Length: Exhaust Inlet |
41.91 mm (1.650 in.) 41.91 mm (1.650 in.) |
40.3 mm (1.587 in.) 40.3 mm (1.587 in.) |
Cylinder, Pistons Cylinder Inside Diameter Piston Diameter Piston/Cylinder Clearance Piston Ring/Groove Clearance: Top Second Piston Ring Groove Width: Top Second Piston Ring Thickness: Top Second Piston Ring End Gap: Top Second |
82.994 83.006 mm |
83.10 mm (3.2716 in.) |
(3.2675 3.2679 in.) |
|
|
82.969 82.984 mm |
82.82 mm (3.2606 in.) |
|
(3.2665 3.2671 in.) |
|
|
0.010 0.037 mm (0.0004 0.0015 in.) |
– – – |
|
0.03 0.07 mm (0.0012 0.0028 in.) |
0.17 mm (0.0067 in.) |
|
0.02 0.06 mm (0.0008 0.0024 in.) |
0.16 mm (0.0063 in.) |
|
0.92 0.94 mm (0.0362 0.0370 in.) |
1.02 mm (0.040 in.) |
|
1.01 1.03 mm (0.0398 0.0406 in.) |
1.11 mm (0.044 in.) |
|
0.87 0.89 mm (0.0342 0.0350 in.) |
0.80 mm (0.031 in.) |
|
0.97 0.99 mm (0.0382 0.0390 in.) |
0.90 mm (0.035 in.) |
|
0.25 0.40 mm (0.0098 0.0157 in.) |
0.7 mm (0.028 in.) |
|
0.40 0.55 mm (0.0157 0.0217 in.) |
0.8 mm (0.031 in.) |
Special Tools and Sealant
Compression
Gauge, 20 kgf/cm²: 57001-221
Valve Seat Cutter, 60° -
30:
57001-1123
Valve
Spring Compressor
Assembly:
57001-241
Valve Seat Cutter Holder Bar: 57001-1128
Valve Seat Cutter, 45° -
35:
57001-1116
Valve Seat Cutter, 45° - 30:
57001-1187
Valve Seat Cutter, 32° - 30:
57001-1120
Valve Seat Cutter, 55° - 35:
57001-1247
Valve Seat Cutter, 32° - 35:
57001-1121
Valve Spring Compressor Adapter, 21: 57001-1272
