Honda 2006 TRX680FA, TRX680FA, TRX680FGA Service Manual 567 Pages
Honda 2006 TRX680FA is a powerful and versatile all-terrain vehicle (ATV) that is perfect for a variety of tasks, from work to recreation. With its 675cc engine, the TRX680FA has plenty of power to tackle even the toughest terrain. It also features a number of features that make it easy to operate, including a fully automatic transmission, electric power steering, and independent suspension. Whether you're looking for an ATV for work or play, the Honda 2006 TRX680FA is a great choice.
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2006 SERVIC \ ANUAL RX680FA/FGA A Few Words About Safety Service Information The service and repair information 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 condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended 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 warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. AWARNING Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. AWARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. Important Safety Precautions Make sure you have a clear 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, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns 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 it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing 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. • Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Use only a nonflammable solvent, not gasoline, to clean parts. • Never drain 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 CONTENTS This service manual describes the service procedures for the TRX680FA and TRX680FGA. GENERAL Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the California Air Resources Board (CARB). TECHNICAL LUBRICATION SYSTEM FUEL SYSTEM Find the section you want on this page, then turn to the table of contents on the first page of the section. COOLING SYSTEM Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. ENGINE ACAUTION You CAN be HURT if you don't follow instructions. REMOVAL/INSTALLATION LU Z CYLINDER o CYLINDER/PISTON HEAD/VALVE/CAMSHAFT ALTERNATOR/STARTER 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 fl\ and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY i i DANGER HURT if you don't follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. PANELS/EXHAUST MAINTENANCE Sections 1 and 4 apply to the whole vehicle.. Section 3 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Sections 5 through 23 describe parts of the vehicle, grouped according to location. AWARNING FEATURES FRAME/BODY SYSTEM Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. If you are not familiar with this vehicle, read Technical Features in section 2. If you don't know the source of the trouble, go to section 25 Troubleshooting. INFORMATION CLUTCH SUB-TRANSMISSION/GEARSHIFT CR AN KCASE/CR AN KSH AFT/BALANCER DRIVE TRAIN SYSTEM FRONT (A < I O REAR WHEEL/SUSPENSION/STEERING WHEEL/SUSPENSION BRAKE SYSTEM FRONT DRIVING MECHANISM Instructions - how to service this vehicle correctly and safely. REAR DRIVING MECHANISM As you read this manual, you will find information that is preceded by a | NOTICE I symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. BATTERY/CHARGING < ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: Nov, 2005 ©Honda Motor Co., Ltd. LINKAGE u cc o UJ UJ SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX 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. 1 Use the recommended engine oil, unless otherwise specified. 1 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). ,.-¥iiitwn 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: Molykote® BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. 1 Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use fork or suspension fluid. 1. GENERAL INFORMATION SERVICE RULES MODEL IDENTIFICATION GENERAL SPECIFICATIONS 1-2 REAR WHEEL/SUSPENSION SPECIFICATIONS 1-9 1-3 BRAKE SYSTEM SPECIFICATIONS 1-10 FRONT DRIVING MECHANISM SPECIFICATIONS • 1-10 REAR DRIVING MECHANISM SPECIFICATIONS 1-10 BATTERY/CHARGING SYSTEM SPECIFICATIONS 1-10 IGNITION SYSTEM SPECIFICATIONS 1-11 ••• 1-5 LUBRICATION SYSTEM SPECIFICATIONS 1-7 FUEL SYSTEM SPECIFICATIONS 1-7 COOLING SYSTEM SPECIFICATIONS CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS 1-7 CYLINDER/PISTON SPECIFICATIONS 1-8 ELECTRIC STARTER SPECIFICATIONS 1-11 1-8 LIGHTS/METERS/SWITCHES SPECIFICATIONS 1-11 STANDARD TORQUE VALUES 1-12 ENGINE & FRAME TORQUE VALUES 1-12 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS SUB-TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS 1-8 1-9 CRANKCASE/CRANKSHAFT/BALANCER SPECIFICATIONS 1-9 LUBRICATION & SEAL POINTS 1-17 DRIVETRAIN SPECIFICATIONS 1-9 CABLE & HARNESS ROUTING 1-20 EMISSION CONTROL SYSTEMS 1-39 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS 1-9 1-1 GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. 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 tightening bolts or nuts, begin with the larger diameter or inner bolt 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. 8. Route all electrical wires as show in the Cable and Harness Routing (page 1-20). ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbrev. term PGM-FI MAP sensor TP sensor ECT sensor IAT sensor CKP sensor VS sensor EOT sensor IACV PCM (ECM/TCM) EEPROM DLC SCS connector HDS DTC MIL A/T Clutch PC solenoid 4WD ESP GPS 1-2 Full term Programmed Fuel Injection Manifold Absolute Pressure sensor Throttle Position sensor Engine Coolant Temperature sensor Intake Air Temperature sensor Crankshaft Position sensor Vehicle Speed sensor Engine Oil Temperature sensor Idle Air Control Valve Powertrain Control Module (Engine Control Module/Transmission Control Module) Electrically Erasable Programmable Read Only Memory Data Link Connector Service Check Short connector Honda Diagnostic System Diagnostic Trouble Code Malfunction Indicator Lamp Automatic Transmission Clutch Pressure Control solenoid 4 Wheel Drive Electric Shift Program Global Positioning System GENERAL INFORMATION MODEL IDENTIFICATION SERIAL NUMBERS The Vehicle Identification Number (V.I.N) is stamped on the front side of the frame. The engine serial number is stamped on the right side of the crankcase. VEHICLE IDENTIFICATION NUMBER VIN ENGINE SERIAL NUMBER 1-3 GENERAL INFORMATION The throttle body identification number is stamped on the left side of the throttle body. THROTTLE BODY IDENTIFICATION NUMBER LABELS The name plate (U.S.A. and AUSTRALIA type) is located on the left frame down tube. U.S.A./AUSTRALIAtype NAME PLATE The safety certification label (Canada type only) is locate on the right frame down tube. Canada type SAFETY CERTIFICATION LABEL The color label is attached on the right side of the frame under the seat. When ordering color coded parts, always specify the designated color code. 1-4 GENERAL INFORMATION The Vehicle Emission Control Information Label is attached on the left side of the rear fender under the seat. EMISSION CONTROL INFORMATION LABEL GENERAL SPECIFICATIONS DIMENSIONS FRAME ITEM Overall length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity SPECIFICATIONS 2,113 mm (83.2 in) 1,189 mm (46.8 in) 1,207 mm (47.5 in) 1,289 mm (50.7 in) 915 mm (36.0 in) 945 mm (37.2 in) 875 mm (34.5 in) 341 mm (13.4 in) 234 mm (9.2 in) 291 kg (642 lbs) 220 kg (485 lbs) Double cradle Double wish-bone 175 mm (6.9 in) Double tube Double wish-bone 203 mm (8.0 in) Single tube AT25x8R12** AT25x 1 0 R 1 2 * * 12x6.0 AT 12x7.5 AT KT515(DUNLOP) KT511 (DUNLOP) Hydraulic disc brake Hydraulic/mechanical disc brake 1.6° 2.1 mm (3/16 in) 0° 17 liters (4.5 US gal, 3.7 Imp gal) 4.1 liters (1.08 US gal, 0.90 Imp gal) 1-5 GENERAL INFORMATION ENGINE CARBURATION DRIVE TRAIN ITEM Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens at 1 mm (0.04 in) lift Intake valve closes at 1 mm (0.04 in) lift Exhaust valve opens at 1 mm (0.04 in) lift Exhaust valve closes at 1 mm (0.04 in) lift Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Type Throttle bore Transmission Shift clutch (1st, 2nd and 3rd clutches) Primary reduction Secondary reduction Final reduction Transmission ratio Gearshift pattern Forward Reverse Front Rear 1st 2nd 3rd Reverse Sub-transmission D (Drive) R (Reverse) ELECTRICAL Ignition system Starting system Charging system Regulator/rectifier Lighting system 1-6 SPECIFICATIONS Single cylinder, longitudinally installed 102 x 82.6 mm (4.02 x 3.25 in) 674.9 cm3 (41.19 cu-in) 9.2: 1 OHV 8° BTDC 45° ABDC 45° BBDC 5° ATDC Forced pressure (dry sump) Trochoid Liquid cooled Oiled urethane foam 60.4 kg (133.2 lbs) PGM-FI (Programmed Fuel Injection) 40 mm (1.57 in) Automatic (Torque converter + 3-speed drive system and reverse) Multi-plate, wet (hydraulic clutch with electric controlled) 1.333 (64/48) 2.000 (38/19) 2.375(38/16) 3.231 (42/13) 3.154(41/13) 2.053 (39/19) 1.375 (33/24) 0.933 (28/30) 2.138(39/19x25/24) D-N-R 2-mode: 3-speed Automatic and Manual (ESP; 3 speeds) 1-mode (fixed low ratio) Full Transistorized Ignition Electric starter motor and emergency recoil starter Triple phase output alternator FET shorted, triple phase full wave rectification Battery GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS ITEM After draining Engine oil capacity After draining/filter change After disassembly Recommended engine oil Oil pressure at 5,000 rpm (min1)/80°C (176°F) Oil pump rotor Tip clearance Body clearance Side clearance STANDARD 2.7 liters (2.9 US qt, 2.4 Imp qt) 2.9 liters (3.1 US qt, 2.6 Imp qt) 4.1 liters (4.3 US qt, 3.6 Imp qt) Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an 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-40, 5W-30 785 kPa (8.0 kgf/cm2,114 psi) 0.15(0.006) 0.12-0.22(0.005-0.009) 0.02-0.09(0.001 -0.004) Unit: mm (in) SERVICE LIMIT — - 0.20 (0.008) 0.25 (0.010) 0.11 (0.004) FUEL SYSTEM SPECIFICATIONS ITEM Throttle body identification number Idle speed Throttle lever free play ECT sensor resistance (20°C/68°F) Fuel injector resistance (at 20°C/68°F) Fuel pressure Fuel pump flow (at 12 V) SPECIFICATIONS GQ67A 1,400 ±50 rpm (min 1 ) 3 - 8 mm (1/8-5/16 in) 2 . 3 - 2.6 k£2 11.1- 12.3 a 284 - 304 kPa (2.9 - 3.1 kgf/cm2,41 - 44 psi) 71 cm 3 (2.4 US oz, 2.5 Imp oz) minimum/10 seconds COOLING SYSTEM SPECIFICATIONS ITEM Radiator and engine Reserve tank Radiator cap relief pressure Thermostat Begin to open Fully open Valve lift Recommended antifreeze Coolant capacity Standard coolant concentration SPECIFICATIONS 2.0 liters (2.1 US qt, 1.8 Imp qt) 0.46 liter (0.49 US qt, 0.40 Imp qt) 108- 137 kPa (1.1 - 1 . 4 kgf/cm2, 1 6 - 2 0 psi) 80 - 84°C 95°C 8 mm (0.3 in) minimum Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors 1:1 mixture with distilled water 1-7 GENERAL INFORMATION CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS ITEM Cylinder compression at 350 rpm (min 1 ) Valve clearance Valve, valve guide Valve stem O.D. Valve guide I.D. Stem-to-guide clearance Valve spring Rocker arm Camshaft and cam follower Valve guide projection above cylinder head Valve seat width Free length Arm I.D. Shaft O.D. Arm-to-shaft clearance Cam lobe height Cam follower O.D. Follower bore I.D. Follower-to-bore clearance Cylinder head warpage IN EX IN EX IN/EX IN EX IN EX IN/EX Inner Outer IN/EX IN/EX IN/EX IN EX IN/EX IN/EX IN/EX STANDARD 550 kPa (5.6 kgf/cm2, 80 psi) 0.15(0.006) 0.33 (0.013) 5.475 - 5.490 (0.2156 - 0.2161) 5.455 - 5.470 (0.2148 - 0.2154) 5.500 - 5.512 (0.2165 - 0.2170) 0.010-0.037 (0.0004-0.0015) 0.030-0.057(0.0012-0.0022) 14.8-15.2(0.58-0.60) 17.3-17.7(0.68-0.70) 1.0-1.1 (0.039-0.043) 37.20 (1.465) 44.20 (1.740) 12.000 - 12.018 (0.4724 - 0.4731) 11.964 - 11.984 (0.4710 - 0.4718) 0.016 - 0.054 (0.0006 - 0.0021) 35.015 - 35.175 (1.3785 - 1.3848) 35.394 - 35.554 (1.3935 - 1.3998) 22.467 - 22.482 (0.8845 - 0.8851) 22.510 - 22.526 (0.8862 - 0.8868) 0.028 - 0.059 (0.0011 - 0.0023) - Unit: mm (in) SERVICE LIMIT 5.45(0.215) 5.43 (0.214) 5.53(0.218) 0.12 (0.005) 0.14 (0.006) 1.4(0.06) 36.3 (1.43) 43.1 (1.70) 12.05(0.474) 11.92 (0.469) 0.08 (0.003) 34.840 (1.3717) 35.144(1.3824) 22.46 (0.884) 22.54 (0.887) 0.07 (0.003) 0.05 (0.002) CYLINDER/PISTON SPECIFICATIONS ITEM Cylinder I.D. Out-of-round Taper Warpage Piston, Piston O.D. at 20 (0.8) from bottom piston pin, Piston pin hole I.D. piston ring Piston pin O.D. Piston-to-piston pin clearance Piston ring end Top gap Second Oil (side rail) Piston ring-to-ring Top groove clearance Second Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance STANDARD 102.000 - 102.015 (4.0157 - 4.0163) 101.960 - 101.990 (4.0142 - 4.0153) 23.002 - 23.008 (0.9056 - 0.9058) 22.994 - 23.000 (0.9053 - 0.9055) 0.002 - 0.014 (0.0001 - 0.0006) 0.25-0.35(0.010-0.014) 0.40-0.55(0.016-0.022) 0.20-0.70(0.008-0.028) 0.045 - 0.080 (0.0018 - 0.0031) 0.025 - 0.060 (0.0010 - 0.0024) 0.010 - 0.055 (0.0004 - 0.0022) 23.030 - 23.050 (0.9067 - 0.9075) 0.030 - 0.056 (0.0012 - 0.0022) Unit: mm (in) SERVICE LIMIT 102.05(4.018) 0.05 (0.002) 0.05 (0.002) 0.05 (0.002) 101.90(4.012) 23.03 (0.907) 22.98 (0.905) 0.04 (0.002) 0.5 (0.02) 0.7 (0.03) 0.9 (0.04) 0.095 (0.0037) 0.075 (0.0030) 0.19 (0.007) 23.06 (0.908) 0.08 (0.003) ALTERNATOR/STARTER CLUTCH SPECIFICATIONS ITEM Starter driven gear boss O.D. Torque limiter slip torque 1-8 STANDARD 51.705 - 51.718 (2.0356 - 2.0361) 53-84N-m(5.4-8.6kgf-m, 3 9 - 6 2 Ibf-ft) Unit: mm (in) SERVICE LIMIT 51.61 (2.032) — GENERAL INFORMATION SUB-TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS ITEM Shift fork Reverse idle gear I.D. Claw thickness Shaft O.D. Collar I.D. Shaft O.D. Collar-to-shaft clearance STANDARD 11.000-11.021 (0.4331-0.4339) 4.93-5.00(0.194-0.197) 10.966 - 10.984 (0.4317 - 0.4324) 13.000 - 13.034 (0.5118 - 0.5131) 12.966 - 12.984 (0.5105 - 0.5112) - Unit: mm (in) SERVICE LIMIT 11.04 (0.435) 4.5(0.18) 10.96(0.431) 13.05(0.514) 12.93(0.509) 0.10 (0.004) CRANKCASE/CRANKSHAFT/BALANCER SPECIFICATIONS Crankshaft 0.05 (0.002) 0.05-0.65(0.002-0.026) 0.006 - 0.018 (0.0002 - 0.0007) Unit: mm (in) SERVICE LIMIT 0.15(0.059) 0.8 (0.03) 0.05 (0.002) Line 1st, 2nd and 3rd clutch STANDARD 785 kPa (8.0 kgf/cm2,114 psi) 785 kPa (8.0 kgf/cm2,114 psi) Unit: mm (in) SERVICE LIMIT — Initial clearance Disc thickness Plate thickness Return spring free length 0.7-0.9(0.03-0.04) 1.88-2.00(0.074-0.079) 1.95-2.05(0.077-0.081) 33.8 (1.33) worn out lining discoloration 31.8(1.25) ITEM Runout Big end side clearance Big end radial clearance STANDARD DRIVETRAIN SPECIFICATIONS ITEM Oil pressure at 5,000 rpm (min-1) Shift clutch (1st, 2nd and 3rd) FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo Tie-rod distance between the ball joints Toe STANDARD 30 kPa (0.30 kgf/cm2, 4.4 psi) 26 kPa (0.26 kgf/cm2, 3.8 psi) 34 kPa (0.34 kgf/cm2, 5.0 psi) 30 kPa (0.30 kgf/cm2, 4.4 psi) 387.5 + 1 mm (15.26 ± 0.4 in) Toe-out: 10.9 ± 15 mm (7/16 ± 9/16 in) SERVICE LIMIT 4 mm (0.16 in) - REAR WHEEL/SUSPENSION SPECIFICATIONS ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo 25 22 28 25 kPa kPa kPa kPa (0.25 (0.22 (0.28 (0.25 STANDARD kgf/cm2, 3.6 psi) kgf/cm2, 3.2 psi) kgf/cm2, 4.0 psi) kgf/cm2, 3.6 psi) SERVICE LIMIT 4 mm (0.16 in) - 1-9 GENERAL INFORMATION BRAKE SYSTEM SPECIFICATIONS ITEM Recommended brake fluid Front brake Brake disc thickness Brake disc runout Master cylinder I.D. Master piston O.D. Caliper cylinder I.D. Caliper piston O.D. Rear brake Brake disc thickness Brake disc runout Master cylinder I.D. Master piston O.D. Caliper cylinder I.D. Caliper piston O.D. Rear (parking) brake lever free play STANDARD Honda DOT 4 brake fluid 4.0(0.16) 14.000 - 14.043 (0.5512 - 0.5529) 13.957 - 13.984 (0.5495 - 0.5506) 33.960 - 34.010 (1.3370 - 1.3390) 33.878 - 33.928 (1.3338 - 1.3357) 7.5 (0.30) 15.870 - 15.913 (0.6248 - 0.6265) 15.827 - 15.854 (0.6231 - 0.6242) 30.230 - 30.280 (1.1902 - 1.1921) 30.165-30.198(1.1876-1.1889) 25-30(1-1-3/16) Unit: mm (in) SERVICE LIMIT 3.0(0.12) 0.30(0.012) 14.055(0.5533) L_13.945 (0.5490) 34.02(1.340) 33.87(1.333) 6(0.2) 0.5 (0.02) 15.925(0.6270) 15.815(0.6226) 30.29(1.193) 30.14(1.187) - FRONT DRIVING MECHANISM SPECIFICATIONS Front differential ITEM Oil capacity At draining At disassembly Recommended oil Gear backlash Backlash difference Slip torque Face cam-to-housing distance Differential ring gear depth Cone spring height STANDARD 175 cm3 (5.9 US oz, 6.2 Imp oz) 220 cm3 (7.4 US oz, 7.7 Imp 02) Hypoid gear oil SAE #80 0.05-0.25(0.002-0.010) 14-17Nm(1.45-1.75kgfm, 10-13 Ibfft) 3.3-3.7(0.13-0.15) 6.55-6.65(0.2579-0.2618) 2.8(0.11) Unit: mm (in) SERVICE LIMIT 0.4 (0.02) 0.2(0.01) 12Nm(1.2 kgfm, 9 Ibfft) 3.3(0.13) 6.55 (0.2579) 2.6(0.10) REAR DRIVING MECHANISM SPECIFICATIONS Final drive ITEM Oil capacity At draining At disassembly Recommended oil Gear backlash Backlash difference Ring gear-to-stop pin clearance STANDARD 78 cm3 (2.6 US 02, 2.7 Imp oz) 90 cm3 (3.0 US oz, 3.2 Imp oz) Hypoid gear oil SAE #80 0.05-0.25(0.002-0.010) 0.3-0.6(0.01-0.02) BATTERY/CHARGING SYSTEM SPECIFICATIONS Battery (YTX20LBS) Alternator 1-10 ITEM Capacity Current leakage Voltage Fully charged (20°C/68°F) Needs charging Charging curNormal rent Quick Capacity Charging coil resistance (20°C/68°F) SPECIFICATIONS 12V-18 Ah 1 mA max. 13.0-13.2V Below 12.3 V 1.8 A/5-10 h 9.0 A/1 .Oh 360 W/5,000 rpm (mirV1) 0 . 1 - 1.0 Q. Unit: mm (in) SERVICE LIMIT 0.4 (0.02) 0.2(0.01) - GENERAL INFORMATION IGNITION SYSTEM SPECIFICATIONS ITEM Standard Spark plug SPECIFICATIONS IFR5L11 (NGK) VK16PRZ11 (DENSO) IFR6L11 (NGK) VK20PRZ11 (DENSO) 1.0-1.1 mm (0.039-0.043 in) 100 V minimum 0.7 V minimum 15°BTDCatidle For extended high speed riding Spark plug gap Ignition coil peak voltage CKP sensor peak voltage Ignition timing ("F" mark) ELECTRIC STARTER SPECIFICATIONS ITEM Starter motor brush length STANDARD 12.0-13.0(0.47-0.51) Unit: mm (in) SERVICE LIMIT 6.5 (0.26) LIGHTS/METERS/SWITCHES SPECIFICATIONS Bulb Fuse ITEM Headlight Brake/taillight Neutral indicator Reverse indicator 4WD indicator Coolant/engine oil temperature indicator MIL (PGM-FI indicator) Meter light Main Sub-fuse SPECIFICATIONS 12V-40/40Wx2 12V-21/5Wx2 LED LED LED LED LED LED x 10 30 A x 2 15Ax1,10Ax4 1-11 GENERAL INFORMATION STANDARD TORQUE VALUES FASTENER TYPE 5 mm hex bolt and nut 6 mm hex bolt and nut 8 mm hex bolt and nut 10 mm hex bolt and nut 12 mm hex bolt and nut N-m (kgf-m, Ibfft) 5 (0.5, 3.6) 10(1.0,7) 22(2.2,16) 34 (3.5, 25) 54 (5.5, 40) FASTENER TYPE 5 mm screw 6 mm screw 6 mm flange bolt (8 mm head, small flange) 6 mm flange bolt (8 mm head, large flange) 6 mm flange bolt (10 mm head) and nut 8 mm flange bolt and nut 10 mm flange bolt and nut N-m (kgf-m, Ibfft) 4 (0.4, 2.9) 9 (0.9, 6.5) 10(1.0,7) 12(1.2,9) 12(1.2,9) 26 (2.7, 20) 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. ENGINE MAINTENANCE ITEM Spark plug Valve adjusting screw lock nut Timing hole cap Engine oil drain bolt Engine oil filter center bolt QTY 1 4 1 1 1 THREAD DIA. (mm) 14 6 14 12 20 TORQUE N m (kgf-m, Ibfft) 22(2.2,16) 17(1.7,12) 10(1.0,7) 25(2.5,18) 18(1.8,13) THREAD DIA. (mm) 6 TORQUE N-m (kgf-m, Ibfft) 12(1.2,9) THREAD DIA. (mm) REMARKS LUBRICATION SYSTEM ITEM Oil pump driven sprocket bolt QTY 1 REMARKS Apply locking agent 1 1 1 3 1 1 2 2 TORQUE N-m (kgf-m, Ibfft) 1.5(0.15,1.1) 3.4(0.35,2.5) 4.2(0.43,3.1) 4.2(0.43,3.1) 5.1 (0.53, 3.8) 2.1 (0.21,1.5) THREAD DIA. (mm) 7 TORQUE N-m (kgf-m, Ibfft) 12(1.2,9) THREAD DIA. (mm) 10 TORQUE N-m (kgf-m, Ibfft) 55(5.6,41) THREAD DIA. (mm) 10 TORQUE N-m (kgf-m, Ibfft) - CJl Insulator band screw (throttle body side) Insulator band screw (engine side) Throttle drum cover screw Sensor unit mounting screw Fuel feed hose bracket screw Harness guide bracket screw Fuel injector/feed hose mounting bolt IACV mounting torx screw QTY 5 4 CJl CJl ITEM CJl FUEL SYSTEM 5 5 REMARKS page 6-42 page 6-46 COOLING SYSTEM ITEM Water pump impeller QTY 4 REMARKS CYLINDER HEAD/VALVE/CAMSHAFT ITEM Cylinder head cover cap nut QTY 4 REMARKS Apply engine oil CYLINDER/PISTON ITEM Cylinder stud bolt 1-12 QTY 4 REMARKS page 10-7 GENERAL INFORMATION ALTERNATOR/STARTER CLUTCH ITEM CD t— CO CN Starter clutch socket bolt Recoil starter driven pulley bolt Alternator stator bolt CKP sensor mounting bolt QTY THREAD DIA. (mm) 8 12 6 5 TORQUE N-m (kgf-m, Ibf-ft) 30(3.1,22) 108(11.0,80) 10(1.0,7) 6 (0.6, 4.3) TORQUE N-m (kgf-m, Ibf-ft) 18(1.8,13) 108(11.0,80) REMARKS Apply locking agent Apply engine oil Apply locking agent DRIVE TRAIN Oil pass bolt Primary driven gear lock nut 1 1 THREAD DIA. (mm) 20 16 Stator shaft inner collar stopper pin Torque converter lock nut 1 1 10 22 14(1.4,10) 108(11.0,80) Oil feed pipe setting cap 1 24 21 (2.1,15) THREAD DIA. (mm) 10 10 TORQUE N-m (kgf-m, Ibf-ft) THREAD DIA. (mm) 8 8 8 5 5 5 8 TORQUE N-m (kgf-m, Ibf-ft) 37 (3.8, 27) 37 (3.8, 27) 23(2.3,17) 3.2 (0.33, 2.4) 5.4 (0,55, 4.0) 3.2 (0.33, 2.4) 32 (3.3, 24) THREAD DIA. (mm) 30 8 30 8 4 12 TORQUE N-m (kgf-m, Ibf-ft) 12(1.2,9) 12(1.2,9) 12(1.2,9) 12(1.2,9) 2(0.2,1.4) 54 (5.5, 40) THREAD DIA. (mm) 4 TORQUE N-m (kgf-m, Ibf-ft) 1.5(0.15, 1.1) THREAD DIA. (mm) 10 10 8 TORQUE N-m (kgf-m, Ibf-ft) 54 (5.5, 40) 54(5.5,40) 32 (3.3, 24) ITEM QTY REMARKS Apply engine oil, Lock nut: replace with a new one Stake Apply locking agent Apply engine oil, Lock nut: replace with a new one Stake LIGHTS/METERS/SWITCHES ITEM ECT sensor EOT sensor QTY 1 1 REMARKS 12(1.2,9) 12(1.2,9) FRAME FRAME/BODY PANELS/EXHAUST SYSTEM ITEM Front carrier and carry pipe bolt Rear carrier bolt Muffler band bolt Front exhaust pipe cover screw Muffler heat protector screw Muffler cover screw Footpeg bracket nut QTY 8 6 2 3 3 2 4 REMARKS MAINTENANCE ITEM QTY Front differential oil filler cap Front differential oil drain bolt Rear final gear case oil filler cap Rear final gear case oil drain bolt Front master cylinder reservoir cap screw Tie-rod lock nut 1 1 1 1 2 4 REMARKS FUEL SYSTEM ITEM Bank angle sensor mounting bolt QTY 2 REMARKS ENGINE REMOVAL/INSTALLATION ITEM CN «CN Lower engine hanger nut (left and right) Upper engine hanger bolt Upper engine hanger bracket bolt QTY REMARKS 1-13 GENERAL INFORMATION SUB-TRANSMISSION/GEARSHIFT LINKAGE ITEM Q'TY Gear selector lever pivot nut Gear selector arm pinch bolt Gear selector cable lock nut THREAD DIA. (mm) 12 6 14 TORQUE N m (kgf-m, Ibfft) 9 (0.9, 6.5) 16(1.6,12) 26 (2.7, 20) TORQUE N m (kgf-m, Ibfft) 39 (4.0, 29) REMARKS FRONT WHEEL/SUSPENSION/STEERING Handlebar lower holder nut 2 THREAD DIA. (mm) 10 Front wheel nut Front wheel hub nut 8 2 10 16 64 (6.5, 47) 78 (8.0, 58) Front brake caliper bracket flange bolt 4 10 44 (4.5, 33) Front brake disc bolt 8 8 42(4.3,31) Front brake splash guard flange bolt 6 6 11 (1.1,8) Shock absorber mounting nut 4 10 44 (4.5, 33) Brake hose clamp flange bolt Upper arm pivot nut 5 2 6 10 12(1.2,9) 34 (3.5, 25) Lower arm pivot nut 4 10 44 (4.5, 33) Upper and lower arm ball joint nut 4 12 29 (3.0, 22) Tie-rod ball joint nut 4 12 54 (5.5, 40) Combination meter stay mounting nut Steering shaft end nut Steering shaft holder bolt Parking lock lever screw Rear brake lever pivot bolt Rear brake lever pivot nut Parking stopper stay screw Parking stopper stay screw Brake light switch (left lever side) 2 1 2 1 1 1 1 1 1 8 14 8 6 6 6 4 6 4 25(2.5,18) 108(11.0,80) 32 (3.3, 24) 7(0.7,5.1) 1 (0.1,0.7) 6 (0.6, 4.3) 2(0.2,1.4) 2(0.2,1.4) 1 (0.1,0.7) ITEM 1-14 QTY REMARKS Lock nut: replace with a new one Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole ALOC bolt: replace with a new one ALOC bolt: replace with a new one ALOC bolt: replace with a new one Lock nut: replace with a new one Lock nut: replace with a new one Lock nut: replace with a new one Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole Lock nut: replace with a new one Apply locking agent GENERAL INFORMATION REAR WHEEL/SUSPENSION Rear wheel nut Rear wheel hub nut 8 2 THREAD DIA. (mm) 10 20 Upper arm pivot nut (frame side) 4 10 34 (3.5, 25) Upper arm pivot nut (knuckle side) 2 12 54 (5.5, 40) Lower arm pivot nut 4 10 34 (3.5, 25) TORQUE N-m (kgf-m, Ibf-ft) 34 (3.5, 25) 5.4 (0.55, 4.0) 23 (2.3, 17) 17(1.7,12) 1 (0.1,0.7) 5.9 (0.6, 4.3) 12(1.2,9) 5.4 (0.55, 4.0) 2(0.2,1.4) 27 (2.8, 20) 32 (3.3, 24) 23(2.3,17) 30(3.1,22) ITEM Q'TY TORQUE N-m (kgf-m, Ibf-ft) 64 (6.5, 47) 137(14.0,101) REMARKS Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole Lock nut: replace with a new one Lock nut: replace with a new one Lock nut: replace with a new one BRAKE SYSTEM Brake hose oil bolt Front caliper bleed valve Front caliper slide pin flange bolt Front brake pipe Front brake lever pivot bolt Front brake lever pivot nut Front master cylinder holder bolt Rear brake caliper bleed valve Rear brake reservoir hose joint screw Rear brake caliper parking nut Rear brake caliper bracket pin bolt Rear brake caliper pin retaining bolt Rear brake caliper mounting bolt 5 2 2 2 1 1 2 1 1 1 1 1 2 THREAD DIA. (mm) 10 8 8 10 6 6 6 8 4 10 8 8 8 Rear brake disc bolt 5 6 20 (2.0, 14) TORQUE N-m (kgf-m, Ibf-ft) 49 (5.0, 36) ITEM Q'TY REMARKS Apply locking agent ALOC bolt: replace with a new one ALOC bolt: replace with a new one FRONT DRIVING MECHANISM Differential ring gear bolt 10 THREAD DIA. (mm) 8 Differential case cover bolt Differential final clutch bolt Differential mounting bolt Differential mounting nut 2 4 3 1 1 10 8 8 10 10 49 (5.0, 36) 25(2.6,19) 25(2.6,19) 44 (4.5, 33) 44 (4.5, 33) Front vehicle speed sensor bolt Rear vehicle speed sensor bolt Speed sensor cover stay bolt Rear vehicle speed sensor cover bolt 1 2 2 2 2 8 6 6 6 6 22(2.2, 16) 10(1.0,7) 10(1.0,7) 10(1.0,7) 7(0.7,5.1) ITEM Q'TY REMARKS Special bolt: replace with a new one Apply locking agent Lock nut: replace with a new one 1-15 GENERAL INFORMATION REAR DRIVING MECHANISM Final gear case pinion bearing lock nut 1 THREAD DIA. (mm) 64 Pinion joint nut Final gear case cover bolt 1 2 4 2 16 10 8 10 108(11.0,80) 49 (5.0, 36) 25(2.6,19) 34 (3.5, 25) 2 10 39 (4.0, 29) 4 10 34 (3.5, 25) ITEM Final gear case mounting nut (main frame) Final gear case mounting nut (sub-frame) Sub-frame joint nut 1-16 Q'TY TORQUE N-m (kgf-m, Ibfft) 98(10.0,72) REMARKS Lock nut: replace with a new one, Stake Apply locking agent Apply locking agent Lock nut: replace with a new one Lock nut: replace with a new one GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL Molybdenum disulfide solution (a mixture of engine oil and molybdenum disulfide grease in a ratio of 1:1) Engine oil Molybdenum disulfide grease Multi purpose grease Locking agent Sealant (Three Bond 1215 or equivalent) LOCATION Water pump impeller shaft sliding surface Camshaft cam lobes Rocker arm shaft sliding surfaces Valve stems (valve sliding surface) Piston pin outer surface Starter driven gear bearing Starter reduction gear shaft splines Starter reduction gear teeth Starter motor shaft splines Crankshaft torque converter contact surface Oil strainer rubber seal Rocker arm followers and adjusting screw tips Cam chain Cam followers (entire surface) Cylinder head cap nut threads and seating surfaces Connecting rod small end inner surface Piston outer surface and piston pin hole Piston rings Cylinder bore Starter sprag clutch (entire surface) Recoil starter driven pulley bolt threads and seating surface Shift fork shaft Shift drum guide groove Transmission gear teeth and sliding surfaces Mainshaft, countershaft and output shaft journals Primary driven gear lock nut threads and seating surface Torque converter sprag clutch and bearings Torque converter lock nut threads and seating surface Oil feed pipes (entire surface) Each bearing rotating area Each O-ring Each oil seal lips REMARKS Camshaft cam surface Specified area (page 9-18) Recoil starter driven pulley oil seal lips Recoil starter drive pulley pivot Recoil starter center bolt Ignition pulse generator bolt threads Starter clutch bolt threads Shift return spring pin threads Shift drum stopper arm pivot bolt threads Oil pump driven sprocket bolt threads Cam chain tensioner pivot bolt threads Alternator wire grommet seating surface Front crankcase cover mating surface Crankcase mating surface Specified area (page 14-58) Specified area (page 13-13) 1-17 GENERAL INFORMATION FRAME MATERIAL Multi purpose grease (NLGI#2) LOCATION Throttle cable ends Throttle cable adjuster threads Throttle lever pivot and dust seal lips Rear brake lever pivot Parking lock arm pivot (screw) Steering shaft bushing inner surface Steering shaft dust seal lips Front knuckle outer dust seal lips Front knuckle inner dust seal lips Front upper arm pivot bushings Front upper arm pivot dust seal lips Front shock absorber lower bearing (upper arm) Front shock absorber lower pivot dust seal lips (upper arm) Rear knuckle dust seal lips Rear upper arm pivot bearings (frame side) Rear upper arm pivot bushings (knuckle) Rear lower arm pivot bushings Rear suspension arm pivot dust seal lips Rear brake pedal pivot Rear brake pedal pivot dust seal lips Rear brake cable ends Differential oil seal lips (2 places; drive shafts) Differential O-rings (3 places) Differential final clutch inside (dust seals and bearing) Vehicle speed sensor O-rings Final gear case oil seal lips (4 places) Final gear case O-rings (3 places) Gear selector lever pivot Gear selector lever gate grooves Molybdenum disulfide grease Molybdenum disulfide paste : NKG205 (KYODO YUSHI) Steering shaft splines Rear suspension arm pivot bolt head and O-rings (knuckle side) Front propeller shaft seal outer surfaces (2 places) Output shaft joint splines (front propeller shaft side) Output shaft joint splines (engine side) Differential pinion joint splines Front drive shaft splines (wheel side) Rear propeller shaft seal outer surface Final gear case pinion joint splines (rear propeller shaft side) Universal joint bearing Universal joint splines (both sides) Rear drive shaft splines (each end) Rear shock absorber pivot bushings (upper and lower) Rear shock absorber pivot dust seal lips Front drive shaft inboard joint inside NKG106(KYODOYUSHI) Front drive shaft outboard joint inside NKG205 (KYODO YUSHI) Rear drive shaft inboard joint inside NKG106 (KYODO YUSHI) Rear drive shaft outboard joint inside Silicone grease Front brake lever-to-master piston contacting area Front brake lever pivot bolt Brake caliper dust seal lips Brake caliper slide pin boot grooves and boots inside Throttle cable outer inside Rear brake cable inside Cable lubricant 1-18 REMARKS Apply 2 - 3 g Fill up 2.5-3 g Fill up 2.5-3 g per each seal Fill up 3 g per each bearing Fill up 5 - 8 g Fill up 5 - 8 g Fill up 5 - 8 g Fill up 40 joint Fill up 55 joint Fill up 60 joint Fill up 45 joint 60 g per each 75 g per each 80 g per each 65 g per each GENERAL INFORMATION MATERIAL DOT4 brake fluid Honda bond A or Honda Hand Grip Cement (U.S.A. only) or equivalent Locking agent LOCATION Brake master cylinder piston and cups Brake caliper piston and piston seals Handlebar grip rubber inside Air cleaner housing-to-connecting tube (throttle body and intake duct) mating areas Cooling fan motor shaft threads REMARKS 1-19 GENERAL INFORMATION CABLE & HARNESS ROUTING 2WD/4WD SELECT SWITCH WIRE DRIVE MODE SELECT SWITCH WIRE BRAKE LIGHT SWITCH WIRE THROTTLE CABLE LEFT HANDLEBAR SWITCH WIRE REAR BRAKE CABLE BRAKE HOSE FRONT BRAKE SWITCH/ BRAKE LIGHT SWITCH WIRE 2WD/4WD SELECT SWITCH WIRE DRIVE MODE SELECT SWITCH WIRE GPS model: GPS RECEIVER BRAKE LIGHT SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE GPS RECEIVER 6PCONNECTOR COMBINATION METER COMBINATION METER WIRE IGNITION SWITCH WIRE 1-20 GENERAL INFORMATION RIGHT HANDLEBAR: THROTTLE CABLE DRIVE MODE SELECT SWITCH WIRE THROTTLE CABLE 2WD/4WD SELECT SWITCH WIRE FRONT BRAKE SWITCH (for starting inhibitor) REAR BRAKE LIGHT SWITCH (Lever side) SKY BLUE WIRE (FRONT SIDE) GRAY WIRE (REAR SIDE) BLACK WIRE (FRONT SIDE) GREEN WIRE (REAR SIDE) LEFT HANDLEBAR: FRONT BRAKE SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE 1-21 GENERAL INFORMATION FUEL LEVEL SENSOR WIRE PCM (POWERTRAIN CONTROL MODULE) DLC SIPHON HOSE OVERFLOW HOSE REAR BRAKE CABLE MAIN WIRE HARNESS THROTTLE CABLE SHIFT SOLENOID SUB-HARNESS FINAL DRIVE! BREATHER HOSE DIFFERENTIAL BREATHER HOSE FUEL LEVEL SENSOR 2P (NATURAL) CONNECTOR FAN MOTOR BREATHER HOSE HEADLIGHT SUB-HARNESS 3P (BLACK) CONNECTOR 1-22 GENERAL INFORMATION THROTTLE CABLE ACCESSORY SOCKET REAR BRAKE CABLE FUEL TANK BREATHER HOSE FUEL LEVEL SENSOR FUEL LEVEL SENSOR WIRE FRONT BRAKE HOSE HARNESS CLIP: - Combination meter wire - 2WD/4WD select switch wire - Ignition switch wire - Left handlebar switch wire - Drive mode select switch wire - Front brake switch/brake light switch wire - Accessory socket wire 1-23 GENERAL INFORMATION HARNESS CLIP: - Combination meter wire - Ignition switch wire - 2WD/4WD select switch wire - Left handlebar switch wire - Drive mode select switch wire - Front brake switch/brake light switch wire - Accessory socket wire - Differential breather hose - Final