- •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
Units of Power:
-
kW
×
1.360
=
PS
kW
×
1.341
=
HP
PS
×
0.7355
=
kW
PS
×
0.9863
=
HP
Units
of Temperature:
Periodic Maintenance Table of Contents
Periodic
Maintenance Chart
................................................................................................... 2-3
Torque and Locking Agent...................................................................................................... 2-6 2
Specifications ......................................................................................................................... 2-11
Special Tools .......................................................................................................................... 2-13
Periodic Maintenance Procedures.......................................................................................... 2-14
Fuel System (DFI)................................................................................................................ 2-14
Air Cleaner Element Cleaning........................................................................................... 2-14
Throttle Control System Inspection................................................................................... 2-15
Engine Vacuum Synchronization Inspection..................................................................... 2-16
Idle Speed Inspection ....................................................................................................... 2-18
Idle Speed Adjustment...................................................................................................... 2-18
Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... 2-19
Evaporative Emission Control System (California Model) ................................................... 2-19
Evaporative Emission Control System Inspection ............................................................ 2-19
Cooling System.................................................................................................................... 2-20
Coolant Level Inspection................................................................................................... 2-20
Radiator Hose Damage and Installation Condition Inspection.......................................... 2-21
Air Suction System .............................................................................................................. 2-21
Air Suction System Damage Inspection............................................................................ 2-21
Engine Top End ................................................................................................................... 2-21