gear case breather hose IGNITION SWITCH 4P (NATURAL) CONNECTOR HANDLEBAR SWITCH 10P (LIGHT GREEN) CONNECTOR HARNESS CLIP: - Ignition switch wire - Front brake switch/brake light switch wire - Drive mode select switch wire - Left handlebar switch wire - Bank angle sensor wire DIFFERENTIAL BREATHER HOSE FRONT FINAL CLUTCH WIRE ACCESSORY SOCKET 2P (WHITE) CONNECTOR REAR VS SENSOR FRONT VS SENSOR BRAKE HOSE HARNESS CLIP: - Front VS sensor wire - Rear VS sensor wire - Front final clutch wire - Differential breather hose 1-24 GENERAL INFORMATION DIFFERENTIAL BREATHER HOSE FRONT FINAL CLUTCH 2P (GREEN) CONNECTOR REAR VS SENSOR FRONT FINAL CLUTCH WIRE REAR VS SENSOR WIRE DIFFERENTIAL BREATHER HOSE FRONT VS SENSOR 1-25 GENERAL INFORMATION RIGHT FRONT BRAKE HOSE RIGHT FRONT BRAKE HOSE 1-26 GENERAL INFORMATION FAN MOTOR BREATHER HOSE COMBINATION METER 14P (GRAY) CONNECTOR COMBINATION METER 4P (NATURAL) CONNECTOR ACCESSORY SOCKET 2P (WHITE) CONNECTOR COMBINATION METER 4P (NATURAL) CONNECTOR FAN MOTOR 2P (NATURAL) CONNECTOR FRONT FINAL CLUTCH 2P (GREEN) CONNECTOR 4WD SWITCH 2P (BLACK) CONNECTOR FRONT VS SENSOR 3P (BLUE) CONNECTOR SHIFT SOLENOID SUB-HARNESS 6P (NATURAL) CONNECTOR REAR VS SENSOR 3P (YELLOW) CONNECTOR 1-27 GENERAL INFORMATION FINAL GEAR CASE BREATHER HOSE MAIN WIRE HARNESS FUEL PUMP 2P (BLACK) CONNECTOR REAR BRAKE CABLE FRONT STOP SWITCH 4P (NATURAL) CONNECTOR BANK ANGLE SENSOR 3P (GREEN) CONNECTOR MODE SELECT SWITCH 3P (BLACK) CONNECTOR 1-28 GENERAL INFORMATION SPARK PLUG WIRE IGNITION COIL SHIFT SOLENOID B 2P (BROWN) CONNECTOR LOWER RADIATOR HOSE SHIFT SOLENOID A 2P (BLACK) CONNECTOR OIL COOLER HOSES SHIFT SOLENOID SUB-HARNESS SHIFT CONTROL CABLE CLUTCH PC SOLENOID 2P (BLACK) CONNECTOR FINAL GEAR CASE BREATHER HOSE FRAME GROUND CABLE MAIN WIRE HARNESS MAIN WIRE HARNESS REAR BRAKE CABLE 20 - 40 BYPASS HOSE STARTER MOTOR CABLE BATTERY GROUND CABLE WATER HOSE 1-29 GENERAL INFORMATION FUEL HOSE (TANK-TO-PUMP) UPPER RADIATOR HOSE THROTTLE CABLE FUEL FEED HOSE SHIFT CONTROL CABLE THROTTLE CABLE FUEL FEED HOSE INJECTOR 2P (GRAY) CONNECTOR GEAR POSITION SWITCH 3P (NATURAL) CONNECTOR THROTTLE BODY HARNESS 1-30 IACV 4P (BLACK) CONNECTOR GENERAL INFORMATION MAP/TP SENSOR 5P (BLACK) CONNECTOR ECT SENSOR 2P (BLACK) CONNECTOR REAR BRAKE CABLE GEAR POSITION SWITCH WIRE STARTER MOTOR CABLE ALTERNATOR WIRE GEAR POSITION SWITCH 3P (NATURAL) CONNECTOR REAR BRAKE SWITCH 2P(GREEN) CONNECTOR MAIN WIRE HARNESS ALTERNATOR 5P (NATURAL) CONNECTOR FINAL GEAR CASE BREATHER HOSE BATTERY GROUND CABLE EOT SENSOR 2P (BLACK) CONNECTOR 1-31 GENERAL INFORMATION REAR BRAKE CABLE 7 REAR BRAKE CALIPER V REAR BRAKE HOSE REAR MASTER CYLINDER BRAKE/TAILLIGHT 3P (BLACK) CONNECTOR f MAIN WIRE HARNESS 1-32 IAT SENSOR 2P (BLACK) CONNECTOR GENERAL INFORMATION FUSE BOX BATTERY SUB-HARNESS 2P (NATURAL) CONNECTOR STARTER RELAY 2P (NATURAL) CONNECTOR BRAKE RESERVOIR HOSE BATTERY STARTER RELAY RELAY MODULE REAR BRAKE SWITCH WIRE BATTERY GROUND CABLE MAIN WIRE HARNESS FINAL GEAR CASE BREATHER HOSE STARTER MOTOR CABLE REGULATOR/ RECTIFIER RELAY MODULE 8P (GRAY) CONNECTOR STARTER RELAY 2P (NATURAL) CONNECTOR 1-33 GENERAL INFORMATION FINAL GEAR CASE BREATHER HOSE REAR BRAKE CAUPER REAR MASTER CYLINDER REAR BRAKE HOSE 1-34 GENERAL INFORMATION LEFT HEADLIGHT RIGHT HEADLIGHT HEADLIGHT SUBHARNESS FRONT CARRIER PIPE HEADLIGHT SUB-HARNESS RIGHT TAILLIGHT LEFT TAILLIGHT TAILLIGHT SUB-HARNESS 1-35 GENERAL INFORMATION AUSTRALIA type only: 2WD/4WD SELECT SWITCH WIRE DRIVE MODE SELECT SWITCH WIRE BRAKE LIGHT SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE REAR BRAKE CABLE 2WD/4WD SELECT SWITCH WIRE FRONT BRAKE SWITCH/ BRAKE LIGHT SWITCH WIRE DRIVE MODE SELECT SWITCH WIRE BRAKE LIGHT SWITCH WIRE HORN WIRE LEFT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR: HORN SWITCH FRONT BRAKE SWITCH WIRE HORN WIRE LEFT HANDLEBAR SWITCH WIRE 1-36 GENERAL INFORMATION AUSTRALIA type only: HARNESS CLIP: - Combination meter wire - Ignition switch wire - 2WD/4WD select switch wire - Left handlebar switch wire - Drive mode select switch wire - Front brake switch/brake light switch wire - Accessory socket wire - Differential breather hose - Final gear case breather hose - Horn wire IGNITION SWITCH 4P (NATURAL) CONNECTOR HANDLEBAR SWITCH 10P (LIGHT GREEN) CONNECTOR HARNESS CLIP: - Ignition switch wire - Front brake switch/brake light switch wire - Drive mode select switch wire '/ - Left handlebar switch wire - Bank angle sensor wire DIFFERENTIAL BREATHER HOSE FRONT FINAL CLUTCH WIRE REAR VS SENSOR WIRE ACCESSORY SOCKET 2P (WHITE) CONNECTOR FRONTVS SENSOR WIRE HORN WIRE BRAKE HOSE HARNESS CLIP: - Front VS sensor wire - Rear VS sensor wire - Front final clutch wire - Differential breather hose - Horn wire 1-37 GENERAL INFORMATION AUSTRALIA type only: REAR BRAKE CABLE THROTTLE CABLE FAN MOTOR BREATHER HOSE FINAL DRIVE BREATHER HOSE DIFFERENTIAL BREATHER HOSE FUEL LEVEL SENSOR 2P (NATURAL) CONNECTOR HORN WIRE HEADLIGHT SUB-HARNESS 3P (BLACK) CONNECTOR DIFFERENTIAL BREATHER HOSE HORN WIRE REAR VS SENSOR WIRE FRONT FINAL CLUTCH WIRE FRONT VS SENSOR WIRE 1-38 HORN UNIT GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency (EPA), and the California Air Resources Board (CARB) require that off-road motorcycle or ATV comply with applicable exhaust emissions standards and evaporative emissions standards during its useful life, when operated and maintained according to the instruction 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 form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various system to reduce carbon monoxide and hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of the PGM-FI system. No adjustments should be made. The exhaust emission control system is separate from the crankcase emission control systems. 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 CRANKCASE BREATHER HOSE Fresh air Blow-by gas SERVICING THE HONDA U.S.A. Only Maintenance, replacement or repair of the emission control devices and systems may be performed by any motorcycle/ 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 engines 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. Vehicles that are used only for competition are exempt from this prohibition. 1-39 GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: US Federal laws prohibit, or Canadian provincial laws 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 new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the 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 the 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. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those specified by the manufacturer. REBUILT ENGINE When you rebuild your engine including a major overhaul in which you replace the engine's pistons 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 (DTC), and clear all DTCs after addressing their cause Use only Genuine Honda parts or equivalents Make sure to maintain all specifications as described in this Service Manual 1-40 2. TECHNICAL FEATURES PCM (POWERTRAIN CONTROL MODULE) PGM-FI SYSTEM -2-3 AUTOMATIC TRANSMISSION SYSTEM 2-7 2-2 2-1 TECHNICAL FEATURES PCM (POWERTRAIN CONTROL MODULE) The engine and drivetrain systems of this model are controlled by the PCM; the ECM (Engine Control Module) and TCM (Transmission Control Module) are integrated into the PCM. The PCM controls the following systems: • Engine management system - PGM-FI system - Ignition system - Cooling fan control system • Drivetrain system - A/T (Automatic Transmission) system - Selectable 4WD system PCM PGM-FI SYSTEM This PGM-FI system for the ATV is composed of the fuel pump, throttle body and its electronic control system by PCM. This system controls and manages the engine operation, and enhances the emission control performance, fuel economy, starting performance and driveability when compared to a conventional carburetor. DRIVETRAIN SYSTEM This manual describes the A/T system and selectable 4WD system as "drivetrain" system. The PCM controls the front final clutch located in the differential by selecting the 2WD/4WD switch. The PCM also controls the A/T system as described in AUTOMATIC TRANSMISSION system feature (page 2-7). SELF-DIAGNOSTIC FUNCTION The PCM has a fail-safe function and also a self-diagnostic function for the PGM-FI, A/T and selectable 4WD system. Some detection items (sensors, etc..) are shared by the PGM-FI and drivetrain systems and so their failure may affect the operation of both systems. If both PGM-FI and DRIVETRAIN DTCs are indicated at the same time, troubleshoot the PGM-FI system first then check all DTCs again. 2-2 TECHNICAL FEATURES PGM-FI SYSTEM INTEGRATED SENSOR THROTTLE BODY This model is equipped with a throttle body that integrates the following sensors and device. This throttle body achieves a compact design with simplified inspection capabilities. • MAP (Manifold Absolute Pressure) sensor: detects the intake air pressure • TP (Throttle Position) sensor: detects the throttle opening position • IACV (Idle Air Control Valve): controls the engine idle speed and enhances the starting • These components can be removed from the throttle body. INJECTOR IACV THROTTLE BODY MAP SENSOR TP SENSOR 2-3 TECHNICAL FEATURES IACV (Idle Air Control Valve) The IACV consists of a step motor and a slide valve, and controls the amount of air bypassed around the closed throttle valve. With the ignition switch ON, the amount of idle air is determined from information detected by the ECT sensor. During engine start-up or while maintaining idle (throttle valve closed), the amount of inlet air is adjusted by various sensors' information. This system eliminates the need for a manual idle speed adjustment and high altitude adjustment settings. THROTTLE BODY IACV STEP MOTOR SLIDE VALVE AIR BYPASS OPERATION The PCM controls the IACV during engine idling only, so the PCM stops controlling the IACV and leaves it in the closed position when the PCM detects the following: • Throttle valve open • Neutral switch off (in gear) During engine idling and warm up, from the time the ignition switch is turned ON, the PCM controls the IACV step motor as follows: With the ignition switch ON • When the ignition switch is turned ON, the IACV is initialized and the step motor will operate: the slide valve goes from open-to close-to the open position STEP MOTOR Engine starting and warm up • While the throttle valve is closed, the bypass opening is optimized by the IACV, and the correct amount of inlet air passes through allowing proper engine starting. • After the engine has started, the PCM controls the IACV step motor to adjust the slide valve position by processing various sensor's information.This results in a reduced amount of bypassed air compared to the amount during engine start-up, and initiates engine warm-up for several minutes. \ SLIDE VALVE 2-4 TECHNICAL FEATURES After warming up - idling • When the PCM receives input signals that indicate the completion of engine warm-up, it operates the step motor to move the slide valve to the downward. This results in a reduced amount of bypassed air compared to the amount during engine warm-up, which maintains proper engine idle speed. STEP MOTOR SLIDE VALVE BANK ANGLE SENSOR The bank angle sensor is located under the steering cover, it detects a vehicle rollover and interrupts the ignition/fuel system control. The bank angle sensor system controls the power supply for the injector, ignition coil and fuel pump directly through the engine stop relay. MAIN4 FUSE £ IGNITION ST/ECM SWITCH FUSE BATTERY INJECTOR IGNITION COIL FUEL PUMP OPERATION When the vehicle topples over or tilts over 70 degrees horizontal or 135 degrees cross direction, the pendulum magnet inside the bank angle sensor tilts and turns the reed switch on. Then, the bank angle sensor opens the engine stop relay. 70° BANK ANGLE POSITION NORMAL POSITION 70° /(approximately) 70° (approximately) 2-5 TECHNICAL FEATURES FUEL SUPPLY SYSTEM The fuel supply system is composed of the fuel tank, sub fuel tank, fuel hoses, fuel vapor return hose, throttle body, and injector. While riding in bumpy conditions, the fuel supply from the fuel tank may be unstable because of changes in the vehicle attitude. To stabilize the supply of fuel, this system is equipped with a sub fuel tank between the fuel tank and throttle body. The fuel pump and pressure regulator are located inside the sub fuel tank. The fuel hose has a quick connector at the sub fuel tank joint. Before disconnecting the quick connector, always relieve the fuel pressure (page 6-32). FUEL TANK SUB FUEL TANK -FUEL PUMP - PRESSURE REGULATOR THROTTLE BODY OPERATION Fuel flows through the fuel strainer inside the fuel tank to the fuel hose (low pressure). Inside the sub fuel tank, fuel flows though the fuel filter and is fed by the fuel pump though the fuel hose (high pressure) to the injector. The fuel pressure through the fuel pump is regulated by a pressure regulator that is located in the fuel passage in the sub fuel tank and always kept under 343 kPa. Fuel vapor generated in the sub fuel tank is returned to the fuel tank through the fuel vapor return hose. FUEL FLOW CHART FUEL TANK FUEL STRAINER VAPOR RETURN HOSE FUEL FEED HOSE (HIGH PRESSURE) - ^ ^ SUB FUEL TANK -FUEL PUMP - PRESSURE REGULATOR 2-6 FUEL HOSE (LOW PRESSURE) \ FUEL FLOW < # I • FUEL VAPOR THROTTLE BODY TECHNICAL FEATURES AUTOMATIC TRANSMISSION SYSTEM OUTLINE This three-speed A/T (Automatic Transmission) system controls gear selection by means of the A/T mechanism that consists of the torque converter and the 3 shift clutches (hydraulic clutch). To control the hydraulic clutch and to shift, the system changes the supply of hydraulic pressure to each clutch (1st, 2nd, 3rd) by activating the respective spool valves with the corresponding solenoid valves. Each solenoid valve is controlled by the PCM, that detects the signal from each sensor and switch. The hydraulic oil for this system is the engine oil, which is supplied from the ordinary oil pump for engine lubrication (page 5-2). The valve body which incorporates solenoid valves and spool valves that control the clutch hydraulic pressure is laid out independently on the crankcase cover to facilitate maintenance (page 14-47) The sub-transmission is laid out in front of the output shaft, and selecting Drive-Neutral-Reverse can be made mechanically by operating the selector lever located near the drivers seat. TORQUE CONVERTER PRIMARY DRIVE GEAR PRIMARY DRIVEN GEAR SUB-TRANSMISSION (COUNTERSHAFT) COUNTERSHAFT 2nd SHIFT CLUTCH OUTPUT SHAFT 3rd SHIFT CLUTCH OUTPUT DRIVEN GEAR 2-7 TECHNICAL FEATURES TORQUE CONVERTER STRUCTURE • Pump The pump, directly connected to the crankshaft, converts engine output (torque) into oil flow. • Turbine Receiving the oil from the pump, the turbine transmits the torque to the transmission by way of the primary drive gear. • Stator The stator changes the direction of the oil flow drained from the turbine. It drains the oil toward the pump. • Stator Shaft It transmits the stator rotation to the one-way clutch. • Stator One-way Clutch The stator one-way clutch locks the stator at stalling and it releases (rotates) the stator at coupling (page 2-8). • Inner Collar The inner collar, prevented from turning by the stopper pin fixed on the crankcase, stops the rotation force at stalling, which is transmitted from the stator by way of the one-way clutch. • Engine Brake One-way Clutch When the engine braking is applied, the engine brake one-way clutch directly transmits the input torque from the primary drive gear to the crankshaft. This allows the machine to slow down by engine braking. • Seal Ring and Seal Collar The seal ring and seal collar are provided to prevent oil leakage. TURBINE BLADES PUMP BLADES ENGINE BRAKE ONE-WAY CLUTCH SEAL RINGS STATOR ONE-WAY CLUTCH STATOR BLADES Hydraulic Oil INNER COLLAR SEAL COLLAR PRIMARY DRIVE GEAR STOPPER PIN OPERATION PRINCIPLE 1. Oil Flow: The oil in the torque converter flows in this order; from the pump, to the turbine, and to the stator. The oil is supplied from the inside of the pump, and the excess oil is drained from the turbine. The torque converter is cooled down by draining (exchanging) the excess oil. 2. Stall Range: When the difference of rotation speed between the pump and turbine is large, the stator turns in the reverse direction from that of the turbine by receiving the reaction force from the turbine. As this motion is locked by the one-way clutch, the counter torque is applied to the stator. To balance the rotation direction, the turbine torque (output torque) becomes the sum of the pump torque and counter torque of the stator. Therefore, the output torque is amplified by the amount of counter torque of the stator. 3. Coupling Range: When the difference of rotation speed between the pump and turbine is small (0.8 or more), the reaction force applied from the turbine to the stator is small and the stator turns in the same direction as that of the turbine. As the torque is not amplified this time, the torque ratio is about 1.0 and the torque transfer efficiency to speed ratio changes in the ratio of 1:1. 4. Engine Braking: The input force from the primary drive gear is directly transmitted to the crankshaft by the one-way clutch, which produces the engine braking (Same as the conventional ATV). 2-8 TECHNICAL FEATURES HYDRAULIC VALVE FUNCTION • A/T Clutch Pressure Control Solenoid Valve (Linear Solenoid Valve) The A/T Clutch PC solenoid valve controls the vehicle creep by diverting the hydraulic pressure that flows to the entire clutch system to the linear valve. • Shift Solenoid Valves (A and B) The shift solenoid valves control the shift timing by supplying and shutting off hydraulic pressure to activate the shift valves. • Shift Valves (1-2 and 2-3) The shift valves switch the hydraulic circuits to the three clutches. • Orifice Control Valve (2nd and 3rd) The orifice control valves operate when clutch fluid pressure rises during shifting. It releases the pressure to reduce shift shock. • Emergency Valve The emergency valve is used when the hydraulic pressure is shut off by a faulty clutch PC solenoid valve (stuck; mechanical lock), and the vehicle is hindered from running. Open the bypass oil circuit manually to supply hydraulic fluid. (In this case, the transmission is held in 2nd range and the vehicle creeps during idling.) 3rd SHIFT CLUTCH 2nd SHIFT CLUTCH 3rd ORIFICE CONTROL VALVE x 1st SHIFT CLUTCH 2ndORIFICE CONTROL VALVE x SHIFT SOLENOID VALVE A 2-3 SHIFT VALVE TORQUE CONVERTER 1-2 SHIFT SHIFT SOLENOID VALVE B EMERGENCY VALVE Cylinder head Alternator Sub-transmission -«- c A/T CLUTCH PC SOLENOID VALVE OIL PUMP 2-9 TECHNICAL FEATURES SHIFT CLUTCH HYDRAULIC CIRCUIT AND OPERATION This system activates the A/T clutch PC solenoid valve, shift solenoid valve A and B as the PCM detects the following signals: - throttle angle, vehicle speed sub-transmission gear position (D - N - Ft) drive mode (AUTO - ESP) - engine oil temperature It controls the shift clutches for the situation according to the combination of the respective solenoid valves operation. Gear in Neutral Gear position Neutral Clutch PC Solenoid ON Shift Solenoid A B OFF OFF 1st - Shift Clutch 2nd - 3rd - • The hydraulic passage is the same as the transmission being in the 2nd range. The A/T clutch PC solenoid valve is on (valve closed) and the hydraulic oil that flows to all shift clutches is shut off. Therefore, all clutches are inactive. 3rd SHIFT CLUTCH 2nd SHIFT CLUTCH 3rd ORIFICE CONTROL VALVE 1st SHIFT CLUTCH 2nd ORIFICE CONTROL VALVE x A_ SHIFT SOLENOID VALVE TORQUE CONVERTER EMERGENCY VALVE A/T CLUTCH PC SOLENOID VALVE OIL PUMP 2-10 TECHNICAL FEATURES 1st gear and Reverse gear Gear position 1st/Reverse (idling) 1st/Reverse (riding) A/T Clutch PC Solenoid ON OFF Shift Solenoid A B ON OFF ON OFF 1st "Engaged" "Engaged" Shift Clutch 2nd - 3rd - The hydraulic passage is connected to supply hydraulic oil to the 1st shift clutch, and the clutch is engaged. Oil is supplied by way of: A/T clutch PC solenoid valve O 1-2 Shift valve =!> 1st Shift clutch (Oil is drained by way of: 2nd Shift clutch O 2-3 Shift valve => 1-2 Shift valve 3rd Shift clutch d> 2-3 Shift valve) At idling, the A/T clutch PC solenoid valve is on (valve closed) to eliminate vehicle creep. At start up, the A/T clutch PC solenoid valve controls the clutch hydraulic pressure to the linear valve according to the signal from the PCM. At riding, the A/T clutch PC solenoid valve is off (valve open) supplying sufficient hydraulic oil to the shift clutch. Control of the hydraulic passage during driving in Reverse gear is the same. However, the vehicle can be driven only in the 1st-hold mode (no shift). 3rd SHIFT CLUTCH 2nd SHIFT CLUTCH 3rd ORIFICE CONTROL VALVE x " 1st SHIFT CLUTCH 2nd ORIFICE CONTROL VALVE A M SHIFT SOLENOID VALVE TORQUE CONVERTER EMERGENCY VALVE A/T CLUTCH PC SOLENOID VALVE OIL PUMP 2-11 TECHNICAL FEATURES Riding in 2nd range Gear position 2nd gear A/T Clutch PC Solenoid OFF Shift Solenoid A B OFF OFF 1st - Shift Clutch 2nd "Engaged" 3rd - The hydraulic passage is connected to supply hydraulic oil to the 2nd shift clutch. Oil is supplied by way of: A/T clutch PC solenoid valve <^> 1-2 Shift valve <=> 2-3 Shift valve O 2nd Shift clutch (Oil is drained by way of: 1st Shift clutch •=> 1-2 Shift valve •=> 2nd Orifice control valve 3rd Shift clutch d> 2-3 Shift valve) When shifting from 1st to 2nd position, the draining volume of the 1st clutch hydraulic oil is controlled by the ordinary orifice and the 2nd orifice control valve to reduce shift shock.* *When the PCM detects system failure (fail-safe mode), the hydraulic passage is the same as above. (Therefore, the vehicle can be ridden only in the 2nd-hold mode and creeping can occur at idle) 3rd SHIFT CLUTCH 2nd SHIFT CLUTCH 3rd ORIFICE CONTROL VALVE 1st SHIFT CLUTCH 2nd ORIFICE CONTROL VALVE A SHIFT SOLENOID VALVE TORQUE CONVERTER -EMERGENCY VALVE A/T CLUTCH PC SOLENOID VALVE OIL PUMP 2-12 TECHNICAL FEATURES Riding in 3rd range Gear position 3rd gear A/T Clutch PC Solenoid OFF Shift Solenoid A B OFF ON 1st - Shift Clutch 2nd j - 3rd "Engaged" The hydraulic passage is connected to supply hydraulic oil to the 3rd shiftclutch. Oil is supplied by way of: A/T clutch PC solenoid valve O 1-2 Shift valve <=$ 2-3 Shift valve <=> 3rd Shift clutch (Oil is drained by way of: 1st Shift clutch O 1-2 Shift valve >=> 2nd Orifice control valve 2nd Shift clutch ^ 2-3 Shift valve <=£ 3rd Orifice control valve) When shifting from 2nd to 3rd position, the draining volume of the 2nd clutch hydraulic oil is controlled by the ordinary orifice and the 3rd orifice control valve to reduce shift shock. 3rd SHIFT CLUTCH 2nd SHIFT CLUTCH 1st SHIFT CLUTCH 3rd ORIFICE CONTROL VALVE 2nd ORIFICE CONTROL VALVE x SHIFT SOLENOID VALVE TORQUE CONVERTER EMERGENCY VALVE A/T CLUTCH PC SOLENOID VALVE OIL PUMP 2-13 TECHNICAL FEATURES AUTOMATIC TRANSMISSION PERFORMANCE CURVE See the following graph for the relationship between vehicle speed and throttle angle, It shows the shift timing (shift-up shown with the solid lines and shift-down with the dotted lines) and the ranges of shift position. 100 90 10 15 20 25 30 35 40 45 Vehicle Speed (mph) The vehicle condition is brake (s) not applied. 2-14 3. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION 3-2 FRONT GRILLE •3-10 TROUBLESHOOTING 3-2 FRONT CARRY PIPE- •3-10 BODY PANEL LOCATIONS 3-3 FRONT CARRIER •3-11 TRIM CLIP 3-4 FRONT FENDER -3-11 SEAT- 3-4 MUFFLER PROTECTOR •3-12 RIGHT SIDE COVER 3-5 REAR CARRIER/MUD GUARD 3-13 STEERING COVER 3-5 REAR FENDER 3-14 FUEL TANK COVER- 3-5 OUTER FENDER •3-16 FUEL TANK SIDE COVER 3-6 ENGINE GUARD- •3-17 CENTER MUD GUARD 3-7 ENGINE SIDE COVER- •3-17 FRONT MUD GUARD- 3-8 METER COVER INNER FENDER 3-9 EXHAUST SYSTEM- 3-18 •3-19 3-1 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels and exhaust system. • Always replace the gaskets after removing the exhaust system. • Always inspect the exhaust system for leaks after installation. TORQUE VALUES Front carrier and carry pipe bolt Rear carrier bolt Muffler band bolt Front exhaust pipe cover band screw Muffler heat protector screw Muffler cover screw Footpeg bracket nut TROUBLESHOOTING Excessive exhaust noise • Broken exhaust system • Exhaust gas leak Poor performance • Deformed exhaust system • Exhaust gas leak • Clogged muffler 3-2 37 N-m (3.8 kgf-m, 27 Ibf-ft) 37 N-m (3.8 kgf-m, 27 Ibf-ft) 23 N-m (2.3 kgf-m, 17 Ibf-ft) 3.2 N-m (0.33 kgf-m, 2.4 Ibf-ft) 5.4 N-m (0.55 kgf-m, 4.0 Ibf-ft) 3.2 N-m (0.33 kgf-m, 2.4 Ibf-ft) 32 N-m (3.3 kgf-m, 24 Ibf-ft) FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (1) Seat (page 3-4) (1) (2) Right side cover (page 3-5) (3) (3) Steering cover (page 3-5) (4) Fuel tank top/center cover (page 3-5) (5) Fuel tank side cover (page 3-6) (6) Center mud guard (page 3-7) (7) Front mud guard (page 3-8) (8) Inner fender (page 3-9) (9) Front grille (page 3-10) (10) Front carry pipe (page 3-10) (11) Front carrier (page 3-11) (12) Front fender (page 3-11) (13) Muffler protector (page 3-12) (14) Rear carrier/mud guard (page 3-13) (15) Rear fender (page 3-14) (16) Outer fender (page 3-16) (17) Engine guard (page 3-17) (18) Engine side cover (page 3-17) (19) Meter cover (page 3-18) (8) (10) (13) 3-3 FRAME/BODY PANELS/EXHAUST SYSTEM TRIM CLIP REMOVAL AND RETAINING PROCEDURE When installing the trim clip, carefully align the clip holes to avoid damaging the clip. Release by pulling the center pin up using a snap ring pliers or a flat blade screwdriver and remove the trim clip. Install the clip and lock it by pushing the center pin securely. Remove and install Release SEAT REMOVAL Unlock the seat by pulling the release lever up. Pull the seat back and remove it. INSTALLATION Install the seat by inserting the prongs into the seat retainer on the frame. Push the seat forward and align the mounting bosses with the rubber mounts, then press down to lock it. SEAT PRONGS RETAINERS LEVER RUBBER MOUNTS 3-4 FRAME/BODY PANELS/EXHAUST SYSTEM RIGHT SIDE COVER Remove the right side cover by releasing the three bosses from the grommets. Be careful not to Install the right side cover in the reverse order of dislodge the grommets. BOSSES removal. COVER STEERING COVER Release the two bosses from the grommets by pulling the rear portion of the cover up and release the two tabs to remove the steering cover. Be careful not to dislodge the grommets. COVER BOSSES Install the cover in the reverse order of removal. TABS FUEL TANK COVER Top Cover Remove the following: - steering cover (page 3-5) two trim clips breather hose and fuel fill cap HOSE TRIM CLIPS CAP Release the four tabs, remove the fuel tank top cover by sliding the cover forward. Installation is in the reverse order of removal. TABS 3-5 FRAME/BODY PANELS/EXHAUST SYSTEM Center Cover Remove the seat (page 3-4). TRIM CLIPS Release the four trim clips and remove the fuel tank center cover. Installation is in the reverse order of removal. COVER FUEL TANK SIDE COVER Right side: Remove the following: - TRIM CLIPS seat (page 3-4) right side cover (page 3-5) fuel tank top cover (page 3-5) setting bolt four trim clips COVER Release the two tabs of the fuel tank side cover, then remove the cover. Installation is in the reverse order of removal. TABS BOLT 3-6 FRAME/BODY PANELS/EXHAUST SYSTEM Left side: Remove the following: - TRIM CLIPS seat (page 3-4) fuel tank top cover (page 3-5) Turning the compartment lid quick screw counterclockwise Release the two tabs, then remove the compartment lid. TABS SCREW COVER Release the two bosses and tabs, then remove the oil filler lid. Remove the following: Be careful not to dislodge the grommets when installing the filler lid. setting bolt six trim clips fuel tank side cover LID Installation is in the reverse order of removal. CENTER MUD GUARD Right side: Remove the right side cover (page 3-5). Remove the two trim clips and then remove the mud guard lid by releasing the three tabs. Remove the following: - two flange bolts and footpeg - five trim clips - socket bolt - • right center mud guard Installation is in the reverse order of removal. SOCKET BOLT TRIM CLIPS FOOTPEG MUDGUARD 3-7 FRAME/BODY PANELS/EXHAUST SYSTEM Left side: Release the two bosses and tabs, then remove the oil filler lid. BOSSES Remove the following: - two flange bolts and footpeg seven trim clips socket bolt left center mud guard Be careful not to Installation is in the reverse order of removal. TABS dislodge the grommets when installing the lid. FLANGE BOLTS TRIM CLIPS SOCKET BOLT FOOTPEG MUDGUARD FRONT MUD GUARD Remove the eight trim clips, then remove the front mud guard from the mud guard stay. Right side shown MUDGUARD Installation is in the reverse order of removal. STAY TRIM CLIPS 3-8 FRAME/BODY PANELS/EXHAUST SYSTEM INNER FENDER Right side: Remove the following: Hook the guide over the frame pipe. TRIM CLIPS two stay bolts two trim clips two tapping bolts setting bolt right inner fender TAPPING BOLTS Installation is in the reverse order of removal. FENDER STAYS SETTING BOLT Left side: Remove the compartment lid (page 3-7). WASHER Remove the following: Hook the guide over the frame pipe. two stay bolts trim clip and setting washer (inside the storage compartment) trim clip tapping bolt setting bolt left inner fender TAPPING BOLT TRIM CLIP Installation is in the reverse order of removal. FENDER SETTING BOLT STAYS 3-9 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT GRILLE Center Grille Remove the stone guard (page 3-10). GRILLE Remove the four setting bolts and the center front grille. BOLTS Side Grille Remove the following: - two trim clips three bolts side front grille BOLTS TRIM CLIPS Installation is in the reverse order of removal. GRILLE FRONT CARRY PIPE Remove the following: - TRIM CLIPS four bolts stone guard center front grill (page 3-10) four trim clips six bolts carry pipe Installation is in the reverse order of removal. TORQUE: 37 N m (3.8 kgf m, 27 Ibf-ft) CARRY PIPE BOLTS BOLTS STONE GUARD 3-10 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT CARRIER The front carrier and fender can be removed as an assembly for service. If removed, use the procedure described on page 3-12. Remove the following: - center front grille (page 3-10) wire band (that secured the headlight wire on the carrier pipe) two 6-mm bolts and collars (attached to fender) two 6-mm bolts and collars (attached to headlight case) four8-mm bolts front carrier CARRIER 8 mm BOLTS Installation is in the reverse order of removal. •BAND TORQUE: 8 mm bolt: 37 N-m (3.8 kgf-m, 27 Ibfft) 6 mm BOLTS AND COLLARS FRONT FENDER The front carrier and fender can be removed as an assembly for service. If removed, use the procedure described on page 3-12. Remove the following: - fuel tank side covers (page 3-6). front carrier (page 3-11). Remove the following connector and fasteners: - headlight 3P (Black) connector (from the frame and disconnect it) 14 trim clips and setting washer (inside the storage compartment) setting bolt and square nut three tapping bolt (loosen) FENDER HEADLIGHT CONNECTOR TAPPING BOLTS SQUARE NUT TRIM CLIPS Remove the front fender while spreading the rear portion of it. Installation is in the reverse order of removal. SETTING BOLT CONNECTOR WASHER 3-11 FRAME/BODY PANELS/EXHAUST SYSTEM Carrier/Fender Assembly Removal Procedure Remove the following: - fuel tank side covers (page 3-6) center front grille (page 3-10) headlight connector and fender fasteners (page 3-11) four 8-mm bolt (carrier mounting fasteners). Loosen the three tapping bolts. Remove the front carrier/fender assembly while spreading the rear portion of the fender. Installation is in the reverse order of removal. TORQUE: 8 mm bolt: 37 N m (3.8 kgf-m, 27 Ibf-ft) SQUARE NUT HEADLIGHT CONNECTOR FRONT FENDER 8 mm BOLTS TAPPING BOLTS (loosen) TRIM CLIPS TRIM CLIPS BOLT MUFFLER PROTECTOR Remove the following: - SOCKET BOLTS two setting bolts four socket bolts muffler protector Installation is in the reverse order of removal. COVER SETTING BOLTS 3-12 FRAME/BODY PANELS/EXHAUST SYSTEM REAR CARRIER/MUD GUARD The rear carrier and Remove the f o l l o w i n g : rear side body pan- _ ( K a es can be removed ' , , , _ „_, as an assembly for " rear corner outer fenders (page 3-16) service. If removed. Disconnect the brake/taillight 3P (Black) connector. use the procedure Release the wires from the clips and remove the 3P described on page connector from the frame. 3-15. Remove the following: - Only loosen the two lower inner bolts. - four trim clips and wire clamps two setting bolts two bolts and collars four 8 mm bolts (two flange bolts and two washer-bolts) rear carrier assembly BRAKE/TAILLIGHT CONNECTOR CARRIER ASSEMBLY SETTING BOLTS TRIM CLIPS CLIPS CONNECTOR v CLAMPS 8 mm BOLTS - Loosen muffler protector (page 3-12) two bolts, collars and rear mud guard three bolts and muffler protector wire bands and wire harness BOLTS AND COLLARS CARRIER Secure the wires Installation is in the reverse order of removal. with the bands TORQUE: 8 mm bolt: 37 N-m (3.8 kgf-m, 27 Ibfft) properly (page 120). PROTECTOR MUDGUARD BOLTS AND COLLARS 3-13 FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER The rear carrier and rear side body panels can be removed as an assembly for service. If removed, use the procedure described on page 3-15. Remove the seat (page 3-4). Right side: Remove the following: - right side cover (page 3-5) fuse box (by releasing the tab from the reverse side of the fender) 2P (White) connector two setting bolts bolt and collar (front side) bolt, collar and setting rubbers (rear side) socket bolt seven trim clips, setting washer and wire clamp right rear fender Left side: Remove the following: - oil filler lid (page 3-8) setting bolt (attached with the fuel tank side cover) bolt and collar (front side) bolt, collar and setting rubbers (rear side) socket bolt eight trim clips, setting washer and wire clamp left rear fender Installation is in the reverse order of removal. Right side shown: FUSE BOX SETTING BOLTS SETTING RUBBER CLAMP TRIM CLIPS SETTING RUBBER WASHER SOCKET BOLT BOLTS AND COLLARS CONNECTOR FENDER 3-14 FRAME/BODY PANELS/EXHAUST SYSTEM Carrier/Fender Assembly Removal Procedure Remove the following: - seat (page'3-4) right side cover (page 3-5) oilfiller lid (page 3-8) Disconnect the brake/taillight 3P (Black) connector. Release the wires from the bands and remove the 3P connector from the frame. Remove the following: - fuse box (by releasing the tab from reverse side of the fender) 2P (White) connector three setting bolts two socket bolts six trim clips Only loosen the - four 8-mm bolts (carrier mounting bolts) two lower inner - rear carrier/fender assembly 0 fs Installation is in the reverse order of removal. TORQUE: 8 mm bolt: 37 N-m (3.8 kgf-m, 27 Ibfft) Right side shown: SETTING BOLTS FUSE BOX 2PCONNECTOR 3P CONNECTOR 8 mm WASHERBOLTS WIRE CLIPS 8 mm BOLTS SOCKET BOLTS TRIM CLIPS 3-15 FRAME/BODY PANELS/EXHAUST SYSTEM OUTER FENDER Front Outer Fender Remove the following: RETAINING CLIPS WASHERS - retaining clips - seven trim clips and three setting washers - front outer fender Installation is in the reverse order of removal. FRONT OUTER FENDER TRIM CLIPS Rear Outer Fender Remove the following: - retaining clip - seven trim clips and four setting washers - rear outer fender Installation is in the reverse order of removal. RETAINING CLIP WASHERS TRIM CLIPS REAR OUTER FENDER Rear Corner Outer Fender Remove the following: - taillight assembly (page 23-5) - three trim clips and setting washer - socket bolt - bolt, collar and setting rubbers - corner outer fender Installation is in the reverse order of removal. WASHER SETTING RUBBERS TRIM CLIPS SOCKET BOLT BOLT AND COLLAR FENDER 3-16 FRAME/BODY PANELS/EXHAUST SYSTEM ENGINE GUARD Remove the following: - four 8 mm bolts and collars four 6 mm bolts engine guard Hook the guide Installation is in the reverse order of removal. over the frame pipe. GUIDE ENGINE GUARD 6 mm BOLTS 8 mm BOLTS AND COLLARS ENGINE SIDE COVER Right side only: Remove the right mudguard (page 3-7). Remove the flange bolts and the right engine side cover. Remove the two bolts, two flange bolts, two flange collars and left engine cover. Install the engine side cover in the reverse order of removal. 3-17 FRAME/BODY PANELS/EXHAUST SYSTEM METER COVER If the lower meter Remove the following: cover will be replaced, remove the accessory socket (page 23-6). screw and collar (rear side) cover lid (release tabs) two setting bolts tapping screw (front side) lower meter cover (release tabs on the upper meter cover) TABS LOWER METER COVER TAPPING SCREW SETTING BOLTS If the upper meter cover will be replaced, remove the ignition switch (page 23-6). breather hose two bracket nuts upper meter cover TABS UPPER METER COVER SCREW AND COLLAR BREATHER HOSE GUIDE NUTS GPS type only: Disconnect the GPS receiver 6P (Natural) connector. BOLTS Remove the bolts and GPS receiver/bracket assembly. 6P (NATURAL) CONNECTOR \ UPPER METER COVER GPS RECEIVER/BRACKET COMBINATION METER 3-18 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the screws and then remove the combination meter from the upper meter cover. Installation is in the reverse order of removal. Insert the hose guide into the steering shaft hole (page 3-18). COMBINATION METER SCREWS EXHAUST SYSTEM REMOVAL Remove the left engine side cover (page 3-17). EXHAUST PIPE Remove the left side cover (page 3-7). Loosen the muffler band bolts. MUFFLER BAND BOLTS Remove the joint nuts and pull the exhaust pipe forward gradually to disconnect it from the muffler. Remove the joint gasket and muffler gasket. JOINT NUTS 3-19 FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER Remove the rear carrier assembly (page 3-13). Loosen the muffler band bolts. Remove the mounting nuts and bolts, and the muffler. Remove the joint gasket. INSTALLATION Install new joint gasket and muffler gasket. Install the muffler and exhaust pipe in the reverse order of removal by loosely tightening all the fasteners. When tightening, adjust the clearance between the exhaust pipe and cover stay as shown so they do not interfere. Tighten the joint nuts first, then tighten the mounting nuts and the band bolts. TORQUE: Muffler band bolt: 23 N m (2.3 kgf-m, 17 Ibf-ft) After installation, inspect the exhaust system for leaks. Install the removed covers in the reverse order of removal. MOUNTING BOLTS JOINT NUTS BAND BOLTS MOUNTING NUTS MUFFLER 3-20 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY 3 places: 3.2 N-m (0.33 kgf-m, 2.4 Ibf-ft) FRONT EXHAUST PIPE COVER MUFFLER COVER 5.4 N-m (0.55 kgf-m, 4.0 Ibf-ft) Section BB (3 places): 3.2 N-m (0.33 kgf-m, 2.4 Ibf-ft) Section AA (2 places): REAR EXHAUST PIPE COVER 3-21 4. MAINTENANCE SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE THROTTLE OPERATION AIR CLEANER AIR CLEANER HOUSING DRAIN HOSE SPARK PLUG VALVE CLEARANCEENGINE OIL ENGINE OIL FILTER RADIATOR COOLANTCOOLING SYSTEM DRIVE SHAFT BOOTS 4-2 REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL 4-15 BRAKE FLUID 4-17 BRAKE PADS WEAR 4-18 BRAKE LIGHT SWITCH 4-19 BRAKE SYSTEM 4-19 SKID PLATE, ENGINE GUARD 4-20 SUSPENSION 4-21 SPARK ARRESTER 4-21 NUTS, BOLTS, FASTENERS 4-22 WHEELS/TIRES 4-22 STEERING SHAFT HOLDER BEARING 4-22 STEERING SYSTEM 4-23 4-3 4-4 4-4 4-5 4-7 4-7 4-8 4-10 4-12 4-12 4-13 4-14 4-1 MAINTENANCE SERVICE INFORMATION GENERAL • Place the vehicle on a level ground before starting any work. SPECIFICATIONS ITEM Throttle lever free play Spark plug Standard For extended high speed riding Spark plug gap Valve clearance IN EX Recommended engine oil Engine oil capacity After draining After draining/filter change After disassembly Engine idle speed Recommended final gear case oil Final gear case At draining oil capacity At disassembly Recommended differential oil At draining Differential oil capacity At disassembly Recommended brake fluid Rear (parking) brake lever free play Cold tire presFront sure Rear Standard Minimum Maximum With cargo Standard Minimum Maximum With cargo Tire size Front Rear Tire bland Front Rear Minimum tire tread depth (Front/Rear) Toe SPECIFICATIONS 3 - 8 mm (1/8-5/16 in) IFR5L11 (NGK), VK16PRZ11 (DENSO) IFR6L11 (NGK), VK20PRZ11 (DENSO) 1.0- 1.1 mm (0.039 - 0.043 in) 0.15 mm (0.006 in) 0.33 mm (0.013 in) Pro Honda GN4 or HP4 (without molybdenum additives) 4stroke oil (U.S.A. and Canada), or Honda 4-stroke oil (Canada only), or an 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-40, 6W-30 2.7 liters (2.9 US qt, 2.4 |mp qt) 2.9 liter (3.1 US qt, 2.6 Imp qt) 4.1 liter (4.3 US qt, 3.6 Imp qt) 1,400 ±50 rpm (min'1) Hypoid gear oil SAE #80 78 cm3 (2.6 US oz, 2.7 Imp oz) 90 cm3 (3.0 US oz, 3.2 Imp oz) Hypoid gear oil SAE #80 175 cm 3 (5.9 US oz, 6.2 Imp oz) 220 cm3 (7.4 US oz, 7.7 Imp oz) Honda DOT 4 brake fluid 2 5 - 3 0 mm (1 -1-3/16 in) 30 kPa (0.30 kgf/cm2, 4.4 psi) 26 kPa (0.26 kgf/cm2, 3.8 psi) 34 kPa (0.34 kgf/cm2, 5.0 psi) 30 kPa (0.30 kgf/cm2, 4.4 psi) 25 kPa (0.25 kgf/cm2, 3.6 psi) 22 kPa (0.22 kgf/cm2, 3.2 psi) 28 kPa (0.28 kgf/cm2, 4.0 psi) 25 kPa (0.25 kgf/cm2, 3.6 psi) AT25x8R12** AT25x10R12** KT511 (DUNLOP) KT515(DUNLOP) 4.0 mm (0.16 in) Toe-out: 10.9 ± 15 mm (7/16 ±9/16 in) TORQUE VALUES Spark plug Valve adjusting screw lock-nut Timing hole cap Engine oil drain-bolt Engine oil filter center bolt Rear Final gear case oil filler cap Rear Final gear case oil drain-bolt Front Differential oil filler cap Front Differential oil drain-bolt Tie-rod lock nut 4-2 22 N m 17 N-m 10 N-m 25 N m 18 N-m 12 N-m 12 N-m 12 N-m 12 N-m 54 N-m (2.2 kgfm, 16 Ibfft) (1-7 kgfm, 12 Ibf-ft) (1.0 kgfm, 7 Ibf-ft) (2.5 kgfm, 18 Ibfft) (1.8 kgfm, 13 Ibfft) (1.2 kgfm, 9 Ibfft) (1.2 kgfm, 9 Ibfft) (1.2 kgfm, 9 Ibfft) (1.2 kgfm, 9 Ibf-ft) (5.5 kgfm, 40 Ibf-ft) MAINTENANCE MAINTENANCE SCHEDULE 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 COMES FIRST (""I INITIAL MAINTENANCE ^> 100 150 20 mi km ITEMS * FUEL LINE THROTTLE OPERATION AIR CLEANER AIR CLEANER HOUSING DRAIN HOSE * HOURS ENGINE OIL ENGINE OIL FILTER RADIATOR COOLANT * COOLING SYSTEM DRIVE SHAFT BOOTS REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL * BRAKE FLUID BRAKE PADS WEAR BRAKE LIGHT SWITCH BRAKE SYSTEM SKID PLATE, ENGINE GUARD * SUSPENSION * SPARK ARRESTER * NUTS, BOLTS, FASTENERS * * WHEELS/TIRES ## STEERING SHAFT HOLDER BEARING ## STEERING SYSTEM NOTE 3 NOTE 2 NOTE 3 NOTE 1,2 600 1,000 100 C I NOTE1 NOTE 2 SPARK PLUG VALVE CLEARANCE REGULAR MAINTENANCE INTERVAL 1,200 2,000 200 I I C I I I I I INITIAL=100mi(150km), 20 operating hours or 1 month: R REGULAR = EVERY 600 mi (1000 km), 100 operating hours or 12 month: R R R R I I I (R: Every 2 years) I I I I I I I I I C ( I REFER TO PAGE 4-4 4-4 4-5 4-7 4-7 4-8 4-10 4-12 4-12 4-13 4-14 4-15 4-17 4-18 4-19 4-19 4-20 4-21 4-21 4-22 4-22 4-22 4-23 * 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 frequently when riding in dusty areas, sand or snow. 2. Service more frequency after riding in very wet or muddy conditions. 3. Replace every 2 years. Replacement requires mechanical skill. 4-3 MAINTENANCE FUEL LINE Remove the following:. - seat (page 3-4) fuel tank side covers (page 3-6) Remove the trim clip and throttle body cover. Check the fuel lines for deterioration, damage or leakage. And also check the fuel hose (fuel tank to fuel pump) and fuel vapor return hose. Replace the fuel hoses if necessary. THROTTLE OPERATION Check for any deterioration or damage to the throttle cable. Check that the throttle lever for smooth operation. Check the throttle opens and automatically closes in all steering positions. If the throttle lever does not return properly, lubri cate the throttle cable and overhaul and lubricate the throttle housing (page 15-10). Reusing an abnormally bent or kinked throttle cable can prevent proper throttle slide operation and may lead to a loss of throttle control while riding. If the throttle lever still does not return properly, replace the throttle cable. With the engine idling, turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If idle speed increases, check the throttle lever free play and the throttle cable connection. Measure the throttle lever free play at the tip of the throttle lever. THROTTLE LEVER FREE PLAY: 3 - 8 mm (1/8-5/16 mm) Throttle lever free play can be adjusted at either end of the throttle cable. 4-4 THROTTLE BODY COVER MAINTENANCE Minor adjustments adjuster. are made with the upper ADJUSTER LOCK NUT Slide the rubber boot off the adjuster. Loosen the lock nut, turn the adjuster as required and tighten the lock nut. Install the rubber boot securely. Major adjustments adjuster. are made with the lower * Remove the seat (page 3-4). Remove the throttle body cover (page 4-4). Slide the rubber boot off the adjuster. Loosen the lock nut, turn the adjuster as required and tighten the lock nut. Install the rubber boot securely. Recheck the throttle operation Install the throttle body cover (page 4-4). Install the seat (page 3-4). AIR CLEANER Remove the seat (page 3-4). Release the retaining clips and lid springs from the air cleaner housing cover and remove the cover. NOTE: • If the vehicle is used in dusty areas, sand or snow, more frequent inspections are required. Loosen the air cleaner element band screw. Remove the air cleaner element holder and then remove the air cleaner element assembly from the housing. 4-5 MAINTENANCE Remove the element band and the element core from the air cleaner element. CORE ELEMENT 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. Install the sub-air cleaner filter onto the air cleaner hose joint and secure it with the clip. Wash Apply approximately 20 g (0.7 oz) of Pro Honda Form Filter Oil or equivalent oil from the inside of the element. Place the element into a plastic bag and spread the oil evenly by hand. Squeeze out PRO HONDA FOAM FILTER OIL PLASTIC BAG Install the element core into the air cleaner element properly. BAND ELEMENT 4-6 CORE MAINTENANCE Install the element band onto the air cleaner element and the element assembly over the connecting tube flange of the housing securely. Tighten the band screw. NOTE: • Failure to properly tighten the band screw will allow the air cleaner element to fall off and engine damage could result. Install the air cleaner element holder while aligning the element core boss with the retainer hole. Install the air cleaner element housing cover while aligning the cover boss with the element holder as shown. Secure the air cleaner housing cover with the retaining clips and lid springs. Install the seat (page 3-4). AIR CLEANER HOUSING DRAIN HOSE Remove the drain hose from the bottom of the air cleaner housing to empty any deposits. Install the drain hose securely. NOTE: • If the vehicle is used in very wet or muddy conditions, more frequent inspections are required. SPARK PLUG Remove the seat (page 3-4). Disconnect the spark plug cap and clean around the spark plug base with compressed air. Remove the spark plug. 4-7 MAINTENANCE This vehicle's spark Check the insulator for cracks or damage, and the plug is equipped electrodes for wear, fouling or discoloration. with an iridium type Replace the plug if necessary. center electrode. Do not clean the electrodes. INSULATOR SIDE ELECTRODE CENTER ELECTRODE Replace the plug if the center electrode is rounded as shown. Always use the specified spark plug on this vehicle. SPECIFIED SPARK PLUG: Standard: IFR5L11 (NGK), VK16PRZ11 (DENSO) For extended high speed riding IFR6L11 (NGK), VK20PRZ11 (DENSO) To prevent damaging the iridium coating of the center electrode, use a wire-type feeler gauge to check the spark plug gap. If the gap is out of specification, replace the spark plug with a new one. Do not adjust the gap Measure the spark plug gap between the center and side electrodes with a wire-type feeler gauge. Make sure the 1.20 mm (0.047 in) wire-type feeler gauge cannot be inserted into the gap. If the gauge can be inserted into the gap, replace the plug with a new one. Screw the spark plug into the cylinder head by hand to prevent cross-threading. Tighten the spark plug. TORQUE: 22 N m (2.2 kgf m, 16 Ibf ft) Install the removed parts in the reverse order of removal. VALVE CLEARANCE NOTE: • Inspect and adjust the valve clearance while the engine is cold (below 35795°F). • After the valve clearance inspection, check the engine idle speed (page 6-55). Remove the following: - right side cover (page 3-5) steering cover (page 3-5) fuel tank cover (page 3-5) rear tank cover (page 3-6) right fuel tank side cover (page 3-6) left fuel tank side cover (page 3-7) fuel tank (page 6-39) intake duct (page 6-41) fuel tank heat guard plate (page 6-40) Remove the timing hole cap. 4-8 ROUNDED ELECTRODE WIRE TYPE FEELER GAUGE X MAINTENANCE Remove the four bolts, intake and exhaust valve adjusting hole caps. Rotate the crankshaft using the recoil starter knob and align the "T" mark on the flywheel with the index mark on the rear crankcase cover. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. This position can be obtained by confirming that there is slack in the rocker arm. If there is no slack, it is because the piston is moving through the exhaust stroke to TDC. Rotate the crankshaft one full turn and match up the "T" mark again. VALVE ADJUSTING HOLE CAP INDEX MARK "T" MARK When checking the clearance, slide the feeler gauge from the center toward the outside. Check the clearance of each valve by inserting a feeler gauge between the adjusting screw and valve stem. VALVE CLEARANCES: IN: 0.15 mm (0.006 in) EX: 0.33 mm (0.013 in) Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge. Hold the adjusting screw and tighten the lock nut. TORQUE: 17 N-m (1.7 kgf-m, 12 Ibf-ft) After tightening the lock nut, recheck the valve clearance. 4-9 MAINTENANCE Coat new O-rings with oil and install them into the grooves in the valve adjusting hole caps. Install the valve adjusting hole caps and tighten the bolts securely. Coat a new O-ring with oil and install it onto the timing hole cap. Install the timing hole cap and tighten it. TORQUE: 10 N-m (1.0 kgfm, 7 Ibf ft) Install the removed parts in the reverse order of removal. ENGINE OIL A CAUTION Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. LEVEL CHECK NOTE: • Check the oil level after starting the engine and allowing the oil to circulate through the engine thoroughly. It is especially important on a dry sump engine, due to the comparatively large volume of oil. • Do not snap the throttle while idling or the oil level reading will be inaccurate. Place the vehicle on level ground. Start the engine and let it idle for 3 - 5 minutes. If the air temperature is below 10C (50°F), let the engine idle for an additional 5 minutes (a total of 10 minutes). Stop the engine, wait for 2 - 3 minutes, and remove the dipstick and wipe it clean. Check the oil level by inserting the dipstick into the engine without screwing it in. 4-10 DIPSTICK MAINTENANCE The engine contains a sufficient amount of oil if the oil level is between the upper and lower level marks on the dipstick. DIPSTICK Q UPPER LEVEL LOWER LEVEL If the oil level is near or below the lower level mark, remove the oil filler cap cover and oil filter cap, and add the recommended engine oil up to the upper level mark. RECOMMENDED ENGINE OIL: Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil (U.S.A. and Canada), or Honda 4-stroke oil (Canada only), or an 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-40, 5W-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 filler cap, oil filler cap cover and dipstick. -30 - 2 0 - 1 0 0 10 20 30 40 50"C -20 6 20 40 60 80 100120T OIL CHANGE NOTE: • Pour the engine oil after replacing the oil filter (page 4-12). • Change the oil with the engine warm to assure complete and rapid draining. OIL DRAIN BOLT Start the engine and let it idle for a few minutes. Stop the engine and remove the oil filler cap. Remove the oil drain bolt and drain the engine oil. 4-11 MAINTENANCE Remove the O-ring and sealing washer from the drain bolt. Install a new sealing washer onto the drain bolt. Coat a new O-ring with oil and install it into the groove in the drain bolt. O-RING After draining the oil completely, install the drain bolt and tighten it. TORQUE: 25 N-m (2.5 kgf m, 18 Ibf-ft) OIL DRAIN BOLT SEALING WAHSER Be careful not to Pour the recommended oil into the engine to the upper level mark on the dipstick (page 4-11). spill the oil out of the filler neck. ENGINE OIL CAPACITY: 2.7 liters (2.9 US qt, 2.4 Imp qt) after draining 2.9 liters (3.1 US q t 2.6 Imp qt) after draining/ filter change 4.1 liters (4.3 US qt, 3.6 Imp qt) after disassembly Install the oil filler cap. Check the oil level (page 4-10). Make sure there are no oil leaks. ENGINE OIL FILTER Drain the engine oil (page 4-11). O-RINGS Remove the oil filter center bolt, cover, spring washer and oil filter. Remove the O-rings from the oil filter cover and center bolt. Coat new O-rings with oil and install them into the grooves in the oil filter cover and center bolt. Install a new oil filter. Reinstall the washer, spring, cover and center bolt. Tighten the center bolt. TORQUE: 18 N m (1.8 kgf m, 13 Ibf-ft) Fill the engine with the recommended oil (page 411). RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" and "LOWER" level lines with the vehicle upright on a level surface. 4-12 OIL FILTER CENTER BOLT MAINTENANCE If the level is low, remove the steering cover (page 3-5). Remove the reserve tank cap, and fill the tank up to the "UPPER" level line with a 1:1 mixture of distilled water and antifreeze (coolant preparation: page 7-6). RECOMMENDED ANTIFREEZE: Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing silicatefree corrosion inhibitors NOTICE Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. Check to see if there are any coolant leaks when the coolant level decreases very rapidly. If 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 7-7). COOLING SYSTEM Check for any coolant leakage from the water pump, water hoses (radiator and by-pass hoses) and hose joints. Check the water hoses for cracks or deterioration and replace if necessary. Check that all hose clamps are tight. Remove the radiator grille by releasing the four retaining clips. RETAINING CLIPS RADIATOR GRILLE 4-13 MAINTENANCE 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. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface. Install the radiator grille. DRIVE SHAFT BOOTS Check the drive shaft boots for cuts or other damage. FRONT: If a boot is damaged, replace it: - Front drive shaft boot replacement (page 18-7) Rear drive shaft boot replacement (page 19-6) REAR: DRIVE SHAFT BOOTS 4-14 MAINTENANCE REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL FINAL GEAR CASE OIL LEVEL CHECK Place the vehicle on a level surface. Remove the oil filler cap. Check that the oil level is to the lower edge of the oil filler hole. Check for leaks if the oil level is low. Pour the oil through the filler hole until it reaches the lower edge of the hole. RECOMMENDED OIL: Hypoid gear oil SAE #80 Coat a new O-ring with grease and install it into the oil filler cap groove. Install the oil filler cap and tighten it. TORQUE: 12 N m (1.2 kgf-m, 9 Ibfft) OIL CHANGE Place the vehicle on a level surface. Remove the oil filler cap and drain bolt to drain the oil. When the oil is completely drained, install the drain bolt with a new sealing washer. TORQUE: 12 N m (1.2 kgfrn, 9 Ibfft) Fill the final gear case with the recommended oil (page 4-15). OIL CAPACITY: 78 cm3 (2.6 US oz, 2.7 Imp oz) at draining 90 cm3 (3.0 US oz, 3.2 Imp oz) at disassembly 4-15 MAINTENANCE DIFFERENTIAL OIL LEVEL CHECK Place the vehicle on a level surface. Remove the oil filler cap. Check that the oil level is up to the lower edge of the oil filler hole. Check for leaks if the oil level is low. Pour the oil through the filler hole until it reaches the lower edge of the hole. RECOMMENDED OIL: Hypoid gear oil SAE #80 Coat a new O-ring with grease and install it into the oil filler cap groove. Install the oil filler cap and tighten it. TORQUE: 12 N m (1.2 kgf m, 9 Ibf-fft) OIL CHANGE Place the vehicle on a level surface. Remove the oil filler cap and drain bolt to drain the oil. When the oil is completely drained, install the drain bolt with a new sealing washer. TORQUE: 12 N m (1.2 kgf m, 9 Ibf ft) Fill the differential case with the recommended oil (page 4-16). OIL CAPACITY: 175 cm3 (5.9 US oz, 6.2 Imp oz) at draining 220 cm3 (7.4 US oz, 7.7 Imp oz) at disassembly 4-16 MAINTENANCE BRAKE FLUID NOTICE • Do not 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. • Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. NOTE. • When the fluid level is low, check the brake pads for wear (page 4-18). • A low fluid level may be due to worn brake shoes or pads. If the brake pads are worn, the caliper piston is pushed out, and this causes a low reservoir level. If the brake pads are not worn and the fluid level is low, check entire system for leaks (page 4-19). FRONT BRAKE Turn the handlebar to the left side so the reservoir is level and check the fluid level through the sight glass. RESERVOIR CAP SIGHT GLASS J LOWER LEVEL MARK If the level is near the "LOWER" level mark, remove the reservoir cap, set plate and diaphragm and fill the reservoir with Honda DOT 4 brake fluid from a sealed container to the casting ledge. CASTING LEDGE Install the diaphragm, set plate and reservoir cap, and tighten the cap screws. 4-17 MAINTENANCE REAR BRAKE Place the vehicle on a level surface. Remove the right fuel tank side cover (page 3-6). Check the fluid level in the rear brake reservoir. If the level is near the "LOWER" level line, remove the reservoir mounting bolt, reservoir cap, set plate and diaphragm and fill the reservoir with Honda DOT 4 brake fluid from a sealed container to the "UPPER" level line. Install the diaphragm, set plate, reservoir cap and mounting bolt, and tighten the bolt. Install the right fuel tank side cover (page 3-6). BRAKE PADS WEAR NOTE: • The front and rear brake has audible brake wear indicator. When the brake pads need replacing, the brake will screech while applying the brake. FRONT Remove the front wheel (page 15-11). Check the brake pads for wear. Replace the front brake pads if the wear limit indicator mark on the caliper aligns with the reference mark on the caliper bracket when the front brake lever is applied. REFERENCE MARK Refer to front brake pad replacement (page 17-10). WEAR LIMIT INDICATOR REAR Check the rear brake pads for wear. Replace the brake pads if the wear limit indicator mark on the caliper aligns with the reference mark on the caliper bracket when the rear brake is applied. Refer to rear brake pad replacement (page 17-11). WEAR LIMIT INDICATOR 4-18 MAINTENANCE BRAKE LIGHT SWITCH NOTE. • The front brake light switch cannot be adjusted. If the front brake light switch actuation and brake engagement are off, either replace the switch unit or the malfunctioning parts of the system. Check that the brake light comes on just prior to the brake actually being engaged. BRAKE LIGHT SWITCH If the light fails to come on, adjust the switch so that the light come on at the proper time. Hold the switch body and turn the adjusting nut. Do not turn the switch body. ADJUSTING NUT 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. Refer to brake bleeding (page 17-7). Inspect the brake hose and fittings for deterioration, clacks, damage or signs of leakage. Tighten any loose fittings. Replace hoses, pipes and fittings as required. REAR BRAKE Firmly apply the brake pedal and check that no air has entered the system. If the brake pedal feels soft or spongy when operated, bleed the system. Refer to brake bleeding (page 17-7). Inspect the brake hoses and fittings for deterioration, cracks, damage or signs of leakage. Tighten any loose fittings. Replace hoses, pipes and fittings as required. 4-19 MAINTENANCE PARKING BRAKE Check the brake lever and brake cable for loose connections or other damage. Replace or repair if necessary. For cable lubrication: Disconnect the brake cable at the brake lever. Thoroughly lubricate the cable and its pivot point with a commercially available cable lubricant or a lightweight oil. Measure the parking brake lever free play at the end of the lever. FREE PLAY: 25 - 30 mm (1 - 1-3/16 in) Make sure the cut- Adjust the parking brake lever free play by turning out in the adjusting the adjusting nut at the brake arm. nut is seated on the brake arm joint. SKID PLATE, ENGINE GUARD Check the skid plates and engine guard for cracks, damage or looseness. Tighten any loose fasteners. Replace the skid plates and engine guard as required. SKID PLATE 4-20 ENGINE GUARD MAINTENANCE SUSPENSION Loose, worn or damaged suspension parts impair vehicle stability and control. Check the action of the front and rear shock absorbers by compressing them several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. REAR: SPARK ARRESTER Remove the three bolts and the spark arrester with the gasket. Use a brush to remove carbon deposits from the screen mesh, being careful not to damage the screen mesh. The screen mesh must be free of breaks and holes. Replace the spark arrester if necessary. 4-21 MAINTENANCE Install the spark arrester with a new gasket and tighten the bolts 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. WHEELS/TIRES Tire pressure Check the tire pressure with the tire pressure gauge. should be checked when the tires are RECOMMENDED TIRE PRESSURE: Front: Standard: 30 kPa (0.30 kg/cm2, 4.4 psi) cold. Minimum: 26 kPa (0.26 kg/cm2, 3.8 psi) Maximum: 34 kPa (0.34 kg/cm2, 5.0 psi) With cargo: 30 kPa (0.30 kg/cm2, 4.4 psi) Rear: Standard: 25 kPa (0.25 kg/cm2, 3.6 psi) Minimum: 22 kPa (0.22 kg/cm2, 3.2 psi) Maximum: 28 kPa (0.28 kg/cm2, 4.0 psi) With cargo: 25 kPa (0.25 kg/cm2, 3.6 psi) Check the tires for cuts, embedded nails, or other damage. Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limit. MINIMUM TREAD DEPTH (Front/rear): 4.0 mm (0.16 in) Raise the wheel off the ground and check the hub, knuckle bearings or tie-rod ball joints for excessive play or abnormal noise. STEERING SHAFT HOLDER BEARING Raise the front wheels off the ground and support the vehicle securely. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has horizontal movement, inspect the steering shaft holder bushing and bearing (page 15-28). 4-22 MAINTENANCE STEERING SYSTEM Place the vehicle on level ground with the front wheels facing straight ahead. Mark the centers of the tires with chalk to indicate the axle center height. Align the gauge with the marks on the tires as shown. TOE-GAUGE Slowly move the vehicle back until the wheels have turned 180° so the marks on the tires are aligned with the gauge height on the rear side. Measure the toe on the rear part of the tires at the same points with no load on the vehicle. FRONT Toe-out: 10.9 ± 15 mm (7/16 + 9/16 in) NOTE. • 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 equally by loosening the lock nuts and turning the tie-rods while holding the ball joints. After adjusting each tie-rod, rotate both tie-rod ends in the same direction, along the tie-rod axis, until they stop against the ball joint stud. Rotate both tie-rod ends in the same direction 4-23 MAINTENANCE Using a 17 mm wrench, hold the tie-rod ends so that the relative angle of both tie-rods may turn into 16 degrees 30 minutes. Then, using a suitable torque wrench, tighten the tie-rod lock nuts, making sure not to force the tie-rod ends against the ball joint studs. STEERING SIDE TIE-ROD END TORQUE: 54 N-m (5.5 kgf-m, 40 Ibfft) After tightening the lock nuts, rotate the tie-rods to make sure the ball joints have operate properly and have an equal range of movement. Raise the wheel off the ground and check the hub, knuckle bearings or tie-rod ball joints for excessive play or abnormal noise. 4-24 LOCK NUT KNUCKLE SIDE 5. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 5-2 OIL PRESSURE CHECK 5-5 SERVICE INFORMATION 5-3 OIL PUMP 5-5 TROUBLESHOOTING 5-4 OIL COOLER 5-12 5-1 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARMS CYLINDER HEAD COVER FLYWHEEL/ STARTER CLUTCH CAMSHAFT REVERSE IDLE GEAR OIL STRAINER SCREEN 5-2 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, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. This section covers service of the oil pump and oil cooler. For oil level check, oil change and filter replacement, refer to page 4-10. 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 not to allow dust or dirt to enter the engine. If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. After oil pump, oil cooler and/or oil hoses have been installed, check for oil leaks. SPECIFICATIONS ITEM Engine oil capacity After draining After draining/filter change After disassembly Recommended engine oil Oil pressure at 5,000 rpm (min1)/80°C (176°F) Oil pump rotor Tip clearance Body clearance Side clearance STANDARD 2.7 liters (2.9 US qt, 2.4 Imp qt) 2.9 liters (3.1 US qt, 2.6 Imp qt) 4.1 liters (4.3 US qt, 3.6 Imp qt) Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil (U.S.A. and Canada), or Honda 4-stroke oil (Canada only), or an 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-40, 5W-30 785 kPa (8.0 kgf/cm2,114 psi) 0.15(0.006) 0.12-0.22(0.005-0.009) 0.02-0.09(0.001 -0.004) Unit: mm (in) SERVICE LIMIT — - 0.20 (0.008) 0.25(0.010) 0.11 (0.004) TORQUE VALUES Oil pump driven sprocket bolt 12N-m(1.2kgf-m, 9 Ibf-ft) Apply locking agent to the threads. TOOLS Oil pressure gauge set 07406-0020005 or 07ZMJ-HN2A100 and 07AMJHN8A100 (U.S.A. Only) 5-3 LUBRICATION SYSTEM TROUBLESHOOTING Oil level too low - high oil consumption • Oil consumption • External oil leak • Worn piston rings or incorrect piston ring installation • Worn cylinder • Worn valve guides or stem seals • Oil pump worn or damaged Low oil pressure • Oil level low • Oil pressure relief valve wear • Clogged oil strainer or filter • Faulty oil pump • Internal oil leak • Incorrect oil being used No oil pressure • Oil level too low • Oil pressure relief valve stuck open • Broken oil pump drive chain • Broken oil pump drive or driven sprocket • Damaged oil pump • Internal oil leak High oil pressure • Oil pressure relief valve stuck closed • Clogged oil gallery or orifice • Incorrect oil being used Oil contamination • Oil or filter not changed often enough • Worn piston rings or incorrect piston ring installation • Worn valve guides or stem seals Oil emulsification • Blown cylinder head gasket • Leaky coolant passage • Water entry 5-4 LUBRICATION SYSTEM OIL PRESSURE CHECK Failure to warm the Check the oil level and add the recommended oil if engine will cause necessary (page 4-10). very high oil pres- Also, warm the engine to normal operating tempersure readings. ature and check for external leaks. External leaks will Remove the oil gallery sealing bolt and washer on cause low oil presthe left side of the front crankcase cover. sure readings. 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 oil pressure gauge and adapter to the oil gallery hole. OIL PRESSURE GAUGE TOOLS: Pressure gauge set 07406-0020005 or Oil pressure gauge 0-160 psi 07ZMJ-HN2A100 and Adapter, banjo 8 x 1.25 mm 07AMJ-HN8A100 Start the engine and check the oil pressure. OIL PRESSURE (80°C/176°F): 785 kPa (8.0 kgf/cm2,114 psi) at 5,000 rpm (min1) Stop the engine and remove the oil pressure gauge and hose. Install the sealing bolt with a new sealing washer and tighten the bolt securely. Start the engine and make sure there are no oil leaks. OIL PUMP REMOVAL Remove the torque converter (page 14-60). Remove the three mounting bolts. Release the oil pump drive chain from the driven sprocket, then remove the oil pump from the crankcase. 5-5 LUBRICATION SYSTEM Remove the two O-rings from the oil joint. Remove the oil pass pipe and O-rings from the oil strainer pipe. Remove the two bolts, oil pipe and O-ring from the crankcase. DISASSEMBLY Remove the following: - 5-6 two oil pump assembly bolts ASSEMBLY BOLTS LUBRICATION SYSTEM oil pump body D outer rotor inner rotor drive pin two dowel pins Mark the rotors so they can be reinstalled in their original locations. DOWEL PINS PUMP BODY D OUTER ROTOR DRIVE PIN - oil pump body C outer rotor inner rotor drive pin PUMP BODY C OUTER ROTOR DRIVE PIN - oil pump body B pressure relief valve - bolt oil pump driven sprocket INNER ROTOR RELIEF VALVE INNER ROTOR PUMP BODY B DRIVEN SPROCKET BOLT 5-7 LUBRICATION SYSTEM - oil pump shaft drive pin outer rotor inner rotor PUMP BODY A INNER ROTOR / OUTER ROTOR Clean all the disassembled parts thoroughly. PUMP SHAFT INSPECTION Remove the O-ring from the pressure relief valve. PISTON Check the operation of the pressure relief valve by pushing on the piston. O-RING Temporarily assemble each inner rotor, outer rotor and drive pin on the pump shaft, and install them into each pump body individually. Measure the rotor tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) Measure the pump body clearance. SERVICE LIMIT: 0.25 mm (0.010 in) 5-8 DRIVE PIN LUBRICATION SYSTEM Remove the oil pump shaft and drive pin. Measure the oil pump side clearance. SERVICE LIMIT: 0.11 mm (0.004 in) ASSEMBLY DRIVEN SPROCKET DRIVE PINS RELIEF VALVE O-RING PUMP BODY A PUMP BODY D PUMP BODY B PUMP BODYC OUTER ROTORS ASSEMBLY BOLTS Dip all parts in clean engine oil. PUMP BODY A Install the outer and inner rotors into oil pump body A. Insert the drive pin onto the pump shaft. Install the pump shaft into the inner rotor and pump body A, aligning the drive pin with the inner rotor grooves. INNER ROTOR OUTER ROTOR PUMP SHAFT 5-9 LUBRICATION SYSTEM Install the oil pump driven sprocket onto the pump shaft, aligning the flats. Apply locking agent to the driven sprocket bolt threads. Install and tighten the driven sprocket bolt. DRIVEN SPROCKET TORQUE: 12 N m (1.2 kgf-m, 9 Ibf ft) BOLT Coat a new O-ring with oil and install it into the relief valve groove. O-RING Install the pressure relief valve into oil pump body B. Install oil pump body B onto pump body A. RELIEF VALVE Insert the drive pin into the pump shaft. Install the inner rotor onto the pump shaft, aligning its grooves with the drive pin. Install the outer rotor into oil pump body C. Install pump body C onto pump body B. PUMP BODY C OUTER ROTOR DRIVE PIN 5-10 PUMP BODY B INNER ROTOR LUBRICATION SYSTEM Install the dowel pins into pump bodies C, B and A. Insert the drive pin into the pump shaft. Install the inner rotor onto the pump shaft, aligning its grooves with the drive pin. Install the outer rotor into oil pump body D. Install pump body D onto pump body C. DOWEL PINS PUMP BODY D OUTER ROTOR DRIVE PIN Install and tighten the two oil pump assembly bolts. INNER ROTOR ASSEMBLY BOLTS INSTALLATION Apply oil to a new O-ring and install it onto the oil pipe. Install the oil pipe onto the crankcase. Set the retainer plate and tighten the two bolts securely. RFTAINER PLATE OIL PIPE 5-11 LUBRICATION SYSTEM Apply oil to new O-rings and install them onto the oil pass pipe. Install the oil pass pipe to the oil strainer pipe. Coat new O-rings with oil and install them onto the oil joint pipes. Install the oil pump drive chain onto the driven sprocket of the oil pump, and install the oil pump onto the crankcase. Install the three mounting bolts and tighten them securely. Install the torque converter (page 14-73). ^ ^ i OIL PUMP OIL COOLER REMOVAL Remove the front fender (page 3-11). - RETAINING CLIPS Remove the radiator grille by releasing the four | retaining clips. 5-12 LUBRICATION SYSTEM Check the oil cooler hose joints and seams for leaks. Check the oil cooler air passage for clogging or damage. Straighten bent fins using a small flat blade screwdriver and remove insects, mud or other obstructions with compressed air or low pressure water. OIL COOLER Remove the bolts and oil pipes from the oil cooler. Remove the O-rings from the oil pipes. Remove the four mounting screws and oil cooler from the radiator. INSTALLATION Install the oil cooler onto the radiator and tighten the mounting screws securely. SCREWS Coat new O-rings with oil and install them onto the oil pipes. Install the oil pipes onto the oil cooler and tighten the bolts securely. Install the removed parts in the reverse order of removal. Check the oil level and add the recommended oil if the level is low (page 4-10). 5-13 6. FUEL SYSTEM (PGM-FI) SYSTEM COMPONENTS 6-2 FUEL PUMP RELAY 6-38 SERVICE INFORMATION 6-3 FUEL TANK 6-39 SYMPTOM TROUBLESHOOTING 6-5 AIR CLEANER HOUSING 6-41 PGM-FI SYSTEM LOCATION 6-6 THROTTLE BODY 6-43 PGM-FI SYSTEM DIAGRAM 6-7 INJECTOR 6-48 PGM-FI CONNECTOR LOCATION 6-8 ECT SENSOR 6-50 BANK ANGLE SENSOR 6-51 ENGINE STOP RELAY 6-52 PGM-FI TROUBLESHOOTING INFORMATION • 6-13 PGM-FI DTC INDEX 6-17 DTC TROUBLESHOOTING 6-18 MIL CIRCUIT INSPECTION 6-31 FUEL LINE INSPECTION 6-32 SUB FUEL TANK/FUEL PUMP 6-36 PCM (POWERTRAIN CONTROL MODULE) 6-53 ENGINE IDLE SPEED 6-55 IACV 6-56 6-1 FUEL SYSTEM (PGM-FI) SYSTEM COMPONENTS 6-2 FUEL SYSTEM (PGM-FI) SERVICE INFORMATION GENERAL • This FUEL SYSTEM section covers service of the electrical and mechanical system of the PGM-FI system, fuel supply system and air cleaner. • Before disconnecting the fuel feed hose, relieve pressure from the system by disconnecting the quick connect fitting in the sub fuel tank (page 6-32). • Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bend, resulting in loss of vehicle control. • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. • Do not 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 bolts, nuts and screws of the throttle body. Loosening or tightening them can cause throttle body malfunction. • Tighten the yellow painted bolts of the throttle body to the specified torque. • A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before proceeding. • When disassembling the PGM-FI parts, note the location of the O-rings. Replace them with new ones upon reassembly. • Use a digital tester for PGM-FI system inspection. • Refer to procedures for fuel level sensor inspection (page 23-10). SPECIFICATIONS ITEM Throttle body identification number Idle speed Throttle lever free play ECT sensor resistance (20°C/68°F) Fuel injector resistance (at 20°C /68°F) Fuel pressure Fuel pump flow (at 12 V) SPECIFICATIONS GQ67A 1,400 + 50 rpm (min 1 ) 3 - 8 mm (1/8-5/16 in) 2.3-2.6 kQ 11.1- 12.3 Q 284 - 304 kPa (2.9 - 3.1 kgf/cm2, 41 - 44 psi) 71 cm3 (2.4 US oz, 2.5 Imp oz) minimum/10 seconds TORQUE VALUES Insulator band screw (throttle body side) Insulator band screw (cylinder head side) Throttle drum cover screw Sensor unit mounting screw Fuel feed hose bracket screw Harness guide bracket screw Fuel injector/feed hose mounting bolt IACV mounting torx screw Bank angle sensor mounting bolt See page 6-42 See page 6-46 1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft) 3.4 N-m (0.35 kgf-m, 2.2 Ibf-ft) 4.2 N-m (0.43 kgf-m, 3.1 Ibf-ft) 4.2 N-m (0.43 kgf-m, 3.1 Ibf-ft) 5.1 N-m (0.53 kgf-m, 3.8 Ibf-ft) 2.1 N-m (0.21 kgf-m, 1.5 Ibf-ft) 1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft) 6-3 FUEL SYSTEM (PGM-FI) TOOLS Fuel pressure gauge 07406-0040004 Pressure gauge manifold 07ZAJ-S5A0111 Pressure gauge hose attachment A 07ZAJ-S5A0120 or 07406-00400B (U.S.A. only) Not available in U.S.A. Not available in U.S.A. Pressure gauge hose attachment B 07ZAJ-S5A0130 Hose attachment B joint 07ZAJ-S5A0150 Pressure manifold hose 07AMJ-HW3A100 (U.S.A. only) Adaptor, male 07AAJ-S6MA200 (U.S.A. only) Adaptor, female 07AAJ-S6MA400 (U.S.A. only) SCS connector 070PZ-ZY30100 HDS pocket tester TDS 3557-0112-01 (U.S.A. Only) Inspection test harness 07GMJ-ML80100 Test probe 07ZAJ-RDJA110 6-4 FUEL SYSTEM (PGM-FI) SYMPTOM TROUBLESHOOTING When the vehicle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 6-17) and begin the appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the PCM memory, do the diagnostic procedure for the symptom, in the sequence listed below, until you find the cause. Symptom Engine cranks but won't start (No DTC and MIL blinking) Diagnosis procedure 1. Inspect the ignition system (page 21-5). 2. Inspect the fuel supply system (page 6-36). Engine cranks but won't start (No fuel pump operation sound when the turning the ignition ON and engine stop switch "O") 1. PCM power/ground circuits malfunction (page 6-53) 2. Inspect the fuel supply system (page 6-36). Engine stalls, hard to start, rough idling 1. Check the idle speed (page 655). 2. Check the IACV (page 6-56). 3. Inspect the fuel supply system (page 6-36). Check the ignition system. Backfiring or misfiring during acceleration Poor performance (driveability) and poor fuel economy Idle speed is below specifications or fast idle too low (No DTC and MIL blinking) Idle speed is above specifications or fast idle too high (No DTC and MIL blinking) MIL stays on but no DTCs set, or MIL never comes on at all MIL stays on at all times (No DTC set) Inspect the fuel supply system (page 6-36). 1. Check the idle speed (page 655) 2. Check the IACV (page 6-56). 1. Check the idle speed (page 655) 2. Check the throttle operation and lever free play (page 4-4) 3. Check the IACV (page 6-56). Troubleshoot the MIL circuit (page 6-31). Check the DLC circuit (Brown/red wire) for short circuit. Also check for » No fuel to injector - Clogged fuel filter - Pinched or clogged fuel feed hose - Pinched or clogged fuel tank breather hose - Faulty fuel pump - Faulty fuel pump circuits 1 Intake air leak » Contaminated/deteriorated fuel » Faulty fuel injector 4• IACV stuck closed 4• Open circuit in the power input and/or ground wire of the PCM > Faulty bank angle sensor or related circuit > Faulty engine stop relay or related circuit > Faulty engine stop switch or related circuit « BlownFI/IGNfuse(10A) > BlownST./ECMfuse(10A) > Restricted fuel feed hose > Contaminated/deteriorated fuel • Intake air leak • Restricted fuel tank breather hose • Faulty ignition system • Faulty ignition system > Pinched or clogged fuel feed hose > Faulty injector > Faulty ignition system IACV stuck closed Faulty fuel supply system > Faulty ignition system > IACV stuck opened > Faulty ignition system Intake air leak Engine top end problem Air cleaner condition • Faulty MIL circuit • Short circuit in the DLC related wire 6-5 FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM LOCATION PCM INJECTOR DLC MAP SENSOR/TP SENSOR BANK ANGLE SENSOR FUSE BOX FRONTVS SENSOR SUB FUEL TANK IAT SENSOR REAR VS SENSOR RELAY MODULE CKPSENSOR IACV ECT SENSOR 6-6 FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM DIAGRAM ENGINE STOP SWITCH ENGINE STOP RELAY BANK ANGLE SENSOR B1 MAIN ENG STOP U G/w - A4 INJ B33 B23 PCP B12 PCM INJ @(29)St IGN B11 B3 VCC B14 TH B2 SG A FLR B21 IGNITION \ ] COIL SPARK PLUG B25 PB FUEL PUMP IAT SENSOR B26 TA ©(9) „ _ , , B27 TW PCM STEP1A B20 STEP1B B32 — Br/R • STEP2A B30 — Br/Bu STEP2B B31 — Br/Y • ECT SENSOR IACV ©(29) I— BVBu —f ©(7) K • LINE B17 — O/W • SCS B6 — Br/R • L DLC/SCS jr MIL COMBINATON METER WARN B19 LCD CPU B4 FRVSP A15 SenVB2 B13 LG FRONT VS SENSOR Bl Y Bu G R W : BLACK : YELLOW : BLUE : GREEN : RED : WHITE B22 PG1 RRVSP B5 SenVBI A16 REAR VS SENSOR B10 PG2 ©(11) Br O Lg P Gr : BROWN : ORANGE : LIGHT GREEN : PINK : GRAY A-23 A-33 B-23 B-33 6-7 FUEL SYSTEM (PGM-FI) PGM-FI CONNECTOR LOCATION FRONT CONNECTOR LOCATIONS Note 1: Note 2: Remove the steering cover (page 3-5). Remove the left inner fender (page 3-9). PCM 33P BLACK CONNECTOR (Note 1) PCM 5P BLACK CONNECTOR (Note 1) PCM (Note 1) PCM 33P GRAY CONNECTOR (Note 1) REAR VS SENSOR 3P (YELLOW) CONNECTOR (Note 2) 6-8 FUEL SYSTEM (PGM-FI) Note 1: Remove the right inner fender (page 3-9). FUEL PUMP 2P (BLACK) CONNECTOR ENGINE STOP RELAY 3P (GREEN) CONNECTOR (Note 1) 6-9 FUEL SYSTEM (PGM-FI) MIDDLE/REAR CONNECTOR LOCATIONS Note 1: Note 2: Remove the seat (page 3-4). Remove the fuel tank side cover (page 3-6). INJ2P (GRAY) CONNECTOR (Note 1) IACV 4P (BLACK) CONNECTOR (Note 1) ECT SENSOR 2P (BLACK) CONNECTOR (Note 2) 6-10 MAP/TP SENSOR 5P (BLACK) CONNECTOR (Note 2) FUEL SYSTEM (PGM-FI) Note 1: Remove the battery case (page 20-6). IAT SENSOR 2P (BLACK) CONNECTOR RELAY MODULE 8P (GRAY) CONNECTOR (Note 1) 6-11 FUEL SYSTEM (PGM-FI) Note 1: Remove the right side cover (page 3-5). ALTERNATOR 5P (NATURAL) CONNECTOR (Note!) 6-12 FUEL SYSTEM (PGM-FI) PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit with the trouble. 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 not work at all. With PCMs this can mean something will work, but not the way it's supposed to. If the MIL has come on Refer to DTC READ OUT (page 6-14). If the MIL did not stay on If the MIL did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 6-5). SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM The PGM-FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system, the PCM turns on the MIL and stores a DTC 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-diagnosis function, running capability is maintained by preprogramed value in the simulated program map. When any abnormality is detected in the injector and crankshaft position (CKP) sensor, the fail-safe function stops the engine to protect it from damage. DTC (Diagnostic Trouble Code) • The DTC is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the PCM with the HDS pocket tester. The digits in front of the hyphen are the main code, they indicate the component of function failure. The digits behind the hyphen are the sub code, they detail the specific symptom of the component or function failure. For example, in the case of the TP sensor: - DTC 08 - 1 = (TP sensor voltage) - (lower than the specified value) - DTC 08 - 2 = (TP sensor voltage) - (higher than the specified value). • The MAP, ECT, TP and IAT sensor diagnosis will be made according to the voltage output of the affected sensor. If a failure occurs, the PCM determines the Function Failure, compares the sensor voltage output to the standard value, and then outputs the corresponding DTC to the HDS Pocket Tester. For example: - If the input voltage line (A) on the MAP sensor is opened, the PCM detects the output voltage is about 5 V, then the DTC 1-2 (MAP sensor circuit high voltage) will be displayed. - If the input voltage line (B) on the TP sensor is opened, the PCM detects the output voltage is 0 V, then the DTC 8-1 (TP sensor circuit low voltage) will be displayed. 5V MAP SENSOR 5V TP SENSOR OUTPUT VOLTAGE OUTPUT VOLTAGE 5V ECT SENSOR I OUTPUT VOLTAGE 5V IAT SENSOR h. OUTPUT VOLTAGE 6-13 FUEL SYSTEM (PGM-FI) MIL Blink Pattern • If the HDS pocket tester is not available, DTC can be read from the PCM memory by the MIL blink pattern. • The number of MIL blinks is the equivalent the main code of the DTC (the sub code cannot be displayed by the MIL). • The MIL will blink the current DTC, in case the PCM detects the problem at present, when the ignition switch ON or idling. The MIL will stay ON when driving (engine speed is over 2,000 rpm (min ')). • 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. One long blink is the equivalent of ten short blinks. For example, when two long blinks are followed by five short blinks, the MIL is 25 (two long blinks = 20 blinks, plus five short blinks). • When the PCM stores more than one DTC, the MIL will indicate them by blinking in the order from the lowest number to highest number. MIL Check When the ignition switch is turned ON and engine stop switch is "O", the MIL will stay on for a few seconds, then go off. If the MIL does not come on, troubleshoot the MIL circuit (page 6-31). CURRENT DTC/FREEZE DTC The DTC is indicated in two ways according to the failure status. • In case the PCM detects the problem at present, the MIL will come on and the MIL will start to blink as its DTC. It is possible to readout the MIL blink pattern as the current DTC. • In case the PCM does not detect any problem at present but has a problem stored in its memory, the MIL will not light and blink. If it is necessary to retrieve the past problem, readout the freeze DTC by following the DTC readout procedure. HDS POCKET TESTER INFORMATION • The HDS can readout the DTC, freeze data, current data and other powertrain control module condition. How to connect the HDS Pocket Tester Turn the ignition switch to OFF. Remove the steering cover (page 3-5). Remove the dummy connector from the DLC. Connect the HDS pocket tester to the DLC. Turn the ignition switch to ON and engine stop switch "O", check the DTC and freeze data. NOTE: • Freeze data indicates the engine conditions when the first malfunction was detected. PCM reset The HDS can reset the PCM data including the DTC, freeze data and some learning memory. DTC READOUT • When the ignition switch is turned ON, the MIL will stay on for a few seconds, then go off. • After performing diagnostic troubleshooting, erase the problem code(s) (page 6-15) and test-ride the vehicle to be sure that the problem(s) have been removed. If the MIL stays on or blinks, connect the HDS Pocket Tester to the DLC (page 6-14). Then read the DTC, freeze data and follow the troubleshooting index (page 6-17). To read the DTC with the MIL blinking, refer to the following procedure. 6-14 FA model shown: 1( (RESET) NT MIL A* I" &3S _ ;6,svy i ADJ l V H:: FUEL SYSTEM (PGM-FI) Reading DTC with the MIL Start the engine and let it idle. Read the MIL blinking that is indicated as the current DTC and refer to the troubleshooting index (page 6-17). When retrieving the freeze DTC, refer to the following procedure. Turn the ignition switch to OFF. Remove the steering cover (page 3-5). Remove the dummy connector and short DLC terminals using the special tool. TOOL: SCS connector 070PZ-ZY30100 CONNECTION: Brown/red - Green Turn the ignition switch to ON and engine stop switch "O", read, note the MIL blinks and refer to the troubleshooting index (page 6 17). NOTE: If the PCM has any DTC in its memory, the MIL will start blinking. CLEARING DTC Connect the HDS Pocket Tester to the DLC (page 6-14). Clear the DTC with the HDS while the engine is stopped. To clear the DTC without HDS, refer to the following procedure. How to clear the DTC with SCS connector 1. Remove the steering cover (page 3-5). 2. Turn the ignition switch to OFF. Make sure the 3. Remove the dummy connector and short the engine stop switch DLC using the special tool. is turned to " O " TOOL1 SCS connector 070PZ-ZY30100 CONNECTION: Brown/red - Green 4. Turn the ignition switch to ON. 5. Remove the special tool from the DLC. 6. The MIL will light for approximately 5 seconds. While the MIL lights, short the DLC terminals again with the special tool. The self-diagnostic memory is erased if the malfunction indicator goes off and starts blinking. NOTE: • The DLC must be jumped while the MIL lights. If not, the MIL will not start blinking. • Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking. 6-15 FUEL SYSTEM (PGM-FI) CIRCUIT INSPECTION INSPECTION AT PCM CONNECTOR • Always clean around and keep any foreign material away from the PCM connector before disconnecting it. • A faulty PGM-FI system is often related to poorly connected or corroded connections. Check those connections before proceeding. • Do not pull the wire harness while disconnecting the PCM connectors. • In testing at PCM connector (wire harness side) terminal, always use the test probe. Insert the test probe into the connector terminal, then attach the digital multimeter probe to the test probe. TOOL: Test probe 6-16 07ZAJ-RDJA110 FUEL SYSTEM (PGM-FI) PGM-FI DTC INDEX DTC (MIL blinks) 1-1(1) 1-2(1) 7-1 (7) 7-2 (7) 8-1 (8) Function Failure MAP sensor circuit low voltage (less than 0.19 V) • MAP sensor or its circuit malfunction MAP sensor circuit high voltage (more than 3.9 V) • Loose or poor contact of the MAP sensor connector • MAP sensor or its circuit malfunction ECT sensor circuit low voltage (less than 0.07 V) • ECT sensor or its circuit malfunction ECT sensor circuit high voltage (more than 4.93 V) • Loose or poor contact of the ECT sensor connector • ECT sensor or its circuit malfunction TP sensor circuit low voltage (less than 0.22 V) • TP sensor or its circuit malfunction 8-2 (8) TP sensor circuit high voltage (more than 4.93 V) • Loose or poor contact of the TP sensor connector • TP sensor or its circuit malfunction 9-1 (9) IAT sensor circuit low voltage (less than 0.07 V) • IAT sensor or its circuit malfunction IAT sensor circuit high voltage (more than 4.93 V) • Loose or poor contact of the IAT sensor connector • IAT sensor or its circuit malfunction Rear VS sensor no signal • Loose or poor contact of the VS sensor connector • VS sensor or its circuit malfunction 9-2 (9) 11-1 (11) 12-1 (12) 29-1 (29) 33-2 (-) Injector circuit malfunction • Loose or poor contact of the injector connector • Injector or its circuit malfunction IACV circuit malfunction • Loose or poor contact of the IACV connector • IACV or its circuit malfunction PCM EEPROM malfunction Symptom/Fail-safe function • • » <» Engine operates normally Fail-safe value: 29 kPa Engine operates normally Fail-safe value: 29 kPa Refer to 6-18 6-19 » Hard start at a low temperature 6-20 • Fail-safe value: 78.6°C/173.5°F 1» Cooling fan turns on 1 1 Hard start at a low temperature 6-22 i • Fail-safe value: 78.6°C/173.5°F » Cooling fan turns on • Poor engine acceleration 6-23 • Fail-safe value: 0° • A/T shift function and anti-creep function does not work (2nd gear only) • Poor engine acceleration 6-24 • Fail-safe value: 0° • A/T shift function and anti-creep function does not work (2nd gear only) • Engine operates normally 6-25 • Pre-program value: 25°C/77°F • Engine operates normally 6-26 • Fail-safe value: 25°C/77°F 4 4 6-27 • Engine operates normally • Selectable 4WD system does not work (2WD mode only) • A/T shift function and anti-creep function does not work (2nd gear only) • Engine does not start 6-28 • Injectors, fuel pump and ignition shut down • Engine stalls, hard to start, rough 6-29 idling • Engine operates normally 6-53 6-17 FUEL SYSTEM (PGM-FI) DTC TROUBLESHOOTING DTC 1-1 (MAP SENSOR LOW VOLTAGE) 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch "O". Check the MAP sensor with the HDS pocket tester. Is about 0 V indicated? YES - GO TO STEP 2. NO - • Intermittent failure • Loose or poor contact on the MAP sensor connector 2. MAP Sensor Input Voltage Inspection Remove the fuel tank left side cover (page 3-6). Turn the ignition switch OFF. Disconnect the MAP/TP sensor 5P (Black) connector. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) Turn the ignition switch ON and engine stop switch "o". Measure the voltage at the wire harness side. Connection: Brown (+) - Green/red (-) Is the voltage within 4.75 - 5.25V? YES - GO TO STEP 4. NO - GO TO STEP 3. 3. MAP Sensor Input Line Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Gray) connector. Check for continuity of the Brown wire between the MAP/TP sensor 5P (Black) connector terminal and the PCM 33P (Gray) connector terminals. TOOL: Test probe 07ZAJ-RDJA110 MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) Connection: B3 - Brown Is there continuity? YES - Replace the PCM with a known good one, and recheck. NO - Open circuit in Brown wire PCM 33P (GRAY) CONNECTOR (Wire side female terminal) 4. MAP Sensor Output Line Short Circuit Inspection Check for continuity between the MAP/TP sensor 5P (Black) connector terminal of the wire harness side and ground. Connection: Light green - ground Is there continuity? 6-18 YES - Short circuit in Light green wire NO - GO TO STEP 5. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) FUEL SYSTEM (PGM-FI) 5. MAP Sensor Inspection Replace the MAP/TP sensor with a known good one (page 6-43). Clear the DTC (page 6-14). Turn the ignition switch ON and engine stop switch "o". Check the MAP sensor with the HDS pocket tester. Is DTC 1-1 indicated? YES - Replace the PCM with a known good one, and recheck NO - Faulty original MAP/TP sensor DTC 1-2 (MAP SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the MAP/TP sensor 5P (Black) connector and recheck the DTC. 1. MAP Sensor System Inspection 1 Turn the ignition switch ON and engine stop switch "o". Check the MAP sensor with the HDS pocket tester. Is about 5 V indicated? YES - GO TO STEP 2. NO - • Intermittent failure Loose or poor contact on the MAP/TP sensor connector 2. MAP Sensor System Inspection 2 Turn the ignition switch OFF. Disconnect the MAP/TP sensor 5P (Black) connector. Jump the MAP sensor terminals at the wire harness side with a jumper wire. Connection: Light green - Green/red Turn the ignition switch ON and engine stop switch "o"Check the MAP sensor with the HDS pocket tester. Is about 0 V indicated? YES - Faulty MAPfTP sensor NO - GO TO STEP 3. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) G \\ JUMPER WIRE 6-19 FUEL SYSTEM (PGM-FI) 3. MAP Sensor Input Voltage Inspection Turn the ignition switch OFF. Remove the jumper wire. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) Turn the ignition switch ON and engine stop switch "O". Measure the voltage at the wire harness side terminals. Connection: Brown (+) - Green/red (-) te the voltage within 4.75 - 5.25V? YES - GO TO STEP 4. NO - Open circuit in Green/red or Brown wire 4. MAP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Gray) connector. Check for continuity of the Light green wire between the MAP/TP sensor 5P (Black) connector terminal and the PCM 33P (Gray) connector terminal. TOOL: Test probe 07ZAJ-RDJA110 Connection: B25 - Light green MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) [ I—I - J I r I w / j B25 te there continuity? YES - Replace the PCM with a known good one, and recheck NO - Open circuit in Light green wire DTC 7-1 (ECT SENSOR LOW VOLTAGE) 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch "O". Check the ECT sensor with the HDS pocket tester. te about 0 V indicated? 6-20 NO - • Intermittent failure. • Loose or poor contact on the ECT sensor connector. YES - GO TO STEP 2. PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) Lg -> FUEL SYSTEM (PGM-FI) 2. ECT Sensor Inspection Remove the fuel tank left side cover (page 3-6). 2P BLACK CONNECTOR Turn the ignition switch OFF. Disconnect the ECT sensor 2P (Black) connector. Turn the ignition switch ON and engine stop switch "O". Check the ECT sensor with the HDS pocket tester. Is about 0 V indicated? NO - GO TO STEP 3. YES - GO TO STEP 4. 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the ECT sensor terminals. Connection: White - Green/red Standard: 2.3 - 2.6 kn (20°C/68°F) ECT SENSOR 2P (BLACK) CONNECTOR (Sensor side of male terminal) Is the resistance within 2.3 - 2.6 kn ? YES - Replace the PCM with a new one, and recheck. No - Faulty ECT sensor. G/R W 4. ECT Sensor Short Circuit Inspection Disconnect the PCM 33P (Gray) connector from the PCM (page 6-53). Check for continuity between the ECT sensor 2P (Black) connector terminal of the wire harness side and ground. ECT SENSOR 2P (BLACK) CONNECTOR (Wire side of female terminal) Connection: White - Ground Is there continuity? YES - Short circuit in White wire. NO - Replace the PCM with a new one, and recheck. 6-21 FUEL SYSTEM (PGM-FI) DTC 7-2 (ECT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the ECT sensor 2P (Black) connector and recheck the DTC. 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch "o". Check the ECT sensor with the HDS pocket tester. Is about 5 V indicated? NO - • Intermittent failure. • Loose or poor contact on the ECT sensor 2P (Black) connector. YES - GO TO STEP 2. 2. ECT Sensor Inspection Remove the fuel tank left side cover (page 3-6). Turn the ignition switch OFF. Disconnect the ECT sensor 2P (Black) connector. Jump the ECT sensor terminals with a jumper wire. Connection: White - Green/red ECT SENSOR 2P (BLACK) CONNECTOR (Wire side of female terminal) Turn the ignition switch ON and engine stop switch "O". Check the ECT sensor with the HDS pocket tester. Is about 0 V indicated? YES - Faulty ECT sensor. NO - GO TO STEP 3. 3. ECT Sensor Open Circuit Inspection Turn the ignition switch OFF. Disconnect the jumper wire. Disconnect the PCM 33P (Gray) connector (page 6-53). Check for continuity between the PCM 33P (Gray) connector terminals and ECT sensor 2P (Black) connector terminals of the wire harness side. TOOL: Test probe 07ZAJ-RDJA110 Connection: B27-White B2- Green/red Is there continuity? 6-22 YES - Replace the PCM with a new one, and recheck. NO - • Open circuit in White wire. • Open circuit in Green/red wire. JUMPER WIRE ECT SENSOR 2P (BLACK) CONNECTOR (Wire side of female terminal) B2 B27 \ r-i PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) FUEL SYSTEM (PGM-FI) DTC 8-1 (TP SENSOR LOW VOLTAGE) • Before starting the inspection, check for loose or poor contact on the MAP/TP sensor 5P (Black) connector and recheck the DTC. 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch "o". Check the TP sensor with the HDS when the throttle is fully closed. Is about 0 V indicated? YES - GO TO STEP 3. NO - GO TO STEP 2. 2. TP Sensor Inspection Check that the TP sensor voltage is increasing uninterrupted when moving the throttle from fully closed to fully opened using the data list menu of the HDS pocket tester. Does the voltage increase continuously? YES - • Intermittent failure. • Loose or poor contact on the MAP/TP sensor connector NO - Faulty TP sensor. 3. TP Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the MAP/TP sensor 5P (Black) connector. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) Turn the ignition switch ON and engine stop switch "O"Measure the voltage at the wire harness side terminals. Connection: Brown (+) - Green/red (-) to the voltage within 4.75 - 5.25 V? YES - GO TO STEP 5. NO - G O TO STEP 4. 4. TP Sensor Circuit Inspection Turn the ignition switch OFF. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) Disconnect the PCM 33P (Gray) connector. Check for continuity at the Brown wire between the MAP/TP sensor 5P (Black) connector terminal and the PCM 33P (Gray) connector terminal. TOOL: Test probe 07ZAJ-RDJA110 Connection: B3 - Brown Is there continuity? YES - Replace the PCM with a known good one, and recheck NO - Open circuit in Brown wire B3 [ i—i Br \ : -—i — i [ j 1 7 ' ' ' ' ' PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) 6-23 FUEL SYSTEM (PGM-FI) 5. TP Sensor Output Line Open Circuit Inspection Check for continuity at the Yellow wire between the MAP/TP sensor 5P (Black) connector terminal and the PCM 33P (Gray) connector terminal. TOOL: Test probe 07ZAJ-RDJA110 MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) B14 ( r-i \ 1 Connection: B14 - Yellow Is there continuity? YES - GO TO STEP 6. NO - Open circuit in Yellow wire PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) 6. TP Sensor Output Line Short Circuit Inspection Disconnect the MAP/TP sensor 5P (Black) connector. Check for continuity between the MAP/TP sensor 5P (Black) connector terminal of the wire harness side and ground. Connection: Yellow - Ground Is there continuity? YES - Short circuit in Yellow wire NO - GO TO STEP 7. 7. TP Sensor Inspection Replace the MAP/TP sensor with a known good one. Reset the PCM (page 6-14). Turn the ignition switch ON and engine stop switch "O". Check the TP sensor with the HDS pocket tester. Is DTC 8-1 indicated? YES - Replace the PCM with a known good one, and recheck NO - Faulty original MAP/TP sensor DTC 8-2 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch "O". Check the TP sensor with the HDS pocket tester. Is about 5 V indicated? 6-24 YES - GO TO STEP 3. NO - GO TO STEP 2. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) V FUEL SYSTEM (PGM-FI) 2. TP Sensor Inspection Check that the TP sensor voltage is increasing continuously when moving the throttle from fully closed to fully opened using the data list menu. Is the voltage increasing continuously? YES - • Intermittent failure. • Loose or poor contact on the MAP/TP sensor connector NO - Faulty TP sensor. 3. TP Sensor Resistance Inspection Turn the ignition switch OFF. Disconnect the MAP/TP sensor 5P (Black) connector. Measure the resistance at the TP sensor side terminals. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Sensor side of male terminal) Connection: Brown - Green/red Is the resistance within 1.0 - 3.0 ki2 YES - GO TO STEP 4. NO - Faulty TP sensor G/R 4. TP Sensor Input Voltage Inspection Turn the ignition switch ON and engine stop switch "O". Measure the voltage at the wire harness side terminals. MAP/TP SENSOR 5P (BLACK) CONNECTOR (Wire side of female terminal) Connection: Brown (+) - Green/red (-) Is the voltage within 4.75 - 5.25 V? YES - Replace the PCM with a known good one, and recheck NO - Open circuit in Green/red or Brown wires G/R DTC 9-1 (IAT SENSOR LOW VOLTAGE) 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch "O". Check the IAT sensor with the HDS pocket tester. Is about 0 V indicated? YES - GO TO STEP 2. NO - • Intermittent failure • Loose or poor contact on the IAT sensor connector 6-25 FUEL SYSTEM (PGM-FI) 2. IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Black) connector. Turn the ignition switch ON and engine stop switch "O"Check the IAT sensor with the HDS pocket tester. Is about 0 V indicated? YES - GO TO STEP 3. NO - Faulty IAT sensor 2P (BLACK) CONNECTOR • 3. IAT Sensor Output Line Short Circuit Inspection Disconnect the PCM 33P (Gray) connector from the PCM (page 6-43). Check for continuity between the IAT sensor 2P (Black) connector terminal of the wire harness side and ground. IAT SENSOR 2P (BLACK) CONNECTOR (Wire side of female terminal) Connection: Gray/blue - ground te there continuity? YES - Short circuit in Gray/blue wire NO - Replace the PCM with a known good one, and recheck DTC 9-2 (IAT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the IAT sensor connector and recheck the DTC. 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch "O". Check the IAT sensor with the HDS pocket tester. Is about 5 V indicated? YES - GO TO STEP 2. NO - • Intermittent failure • Loose or poor contact on the IAT sensor connector 2. IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the IAT sensor 2P (Black) connector. Jump the IAT sensor terminals with a jumper wire. Connection: Gray/blue - Green/red IAT SENSOR 2P (BLACK) CONNECTOR (Wire side of female terminal) Turn the ignition switch ON and engine stop switch "O". (> pj Check the IAT sensor with the HDS pocket tester. Is about 0 V indicated? 6-26 YES - Faulty IAT sensor NO - GO TO STEP 3. Gr/Bu G/R JUMPER WIRE FUEL SYSTEM (PGM-FI) 3. IAT Sensor Open Circuit Inspection Turn the ignition switch OFF. IAT SENSOR 2P( BLACK) CONNECTOR (Wire side of fern ale terminal) / B2 B26 \ ^ ^ ^ G/R/ i Vi j\ Disconnect the PCM 33P (Gray) connector. Check for continuity at the Gray/blue and Green/ red wire between the IAT sensor 2P (Black) connector terminals and the PCM 33P (Gray) connector terminals. TOOL: Test probe 07ZAJ-RDJA110 Connection: B2 - Green/red B26- Gray/blue te there continuity? YES - Replace the PCM with a known good one, and recheck. NO - • Open circuit in Gray/blue wire • Open circuit in Green/red wire i i i r I I J ' -2 1 ' (3D Gr/Bu PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) DTC 11-1 (REAR VS SENSOR NO SIGNAL) • Before starting the inspection, check for loose or poor contact on the rear VS (Vehicle Speed) sensor 3P (Yellow) connector and recheck the DTC. 1. Rear VS Sensor System Inspection Test-ride the vehicle and check the rear VS sensor with HDS pocket tester. Is vehicle speed indicated normally? YES - Intermittent failure. NO - GO TO STEP 2. 2. Rear VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the rear VS sensor 3P (Yellow) connector (page 23-9). REAR VS SENSOR 3P (YELLOW) CONNECTOR (Wire side of male terminal) Turn the ignition switch ON and engine stop switch "O". Measure the voltage at the rear VS sensor connector terminals of the wire harness side. Connection: Black/pink (+) - Green (-) Is there battery voltage? NO - • Open or short circuit in the Black/ pink wire. • Open circuit in the Green wire. YES Bl/P - GO TO STEP 3. 6-27 FUEL SYSTEM (PGM-FI) 3. Rear VS Sensor Output Line Inspection Measure the voltage between the wire harness side rear VS sensor 3P (Yellow) connector terminals. Connection: Pink/green (+) - Green (-) REAR VS SENSOR 3P (YELLOW) CONNECTOR (Wire side of male terminal) Is the voltage about 5 V? NO - Open or short circuit in the Pink/green wire. YES - GO TO STEP 4. 4. Rear VS Sensor Inspection Turn the ignition switch OFF. Replace the rear VS sensor with a new one (page 23-9). Clear the DTC, test ride the vehicle and recheck the DTC. Is the DTC 11-1 indicated? YES - Replace the PCM with a new one, and recheck. NO - Faulty original rear VS sensor. DTC 12-1 (INJECTOR) • Before starting the inspection, check for loose or poor contact on the injector 2P (Gray) connector and recheck the DTC. 1. Injector System Inspection Clear the DTC (page 6-15). Turn the ignition switch ON and engine stop switch "o", or start the engine, recheck the DTC. te the DTC 12-1 indicated? NO - • Intermittent failure. Loose or poor contact on the injector 2P (Gray) connector. YES - GO TO STEP 2. 2. Injector Resistance Inspection Remove the seat (page 3-4). Remove the trim clip and throttle body cover (page 6-43). Disconnect the injector 2P (Gray) connector. INJ 2P (GRAY) CONNECTOR (Injector side of male terminal) Turn the ignition switch ON and engine stop switch "o"Measure the resistance of the injector connector terminals on the injector side. Connection: Black/yellow - Green/blue Standard: 11.1 - 12.3 Q (20°C/68°F) te the resistance within 11.1 - 12.3 £2 (20°C/ 68°F)? 6-28 NO - Faulty injector. YES - GO TO STEP 3. Bl/Y G/Bu FUEL SYSTEM (PGM-FI) 3. Injector Open Circuit Inspection Turn the ignition switch OFF. Disconnect the PCM 33P (Gray) and 33P (Black) connector (page 6-43). Check for continuity between the PCM 33P (Gray and Black) connectors and injector 2P (Gray) connector of the wire harness side. TOOL: Test probe 07ZAJ-RDJA110 PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) A4 i \ „,,[—iV IS Bl/Y B33 h1 INJ2P (GRAY) CONNECTOR (Wire side of female terminal) G/Bu Connection: B33 - Green/blue A4 - Black/yellow Is there continuity? NO - • Open circuit in Green/blue wire. • Open circuit in Black/yellow wire. YES - GO TO STEP 4. PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) 4. Injector Signal Line Short Circuit Inspection Be sure to disconnect the PCM connector. Check for continuity between the injector connector terminal and ground. Connection: Green/blue - Ground INJ 2P (GRAY) CONNECTOR (Wire side of female terminal) fe there continuity? YES - Short circuit in the Green/blue wire. NO - Replace the PCM with a new one, and recheck. DTC 29-1 (IACV) • Before starting the inspection, check for loose or poor contact on the IACV 4P (Black) connector and recheck the DTC. 1. Recheck DTC Clear the DTC (page 6-15). Start the engine and recheck the DTC. Is the DTC 29-1 indicated? NO - • Intermittent failure. • Loose or poor contact on the IACV connector. YES - GO TO STEP 2. 6-29 FUEL SYSTEM (PGM-FI) 2. lACV Short Circuit Inspection Remove the seat (page 3-4). Remove the trim clip and throttle body cover (page 6-43). lACV 4P (BLACK) CONNECTOR (Wire side of female terminal) Turn the ignition switch OFF. Disconnect the lACV 4P (Black) connector. Check for continuity between the lACV 4P (Black) connector and ground on all wires. Connection: Black - Ground Brown/blue - Ground Brown/yellow - Ground Brown/red - Ground Bl Br/Bu Br/Y Br/R Is these continuity on all wires? YES - • Short circuit in Black or Brown/red wire. • Short circuit in Brown/blue or Brown/ yellow wire. NO - GO TO STEP 3. 3. lACV Circuit Continuity Inspection Disconnect the PCM 33P (Gray) connector. Check for continuity between the PCM 33P (Gray) connector and the lACV 4P (Black) connector. TOOL: Test probe 07ZAJ-RDJA110 Connection: B20 B30 B31 B32 - lACV 4P (WHITE) CONNECTOR (Wire side of female terminal) Black Brown/blue Brown/yellow Brown/red Are there continuities? YES - GO TO STEP 4. NO - • Open or loose contact in Black or Brown/red wire. • Open or loose contact in Brown/blue or Brown/yellow wire. Br/Y •{§) Br/R • PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) 4. lACV Resistance Inspection Measure the resistance at the terminals of the lACV 4P (Black) connector on the valve side Connection: Black - Brown/red Brown/blue - Brown/yellow Standard: 120-140 Q (20°C/68°F) lACV 4P (BLACK) CONNECTOR (Valve side of male terminal) te the resistance within 120 - 140 Q {20°C/68°F)7 YES - Replace the PCM with a new one, and recheck. NO - Faulty lACV. Br/Bu 6-30 ^-^ Br/Y J FUEL SYSTEM (PGM-FI) MIL CIRCUIT INSPECTION If the engine can be started but the MIL does not come on with the ignition switch ON and engine stop switch "O", check as follows: FA model shown: MIL Check the various functions of the combination meter. - If they do not function, check the combination meter power input line (page 23-8). If they function properly, check as follows: Turn the ignition switch OFF. Disconnect the PCM 33P (Gray) connector. Ground the White/blue (B19) wire terminal of the wire harness side connector with a jumper wire. TOOL: Test probe PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) 07ZAJ-RDJA110 B19 V Turn the ignition switch ON and engine stop switch "O", the MIL should come on. - If the MIL comes on, replace the PCM. If the MIL does not come on, check for open circuit in the White/blue wire between the combination meter and PCM. If the wire is OK, replace the combination meter. —\ r v i 1 i 1 6-31 FUEL SYSTEM (PGM-FI) FUEL LINE INSPECTION FUEL PRESSURE RELIEVING/QUICK CONNECT FITTING REMOVAL • Before disconnecting fuel feed hose, relieve pressure from the system as following procedures. • Do not bent or twist fuel feed hose. 1. Turn the ignition switch OFF. QUICK CONNECT FITTING Pull up the rubber boot and disconnect the fuel pump 2P (Black) connector. 2. Start the engine, and let it idle until it stalls. 3. Turn the ignition switch OFF. 4. Disconnect the battery cable (page 20-6). 5. Check the fuel quick connect fitting for dirt, and clean if necessary. Place a shop towel over the quick connect fitting. 2P (BLACK) CONNECTOR 6. Hold the connector with one hand and squeeze the retainer tabs with the other hand release them from the locking pawls. Pull the connector off. • Prevent 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. • Do not use tools. • If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it releases. CONNECTOR RETAINER TABS JOINT RUBBER 7. To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with the plastic bags. 6-32 PLASTIC EiAGS LOCKING PAWLS FUEL SYSTEM (PGM-FI) QUICK CONNECT FITTING INSTALLATION • Always replace the retainer of the quick connect fitting and joint rubber when the fuel feed hose is disconnected. • If any retainer needs replacing, use the same manufacture's retainer as the ones being removed (The several manufactures feature different retainer specifications). • If any damage or cut-out on the rubber cap, replace it with a new one. • Do not bent or twist the fuel feed hose. 1. Insert a new retainer into the connector. RETAINER CONNECTOR 2. Set a new joint rubber to the fuel pipe as shown. 3. Align the quick connect fitting with the pipe and align the new retainer locking pawls with the connector grooves in the rubber lock piece. Then press the quick connect fitting onto the pipe until both retainer pawls lock with a "CLICK". If it is hard to connect, put a small amount of engine oil on the pipe end. CONNECTOR LOCKING PAWLS JOINT RUBBER 4. Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector. CONNECTOR 6-33 FUEL SYSTEM (PGM-FI) 5. Connect the fuel pump 2P (Black) connector. Install the boot properly. 2P (BLACK CONNECTOR Temporarily connect the positive cable and negative cable to the battery. Turn the ignition switch ON and engine stop switch "O". Do not start the engine. The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat 2 or 3 times, and check that there is no leakage in the fuel supply system. FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fitting (page 6-32). MANIFOLD FUEL PRESSURE GAUGE Attach the fuel pressure gauge, attachment and manifold between the fuel pump and quick connector. TOOLS: Fuel pressure gauge Pressure gauge manifold Pressure gauge hose attachment A Pressure gauge hose attachment B Hose attachment B joint 07406-0040004 07ZAJ-S5A0111 07ZAJ-S5A0120 07ZAJ-S5A0130 07ZAJ-S5A0150 U.S.A. TOOLS: Fuel pressure gauge, lOOpsi Pressure manifold hose Adaptor, male Adaptor, female 07406-004000B 07AMJ-HW3A100 07AAJ-S6MA200 07AAJ-S6MA400 Temporarily connect the positive cable and negative cable to the battery. Start the engine and let it idle. Read the fuel pressure. Standard: 284 - 304 kPa (2.9 - 3.1 kgf/cm2, 4 1 - 4 4 psi) If the fuel pressure is higher than specified, replace the fuel pump assembly (faulty fuel pump or fuel pressure regulator). If the fuel pressure is lower than specified, inspect the following: - 6-34 Check the fuel flow Pinched or clogged fuel feed hose or fuel tank breather hose Fuel pump (page 6-36) Clogged fuel filter (Faulty fuel pump assembly) HOSE ATTACHMENTS FUEL SYSTEM (PGM-FI) Wrap a shop towel After inspection, relieve the fuel pressure by starting around the attach- the engine and let it idle until it stalls. ment to soak up Remove the fuel pressure gauge, attachment and any spilled fuel. manifold from the fuel pump. Connect the quick connect fitting (page 6-33). FUEL FLOW INSPECTION Relieve the fuel pressure and disconnect the quick connect fitting (page 6-32). Turn the ignition switch OFF. RELAY MODULE 8P (GRAY) CONNECTOR (Wire side of female terminal) Disconnect the relay module 8P (Gray) connector. Jump the Black/yellow and Violet wire terminals of the wire harness side using a jumper wire. B/Y JUMPER WIRE Connect the hose attachment to the fuel pump joint. TOOL: Pressure gauge hose attachment U.S.A. TOOLS: Pressure manifold hose Adaptor, female HOSE ATTACHMENT 07ZAJ-S5A0130 07AMJ-HW3A100 07AAJ-S6MA400 Wipe spilled gaso- Place the end of the hose into an approved gasoline line out of the con- container. tamer. j e m p O r a r j | y COnnect the positive cable and negative cable to the battery. Turn the ignition switch ON, engine stop switch "o" for 10 seconds. Measure the amount of fuel flow. Amount of fuel flow: 71 cm3 (2.4 US oz, 2.5 Imp oz) minimum /10 seconds at 12 V If the fuel flow is less than specified, inspect the following: - Fuel pump (page 6-36). Clogged fuel filter (Faulty fuel pump assembly) Connect the quick connect fitting (page 6-33). 6-35 FUEL SYSTEM (PGM-FI) SUB FUEL TANK/FUEL PUMP INSPECTION Turn the ignition switch ON, engine stop switch "O" and confirm that the fuel pump operates for a few seconds. If the fuel pump does not operate, inspect as follows: Turn the ignition switch OFF. Pull up the rubber boot and disconnect the fuel pump 2P (Black) connector. 2P (BLACK CONNECTOR Turn the ignition switch ON, engine stop switch "O" and measure the voltage between the terminals. FUEL PUMP 2P (BLACK) CONNECTOR (Wire side of female terminal) Connection: Violet (+) - Green (-) There should be battery voltage for a few seconds. If there is battery voltage, replace the sub fuel tank assembly. If there is no battery voltage, inspect the following: - open circuit in Violet wire and/or Green wire fuse fuel pump relay (page 6-38) engine stop relay (page 6-52) engine stop switch (page 23-7) bank angle sensor (page 6-51) PCM (page 6-53) REMOVAL NOTE: • Do not disassemble the sub fuel tank. After disconnecting the fuel pump 2P (Black) connector, be sure to relieve the fuel pressure by starting the engine and let it idle until it stalls. 6-36 Remove the following: - fuel fuel fuel fuel pump 2P (Black) connector feed hose vapor return hose hose 2P (BLACK) CONNECTOR FUEL SYSTEM (PGM-FI) Remove the bolts and sub fuel tank/bracket assembly. , SUB FUEL TANK/BRACKET ASSEMBLY Remove the bolts, then remove the sub fuel tank and collars from the bracket. BRACKET BOLTS/COLLARS Check the sub-fuel tank for damage. Replace the sub fuel tank as necessary. SUB FUEL TANK ASSEMBLY INSTALLATION Install the collars into the pump mounting rubbers. BRACKET BOLTS/COLLARS Install the fuel pump onto the bracket while aligning the boss with the grommet on the bracket. Install and tighten the fuel pump mounting bolts. Align SUB FUEL TANK ASSEMBLY Install the sub fuel tank/bracket assembly onto the frame, tighten the bolts securely. I_SUB FUEL TANK/BRACKET ASSEMBLY 6-37 FUEL SYSTEM (PGM-FI) Connect the fuel hose and fuel vapor return hose to the sub fuel tank/fuel pump. 2P BLACK) CONNECTOR Connect the fuel feed hose (page 6-33). Connect the fuel pump 2P (Black) connector. FUEL PUMP RELAY INSPECTION Remove the battery and battery case (page 20-6). Disconnect the relay module 8P (Gray) connector. 8P (GRAY) CONNECTOR Connect an ohmmeter to the 8P (Gray) connector of the module side connector terminals. RELAY MODULE 8P (GRAY) CONNECTOR (Module side of male terminal) Connection: Black/yellow - Violet Connect the 12V battery to the 8P (Gray) connector of the module side connector terminals. Connection: Yellow/black - Yellow/blue There should be continuity only when the 12V battery is connected. If there is no continuity when the 12V battery is connected, replace the fuel pump relay. 6-38 Bl/Y FUEL SYSTEM (PGM-FI) FUEL TANK REMOVAL/INSTALLATION Remove both fuel tank side covers (page 3-6). Disconnect the fuel level sensor 2P (Natural) connector. Release the sensor wire from the clamp. 2P NATURAL) CONNECTOR Disconnect the fuel vapor return hose from the fuel tank joint. FUEL VAPOR RETURN HOSE Release the return hose from the hose guide. Remove the two fuel tank holder bands and mounting bolts. 6-39 FUEL SYSTEM (PGM-FI) Lift the fuel tank and disconnect the fuel hose from the fuel tank joint. Unhook the heat guard rubbers from the heat guard plate bosses and frame bosses. Remove the heat guard rubbers. FUEL TANK JOINT HEAT GUARD RUBBERS BOSSES BOSSES Remove the fuel feed hose, radiator hose and throttle cable from the clamp on the heat guard plate. Remove the heat guard plate from the frame by releasing the two bosses. BOSSES RADIATOR HOSE FUELHOSE Install the heat guard plate, rubber heat guard and fuel tank in the reverse order of removal. NOTE: • After installing the fuel tank, turn the ignition switch ON and check that there is no fuel leak. THROTTLE CABLE FUEL STRAINER SCREEN CLEANING Remove the fuel tank (page 6-39). Drain the gasoline into an approved fuel container. Remove the two mounting bolts, collars and the fuel joint. 6-40 HEAT GUARD PLATE FUEL SYSTEM (PGM-FI) Remove the O-ring and fuel strainer screen. Clean the strainer screen with non-flammable or high flash point solvent. Dry the strainer screen thoroughly. Install the strainer screen and a new O-ring onto the fuel valve. Install the fuel joint onto the fuel tank. Install the collars and mounting bolts, and tighten the bolts securely. Install the fuel tank (page 6-39). AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the following: - seat (page 3-4) right side cover (page 3-5) fuel tank rear cover (page 3-6) Loosen the screw and remove the retaining clip. Loosen the band screw and remove the resonator chamber from the air duct. RESONATOR CHAMBER Remove the trim clip, loosen the band screw and remove the intake duct from the air cleaner housing. Disconnect the crankcase breather hose from the cylinder. 6-41 FUEL SYSTEM (PGM-FI) Disconnect the IAT sensor 2P (Black) connector. 2P (BLACK CONNECTOR Loosen the air cleaner connecting hose band screw For ease of air cleaner housing removal, remove the rear fender mounting bolts. Be careful not to Remove the two bolts and the air cleaner housing damage the con- from the frame. nectmg hose. HOUSING MOUNTING BOLTS Installation is in the reverse order of removal. Tighten the connecting hose band screw as shown. 6-42 12 ± 1 mm(0.5 + 0.04in) FUEL SYSTEM (PGM-FI) THROTTLE BODY REMOVAL NOTICE Before disconnecting fuel feed hose, relieve pressure from the system (page 6-32). Remove the following: - relieve the fuel pressure and disconnect the quick connect fitting (page 6-32). seat (page 3-4) air cleaner housing (page 6-41) Remove the trim clip and throttle body cover. Unhook and remove the MAP/TP sensor connector cover, then disconnect the MAP/TP sensor 5P (Black) connector. Disconnect the IACV 4P (Black) connector, injector 2P (Gray) connector and release the wire harness from the wire clamp. 5P (BLACK) CONNECTOR 4PJBLACK) CONNECTOR 2P (GRAY) CONNECTOR 6-43 FUEL SYSTEM (PGM-FI) Remove the fuel feed hose clamp screw. Remove the bolts and fuel injector holder and fuel injector. Remove the screw and throttle drum cover. THROTTLE DRUM COVER Loosen the throttle cable lock nut and adjusting nut then disconnect the throttle cable from the throttle drum and throttle body. Loosen the insulator band screw. Remove the throttle body from the insulator. 6-44 ADJUSTING NUT OCK NUT FUEL SYSTEM (PGM-FI) DISASSEMBLY NOTICE • The throttle body is factory preset. 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 white painted bolts, nuts and screws of the throttle body. • Always clean the throttle body before disassembly to prevent dirt and debris from entering the passages. • Do not remove the sensor unit unless it is replaced. For IACV replacement (page 6-56). If necessary, remove the screws and MAP/TP sensor unit from the throttle body. SENSOR UNIT Install a new O-ring into the groove of the throttle body. Install the new MAP/TP sensor unit while aligning the lug in the sensor unit with the throttle shaft. SCREWS SENSOR UNIT Align Tighten the screws to the specified torque. TORQUE: 3.4 N m (0.35 kgfm, 2.5 Ibfft) 6-45 FUEL SYSTEM (PGM-FI) TOP VIEW: YELLOW PAINTED THROTTLE DRUM VIEW: LEFT SIDE VIEW: YELLOW PAINTED WHITE PAINTED INSTALLATION Install the insulator and throttle body by aligning the boss and groove. Tighten the insulator band screws. 5.5+ 1 mm(0.22±0.04in) — • EJ 6-46 FUEL SYSTEM (PGM-FI) Connect the throttle cable to the throttle drum and throttle body. ADJUSTING NUT LOCK NUT THROTTLE DRUM THROTTLE CABLE END Install the throttle drum cover while aligning its boss with the groove in the throttle body. Install and tighten the screw. TORQUE: 1.5 N-m (0.15 kgf-m, 1.1 Ibf-ft) THROTTLE DRUM COVER Install the injector onto the throttle body. Connect the fuel feed hose and tighten the bolts to the specified torque. FUEL INJECTOR TORQUE: 5.1 N-m (0.53 kgf-m, 3.8 Ibf-ft) Install the fuel feed hose guide while aligning it hole with the throttle body boss, then install and tighten the screw to the specified torque. TORQUE: 4.2 N-m (0.43 kgf-m, 3.1 Ibf-ft) FEED HOSE CLAMP Route the wire harness to the throttle body and clamp it with wire clamp. Connect the fuel injector 2P (Gray) connector and IACV 4P (Black) connector. 4P (BLACK) CONNECTOR 2P (GRAY CONNECTOR WIRE CLAMP 6-47 FUEL SYSTEM (PGM-FI) Connect the MAP/TP sensor 5P (Black) connector. Install the MAP/TP sensor connector cover. After throttle cable disconnection, adjust the throttle lever free play (page 4-4). Install the throttle body cover and secure it with a trim clip. Install the air cleaner housing (page 6-41). Install the seat (page 3-4). INJECTOR REMOVAL NOTICE Before disconnecting fuel feed hose, relieve pressure from the system (page 6-32). Relieve the fuel pressure and disconnect the quick connect fitting (page 6-32). Remove the seat (page 3-4). Remove the trim clip and throttle body cover. 6-48 5P (BLACK) CONNECTOR FUEL SYSTEM (PGM-FI) Clean around the injector base with compressed air before removing the injector, and be sure that no debris is allowed to enter into the combustion chamber. 2P (GRAY) CONNECTOR Disconnect the injector 2P (Gray) connector. Remove the injector holder bolts. Release the fuel feed hose from the hose guide. Remove the injector from the fuel feed hose. Remove the O-ring and seal ring. SEAL RING • I N J E C T O R 4 CUSHION RING INSTALLATION Coat a new O-ring and new seal ring with engine oil. Replace the O-ring Install a new O-ring, new cushion ring and new seal and seal ring with ring, being careful not to damage them. new ones as a set. INJECTOR CUSHION RING Install the injector into the fuel feed hose, being careful not to damage the O-ring by aligning the boss of the injector and groove of the hose. 6-49 FUEL SYSTEM (PGM-FI) Set the fuel feed hose into the hose guide. Install the fuel feed hose/injector assembly to the throttle body, being careful not to damage the seal ring. 2P (GRAY) CONNECTOR Install and tighten the injector holder bolts to the specified torque. TORQUE: 5.1 N m (0.53 kgf-m, 3.8 Ibf-ft) Connect the injector 2P (Gray) connector. Install the throttle body cover and secure it with trim clip. ECT SENSOR REMOVAL/INSTALLATION Drain the coolant (page 7-6). Remove the left engine side cover (page 3-17). ECT SENSOR • 2P (BLACK) CONNECTOR Replace the ECT Disconnect the ECT sensor 2P (Black) connector sensor while the from the sensor. engine is cold. Remove the ECT sensor and O-ring. Always replace the Install the new O-ring and ECT sensor. O-ring with a new Tighten the ECT sensor to the specified torque. °ne TORQUE: 12 N-m (1.2 kgf m, 9 Ibf-ft) Connect the ECT sensor 2P (Black) connector. Install the fuel tank right side cover (page 3-6). Fill the cooling system with recommended coolant (page 7-6). 6-50 O-RING ^ H ECT SENSOR FUEL SYSTEM (PGM-FI) BANK ANGLE SENSOR INSPECTION Remove the right inner fender (page 3-9). Disconnect the bank angle sensor 3P (Green) connector and connect the inspection test harness. TOOL: Inspection test harness 07GMJ-ML80100 Turn the ignition switch ON and engine stop switch to "O". Measure the voltage between the test harness terminals. CONNECTION White(+) - Red(-) Red(+) - Green(-) STANDARD Battery voltage 0-1 V Turn the ignition switch OFF. Do not disconnect Remove the right bolt and loosen the left bolt. the bank angle Remove the bank angle sensor from left side of sensor connector grommet. during inspection. Connect the bank angle sensor 3P (Green) connector. Before you per- Place the bank angle sensor is normal position as form this test, turn shown, and ignition switch ON and engine stop the ignition switch switch "O", bank angle sensor is normal if the OFF, then turn the engine stop relay clicks and power supply is closed. ignition switch ON Incline the bank angle sensor approximately 70° to and engine stop the left or right with keep the ignition switch ON and switch 'O". engine stop switch "o" the bank angle sensor is normal if the engine stop relay clicks and power supply is open. 70° BANK ANGLE POSITION NORMAL POSITION 70° (approximately) (approximately) REMOVAL/INSTALLATION Remove the right inner fender (page 3-9). Disconnect the bank angle sensor 3P (Green) connector. 3P (GREEN) CONNECTOR 6-51 FUEL SYSTEM (PGM-FI) Remove the right side screw and loosen the left side screw. Remove the bank angle sensor from the left side grommet. Route the sensor Install the bank angle sensor with its "UP" mark facwire correctly ing up. (page 1-20). Tighten the mounting bolts to the specified torque. TORQUE: 1.5 N m (0.15 kgf m, 1.1 Ibf-ft) Connect the bank angle sensor 3P (Green) connector. Install the right inner fender (page 3-9). ENGINE STOP RELAY INSPECTION Remove the battery and battery case (page 20-6). Disconnect the relay module 8P (Gray) connector. 8P (GRAY) CONNECTOR 6-52 FUEL SYSTEM (PGM-FI) Connect the ohmmeter to the 8P (Gray) connector of the module side connector terminals. Connection: Black/blue - Red/yellow Connect a 12V battery to the 8P (Gray) connector of the module side connector terminals. RELAY MODULE 8P (GRAY) CONNECTOR (Module side of male terminal) —* A 1 \ Bl/W R/W s Connection: Black/white - Red/white k n 00DOis DC][ ] • There should be continuity only when the 12V battery is connected. UL-JU If there is no continuity when the 12V battery is connected, replace the relay. R/Y Bl/Bu I —@— _J PCM (POWERTRAIN CONTROL MODULE) PCM POWER GROUND LINE MALFUNCTION Engine does not start (No DTC and MIL blinking) 1. PCM Power Input Voltage Inspection • Before starting the inspection, check for loose or poor contact on the PCM 33P connectors and recheck the MIL blinking. Disconnect the PCM 33P connectors. Turn the ignition switch ON and engine stop switch "O". Measure the voltage between the PCM 33P (Gray) connector terminal and ground. TOOL: Test probe 07ZAJ-RDJA110 PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) Connection: B1 {+) - Ground (-) Does battery voltage exit? YES - GO TO STEP 2. NO - GO TO STEP 3. 2. PCM Ground Line Inspection Turn the ignition switch OFF. Check for continuity between the PCM33P (Gray) terminals and ground. TOOL: Test probe 07ZAJ-RDJA110 PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) 1 Connection: B2-Ground B10-Ground Is there continuities? YES - Replace the PCM with a new one, and recheck. NO - Open circuit in the Green wire. B1O B2 6-53 FUEL SYSTEM (PGM-FI) 3. Engine Stop Relay Inspection 1 Turn the ignition switch OFF. Disconnect the relay module 8P (Gray) connector. Turn the ignition switch ON and engine stop switch "o". Measure the voltage at the engine stop relay connector terminal of the wire harness side. RELAY MODULE 8P (GRAY) CONNECTOR (Wire side of female terminal) * 1r If >~ Til " 1 Does battery voltage exist? NO - • Faulty sub fuse. • Open circuit in the Black/blue wire. YES 1 Bl/Bu Connection: Black/blue (+) - Ground (-) (v) - G O TO STEP 4. 4. Engine Stop Relay Inspection 2 Turn the ignition switch OFF. Jump the engine stop relay connector terminals with jumper wire. Connection: Black/white - Red/white Turn the ignition switch ON and engine stop switch "(")"• Measure the voltage at the PCM 33P (Gray) terminal and ground. Connection: B1 -Ground (-) Does battery voltage exit? YES - • Inspect the engine stop relay (page 6-52). • Inspect the engine stop switch (page 23-7). • Inspect the bank angle sensor (page 6-51). NO - Open circuit in Black/white wire between the engine stop relay and the PCM. REMOVAL/INSTALLATION Remove the steering cover (page 3-5). Remove the PCM from the holder bracket. 6-54 JUMPER WIRE R/W | > / Bl/W / ^~A RELAY MODULE 8P (GRAY) CONNECTOR (Wire side of female terminal) FUEL SYSTEM (PGM-FI) Do not pull the wire Disconnect the PCM 33P (Black), 33P (Gray) and 5P harness while dis- (Black) connectors and then remove the PCM. connecting the PCM connectors. 33P (GRAY) CONNECTOR Install the PCM in the reverse order of removal. 5P (BLACK) CONNECTOR ENGINE IDLE SPEED IDLE SPEED INSPECTION NOTE: • Inspect the idle speed after all other engine maintenance items have been performed and are within specifications. • Before checking the idle speed, inspect the following items. - No DTC and MIL blinking - Spark plug condition (page 4-7) - Air cleaner condition (page 4-5) • 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 (min 1 ) or smaller that will accurately indicate a 50 rpm (min"') change. Remove the fuel tank left side cover (page 3-6). Start the engine and warm it up to coolant temperature 80 °C (176 °F). Stop the engine and connect a tachometer according to the tachometer manufacturer's instructions. Start the engine and let it idle. Check the idle speed. ENGINE IDLE SPEED: 1,400 + 50 rpm (min 1) If the idle speed is out of the specification, check the following: • Throttle operation and throttle lever free play (page 4-4). • Intake air leak or engine top-end problem (page 9-3) • IACV operation (page 6-56) 6-55 FUEL SYSTEM (PGM-FI) lACV INSPECTION The lACV is installed on the throttle body and is operated by the step motor. When the ignition switch is turned ON, the lACV operates for a few seconds. Check the step motor operating (beep) sound with the ignition switch turned ON. NOTE: The lACV operation can be checked visually as following: • Remove the lACV from the throttle body with its 4P (Black) connector in place, then turn the ignition switch ON. REMOVAL • Always clean the throttle body before the lACV removal to prevent dirt and debris from entering the lACV passage. Disconnect the lACV 4P (Black) connector. Remove the two screws, lACV retainer and lACV. lACV •4P(BLACK)CONNECTOR INSTALLATION Install new O-ring and seal plate onto the lACV. Install the lACV into the throttle body while aligning the valve slit with the guide pin in the throttle body. 6-56 FUEL SYSTEM (PGM-FI) Install the IACV retainer while aligning the valve boss with the groove in the retainer. Install and tighten the two screws to the specified torque. TORQUE: 2.1 N m (0.21 kgf-m, 1.5 Ibfft) Connect the IACV 4P (Black) connector. IACV H 4 P BLACK CONNECTOR 6-57 7. COOLING SYSTEM SYSTEM FLOW PATTERN 7-2 THERMOSTAT- SERVICE INFORMATION 7-3 RADIATOR RESERVE TANK 7-9 TROUBLESHOOTING 7-4 RADIATOR/COOLING FAN 7-10 SYSTEM TESTING 7-5 WATER PUMP 7-13 COOLANT REPLACEMENT- 7-6 •7-8 7-1 COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR THERMOSTAT RESERVE TANK WATER PUMP 7-2 COOLING SYSTEM SERVICE INFORMATION GENERAL iiWARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. ACAUTION Radiator coolant is toxic. Keep it away from eyes and mouth. • If any coolant gets in your eyes, rinse them with water and consult a physician immediately. • If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately. • If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. NOTICE Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passage. Using tap water may cause engine damage. Add coolant to the system at the reserve tank. Do not remove the radiator cap except to refill or drain the system. All cooling system service can be done with the engine in the frame. Avoid spilling coolant on painted surfaces. After servicing the system, check for leaks with a cooling system tester. For ECT sensor information (page 6-3). For coolant temperature indicator information (page 23-13). SPECIFICATIONS ITEM Radiator and engine Reserve tank Radiator cap relief pressure Begin to open Thermostat Fully open Valve lift Recommended antifreeze Coolant capacity Standard coolant concentration SPECIFICATIONS 2.0 liters (2.1 US qt, 1.8 Imp qt) 0.46 liter (0.49 US qt, 0.40 Imp qt) 108 - 137 kPa (1.1 - 1.4 kgf/cm 2 ,16-20 psi) 80 - 84°C 95°C 8 mm (0.3 in) minimum Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors 1:1 mixture with distilled water TORQUE VALUE Water pump impeller 12 N-m (1.2 kgfm, 9 Ibf-ft) 7-3 COOLING SYSTEM TOOLS Bearing remover shaft 07936-KC10100 Bearing remover head, 15 mm 07936-KC10200 Remover weight 0/741-0010201 or 07936-KC10500 or 07936-KC10500 or 07936-371020A or 07936-3710200 (U.S.A. only) Mechanical seal driver attachment 07945-4150400 or 07965-415000A (U.S.A. only) 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 Faulty temperature indicator drive circuit (page 23-13) Coolant leaks Faulty water pump mechanical seal Deteriorated O-rings Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or deteriorated hoses 7-4 COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the steering cover (page 3-5). The engine must be Remove the radiator cap. cool before removing the radiator cap, or severe scalding may result. Test the coolant gravity using a hydrometer. STANDARD COOLANT CONCENTRATION: 1:1 (distilled water and the recommended antifreeze) Look for contamination and replace the coolant if necessary. C CO o o 5 10 15 20 25 30 35 40 45 50 55 60 0 (32) 1.009 1.018 1.028 1.036 1.045 1.053 1.063 1.072 1.080 1.086 1.095 1.100 5 (41) 1.009 1.017 1.027 1.035 1.044 1.052 1.062 1.070 1.078 1.084 1.093 1.098 10 (50) 1.008 1.017 1.026 1.034 1.043 1.051 1.060 1.068 1.076 1.082 1.091 1.095 Coolant temperature C ( 30 15 20 25 (86) (68) (77) (59) 1.008 1.007 1.006 1.005 1.016 1.015 1.014 1.013 1.025 1.024 1.022 1.020 1.033 1.031 1.029 1.027 1.042 1.040 1.038 1.036 1.047 1.046 1.045 1.043 1.058 1.056 1.054 1.052 1.066 1.064 1.062 1.059 1.074 1.072 1.069 1.066 1.080 1.077 1.074 1.071 1.088 1.085 1.082 1.079 1.092 1.089 1.086 1.083 F) 35 (95) 1.003 1.011 1.018 1.025 1.034 1.041 1.049 1.056 1.063 1.068 1.076 1.080 40 (104) 1.001 1.009 1.016 1.023 1.031 1.038 1.046 1.053 1.060 1.065 1.073 1.077 45 50 (113) (122) 0.999 0.997 1.007 1.005 1.014 1.012 1.021 1.019 1.028 1.025 1.035 1.032 1.043 1.040 1.050 1.047 1.057 1.054 1.062 1.059 1.070 1.067 1.074 1.071 7-5 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 7-5). TESTER RADIATOR CAP Wet the sealing surfaces of the cap, then install the cap onto tester. TOOLS: Cooling system pressure tester Cooling system adaptor SVTS4AH OTCJ33984A Pressurize the radiator cap using the tester. Replace the radiator 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/cm2, 16 - 20 psi) Excessive pressure can damage the cooling system components- Do not exceed 137 kPa (1.4 kgf/cm2, 20 psi). Pressure test the radiator, engine and hoses, and check for leaks. TESTER Repair or replace components if the system will not hold the specified pressure for at least 6 seconds. Remove the tester and install the radiator cap. Install the steering cover (page 3-5). COOLANT REPLACEMENT PREPARATION NOTICE Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. NOTE: • The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant regularly as specified in the maintenance schedule. Mix only distilled, low mineral water with the recommended antifreeze. RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors RECOMMENDED MIXTURE: 1:1 (distilled water and the recommended antifreeze) 7-6 ANTIFREEZE SOLUTION (ETHYLENE GLYCOLBASE SOLUTION) LOW MINERAL OR DISTILLED WATER 'COOLANT COOLING SYSTEM REPLACEMENT/AIR BLEEDING NOTE: • When filling the system with a coolant, place the vehicle on a flat, level surface. Remove the steering cover (page 3-5). The engine must be cool before removing the radiator cap, or severe scalding may result. Drain the coolant from the system by removing the drain bolt and sealing washer on the water pump, and the radiator cap. Reinstall the drain bolt with a new sealing washer securely. DRAIN BOLT AND WASHER Disconnect the siphon hose from the reserve tank and drain the reserve coolant. Empty the coolant, remove the reserve tank cap and rinse the inside of the reserve tank with water. Reconnect the siphon hose. Fill the system with the recommended coolant up to the filler neck. Bleed air from the system as follows: 1. Shift the transmission into neutral. Start the engine and let it idle for 2 - 3 minutes. 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. Install the radiator cap. Fill the reserve tank to the upper level line and install the tank cap. Install the steering cover (page 3-5). 7-7 COOLING SYSTEM THERMOSTAT REMOVAL Drain the coolant from the system (page 7-7). Remove the fuel tank covers (page 3-5). Remove the throttle body cover (page 6-48). Loosen the band screw. Remove the trim clip and the air intake duct from the air cleaner housing. Remove the two bolts and thermostat cover. Remove the thermostat from the housing. INSPECTION Visually inspect the thermostat for damage. Replace the thermostat if the valve stays open at room temperature. Wear insulated gloves and adequate eye protection. Keep flammable materials away from the electric heating element. Do not let the thermostat or thermometer touch the pan, or you will get a false reading 7-8 Heat a container of water with an electric heating element for 5 minutes. Suspend the thermostat in heated water to check its operation. THERMOSTAT BEGIN TO OPEN: 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. THERMOSTAT THERMOMETER COOLING SYSTEM INSTALLATION Make sure the rubber seal on the thermostat is in good condition. Install the thermostat into the housing, aligning the hole with the lug. Install the thermostat and tighten the two bolts securely. Insert the air intake duct against the connecting tube and secure it onto the heat guard with the trim clip. Tighten the band screw securely. Fill and bleed the cooling system (page 7-6). Install the injector cover (page 6-48). Install the fuel tank covers (page 3-5). RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the front fender (page 3-12). BREATHER HOSE Remove the breather hose from the grill cover. Remove the mounting bolt. Release the boss on the tank bottom from the radia- | tor and drain the coolant. Disconnect the siphon hose to remove the reserve tank. Install the reserve tank in the reverse order of removal. Fill the reserve tank to the upper level line. 7-9 COOLING SYSTEM RADIATOR/COOLING FAN RADIATOR REMOVAL Remove the following: - GRILL COVEiR oil cooler (page 5-12) radiator reserve tank (page 7-9) left inner fender (page 3-9) Drain the coolant from the system (page 7-7). Remove the two trim clips (page 3-4) and each grill cover. Disconnect the breather hose (pink) from the frame pipe. Release the clip to free the fan motor wire and disconnect the motor 2P (White) connector. The engine must be Remove the radiator cap and the rubber heat guard cool before remov- from the filler neck. ing the radiator cap, Reinstall the radiator cap. or severe scalding may result. 2P (WHITE) CONNECTOR Disconnect the upper and lower water hoses. Be careful not to damage the radiator fins with the oil pipe. Remove the two mounting bolts. Release the mounting bosses on the radiator bottom from the frame and remove the radiator assembly while pulling the oil pipes aside. PIPES COOLING FAN DISASSEMBLY Release the fan motor wire and breather hose from the clamp of the motor stay, and disconnect the breather hose. Remove the three washer-bolts and stay/motor assembly from the radiator. HOSE CLAMP BOLTS 7-10 STAY/MOTOR COOLING SYSTEM Remove the nut and cooling fan. Remove the three bolts and fan motor. FLANGE NUT * COOLING FAN STAY MOTOR ASSEMBLY RADIATOR COOLING FAN FAN MOTOR STAY 7-11 COOLING SYSTEM Install the fan motor on the motor stay in the direction as shown and tighten the three bolts securely. CTAV Install the cooling fan on the fan motor shaft, aligning the flat surfaces. Apply locking agent to the motor shaft threads. Install the nut and tighten it. Install the stay/motor assembly onto the radiator and tighten the three washer-bolts securely. Connect the breather hose to the motor breather joint. Route the fan motor wire and breather hose through the clamp. FLANGE NUT HOSE CLAMP BOLTS 7-12 * COOLING FAN STAY/MOTOR COOLING SYSTEM INSTALLATION Be careful not to damage the radiator fins with the oil Pipe- Insert the bosses on the radiator bottom into the holes (mounting rubbers) in the frame to install the radiator assembly. Install the mounting bolts and tighten them. RADIATOR Connect the upper and lower water hoses, and tighten the hose clamps securely. Route the wire and Connect the fan motor 2P (White) connector and hose properly (page secure the wires with the clip. 1-20). Connect the breather hose (pink) to the frame pipe. Remove the radiator cap and install the rubber heat guard over the filler neck. Reinstall the radiator cap. Set the rubber heat guard properly (page 1-20). 2P WHITE) CONNECTOR Install the left and right grill covers with the trim clips (page 3-4). For the left grill cover, align the tab with the groove in the radiator. Install the following: - oil cooler (page 5-13) - radiator reserve tank (page 7-9) Fill and bleed the cooling system (page 7-6). After bleeding, install the following: - left inner fender (page 3-9) front fender (page 3-12) WATER PUMP MECHANICAL SEAL INSPECTION Check the drain hose for signs of coolant leakage. If there is leakage, the mechanical seal is defective, and the mechanical seal should be replaced. 7-13 COOLING SYSTEM REMOVAL Remove the following: - mud guard lid (page 3-7) - right front mud guard (page 3-8) - right inner fender (page 3-9) Drain the coolant from the system (page 7-7). Disconnect the water hoses and bypass hose from the water pump. Remove the following: - drain hose three cover bolts and sealing washer drain hose guide two mounting bolts pump cover O-ring water pump body O-ring GUIDE DRAIN HOSI BOLTS/SEALING WASHERS MECHANICAL SEAL REPLACEMENT Loosen the impeller by turning it counterclockwise while holding the pump shaft slot. WASHER IMPELLER Remove the following: - impeller assembly washer pump shaft thrust washer WASHER Remove the mechanical seal using the special tools. TOOLS: Remover head, 15 mm Bearing remover shaft Bearing remover, 15 mm Remover weight SHAFT MECHANICAL SEAL 07936-KC10200 07936-KC10100 or 07936-KC10500 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) BEARING REMOVER 7-14 COOLING SYSTEM Remove the oil seal. Apply engine oil to a new oil seal lips. Install the oil seal with the flat side facing out until it is flush with the pump body edge. Press a new mechanical seal in until it is seated. TOOL: Mechanical seal driver attachment Mechanical seal installer 07945-4150400 or 07965-415000A (U.S.A. only) Do not get oil on Install the thrust washer onto the pump shaft. the pump shaft Apply molybdenum disulfide solution to the sliding threads, surface of the pump shaft and insert the shaft into the pump body. IMPELLER WASHER Install the washer and impeller assembly, and tighten the impeller. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft) WASHER INSTALLATION Coat a new O-ring with engine oil and install it on the stepped section of the pump body. Install the water pump while turning the impeller engage the pump shafts. 7-15 COOLING SYSTEM Align the mounting bolt holes in the pump body and crankcase cover, and be sure the water pump is fully seated. Install a new O-ring into the pump body groove. Install the pump cover with the two mounting bolts fm'ii.DVraicD but do not tighten them. I PUMP COVER Install the drain hose guide while aligning its cut-out with the boss on the water pump cover. Note the installation Install the three cover bolts with a new sealing location of the seal- washer as shown, and tighten all the bolts in a crissing washer. cross pattern in several steps being careful not to pinch the O-ring. BOLTS/SEALING WASHERS Connect the water hoses and bypass hose, and secure them with the hose clamps. Fill and bleed the cooling system (page 7-6). Install the following: - 7-16 inner fender (page 3-9) front mud guard (page 3-8) mud guard lid (page 3-7) 8. ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS 8-2 ENGINE REMOVAL 8-4 SERVICE INFORMATION 8-3 ENGINE INSTALLATION 8-8 8-1 ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS 54 N-m (5.5 kgfm, 40 Ibf-ft) 54 N-m (5.5 kgfm, 40 Ibf-ft) 32 N-m (3.3 kgfm, 24 Ibf-ft) 6 kgfm, 12 Ibfft) 8-2 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • When removing/installing the engine, tape the frame around the engine beforehand for frame protection. • The following components require engine removal for service: - mainshaft and 2nd/3rd shift clutch (countershaft) (page 14-62) - crankshaft/balancer (page 13-2) SPCIFICATIONS ITEM SPECIFICATIONS Engine dry weight Engine oil capacity 60.4 kg (133.2 lbs) 2.7 liters (2.9 US qt, 2.4 Imp qt) 2.9 liters (3.1 US qt, 2.6 Imp qt) After draining After draining/filter change After disassembly Coolant capacity (radiator and engine) 4.1 liters (4.3 US qt, 3.6 Imp qt) 2.0 liters (2.1 US qt, 1.8 Imp qt) TORQUE VALUES Lower engine hanger nut (left and right) Upper engine hanger bolt Upper engine hanger bracket bolt Differential mounting bolt (10 mm) Differential mounting nut (10 mm) Differential mounting nut (8 mm) Gear selector arm pinch bolt 54 N-m 54 N-m 32 N-m 44 N-m 44 N-m 22 N-m 16 N-m (5.5 kgf-m, 40 Ibf-ft) (5.5 kgf-m, 40 Ibf-ft) (3.3 kgf-m, 24 Ibf-ft) (4.5 kgf-m, 33 Ibf-ft) (4.5 kgf-m, 33 Ibf-ft) (2.2 kgf-m, 16 Ibf-ft) (1.6 kgf-m, 12 Ibf-ft) 8-3 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 4-11). Drain the coolant (page 7-7). Remove the following: - front center grille (page 3-10) center mud guards (page 3-7) front mud guards (page 3-8) inner fenders (page 3-9) rear fender assembly (page 3-15) engine side covers (page 3-17) exhaust system (page 3-19) throttle body (page 6-43) heat guard plate (page 6-39) Remove the bolt and the left mud guard stays from the footpeg bracket. Disconnect the ECT sensor 2P (Black) connector. 2P(BLACK)CONNEClOH Remove the spark plug cap from the spark plug. Disconnect the water hose from the thermostat housing. Disconnect the alternator 5P (Natural) connector. Disconnect the gear position switch 3P (Natural) connector. 3P NATURAL CONNECTOR 5P NATURAL) CONNECTOR 8-4 ENGINE REMOVAL/INSTALLATION Disconnect the EOT sensor 2P (Black) connector. 2P (BLACK) CONNECTOR Remove the terminal cap, terminal nut and starter motor cable from the starter motor terminal. Remove the each bolt and then remove the each ground cable from the engine and frame. MOTOR CABLE GROUND CABLE Release the gearshift switch wire from the wire clamp. Remove the gearshift arm A pinch bolt and then remove the arm from the gearshift spindle. Remove the two holder bolts and gear selector cable. Reinstall the valve body cover after disconnecting the connectors to avoid damaging the solenoid valve. Remove the wire clip. Remove the two set bolts and shift valve body cover, and disconnect the following connectors: - shift solenoid A 2P (Black) and shift solenoid B 2P (Brown) connectors clutch PC solenoid 2P (Black) connector 8-5 ENGINE REMOVAL/INSTALLATION Remove the following: - oil pipes (by removing each joint bolt) water hose (from the water pump) Remove the differential mounting fasteners, spacer and bracket. Move the front differential forward to get the clearance for front propeller shaft removal. Pull the propeller shaft joint out of the output shaft. Remove the boot band from the dust boot and release the boot off the pinion joint of the differential. Pull the propeller shaft to force the stopper ring at the shaft end past the groove in the pinion joint and remove the propeller shaft. PROPELLER SHAFT JOINT Remove the upper engine hanger bolt and nut. Remove the upper engine hanger bracket bolts, bracket and mounting rubbers. 8-6 MOUNTING RUBBERS MOUNTING BOLT/NUT ENGINE REMOVAL/INSTALLATION Set suitable wooden blocks between the engine and lower frame pipe to support the engine for ease of bolt removal. Remove the left lower engine hanger nut, bolt and mounting rubbers. Remove the two bolts and hanger bracket. MOUNTING RUBBERS Remove the right lower engine hanger nut, bolt, spacer and mounting rubbers. SPACER • BOLT Move the engine forward and disconnect the output shaft from the rear propeller shaft. Remove the universal joint. Hold the engine Remove the engine out of the frame toward the left securely and take side. care not to damage the frame and NOTICE engine. Do not hold or strike the solenoid valves on the shift valve body during engine removal. Holding the solenoid valve or excessive shock may damage the solenoid valve. Remove the engine hanger bushings and dust seals. DUST SEAL 8-7 ENGINE REMOVAL/INSTALLATION Check the mounting rubbers, hanger bushings and dust seals for wear or damage. BUSHING MOUNTING RUBBERS ENGINE INSTALLATION NOTE: • Before installing the engine, install the valve body cover onto the shift valve body to avoid damaging the solenoid valve (page 8-11). • Route the wires, cables and hoses properly (page 1-20). Install the lower hanger bushings into the engine lower mounts. SEAL LIPS Install the dust seals with the lip side facing out. BUSHING Hold the engine Place the engine in the frame from the left side and securely and be support it with suitable wooded blocks. careful not to damage the frame and NOTICE engine. Do not hold or strike the solenoid valves on the shift valve body during engine removal. Holding the solenoid valve or excessive shock may damage the solenoid valve. Coat new O-rings with molybdenum disulfide grease and install them into the grooves in the output shaft and rear propeller shaft. Apply molybdenum disulfide grease to the universal joint splines (both sides) and install the universal joint onto the output shaft. Carefully move the engine and engage the universal joint on the engine with the propeller shaft. 8-8 ENGINE REMOVAL/INSTALLATION Be sure the univer- Set the right lower mounting portion of the engine sal joint is not dis- between the hanger stays on the frame. engaged. Install the mounting rubbers onto the right lower hanger bushing with the large I.D. side facing in. Install the spacer and the hanger bolt (from the front side) while aligning the bolt holes carefully. Loosely install the hanger nut. Install the mounting rubbers onto the left lower hanger bushing in the same manner as above. Install the hanger bracket and bolts, and the hanger bolt (from the front side) while aligning the bolt holes carefully. Loosely install the hanger nut. Install the mounting rubbers onto the upper hanger bushing in the same manner as above. Install the upper engine hanger bracket and the three bolts. After installing all the mounting fasteners and seat them, tighten the fasteners in order as follows: - left and right lower engine hanger nuts TORQUE: 54 N m (5.5 kgf-m, 40 Ibfft) - left lower engine hanger bracket bolts upper engine hanger bracket bolts TORQUE: 32 N m (3.2 kgf m, 24 Ibfft) - upper engine hanger bolt TORQUE: 54 N m (5.5 kgf-m, 40 Ibfft) Install a new stopper ring into the groove on the propeller shaft end. Apply 5 - 8 g of molybdenum disulfide grease to the pinion joint splines of the differential. Place the boot band over the propeller shaft. Install the propeller shaft into the pinion joint, aligning the joint and shaft 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 over the pinion joint securely and the boot band into the boot groove. 8-9 ENGINE REMOVAL/INSTALLATION Coat a new O-ring with molybdenum disulfide grease and install it in the output shaft groove. Apply molybdenum disulfide grease to the propeller shaft joint splines. Engage the propeller shaft joint over the output shaft, aligning the joint and shaft splines while moving the differential rearward. PROPELLER SHAFT JOINT Upper side: Align the mounting points of the differential and frame, and install the spacer (between the left side of the differential and frame) and 10-mm bolt from the right side. Install a new 10-mm nut. Lower side: Install the 10-mm bolt from the right side. Front side: Install the mounting bracket, 8-mm bolts and nut. Tighten the all the differential mounting fasteners. TORQUE: 10 mm nut: 44 N-m (4.5 kgf m, 33 Ibfft) 8 mm nut: 22 N-m (2.2 kgf m, 16 Ibfft) Coat new O-rings with engine oil and install them into each oil pipe grooves. Install the oil pipes to the joint with the oil pipe lug facing forward and tighten the bolts securely. Connect the water hose and tighten the clamp screw securely. 8-10 ENGINE REMOVAL/INSTALLATION Connect the clutch PC solenoid 2P (Black) connector and shift solenoid 2P (Black and Brown) connectors. Install the valve body cover and tighten the two set bolts. Install the wire clip over the wire and into the cover. Install the gear selector arm A by aligning the groove with the wide tooth of the spindle. Install the pinch bolt and tighten it. SELECTOR CABLE PINCH BOLT TORQUE: 16 N-m (1.6 kgfm, 12 Ibf-ft) Secure the selector cable onto the engine with the two cable holder bolts. Route the starter motor cables and ground cable properly. Install the ground cable onto the engine and frame, tighten the bolts securely. Install the starter motor cable eyelet to the motor terminal and install and tighten the terminal nut. Install the terminal rubber. MOTOR CABLE GROUND CABLE 8-11 ENGINE REMOVAL/INSTALLATION Connect the EOT sensor 2P (Black) connector. 2P(BLACKi CONNECTOR Connect the gear position switch 3P (Natural) connector. Connect the alternator 5P (Natural) connector. 3P (NATURAL) CONNECTOR 5P (NATURAL) CONNECTOR Connect the water hose to the thermostat housing, tighten the hose band. Install the spark plug cap to the plug. Connect the ECT sensor 2P (Back) connector. 8-12 ENGINE REMOVAL/INSTALLATION Hook the mud guard stays to the footpeg bracket and install the rear side stay on the frame with the washer-bolt. Check the gear selector lever for smooth operation. Install the following: - heat guard plate and fuel tank (page 6-39) throttle body (page 6-43) exhaust system (page 3-19) engine side covers (page 3-17) rear fender assembly (page 3-15) inner fenders (page 3-9) front mud guards (page 3-8) center mud guards (page 3-7) front center grille (page 3-10) Fill the engine with recommended oil (page 4-11). Fill and bleed the cooling system (page 7-6). Check the engine oil level (page 4-10). 8-13 9. CYLINDER HEAD/VALVE/CAMSHAFT SYSTEM COMPONENTS 9-2 CYLINDER HEAD INSPECTION 9-11 SERVICE INFORMATION 9-3 VALVE GUIDE REPLACEMENT 9-12 TROUBLESHOOTING 9-5 VALVE SEAT INSPECTION/REFACING 9-13 CYLINDER COMPRESSION 9-6 CAMSHAFT 9-16 CYLINDER HEAD COVER REMOVAL/ DISASSEMBLY CYLINDER HEAD ASSEMBLY 9-19 9-6 CYLINDER HEAD INSTALLATION 9-20 CYLINDER HEAD REMOVAL 9-9 CYLINDER HEAD COVER ASSEMBLY/ INSTALLATION 9-22 CYLINDER HEAD DISASSEMBLY - 9-10 9-1 CYLINDER HEAD/VALVE/CAMSHAFT SYSTEM COMPONENTS 55 N-m (5.6 kgfm, 41 Ibf ft) 32 N-m (3.3 kgf-m, 24 Ibf-ft) 18Nm 12 N-m (1.2 kgfm, 9 Ibf-ft) 54 N-m (5.5 kgf-m, 40 Ibf-ft) 9-2 CYLINDER HEAD/VALVE/CAMSHAFT 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 cleaning solvent and dry them by blowing them off with compressed air before inspection. • Rocker arm, valve and camshaft lubricating oil is fed through oil passages in the cylinder head and head cover. Clean the oil passages before assembling cylinder head and head cover. • Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. SPECIFICATIONS ITEM Cylinder compression at 350 rpm (min 1 ) Valve clearance Valve, valve guide Valve stem O.D. Valve guide I.D. Stem-to-guide clearance Valve spring Rocker arm Camshaftand cam follower Valve guide projection above cylinder head Valve seat width Free length Arm I.D. Shaft O.D. Arm-to-shaft clearance Cam lobe height Cam follower O.D. Follower bore I.D. Follower-to-bore clearance Cylinder head warpage IN EX IN EX IN/EX IN EX IN EX IN/EX Inner Outer IN/EX IN/EX IN/EX IN EX IN/EX IN/EX IN/EX STANDARD 550 kPa (5.6 kgf/cm2, 80 psi) 0.15 (0.006) 0.33(0.013) 5.475 - 5.490 (0.2156 - 0.2161) 5.455 - 5.470 (0.2148 - 0.2154) 5.500 - 5.512 (0.2165 - 0.2170) 0.010 - 0.037 (0.0004 - 0.0015) 0.030 - 0.057 (0.0012 - 0.0022) 14.8-15.2(0.58-0.60) 17.3-17.7(0.68-0.70) 1.0-1.1 (0.039-0.043) 37.20 (1.465) 44.20 (1.740) 12.000 - 12.018 (0.4724 - 0.4731) 11.964 - 11.984 (0.4710 - 0.4718) 0.016 - 0.054 (0.0006 - 0.0021) 35.015 - 35.175 (1.3785 - 1.3848) 35.394 - 35.554 (1.3935 - 1.3998) 22.467 - 22.482 (0.8845 - 0.8851) 22.510 - 22.526 (0.8862 - 0.8868) 0.028 - 0.059 (0.0011 - 0.0023) - Unit: mm (in) SERVICE LIMIT 5.45(0.215) 5.43 (0.214) 5.53(0.218) 0.12 (0.005) 0.14(0.006) 1.4 (0.06) 36.3 (1.43) 43.1 (1.70) 12.05 (0.474) 11.92 (0.469) 0.08 (0.003) 34.840 (1.3717) 35.144(1.3824) 22.46 (0.884) 22.54 (0.887) 0.07 (0.003) 0.05 (0.002) TORQUE VALUE Cylinder head cover cap nut Upper engine hanger bolt Upper engine hanger bracket bolt ECT sensor 55 N-m 54 N-m 32 N-m 12 N-m (5.6 kgf-m, 41 Ibf-ft) (5.5 kgfm, 40 Ibf-ft) (3.3 kgf-m, 24 Ibf-ft) (1.2 kgf-m, 9 Ibf-ft) Apply engine oil 9-3 CYLINDER HEAD/VALVE/CAMSHAFT TOOLS Valve spring compressor 07757-0010000 Valve guide driver, 5.5 mm 07742-0010100 Valve guide reamer, 5.5 mm 07984-2000001 or 07984-200000D (U.S.A. only) Valve seat cutter, 35 mm (45° IN/EX) 07780-0010400 Flat cutter, 38.5 mm (32° IN) 07780-0012400 Flat cutter, 35 mm (32° EX) 07780-0012300 or equivalent commercially available in U.S.A. or equivalent commercially available in U.S.A. dr equivalent commercially available in U.S.A. Interior cutter, 34 mm (60° IN/EX) 07780-0014700 Cutter holder, 5.5 mm 07781-0010101 lensioner holder B 072MG-MCAA400 or equivalent commercially available in U.S.A. or equivalent commercially available in U.S.A. cir 07AMG-001A100 (U.S.A. only) 9-4 CYLINDER HEAD/VALVE/CAMSHAFT TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-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 10-2). Compression too low, hard starting or poor performance at low speed • Valves: - Incorrect valve adjustment - Burned or bent valve - Incorrect valve timing - Broken valve spring - Uneven valve seating - Valve stuck open • Cylinder head: - Leaking or damaged cylinder head gasket - Loose spark plug - Warped or cracked cylinder head • Cylinder/piston problem (page 10-3) Compression too high, overheating or knocking • 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 • Cylinder/piston problem (page 10-3) 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 10-3) Rough idle • Low cylinder compression 9-5 CYLINDER HEAD/VALVE/CAMSHAFT CYLINDER COMPRESSION Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug cap and remove the spark plug (page 4-7). COMPRESSION GAUGE Install the compression gauge into the spark plug hole. TOOLS: Compression tester Adaptor EEPV303A MT26J200 Shift the transmission in neutral. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising. The maximum reading is usually reached within 4 - 7 seconds. COMPRESSION PRESSURE: 510 kPa (5.2 kgf/cm2, 74 psi) at 390 rpm (min1) Check that there is no leakage at the gauge connection. Low compression can be caused by: - blown cylinder head gasket 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/ DISASSEMBLY REMOVAL Remove the fuel tank and heat guard plate (page 639). Remove the following and set the piston position to Top Dead Center on the compression stroke (page 4-8): - 9-6 timing hole cap four bolts and valve adjusting hole caps VALVE ADJUSTING HOLE CAPS CYLINDER HEAD/VALVE/CAMSHAFT Remove the following: - spark plug cap seven bolts and three washers four cap nuts and washers cylinder head cover BOLTS AND SEALING WASHERS push rods gasket dowel pins Mark the push rods so they can be placed back in their original locations. - cam followers DISASSEMBLY Remove the two bolts and sealing washers. Push the rocker arm shaft with the small screwdriver through the bolt hole until the O-ring on the shaft is removed out of the head cover. BOLTS AND WASHERS ROCKER ARM SHAFTS 9-7 CYLINDER HEAD/VALVE/CAMSHAFT Mark all the parts Remove the following: so they can be _ r o c k e r a r m shafts placed back mthe.r _ r o c k e r a r m s ongmal locavons. _ w a v e w a s h e r s WAVE WASHERS ROCKER ARMS INSPECTION ROCKER ARM/SHAFT Check the rocker arms and shafts for wear or damage. If the rocker arm follower is worn or damaged, check the push rod and oil passages. Measure each rocker arm shaft O.D. SERVICE LIMIT: 11.92 mm (0.469 in) Measure each rocker arm I.D. SERVICE LIMIT: 12.05 mm (0.474 in) Subtract each rocker arm shaft O.D. from the corresponding rocker arm I.D. to obtain the rocker armto-shaft clearance. SERVICE LIMIT: 0.08 mm (0.003 in) PUSH ROD Check the push rods for wear or damage. If the push rod is worn or damaged, check the cam follower and camshaft. CAM FOLLOWER Check the cam follower and follower bore in the cylinder head for scoring, scratches or damage. Measure each follower O.D. SERVICE LIMIT: 22.46 mm (0.884 in) 9-8 CYLINDER HEAD/VALVE/CAMSHAFT Measure each follower bore I.D. SERVICE LIMIT: 22.54 mm (0.887 in) Subtract each follower O.D. from the corresponding bore I.D. to obtain the follower-to-bore clearance. SERVICE LIMIT: 0.07 mm (0.003 in) CYLINDER HEAD REMOVAL Remove the following: - thermostat (page 7-8) throttle body (page 6-43) exhaust pipe (page 3-19) cylinder head cover (page 9-6) Disconnect the ECT sensor 2P (Black) connector. If necessary, remove the ECT sensor and O-ring from the cylinder head. 2P BLACK CONNECTOR Remove the spark plug cap. Loosen the band screw and remove the insulator. Remove the following: - bypass hose from the cylinder head upper engine hanger bracket bolts upper engine hanger bolt hanger bracket and mounting rubbers 9-9 CYLINDER HEAD/VALVE/CAMSHAFT Do not strike the cylinder head too hard and do not damage the mating surface with a screwdriver. five bolts cylinder head CYLINDER HEAD - gasket dowel pins DOWEL PINS CYLINDER HEAD DISASSEMBLY To prevent loss of tension, do not compress the valve springs more than necessary. Remove the valve spring cotters using the valve spring compressor. TOOL: Valve spring compressor 07757-0010000 Mark all the parts Remove the following: so they can be - spring retainer placed back in their - inner and outer valve springs original locations. - valve - stem seal - spring seat VALVE SPRING SEAT STEM SEAL 9-10 CYLINDER HEAD/VALVE/CAMSHAFT CYLINDER HEAD INSPECTION CYLINDER HEAD Be careful not to Remove the carbon deposits from the combustion damage the gasket chamber, being careful not to damage the gasket surface, surface. Check the spark plug hole and valve areas for cracks. COMBUSTION CHAMBER Check the cylinder head for warpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) VALVE SPRING Measure the valve spring free length. SERVICE LIMITS: Inner: 36.3 mm (1.43 in) Outer: 43.1 mm (1.70 in) VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide. Check the valve for bending, burning or abnormal wear. Measure each valve stem O.D. and record it. SERVICE LIMITS: IN: 5.45 mm (0.215 in) EX: 5.43 mm (0.214 in) 9-11 CYLINDER HEAD/VALVE/CAMSHAFT Ream the valve guide to remove any carbon buildup before measuring the guide. Insert the reamer from the combustion chamber side of the cylinder head and always rotate the reamer clockwise. TOOLS: Valve guide reamer, 5.5 mm REAMER 07984-2000001 or 07984-200000D (U.S.A. only) Measure each valve guide I.D. and record it. SERVICE LIMIT: 5.53 mm (0.218 in) Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.12 mm (0.005 in) EX: 0.14 mm (0.006 in) Inspect and reface If the stem-to-guide clearance exceeds the service the valve seats limit, determine if a new guide with standard whenever the valve dimensions would bring the clearance within toler guides are replaced ance. (page 9-13). If so, replace any guides as necessary and ream to fit. If the stem-to-guide clearance exceeds the service limit with a new guide, also replace the valve. VALVE GUIDE REPLACEMENT Mark new valve guides at the specified height indicated below, using a marker. Chill the new valve guides in a freezer for about an hour. Be sure to wear heavy gloves to avoid burns when handling the heated cylinder head. Using a torch to heat the cylinder head may cause warpage. Heat the cylinder head to 130°C-140°C (275'F290°F) with a hot plate or oven. Do not heat the cylinder head beyond 150°C (300°F). Use temperature indicator sticks, available from welding supply stores, to be sure the cylinder head is heated to the proper temperature. Support the cylinder head and drive the valve guides out of the cylinder head from the combustion chamber side using the special tool. TOOL: Valve guide driver, 5.5 mm 07742-0010100 While the cylinder head is still heated, remove the new valve guides from the freezer and drive them into the cylinder head from the rocker arm side until the exposed height is at the specified value (at the mark). TOOL: Valve guide driver, 5.5 mm 07742-0010100 VALVE GUIDE PROJECTION: IN: 14.8-15.2 mm (0.58-0.60 in) EX: 17.3-17.7 mm (0.68-0.70 in) Let the cylinder head cool to room temperature. 9-12 VALVE GUIDE DRIVER CYLINDER HEAD/VALVE/CAMSHAFT Take care not to tilt or lean the reamer in the guide while reaming. Use cutting oil on the reamer during this operation. Ream the new valve guides. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise. TOOL: Valve guide reamer, 5.5 mm REAMER 07984-2000001 or 07984-200000D (U.S.A. only) Clean the cylinder head thoroughly to remove any metal particles after reaming and reface the valve seat (page 9-14). VALVE SEAT INSPECTION/REFACING INSPECTION Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coat of Prussian 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. The valve cannot be ground. If the valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve. Remove the valve and inspect the valve seat face. The valve seat contact should be within the specified width and even all around the circumference. STANDARD: 1.0 - 1.1 mm (0.039 - 0.043 in) SERVICE LIMIT: 1.4 mm (0.06 in) If the valve seat width is not within specification, reface the valve seat. ¥ mmmmawK ' I SEAT WIDTH Inspect the valve face for: • Damaged face: - Replace the valve and reface the valve seat. • Uneven seat width: - Replace the valve and reface the valve seat. DAMAGED FACE UNEVEN SEAT WIDTH 9-13 CYLINDER HEAD/VALVE/CAMSHAFT • Contact area (too high or too low) - Reface the valve seat. TOO HIGH TOO LOW REFACING NOTE: • Follow the refacer manufacturer's operating instructions. • Be careful not to grind the seat more than necessay. 45° 60° 32° If the contact area is too high on the valve, the seat must be lowered using a 32° flat cutter. CONTACT tOO HIGH If the contact area is too low on the valve, the seat must be raised using a 60° interior cutter. CONTACT TOO LOW OLD SEAT WIDTH Using a 45° seat cutter, remove any roughness or irregularities from the seat. TOOLS: Seat cutter, 35 mm (IN/EX) Cutter holder, 5.5 mm ROUGHNESS 07780-0010400 07781-0010101 or equivalent commercially available in U.S.A. 9-14 CYLINDER HEAD/VALVE/CAMSHAFT Using a 32° flat cutter, remove 1/4 of the existing valve seat material. TOOLS: Flat cutter, 38.5 mm (IN) Flat cutter, 35 mm (EX) Cutter holder, 5.5 mm OLD SEAT WIDTH 07780-0012400 07780-0012300 07781-0010101 or equivalent commercially available in U.S.A. Using a 60° interior cutter, remove 1/4 of the existing valve seat material. OLD SEAT WIDTH TOOLS: Interior cutter, 34 mm (IN/EX) 07780-0014700 Cutter holder, 5.5 mm 07781-0010101 or equivalent commercially available in U.S.A. Using a 45° seat cutter, cut the seat to the proper width. SEAT WIDTH VALVE SEAT WIDTH: 1.0 - 1.1 mm (0.039 - 0.043 in) Make sure all pitting and irregularities are removed. Excessive lapping pressure may deform or damage the seat. Do not allow lapping compound to enter the guides. After cutting the seat, apply lapping compound and engine oil to the valve face, and lap the valve using light pressure. Change the angle of lapping tool frequently to prevent uneven seat wear. HAND-LAPPING TOOL After lapping, wash any residual compound off the cylinder head and valve. Recheck the seat contact after lapping. 9-15 CYLINDER HEAD/VALVE/CAMSHAFT CAMSHAFT REMOVAL Remove the cylinder head (page 9-9). Remove the sealing bolt and washer on the cam chain tensioner lifter. Install the special tool so its blade is into the tensioner lifter and the tabs are just above the slots in the lifter (there should be space between the bottom of tool and lifter body). Then turn the tool clockwise until it stops turning and engage the tabs with the slots (the lifter shaft is fully secured with the special tool). TOOL: Tensioner holder B 07ZMG-MCAA400 or 07AMG-001A100 (U.S.A. only) Remove the four camshaft holder bolts. Suspend the cam chain with a piece of wire to prevent it from falling into the crankcase. Raise the holder plate so the dowel pins fitted in the camshaft holders are removed off the cylinder. Release the cam chain from the cam sprocket to remove the camshaft assembly and holder plate. Remove the camshaft holder B from the camshaft assembly. Do not forcibly remove the dowel pins from the camshaft holders. Remove the dowel pins. INSPECTION For cam chain ten- Check the sprocket teeth for wear or damage. sioner i er mspec y u m t ^ e c a r n s n a f t holder to check each bearing. ion, seepage Replace the camshaft assembly if the bearing does not turn smoothly and quietly. Check the cam surfaces for scoring, scratches or evidence of insufficient lubrication. Measure each cam lobe height. SERVICE LIMITS: IN: 34.840 mm (1.3717 in) EX: 35.144 mm (1.3824 in) 9-16 DOWEL PINS HOLDER B CYLINDER HEAD/VALVE/CAMSHAFT Check the decompressor cam operation. Press on the decompressor cam as shown. As you press on one side, the decompressor cam should lock above the base of the exhaust cam lobe. As you press on other side, the decompressor cam lobe should extend below the base of the exhaust cam lobe. Push Push DECOMPRESSOR CAM INSTALLATION Carefully rotate the crankshaft while holding the cam chain to avoid jamming the cam chain against the timing sprocket of the crankshaft. Turn the crankshaft clockwise using the recoil starter and align the "T" mark on the flywheel with the index notch in the crankcase cover. Retract the tensioner lifter shaft and secure it with the stopper tool (page 9-16). INDEX NOTCH Install the dowel pins if they are removed. Install the camshaft holder B onto the camshaft assembly. "T" MARK DOWEL PINS HOLDER B Before installing the camshaft, be sure the cylinder bolt (under the cam shaft) is tightened securely (page 109). Lubricate the camshaft bearings and cam chain with engine oil. Install the camshaft holder plate onto the camshaft holders, aligning the holes with the dowel pins. Place the camshaft assembly onto the cylinder and install the cam chain over the sprocket while aligning the timing marks (index lines) on the sprocket with the cylinder top surface and holder plate edge. Locate the dowel pins into the holes in the cylinder securely. Be sure the timing marks lines up with the cylinder top surface and holder plate edge. 9-17 CYLINDER HEAD/VALVE/CAMSHAFT Install the four holder bolts and tighten them. Apply molybdenum oil solution to the cam lobes. Make sure the tim- Remove the stopper tool, and install the sealing bolt ing mark on the with a new sealing washer and tighten it. sprocket aligns with Install the cylinder head (page 9-20). the cylinder surface when the "T" mark is aligned with the index notch. 9-18 SEALING WASHER BOLT CYLINDER HEAD/VALVE/CAMSHAFT CYLINDER HEAD ASSEMBLY COTTERS SPRING RETAINER OUTER VALVE SPRING INNER VALVE SPRING STEM SEAL SPRING SEAT VALVE GUIDE INTAKE VALVE EXHAUST VALVE Blow through the oil passage (stud bolt hole) in the cylinder head with compressed air. Install the valve spring seats and new stem seals. Lubricate the valve stem sliding surface with molybdenum oil solution. Insert the valve into the guide while turning it slowly to avoid damaging to the stem seal. VALVE SPRINGS RETAINER VALVE SPRING SEAT STEM SEAL Install the inner and outer valve springs with the tightly wound coils facing the combustion chamber. Install the spring retainer. Combustion chamber side 9-19 CYLINDER HEAD/VALVE/CAMSHAFT Grease the cotters Install the valve cotters using the valve spring cornto ease installation, pressor. To prevent loss of tension, do not TOOL: compress the valve Valve spring compressor springs more than necessary. 07757-0010000 Support the cylin- Tap the valve stems gently with two plastic hamder head so the mers to seat the cotters firmly. valve heads will not contact anything that cause damage. CYLINDER HEAD INSTALLATION Clean the mating surface of the cylinder and head. Install the dowel pins and a new gasket. Install the cylinder head on the cylinder. Tighten the cylin- Install the five bolts and temporarily tighten them. der head bolts after installing the cylinder head cover. 9-20 CYLINDER HEAD/VALVE/CAMSHAFT Install the mounting rubbers on the upper engine hanger bushing with the large I.D.side facing in. Install the upper engine hanger bracket and the three hanger bolts. Tighten the hanger Temporarily tighten the three bolts. bolts after installing Connect the bypass hose to the thermostat housing the cylinder head of the cylinder head. cover. Connect the sensor connector. Install the carburetor insulator, aligning the groove with the lug on the cylinder head. Tighten the insulator band screw until the band ends clearance is 5.5 mm. If the ECT sensor is removed, install a new O-ring onto the sensor. Install and tighten the ECT sensor to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibfft) Connect the ECT sensor 2P (Black) connector. Install the following: - spark plug (page 4-7) cylinder head cover (page 9-22) thermostat (page 7-9) throttle body (page 6-43) exhaust pipe (page 3-19) 2P (BLACK) CONNECTOR J 9-21 CYLINDER HEAD/VALVE/CAMSHAFT CYLINDER HEAD COVER ASSEMBLY/ INSTALLATION ASSEMBLY INTAKE ROCKER ARM EXHAUST ROCKER ARM WAVE WASHERS ROCKER ARM SHAFTS SEALING WASHERS SETTTING BOLTS Coat new O-rings with engine oil and install them in each groove on the rocker arm shafts. Apply molybdenum oil solution to the rocker arm shaft sliding surface. .—j^. ' Q • ROCKER ARM SHAFTS WAVE WASHERS Install the rocker arms, wave washers (setting bolt side) and arm shafts. Align the bolt holes in the head cover and rocker arm shaft by turning the shaft. Install the setting bolts with new sealing washers and tighten the bolts securely. SEALING WASHER 9-22 ROCKER ARM SHAFT CYLINDER HEAD/VALVE/CAMSHAFT INSTALLATION Turn the crankshaft using the recoil stater knob and align the "T" mark with the index notch, then check the cam lobes through the cam follower holes. If the cam lobes face up, rotate the crankshaft one full turn and match up the "T" mark again so the cam lobes face down. "T" MARK INDEX NOTCH Coat the cam followers with engine oil and install them into the cylinder head. Install the dowel pins and a new gasket. GASKET H PUSH RODS Install the push rods in the cam followers and rest them on the gasket cutout as shown. DOWEL PINS Apply engine oil to the rocker arm followers and adjusting screw tips. Installing the head cover incorrectly will result in severe engine damage. Do not tighten the head cover fasteners when the rocker arm are not aligned with the push rod end. HEAD COVER Install the cylinder head cover while holding the rocker arms that align the rocker arm followers with the push rod ends. Be sure to seat the rocker arm followers to the push rods properly by turning the crankshaft slowly with the recoil starter. 9-23 CYLINDER HEAD/VALVE/CAMSHAFT Apply engine oil to the cap nut threads and seating surfaces and install the following fasteners: - four washers and cap nuts three new washers and seven bolts Tighten the nuts and bolts in a crisscross pattern in several steps. TORQUE: Cap nut:55 N m (5.6 kgf m, 41 Ibf-ft) Install the spark plug cap. If the cylinder and/or cylinder head were removed, tighten the following: - three cylinder bolts - five cylinder head bolts - upper engine hanger bracket bolts TORQUE: 32 N m (3.3 kgf m, 24 Ibf-ft) - upper engine hanger bolt TORQUE: 54 N m (5.5 kgf m, 40 Ibf-ft) Install the following: - 9-24 valve adjusting hole caps and timing hole cap (page 4-10) heat guard plate and fuel tank (page 6-39) 10. CYLINDER/PISTON SYSTEM COMPONENTS 10-2 CYLINDER/PISTON REMOVAL 10-4 SERVICE INFORMATION 10-3 CYLINDER/PISTON INSPECTION 10-5 TROUBLESHOOTING 10-3 CYLINDER/PISTON INSTALLATION 10-8 10-1 CYLINDER/PISTON SYSTEM COMPONENTS 10-2 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. • When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. SPECIFICATIONS Unit: mm (in) ITEM Cylinder Piston, piston pin, piston ring I.D. Out-of-round Taper Warpage Piston O.D. at 20 (0.8) from bottom Piston pin hole I.D. Piston pin O.D. Piston-to-piston pin clearance Piston ring end Top gap Second Oil (side rail) Piston ring-to-ring groove clearance Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance Top Second STANDARD 102.000 - 102.015 (4.0157 - 4.0163) 101.960 - 101.990 (4.0142 - 4.0153) 23.002 - 23.008 (0.9056 - 0.9058) 22.994 - 23.000 (0.9053 - 0.9055) 0.002 - 0.014 (0.0001 - 0.0006) 0.25-0.35(0.010-0.014) 0.40-0.55(0.016-0.022) 0.20-0.70(0.008-0.028) 0.045 - 0.080 (0.0018 - 0.0031) 0.025 - 0.060 (0.0010 - 0.0024) 0.010 - 0.055 (0.0004 - 0.0022) 23.030 - 23.050 (0.9067 - 0.9075) 0.030 - 0.056 (0.0012 - 0.0022) SERVICE LIMIT 102.05(4.018) 0.05 (0.002) 0.05 (0.002) 0.05 (0.002) 101.90(4.012) 23.03 (0.907) 22.98 (0.905) 0.04(0.002) 0.5 (0.02) 0.7 (0.03) 0.9 (0.04) 0.095 (0.0037) 0.075 (0.0030) 0.19 (0.007) 23.06 (0.908) 0.08 (0.003) TORQUE VALUES Cylinder stud bolt See page 10-7 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 built-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 Abnormal noise • Worn piston pin or piston pin bore • Worn connecting rod small end • Worn cylinder, piston or piston rings 10-3 CYLINDER/PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL Remove the camshaft (page 9-16). Remove the following: - two bolts and cam chain tensioner lifter gasket bolt and water pipe O-ring TENSIONER LIFTER Do not strike the cylinder head too hard and do not damage the mating surface with a screwdriver. four bolts cylinder cam chain guide gasket dowel pins PISTON REMOVAL Place a clean shop towel over the crankcase to prevent the piston pin clip from falling into the crankcase. Remove the piston pin clips with pliers. Push the piston pin out of the piston and connecting rod, and remove the piston. 10-4 CYLINDER/PISTON Do not damage the Spread each piston ring and remove it by lifting up piston ring by at a point opposite the gap. spreading the end too far. Never use a wire Clean carbon deposits from the piston ring grooves brush; it will scratch with a ring that will be discarded. the groove. ^ CYLINDER/PISTON INSPECTION CYLINDER Inspect the cylinder bore for scratch or wear. Measure the cylinder I.D. at three levels in an X and Y axis. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 102.05 mm (4.018 in) Calculate the cylinder-to-piston clearance. Refer to page 10-6 for measurement of the piston O.D. SERVICE LIMIT: 0.19 mm (0.007 in) Calculate the cylinder taper and out-of-round at three levels in an X and Y axis. Take the maximum reading to determine the taper and out-of-round. 1 SERVICE LIMITS: Taper: 0.05 mm (0.002 in) Out of round: 0.05 mm (0.002 in) TOP 1 . . - - • • • N MIDDLE / BOTTOM N V 10-5 CYLINDER/PISTON Check the top of the cylinder for warpage with a straight edge and feeler gauge across the stud holes. SERVICE LIMIT: 0.05 mm (0.002 in) PISTON/PISTON RING Inspect the piston rings for smooth movement by rotating the them. The rings should be able to move in their grooves without catching. Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring-to-ring groove clearance. SERVICE LIMITS: Top: 0.095 mm (0.0037 in) Second: 0.075 mm (0.0030 in) Insert the piston ring into the bottom of the cylinder squarely using the piston crown. Measure the ring end gap. SERVICE LIMITS: Top: 0.5 mm (0.02 in) Second: 0.7 mm (0.03 in) Oil (side rail): 0.9 mm (0.04 in) Measure the piston O.D. at a point 20 mm (0.8 in) from the bottom and 90° to the piston pin hole. SERVICE LIMIT: 101.90 mm (4.012 in) Compare this measurement against the maximum cylinder I.D. measurement and calculate the cylinder-to-piston clearance (page 10-5). 10-6 CYLINDER/PISTON Measure the piston pin hole I.D. Take the maximum reading to determine the I.D. SERVICE LIMIT: 23.03 mm (0.907 in) Measure the piston pin O.D. at three points. SERVICE LIMIT: 22.98 mm (0.905 in) Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.04 mm (0.002 in) CONNECTING ROD Measure the connecting rod small end I.D. SERVICE LIMIT: 23.06 mm (0.908 in) Calculate the connecting rod-to-piston pin clearance. SERVICE LIMIT: 0.08 mm (0.003 in) CAM CHAIN TENSIONER LIFTER The lifter shaft should not go into the lifter body when it is pushed. When the shaft (inside of the body) is turned clockwise with a screwdriver, the lifter shaft should be pulled into the lifter body. The shaft should spring out of the body as soon as the screwdriver is released. CYLINDER STUD BOLT REPLACEMENT Thread two nuts onto the stud and tighten them together, and use a wrench on them to turn the stud bolt out. Install a new stud bolt in the direction as shown. - Front crankcase: 90033-HN8-0000 (Yellow mark on bolt head) Rear crankcase: 90032-HN8-0000 (No mark) Be sure to verify the stud height from the crankcase surface. Adjust the height if necessary. 10-7 CYLINDER/PISTON CYLINDER/PISTON INSTALLATION PISTON RING INSTALLATION Be careful not to Carefully install the piston rings into the piston ring damage the piston grooves with the markings facing up. and rings. NOTE: • Do not confuse the top and second rings. • To install the oil ring, install the spacer first, then install the side rails. Stagger the piston ring end gaps 120° apart from each other. Stagger the side rail end gaps as shown. PISTON INSTALLATION Place a clean shop towel over the crankcase to prevent the piston pin clip from falling into the crankcase. Apply molybdenum oil solution to the piston pin outer surface. Apply engine oil to the piston pin hole and connecting rod inner surface. Install the piston with the "IN" mark toward the intake side and insert the piston pin through the piston and connecting rod. Instal new piston pin clips. NOTE: • Make sure the piston pin clips are seated securely. • Do not align the clip end gap with the piston cutout. 10-8 MARKING TOP RING SECOND RING CYLINDER/PISTON CYLINDER INSTALLATION Clean the gasket surface of the crankcase thoroughly, being careful not to damage them, and being careful not to allow gasket material into the crankcase. Blow through the oil passage (stud bolt hole) in the cylinder with compressed air. CHAIN GUIDE Install the cam chain guide into the crankcase so its end rests in the groove properly. Install the dowel pins and a new gasket. Apply engine oil to the cylinder wall, piston outer surface and piston rings. Be careful not to Route the cam chain through the cylinder and install damage the piston the cylinder over the piston while compressing the rings and cylinder piston rings with your fingers. wall. Align the cam chain guide bosses with the grooves in the cylinder properly to seat the cylinder on the crankcase. Tighten the three Make sure that the cylinder touches the crankcase outside bolts again evenly. Install the four cylinder bolts and tighten after installing the them securely. cylinder head cover. BOLTS 10-9 CYLINDER/PISTON Install the cam chain tensioner lifter with a new gasket and tighten the two mounting bolts. Coat a new O-ring with coolant and install it on the water pipe. Connect the water pipe and secure it with the bolt. Install the camshaft (page 9-17). 10-10 11. ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS 11-2 RECOIL STARTER 11-5 SERVICE INFORMATION 11-3 ALTERNATOR STATOR/STARTER REDUCTION GEARS 11-9 TROUBLESHOOTING 11-4 FLYWHEEL/STARTER CLUTCH 11-14 11-1 ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS 108 Nm (11.0 kgfm, 80 Ibf-ft) 11-2 ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL • This section covers service of the recoil starter, alternator stator and flywheel/starter clutch. These parts can be serviced with the engine installed in the frame. • Crankshaft lubricating oil is fed through the oil passage in the alternator cover. Clean the oil passage before installing the alternator cover. • Be careful not to damage the mating surfaces of the alternator and crankcase covers when servicing. • Rear crankcase cover removal/installation (page 12-5). • Alternator stator inspection (page 20-8). • Starter motor servicing (page 22-6). SPECIFICATION ITEM Starter driven gear boss O.D. Torque limiter slip torque STANDARD 51.705 - 51.718 (2.0356 - 2.0361) 53-84N-m(5.4-8.6kgfm, 3 9 - 6 2 Ibfft) Unit: mm (in) SERVICE LIMIT 51.61 (2.032) TORQUE VALUES Starter clutch socket bolt Recoil starter driven pulley bolt 30 N-m (3.1 kgf-m, 22 Ibfft) 108 N-m (11.0 kgfm, 80 Ibfft) Alternator stator bolt CKP sensor mounting bolt 10 N-m (1.0 kgfm, 7 Ibfft) 6 N-m (0.6 kgfm, 4.3 Ibfft) Apply locking agent to the threads Apply engine oil to the threads and seating surface Apply locking agent to the threads TOOLS Flywheel holder 07725-0040000 Rotor puller 07733-0020001 Remover weight 07741-0010201 or equivalent commercially available in U.S.A. or 07933-3950000 (U.S.A. only) or 07936-371020A or 07936-3710200 (U.S.A. only) Attachment, 42 x 47 mm 07746-0010300 Attachment, 24 x 26 mm 07746-0010700 Pilot, 10 mm 07746-0040100 11-3 ALTERNATOR/STARTER CLUTCH Pilot, 30 mm 07746-0040700 Driver 07749-0010000 Searing remover shaft, 10 mm 07936-GE00100 dr 07936-GEOOAOO (U.S.A. only) Bearing remover head, 10 mm 07936-GE00200 Recoil pulley holder 07SMB-HM70100 or 07936-GEOOAOO (U.S.A. only) Torque limiter attachment D 070MJ-HN80100 riot available in U.S.A. Remover handle 07936-3710100 not available in U.S.A. TROUBLESHOOTING Starter motor turns, but engine does not turn • Faulty starter clutch • Damaged reduction gears or torque limiter 11-4 Ibrque limiter attachment B rj7YMJ-MCF0200 ALTERNATOR/STARTER CLUTCH RECOIL STARTER REMOVAL Remove the right side cover (page 3-5). CLAMP Remove the following: - four bolts and clamp recoil starter assembly BOLTS STARTER ROPE REPLACEMENT When the rope has broken or the pulley has rewound, align the rope holes by turning the pulley 51/2 turns counterclockwise and hold it. Pull the starter rope fully to align the rope holes in the drive pulley and housing, and secure the pulley with a vise pliers or equivalent tool to prevent the pulley from rewinding. GRIP HOUSING PULLEY Untie the starter rope and remove the rope. Insert a new starter rope through the pulley, housing and grip, 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. Rope ends DISASSEMBLY Replace the recoil Untie the starter rope and remove the starter grip to starter as an release the starter rope slowly while holding the assembly. drive pulley. Remove the center bolt (T30), and friction plate and spring. ROPE BOLT Remove the ratchet and spring. 11-5 ALTERNATOR/STARTER CLUTCH Wear eye pmtec- Carefully remove the starter drive pulley. tion and use care when removing the drive pulley and starter spring. The spring can pop out of the housing if care is not used. PULLEY Remove the starter rope from the drive pulley. Check the starter rope for wear or damage. Check the recoil starter spring for damage or broken. OUTER END ASSEMBLY Be sure to wear Install the starter spring by hooking the outer end heavy gloves when onto the starter housing as shown. installing the spring. SPRING OUTER END 11-6 ALTERNATOR/STARTER CLUTCH Insert the starter rope into the drive pulley and tie the rope end in a square knot (page 11-5). Set the rope end into the cavity as shown. SQUARE KNOT Wrap the rope around the pulley in a counterclockwise direction as viewed from the ratchet side as shown. Set the rope into the pulley cutout. ROPE CUTOUT Apply grease to the pulley pivot. PULLEY Install the pulley while hooking the inner end of the spring onto the pulley hook. Preload the starter spring by turning the pulley 2 turns counterclockwise and hold it. Route the rope end through the starter housing and starter grip holes while the pulley remains held in place. Tie the rope end in a square knot. 11-7 ALTERNATOR/STARTER CLUTCH Install the ratchet return spring by inserting the long end into the hole in the pulley. Apply grease to the ratchet pivot pin. Install the starter ratchet onto the pivot pin while setting the spring short end onto the ratchet groove properly. Install the friction spring onto the friction plate with the ends facing the pulley. Install the friction plate, aligning the holes in the plate with the pins on the pivot boss so the friction spring loop is against the ratchet pawl. Apply locking agent to the center bolt threads. Install the center bolt and tighten it. Check the recoil starter for smooth operation by pulling the grip. INSTALLATION Install the recoil starter assembly with the four bolts and clamp, and tighten the bolts in a crisscross pattern in several steps. Secure the alternator wire with the clamp. Install the right side cover (page 3-5). 11-8 SPRING HOLES PLATE ALTERNATOR/STARTER CLUTCH ALTERNATOR STATOR/STARTER REDUCTION GEARS ALTERNATOR COVER REMOVAL Remove the following: - air cleaner housing (page 6-41) recoil starter (page 11-5) - engine guard (page 3-17) 5P NATURAL CONNECTOR Drain the engine oil (page 4-11). Disconnect the alternator 5P (Natural) connector. Hold the recoil starter driven pulley using the special tool and loosen the bolt. TOOL: Recoil pulley holder 07SMB-HM70100 Remove the following: - bolt and O-ring driven pulley B PULLEY BOLT The cover (stator) is magnetically attracted to the flywheel, be careful during removal. ten bolts and four sealing washers alternator cover 11-9 ALTERNATOR/STARTER CLUTCH - starter torque limiter reduction gear gear shaft LIMITER SHAFT - dowel pins gasket GASKET DOWEL PINS INSPECTION Check the bearings in the alternator and rear crankcase covers. Turn the inner race of each bearing with your finger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the covers. Check the teeth of the reduction gears and torque limiter for abnormal wear or damage. 11-10 BEARINGS ALTERNATOR/STARTER CLUTCH Hold the torque limiter in a vise with the special tool. ATTACHMENT D Replace the torque Check the slip torque with the special tool and a limiter as an assem- torque wrench. bly - TOOLS: Torque limiter attachment B 07YMJ-MCF0200 (not available in U.S.A.) Torque limiter attachment D 070MJ-HN80100 (not available in U.S.A.) STANDARD SLIP TORQUE: 53 - 84 N m (5.4 - 8.6 kgf-m, 39 - 62 Ibfft) LIMITER / ; / ATTACHMENT B STATOR/CKP SENSOR REMOVAL/ INSTALLATION Remove the CKP sensor mounting bolts. STATOR BOLTS Release the wire grommet off the alternator cover. Remove the three bolts and alternator stator/CKP sensor assembly. For bearing replacement (page 11-11). IGNITION PULSE GENERATOR Install the stator/CKP sensor assembly onto the alternator cover. Apply sealant to the wire grommet seating surface and install the grommet into the cover groove securely. STATOR BOLTS Install and tighten the stator mounting bolts to the specified torque. TORQUE: 10 N m (1.0 kgfm, 7 Ibfft) Apply locking agent Install and tighten the CKP sensor mounting bolts to to the CKP sensor the specified torque. mountmg bolt threads. T0RQUE .6 N . m (Q 6 k g f , m 4 3 |bf.ft) CKPSENSOR BEARING REPLACEMENT Remove the stator and CKP sensor (page 11-11). FLYWHEEL BEARING OIL SEAL Remove the driven pulley oil seal. Drive the flywheel bearing out of the alternator cover. 11-11 ALTERNATOR/STARTER CLUTCH Remove the torque limiter bearings in the alternator and rear crankcase covers, using the special tools. BEARING REMOVER TOOLS: Bearing remover head, 10 mm 07936-GE00200 Remover shaft, 10 mm 07936-GE00100 Remover weight 07741-0010201 U.S.A. only tools: Bearing remover, 10 mm Remover handle Remover weight 07936-GE00A00 07936-3710100 07936-371020A or 07936-3710200 Drive new bearings in with the marks facing up. TOOLS: Torque limiter bearing: Driver Attachment, 24 x 26 mm Pilot, 10 mm Flywheel bearing: Driver Attachment, 42 x 47 mm Pilot, 30 mm 07749-0010000 07746-0010700 07746-0040100 07749-0010000 07746-0010300 07746-0040700 Install the stator and CKP sensor (page 11-11). ATTACHMENT/PILOT ALTERNATOR COVER INSTALLATION Blow through the oil passage in the alternator cover with compressed air. Clean the cover mating surfaces. Apply molybdenum oil solution to the gear teeth and splines. Install the reduction gear shaft into the crankcase and the reduction gear onto the gear shaft. Install the torque limiter. Install the two dowel pins and a new gasket. DOWEL PINS 11-12 ALTERNATOR/STARTER CLUTCH The cover (stator) is magnetically attracted to the flywheel, be careful not to get anything caught between these parts when installing. Carefully install the alternator cover. COVER Install the ten bolts with four new sealing washers and the clip stay, and tighten them in a crisscross pattern in several steps. NOTE: • The location for the bolt with sealing washer is marked A on the cover (inside of the recoil starter housing). Apply engine oil to the lips of a new oil seal, and install it into the alternator cover until it is seated. BOLTS/ «& Install the starter driven pulley, aligning the bosses with the grooves in the crankshaft. SEALING WASHER PULLEY Coat a new O-ring with engine oil and install it onto the pulley bolt. Apply engine oil to the pulley bolt threads and seating surface, and install the bolt. BOLT Hold the driven pulley using the special tool and tighten the bolt. TOOL: Recoil pulley holder 07SMB-HM70100 TORQUE: 108 N-m (11.0 kgf-m, 80 Ibfft) Route the wires Connect the alternator 5P (Natural) connector. properly Install the following: (page 1-20). 5P (NATURAL) CONNECTOR - recoil starter (page 11-8) - air cleaner housing (page 6-41) - engine guard (page 3-17) Fill the engine with recommended oil (page 4-11). 11-13 ALTERNATOR/STARTER CLUTCH FLYWHEEL/STARTER CLUTCH REMOVAL Remove the rear crankcase cover (page 12-5). Remove the flywheel and starter driven gear using the special tool. TOOL: Rotor puller 07733-0020001 or 07933-3950000 (U.S.A. only) Remove the needle bearing and thrust washer, and the woodruff key. STARTER CLUTCH DISASSEMBLY/ INSPECTION Make sure that the starter driven gear turns clockwise smoothly and does not turn counterclockwise. Remove the driven gear while turning it clockwise. Hold the flywheel with the special tool and remove the starter clutch bolts (T40). TOOL: Flywheel holder 07725-0040000 or equivalent commercially available in U.S.A. Remove the starter clutch assembly from the flywheel. 11-14 DRIVEN GEAR \ FLYWHEEL HOLDER BOLTS ALTERNATOR/STARTER CLUTCH Remove the sprag clutch from the clutch outer. Check the clutch outer and sprag clutch for abnormal wear or damage. CLUTCH OUTER SPRAG CLUTCH Check the starter driven gear teeth and needle bearing for wear or damage. Measure driven gear boss O.D. SERVICE LIMIT: 51.61 mm (2.032 in) STARTER CLUTCH ASSEMBLY Lubricate the sprag clutch with engine oil and install it into the clutch outer with the flanged side facing the flywheel side. Apply locking agent to the starter clutch bolt threads. Install the flywheel onto the clutch outer and the clutch bolts (T40). FLYWHEEL HOLDER Hold the flywheel with the special tool and tighten the bolts. TOOL: Flywheel holder 07725-0040000 or equivalent commercially available in U.S.A. TORQUE: 30 N m (3.1 kgf-m, 22 Ibfft) 11-15 ALTERNATOR/STARTER CLUTCH Install the starter driven gear while turning it clock- _„..„.. wise. INSTALLATION Lubricate the needle bearing with molybdenum oil solution. Install the washer and bearing onto the crankshaft. Install the woodruff key into the key groove. Clean any oil from the tapered portion of the crankshaft and flywheel thoroughly. Install the flywheel/starter driven gear by aligning the key-way with the key on the crankshaft. Apply engine oil to the pulley bolt threads and seating surface. Install the starter driven pulley, aligning the bosses with the grooves in the crankshaft, and secure it with the bolt. Hold the driven pulley using the special tool and tighten the bolt. TOOL: Recoil pulley holder 07SMB-HM70100 TORQUE: 108 N-m (11.0 kgf-m, 80 Ibf-ft) Loosen the pulley bolt, and remove the tool, bolt and driven pulley. Install the rear crankcase cover (page 12-7). 11-16 PULLEY HOLDER 12. SUB-TRANSMISSION/GEARSHIFT LINKAGE SYSTEM COMPONENTS 12-2 SUB-TRANSMISSION 12-9 SERVICE INFORMATION 12-3 GEAR SELECTOR LEVER LINKAGE 12-14 TROUBLESHOOTING 12-4 SELECTOR CABLE ADJUSTMENT 12-15 REAR CRANKCASE COVER 12-5 12-1 SUB-TRANSMISSION/GEARSHIFT LINKAGE SYSTEM COMPONENTS 16N-m(1.6kgfm,12lbfft) 12N-m(1.2kgfm, 9 Ibfft) 25 N-m (2.5 kgf-m, 18 Ibfft) 12-2 SUB-TRANSMISSION/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL • This section covers service of the sub-transmission and gearshift linkage (forward-reverse). These parts can be serviced with the engine installed in the frame. • Sub-transmission lubricating oil is fed through the oil passage in the rear crankcase cover. Clean the oil passage before installing the crankcase cover. • Be careful not to damage the crankcase and cover mating surfaces when servicing. • For automatic transmission service (page 14-3). SPECIFICATIONS ITEM Shift fork Reverse idle gear STANDARD 11.000-11.021 (0.4331-0.4339) 4.93-5.00(0.194-0.197) 10.966 - 10.984 (0.4317 - 0.4324) 13.000 - 13.034 (0.5118 - 0.5131) 12.966 - 12.984 (0.5105 - 0.5112) - I.D. Claw thickness Shaft O.D. Collar I.D. Shaft O.D. Collar-to-shaft clearance Unit: mm (in) SERVICE LIMIT 11.04 (0.435) 4.5(0.18) 10.96(0.431) 13.05(0.514) 12.93 (0.509) 0.10 (0.004) TORQUE VALUES Gear selector lever pivot nut Gear selector arm pinch bolt Gear selector cable lock nut Engine oil drain bolt 9 N-m (0.9 kgfm, 6.5 Ibfft) 16 N-m (1.6 kgf-m, 12 Ibfft) 26 N-m (2.7 kgf-m, 20 Ibfft) 25 N-m (2.5 kgf-m, 18 Ibfft) TOOLS Remover weight 07741-0010201 Attachment, 37 x 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 Driver 07749-0010000 Attachment, 28 x 30 mm 07946-1870100 or 07936-371020A or 07936-3710200 (U.S.A. Only) Pilot, 25 mm 07746-0040600 12-3 SUB-TRANSMISSION/GEARSHIFT LINKAGE Bearing remover, 17 mm 07936-3710300 Remover handle 07936-3710100 TROUBLESHOOTING NOTE: • Be sure the gear position indicator is not blinking (No drivetrain DTC) before checking the following (page 14-3). Excessive shift shock or Abnormal noise when shifting sub-transmission (D-N-R) 1. Shift condition check Check shift lever free play between the NeutralDrive and Neutral-Reverse. Is the free play the same for each gear? NO - Faulty gearshift linkage (page 12-4). YES - GO TO STEP 2. 2. Vehicle creep check Start the engine. Shift the sub-transmission in Drive position with the brake applied. Wait several seconds. Release the brake and check the vehicle condition. Does the vehicle creep? YES - Perform the inspection "Vehicle creeps when idling" on page 14-8 while applying the brake as same manner as above. NO - Adjust the selector cable (page 12-15). Hard to shift Bent shift fork claw Bent shift fork shaft Damaged shift drum guide groove Damaged shift fork guide pin Damaged gearshift spindle and drum teeth Damaged selector lever linkage Improperly adjusted selector cable Improperly installed gearshift spindle and drum Transmission jumps out of gear Worn gear and shifter dogs Worn gear shifter groove Bent shift fork shaft Broken shift drum stopper arm Weak or broken stopper arm spring Damaged shift drum center plate 12-4 SUB-TRANSMISSION/GEARSHIFT LINKAGE REAR CRANKCASE COVER REMOVAL Remove the following: - 3P (NATURAL) CONNECTOR left front mud guard (page 3-8) inner fenders (page 3-9) front center grille (page 3-10) center mud guards (page 3-7) engine side covers (page 3-17) engine guard (page 3-17) starter motor (page 22-6) final drive/sub-frame assembly (page 19-12) Disconnect the front propeller shaft from the output shaft (page 8-6). Disconnect the oil temperature sensor 2P (Black) connector and gear position switch 3P (Natural) connector. 2P (BLACK) CONNECTOR Release the gear position switch wire from the clamp on the cable holder. Shift the sub-transmission into neutral. Remove the following: - two cable holder bolts pinch bolt selector arm A Release the gear position switch wire from the wire clip on the oil filler pipe. GEAR POSITION SWITCH Remove the bolts, gear position switch and O-ring. Remove the following: - alternator cover and reduction gears (page 11-9) two pipe bolts oil filler pipe and O-ring two 8-mm bolts oil drain bolt, sealing washer and O-ring eleven 6-mm bolts side cover stays rear crankcase cover REAR CRANKCASE COVER DRAIN BOLT 12-5 SUB-TRANSMISSION/GEARSHIFT LINKAGE - two dowel pins oil joint collar and O-rings gasket JOINT COLLAR GASKET DOWEL PINS BEARING REPLACEMENT For replacement of the bearings in the crankcase, refer to page 13-10. OUTPUT SHAFT BEARING OUTPUT SHAFT BEARING Remove the output shaft oil seal. Press the needle bearing out of the crankcase cover. TOOLS: Driver Attachment, 28 x 30 mm Pilot, 25 mm 07749-0010000 07946-1870100 07746-0040600 Press in a new bearing until it is seated. TOOLS: Driver Attachment, 37 x 40 mm Pilot, 25 mm 07749-0010000 07746-0010200 07746-0040600 COUNTERSHAFT BEARING Remove the bearing using the special tools. TOOLS: Bearing remover, 17 mm Remover handle Remover weight 07936-3710300 07936-3710100 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) Drive a new bearing in with the sealed side facing down. TOOLS: Driver Attachment, 37 x 40 mm Pilot, 17 mm 12-6 07749-0010000 07746-0010200 07746-0040400 COUNTERSHAFT BEARING SUB-TRANSMISSION/GEARSHIFT LINKAGE INSTALLATION Blow through the oil passage in the crankcase cover with compressed air. Clean the crankcase and cover mating surfaces. Apply engine oil to the lips of new oil seals, and install them into the crankcase cover until they are fully seated. Coat new O-rings with engine oil and install them into the joint collar grooves. Install the oil joint collar into the crankcase. Install the two dowel pins and a new gasket. Make sure that the washers are installed on the output shaft, reverse idle shaft and gearshift spindle, and that the shift drum position is neutral as shown (switch pin groove is in positioned lengthwise). GASKET Install a new sealing washer onto the drain bolt. Coat a new O-ring with engine oil and install it into the drain bolt groove. DOWEL PINS 6 mm BOLTS STAYS Install the rear crankcase cover with the following fasteners: - eleven 6-mm bolts (with the side cover stays) two 8-mm bolts oil drain bolt Tighten the bolts in a crisscross pattern in several steps. TORQUE: Drain bolt: 25 N m (2.5 kgf-m, 18 Ibfft) REAR CRANKCASE COVER DRAIN BOLT Coat a new O-ring with engine oil and install it onto the oil filler pipe. Install the filler pipe with the two bolts. FILLER PIPE 12-7 SUB-TRANSMISSION/GEARSHIFT LINKAGE Coat a new O-ring with engine oil and install it into the groove in the gear position switch. Be careful not to damage the switch pin during installstion. O-RING I GEAR POSITION SWITCH Align the long end of the switch pin with the " N " mark. Install the switch by aligning the switch pin with the slot in the crankcase cover. Install the bolts and tighten it. Install the wire clip into the stay of the filler pipe. Install the alternator cover and reduction gears (page 11-12). Install the gear selector arm A by aligning the groove with the wide tooth of the spindle. Install the pinch bolt and tighten it. TORQUE: 16 N m (1.6 kgf m, 12 Ibf ft) Secure the selector cable onto the engine with the two cable holder bolts. Route the gear position switch wire properly, secure the wire with the clamp on the cable holder. Route the wires Connect the oil temperature sensor 2P (Black) conproperly (page 1- nector and gear position switch 3P (Natural) con20). nector. 3P (NATURAL) CONNECTOR Adjust the gear selector cable if necessary (page 12- 15). Connect the front propeller shaft over the output shaft (page 8-10). Install the following: - final drive/sub-frame assembly (page 19-27) starter motor (page 22-11) engine guard (page 3-17) engine side covers (page 3-17) center mud guards (page 3-7) inner fenders (page 3-9) front mud guard (page 3-8) front center grille (page 3-10) Fill the engine with recommended oil (page 4-10). 12-8 2P (BLACK) CONNECTOR SUB-TRANSMISSION/GEARSHIFT LINKAGE SUB-TRANSMISSION DISASSEMBLY Remove the rear crankcase cover (page 12-5). SHAFT/COLLAR/WASHER Remove the following: - washer idle gear (25T) gear shaft and gear collar (inner and outer) washer idle gear (16T) The output shaft can be removed at this time (page 12-10). (OUTPUT SHAFT) Remove the following: - FORK SHAFT shift fork shaft shift fork countershaft assembly Remove the shift drum while lifting the stopper arm with a screwdriver. Remove the following: - washer gearshift spindle pivot bolt stopper arm washer return spring STOPPER ARM RETURN'S PR ING GEARSHIFT SPINDLE j g BOLT B WASHER 12-9 SUB-TRANSMISSION/GEARSHIFT LINKAGE - washer output shaft (while holding the driven gear) output driven gear OUTPUT SHAFT Remove the washers on the shaft ends with a screwdriver and disassemble the countershaft. INSPECTION COUNTERSHAFT Check the gear dogs and teeth for abnormal wear or damage. COUNTERSHAFT SHIFTER Check the gear shifter for smooth operation. Check the gear shifter groove, dogs and splines for abnormal wear or damage. Check the counter shaft and bearings for abnormal wear or damage. R. GEAR D. GEAR OUTPUT SHAFT Check the gear teeth and splines for abnormal wear or damage. Check the output shaft for abnormal wear or damage. 12-10 SUB-TRANSMISSION/GEARSHIFT LINKAGE REVERSE IDLE GEAR Check the gear teeth for abnormal wear or damage. Check the splines of the gears and collar for abnormal wear or damage. COLLAR SHAFT Check the gear shaft and collar for abnormal wear or damage. Measure each end of the gear collar I.D. SERVICE LIMIT: 13.05 mm (0.514 in) Measure the shaft O.D. SERVICE LIMIT: 12.93 mm (0.509 in) Calculate the collar-to-shaft clearance. SERVICE LIMIT: 0.10 mm (0.004 in) SHIFT FORK AND SHAFT Check shift fork guide pin for abnormal wear or damage. Measure each shift fork claw thickness. SERVICE LIMIT: 4.5 mm (0.18 in) Measure the shift fork I.D. SERVICE LIMIT: 11.04 mm (0.435 in) Measure the shift fork shaft O.D. SERVICE LIMIT: 10.96 mm (0.431 in) SHIFT DRUM Replace the shift Check the guide groove for abnormal wear or dam- GEAR drum as an assem- age. bly. CENTER PLATE Check the drum center plate and shifter gear for abnormal wear or damage. GUIDE GROOVE 12-11 SUB-TRANSMISSION/GEARSHIFT LINKAGE GEARSHIFT SPINDLE Check the shifter gear and splines for abnormal wear or damage. INSTALLATION Apply locking agent to the pivot bolt threads. Install the spring, washer (between the crankcase and arm) and stopper arm with the bolt as shown and tighten the bolt. Install the snap ring into the spindle groove with the chamfered edge facing the crankcase cover side Install the shifter gear with the index line facing the snap ring, aligning the wide groove with the wide tooth. Install the gearshift spindle and rest it onto the stopper on the crankcase. Install the washer onto the spindle. Apply engine oil to the shift drum guide groove. Lift the stopper arm and install the shift drum so the index line on the spindle shifter gear is aligned between the punch marks. Turn the shift drum clockwise and set it in neutral position so its groove position is lengthwise. 12-12 SUB-TRANSMISSION/GEARSHIFT LINKAGE Apply engine oil to the bearings, gear teeth and sliding areas. Assemble the countershaft. WASHER LOCK WASHER GEAR SHIFTER REVERSE GEAR WASHER BEARING (20x24x17) OUTPUT DRIVE GEAR BEARING (20x24x12) LOCK WASHER : Bearings, Gear teeth and Sliding areas BEARING (20x24x17) The output shaft Install the countershaft assembly by engaging the may be installed splines. before installing the countershaft (page 12-13). COUNTERSHAFT Apply engine oil to the fork shaft outer surface. FORK SHAFT Before installation, Install the shift fork into the gear shifter groove and be sure that the drum guide groove. switch pin groove in Insert the fork shaft through the fork and install it the shift drum is into the crankcase. lengthwise as shown above. Apply engine oil to the gear teeth and set the output driven gear into the crankcase. Insert the output shaft through the driven gear and install it into the crankcase. Install the washer. OUTPUT SHAFT 12-13 SUB-TRANSMISSION/GEARSHIFT LINKAGE Install the gear shaft with the washer into the crank- I „ _ . . . „ case. 'UULLAM Install the idle gear (16T) onto the gear collar and install them onto the gear shaft. Install the idle gear (25T) and washer. Install the rear crankcase cover (page 12-5). GEAR SELECTOR LEVER LINKAGE DISASSEMBLY Remove the fuel tank (page 6-39). PIVOT NUT AND BOLT Loosen the pivot nut and remove the following: - return spring pinch bolt selector arm B lever/shaft assembly (from the pivot pipe) Remove the pivot nut and bolt to separate the selector lever from the pivot shaft. ASSEMBLY Apply grease to the pivot bolt groove. Install the selector lever into the pivot shaft with the pivot bolt and nut so the guide rod is facing toward the punch mark on the shaft bottom. Before installing, mark the spline of the shaft at the same position with the punch mark to indicate the aligning point for installing the selector arm. 12-14 Install the lever/shaft assembly while setting the guide rod into the selector gate slot. LEVER/SHAFT ASSEMBLY SUB-TRANSMISSION/GEARSHIFT LINKAGE Install the arm B by aligning the slit with the mark (punch mark). Install the pinch bolt and tighten it. TORQUE: 16 N m (1.6 kgf m, 12 Ibf-ft) Tighten the pivot nut. TORQUE: 9 N m (0.9 kgf m, 6.5 Ibf-ft) Install the return spring in the direction as shown. Apply grease to the gate groove. Check the selector lever for smooth operation. Adjust the selector cable if necessary (page 12-15). Install the fuel tank (page 6-39). SELECTOR CABLE ADJUSTMENT Remove the following: - fuel tank and head guard plate (page 6-39). left engine side cover (page 3-17) Loosen the cable lock nuts fully. 12-15 SUB-TRANSMISSION/GEARSHIFT LINKAGE Turn the ignition Operate the selector lever several times and shift switch ON and the sub-transmission into neutral. check that the neutral indicator comes on at this time. Make sure that the selector arm A stops at the center (neutral) position when setting the guide rod of the lever into the center (neutral) groove in the selector gate. Turn one of the lock nuts until it touches the cable holder while holding the cable. Then, turn the other nut in the same manner. Be sure the nuts are seated on the cable holder and tighten them together to secure the cable. TORQUE: 26 N m (2.7 kgf m, 20 Ibf-ft) Check that the selector lever operates properly. Install the following: - 12-16 left engine side cover (page 3-17) head guard plate and fuel tank (page 6-39). LEVER 13. CRANKCASE/CRANKSHAFT/BALANCER SYSTEM COMPONENTS 13-2 CRANKSHAFT SERVICE INFORMATION 13-3 CRANKCASE BEARING REPLACEMENT 13-10 CRANKCASE ASSEMBLY 13-12 TROUBLESHOOTING CRANKCASE SEPARATION 13-7 13-5 13-6 13-1 CRANKCASE/CRANKSHAFT/BALANCER SYSTEM COMPONENTS 13-2 CRANKCASE/CRANKSHAFT/BALANCER SERVICE INFORMATION GENERAL • The crankcase halves must be separated to service the crankshaft and A/T (mainshaft and 2nd/3rd shift clutch [countershaft]). To service these parts, the engine must be removed from the frame (page 8-2). • For A/T service (page 14-2). • Be careful not to damage the crankcase mating surfaces when servicing. SPECIFICATIONS Unit: mm (in) Crankshaft ITEM Runout Big end side clearance Big end radial clearance STANDARD 0.05 (0.002) 0.05-0.65(0.002-0.026) 0.006 - 0.018 (0.0002 - 0.0007) SERVICE LIMIT 0.15(0.059) 0.8 (0.03) 0.05 (0.002) TOOLS Remover weight 07741-0010201 Attachment, 37 x 40 mm 07746-0010200 Attachment, 42 x 47 mm 07746-0010300 Attachment, 52 x 55 mm 07746-0010400 Attachment, 62 x 68 mm 07746-0010500 Attachment, 20 mm I.D. 07746-0020400 Pilot, 17 mm 07746-0040400 Pilot, 20 mm 07746-0040500 Pilot, 35 mm 07746-0040800 or 07936-371020A or 07936-3710200 (U.S.A. only) 13-3 CRANKCASE/CRANKSHAFT/BALANCER Pilot, 40 mm 07746-0040900 Pilot, 28 mm 07746-0041100 Driver 07749-0010000 Remover handle 07936-3710100 Bearing remover, 17 mm 07936-3710300 Bearing remover, 20 mm 07&36-3710600 Assembly shaft 07965-VM00200 Threaded adaptor 07965-VM00300 Attachment, 78 x 90 mm 07GAD-SD40101 or 07931-ME4010B and 07931-HB3020A (U.S.A. Only) or 07931-KF00200 (U.S.A. only) Ball joint remover/installer 07WMF-HN00100 Assembly collar spacer 07AMF-HM8A100 (U.S.A. only) 13-4 Assembly collar 07&65-VM00100 CRANKCASE/CRANKSHAFT/BALANCER TROUBLESHOOTING Excessive engine noise • Worn or damaged connecting rod bearing • Worn crankshaft main journal bearing • Worn connecting rod small end • Worn balancer bearing • Worn, seized or chipped transmission gear • Worn transmission bearings Abnormal vibration • Improper balancer timing 13-5 CRANKCASE/CRANKSHAFT/BALANCER CRANKCASE SEPARATION Remove the following: CAM CHAIN engine (page 8-2) cylinder and piston (page 10-4) sub-transmission/gearshift linkage (page 12-9) flywheel/starter clutch (page 11-14) torque converter (page 14-60) 1st shift clutch (page 14-62) oil pump (page 5-5) cam chain oil pump drive chain pivot bolt cam chain tensioner and collar BOLT The crankcase bolts are loosened in a crisscross pattern in several steps. Remove the nine rear crankcase bolts. REAR CRANKCASE BOLTS Remove the five front crankcase bolts. FRONTCRANKCASE Place the crankcase assembly with the rear crankcase down. Do not pry the Remove the front crankcase while tapping it at sevcrankcase apart eral locations with a soft hammer. with a screwdriver. D . , ., Remove the following: - crankshaft bearing inner race - two dowel pins - oil joint collar and O-rings JOINT COLLAR 13-6 INNER RACE CRANKCASE/CRANKSHAFT/BALANCER Remove the oil strainers. 1 Clean each strainer screen thoroughly. Install the oil tank Install the strainers properly as shown. strainer with the thin edge facing the crankcase. OIL PAN STRAINER CRANKSHAFT REMOVAL Separate the crankcase (page 13-6). MAINSHAFT COUNTERSHAFT Remove the following: - oil strainers (page 13-7) mainshaft and countershaft For A/T service, see (page 14-64). Be careful not to Remove the crankshaft and balancer from the rear damage the crank- crankcase using a hydraulic press. Be sure to hold case mating sur- the crankshaft and balancer while pressing them face and crankshaft out of the crankcase. assembly. Remove crankshaft bearing using a bearing puller with a suitable protector. PULLER(Commercially available) BEARING NOTE: • Always replace the rear crankshaft bearing with a new one whenever the crankshaft is removed. PROTECTOR 13-7 CRANKCASE/CRANKSHAFT/BALANCER INSPECTION Set the crankshaft in a stand or V-blocks and measure the runout using a dial indicator. SERVICE LIMIT: 0.15 mm (0.059 in) 6 mm Measure the side clearance between the connecting rod big end and crank weight with a feeler gauge. SERVICE LIMIT: 0.8 mm (0.03 in) Measure the radial clearance at the connecting rod big end in an X and Y directions. SERVICE LIMIT: 0.05 mm (0.002 in) Check the balancer gear for wear or damage. 13-8 14 mm CRANKCASE/CRANKSHAFT/BALANCER CRANKSHAFT AND BALANCER 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 Attachment, 78 x 90 mm Pilot, 40 mm DRIVER 07749-0010000 07GAD-SD40101 07746-0040900 For other bearing replacement in the crankcase halves, see page 13-10. ATTACHMENT/PILOT Engage the crankshaft and balancer by aligning the index lines on the sides of the balancer drive and driven gears as shown, and install them together into the rear crankcase. BALANCER DRIVEN GEAR BALANCER DRIVE GEAR Assemble the special tools onto the crankshaft. Be careful not to let the connecting rod press against the crankcase mating surface while drawing. Draw the crankshaft into the bearing inner race by turning the assembly shaft while holding the shaft nut. TOOLS: Ball joint remover/installer Attachment, 20 mm I.D. Assembly shaft Threaded adapter U.S.A. only: Puller shaft Special nut Threaded adapter Assembly collar Assembly collar spacer REMOVER/INSTALLER ATTACHMENT 07WMF-HN00100 07746-0020400 07965-VM00200 07965-VM00300 07931-ME4010B 07931-HB3020A 07931-KF00200 07965-VM00100 07AMF-HN8A100 SHAFT ADAPTER After installing the crankshaft in, make sure the index line on the crank weight is aligned between the index lines on the balancer driven gear. 13-9 CRANKCASE/CRANKSHAFT/BALANCER Install the mainshaft and countershaft assemblies as a set into the rear crankcase. MAINSHAFT Install the oil strainers (page 13-7). Assemble the crankcase halves (page 13-12). CRANKCASE BEARING REPLACEMENT REAR CRANKCASE Remove the balancer, mainshaft and shift drum bearings with the special tools. TOOLS: Balancer and Shift Drum Bearings: Bearing remover, 17 mm 07936-3710300 Remover handle 07936-3710100 Remover weight 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) Mainshaft Bearing: Bearing remover, 20 mm Remover handle Remover weight 07936-3710600 07936-3710100 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) Drive the countershaft and output shaft bearings out of the rear crankcase. COUNTERSHAFT BEARING MAINSHAFT BEARING I BALANCER HEARING FOUTPUT SHAFT BEARING 13-10 CRANKCASE/CRANKSHAFT/BALANCER Apply engine oil to new bearings. Drive the bearings in with the marks facing up. The mainshaft bearing is installed with the sealed side facmg down. TOOLS: Mainshaft Bearing Driver Attachment, 42 x 47 mm Pilot, 20 mm 07749-0010000 07746-0010300 07746-0040500 Countershaft Bearing Driver Attachment, 52 x 55 mm Pilot, 28 mm 07749-0010000 07746-0010400 07746-0041100 ATTACHMENT/PILOT Balancer and Shift Drum Bearing Driver 07749-0010000 Attachment, 37 x 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 Output Shaft Bearing Driver Attachment, 62 x 68 mm Pilot, 28 mm 07749-0010000 07746-0010500 07746-0041100 FRONT CRANKCASE Remove the balancer and countershaft bearings with the special tools. TOOLS: Balancer Bearing: Bearing remover, 17 mm Remover handle Remover weight Countershaft Bearing: Bearing remover, 20 mm Remover handle Remover weight BEARING REMOVER 07936-3710300 07936-3710100 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) 07936-3710600 07936-3710100 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) Remove the oil feed pipe oil seal. Drive the mainshaft and crankshaft bearings out of the front crankcase. Apply engine oil to the lips of a new feed pipe oil seal. Install the oil seal with the flat side facing the crankcase until it is fully seated. COUNTERSHAFT BEARING MAINSHAFT BEARING BALANCER BEARING CRANKSHAFT BEARING 13-11 CRANKCASE/CRANKSHAFT/BALANCER Apply engine oil to new bearings. Drive the bearings in with the marks facing up. TOOLS: Mainshaft Bearing Driver Attachment, 62 x 68 mm Pilot, 35 mm The countershaft Countershaft Bearing bearing is installed Driver with the sealed Attachment, 42 x 47 mm side facing down. pj|ot 2n mm 07749-0010000 07746-0010500 07746-0040800 07749-0010000 07746-0010300 07746-0040500 ATTACHMENT/PILOT Crankshaft Bearing Driver Attachment, 78 x 90 mm 07749-0010000 07GAD-SD40101 Balancer Bearing Driver Attachment, 37 x 40 mm Pilot, 17 mm 07749-0010000 07746-0010200 07746-0040400 CRANKCASE ASSEMBLY Before installing the front crankcase cover, make sure the gear side surfaces (C1 and M l gears) of the countershaft and mainshaft are flush. Clean the front and rear crankcase mating surfaces thoroughly, being careful not to damage them. Blow through the oil passages in the crankcases with compressed air. Coat new O-rings with engine oil and install them into the joint collar grooves. Install the oil joint collar into the crankcase. 13-12 MAINSHAFT N COUNTERSHAFT CRANKCASE/CRANKSHAFT/BALANCER Install the two dowel pins. DOWEL PINS Install the bearing inner race onto the crankshaft with the flange side facing in. Make sure the mat- Apply liquid sealant (Three Bond 1215 or equivaing surfaces evenly lent) to the mating surface of the front crankcase. touch, that there is no clearance between the cases. Install the front crankcase over the rear crankcase, aligning the oil strainer pipe with the pipe hole. Install the five front crankcase bolts. Check that the mainshaft and crankshaft turns smoothly and quietly. BOLTS Install the nine rear crankcase bolts. REAR CRANKCASE Tighten all the crankcase bolts in a crisscross pattern in several steps. BOLTS 13-13 CRANKCASE/CRANKSHAFT/BALANCER Apply locking agent to the threads of the tensioner pivot bolt. Install the cam chain tensioner and pivot collar with the flange side of the collar facing to the crankcase. Install and tighten the cam chain tensioner pivot bolt. Install the oil pump drive and cam chains onto the crankshaft. Install the following: - oil pump (page 5-11) 1st shift clutch and torque converter (page 14-72) flywheel/starter clutch (page 11-16) sub-transmission/gearshift linkage (page 12-12) cylinder and piston (page 10-8) engine (page 8-8) PUMP DRIVE! 13-14 14. DRIVETRAIN SYSTEM SYSTEM COMPONENTS 14-2 GEARSHIFT SWITCH 14-45 SERVICE INFORMATION 14-3 DRIVE MODE SELECT SWITCH 14-46 SYMPTOM TROUBLESHOOTING 14-6 SHIFT VALVE BODY 14-47 DRIVETRAIN SYSTEM LOCATION 14-15 FRONT CRANKCASE COVER 14-54 DRIVETRAIN SYSTEM DIAGRAM 14-16 TORQUE CONVERTER REMOVAL 14-60 TORQUE CONVERTER INSPECTION 14-61 SHIFT CLUTCH/MAINSHAFT DISASSEMBLY 14-62 DRIVETRAIN CONNECTOR LOCATION • 14-17 DRIVETRAIN TROUBLESHOOTING INFORMATION 14-20 DRIVETRAIN DTC INDEX 14-24 SHIFT CLUTCH/MAINSHAFT ASSEMBLY 14-67 DRIVETRAIN DTC TROUBLESHOOTING 14-26 TORQUE CONVERTER INSTALLATION 14-73 GEAR POSITION SWITCH 14-44 14-1 DRIVETRAIN SYSTEM SYSTEM COMPONENTS 14 N-m (1.4 kgf-m, 10 Ibfft) 108 N-m (11.0 kgf-m, 80 Ibfft) 108 N-m (11.0 kgfm, 80 Ibf-ft) 21 N-m (2.1 kgfm, 15 Ibfft) 14-2 DRIVETRAIN SYSTEM SERVICE INFORMATION GENERAL • This "Drivetrain System" section covers service of the electrical system of the A/T (Automatic Transmission), selectable 4WD system and the mechanical system of the A/T. • Refer to "Front driving mechanism" for the front final clutch service (page 18-14). • Refer to "Technical Features" for the control and function of each components by the PCM (page 2-7). • 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. • A faulty drivetrain system is often related to poorly connected or corroded connectors. Check those connections before proceeding. • Read "Drivetrain Troubleshooting Information" carefully, and inspect and troubleshoot the drivetrain system according to the DTC. Observe each step of the procedures one by one. Note the DTC and probable faulty part before starting diagnosis and troubleshooting. • The PCM may be damaged if dropped. Also, if a connector is disconnected when current is flowing, the excessive voltage may damage the PCM. Always turn off the ignition switch before servicing. • The drive mode (2WD or 4WD) is changed electrically by operating front final clutch with the 2WD/4WD select switch. • The torque converter and 1st shift clutch can be serviced with the engine installed in the frame. To service the mainshaft and 2nd/3rd shift clutch (countershaft), the crankcase halves must be separated. For crankcase separation and assembly (page 13-6). • For sub-transmission (Forward-Neutral-Reverse) service (page 12-2). • The engine oil is used for A/T oil. For lubrication system service (oil pump and oil cooler) (page 5-2). • A/T and lubricating oil is fed through the oil passage in the front crankcase cover. Clean the oil passages before installing the crankcase cover. • Be careful not to damage the crankcase and cover mating surfaces when servicing. • Replace the torque converter as an assembly, when it is faulty. For Drivetrain System Troubleshooting The PCM (Powertrain Control Module) is integrated with the ECM (Engine Control Module), the TCM (Transmission Control Module) and the selectable 4WD system control. Therefore some detection items that are shared in the PGM-FI and drivetrain system 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 DTC for the Fuel system (page 6-13). 2. Gear position indicator blinks, 4WD indicator or DTC for the Drivetrain system (page 14-20). 3. Symptom of the A/T and selectable 4WD system operation (page 14-6). Refer to "PGM-FI Troubleshooting Information" for the general troubleshooting information (page 6-13). SPECIFICATIONS Line 1st, 2nd and 3rd clutch STANDARD 785 kPa (8.0 kgf/cm2, 114 psi) 785 kPa (8.0 kgf/cm2,114 psi) Unit: mm (in) SERVICE LIMIT — Initial clearance Disc thickness Plate thickness Return spring free length 0.7 - 0.9 (0.03 - 0.04) 1.88-2.00(0.074-0.079) 1.95-2.05(0.077-0.081) 33.8(1.33) worn out lining discoloration 31.8(1.25) ITEM Oil pressure at 5,000 rpm (min 1 ) Shift clutch (1st, 2nd and 3rd) TORQUE VALUES Oil pass bolt Primary driven gear lock nut 18 N-m (1.8 kgf-m, 13 Ibf-ft) 108 N-m (11.0 kgfm, 80 Ibfft) Stator shaft inner collar stopper pin Torque converter lock nut 14 N-m (1.4 kgf-m, 10 Ibf-ft) 108 N-m (11.0 kgf-m, 80 Ibf-ft) Oil feed pipe setting cap 21 N-m (2.1 kgf-m, 15 Ibf-ft) Lock nut: replace with a new one. Apply engine oil to the threads and seating surface. Stake. Apply locking agent to the threads. Lock nut: replace with a new one. Apply engine oil to the threads and seating surface. Stake. 14-3 DRIVETRAIN SYSTEM TOOLS Pressure gauge set 07406-0020005 Bearing remover weight 07741-0010201 Attachment, 42 x 47 mm 07746-0010300 or 07ZMJ-HN2A100 and 07AMJHN8A100 (U.S.A. only) Pilot, 17 mm 07746-0040400 or 07936-371020A or 07936-3710200 (U.S.A. only) Pilot, 25 mm 07746-0040600 Driver CI7749-0010000 Puller, 35 x 1.0 mm 07933-HA80000 Bearing remover handle 07936-3710100 Bearing remover, 17 mm 07936-3710300 or 07933-HB3000A (U.S.A. only) Compressor bolt assembly 07GAE-PG40200 Clutch compressor attachment 07LAE-PX40100 (2 required) Inspection adaptor 07GMJ-ML80100 or 07GAE-PG4020A (U.S.A. only) 14-4 DRIVETRAIN SYSTEM SCS connector 070PZ-ZY30100 HDS pocket tester TDS 3557-0112-01 (U.S.A. only) Test probe 07ZAJ-RDJA110 14-5 DRIVETRAIN SYSTEM SYMPTOM TROUBLESHOOTING GENERAL INFORMATION If the ATV has any A/T trouble, check the DTC or gear position indicator blinking, refer to the DTC index and begin the appropriate troubleshooting procedure (page 14-24) If there are no DTC stored in the PCM memory, do the troubleshooting as following symptom and then inspect the oil pressure and diagnose according to the troubleshooting chart (page 14-14). Symptom Acceleration control failure Shift control failure Gear position indicator indicates "--" but no DTC set Gear position indicator indicates " - - " and MIL is stays ON at all (No DTC set) Diagnosis procedure Refer to the following symptom troubleshooting (page 14-6): • Vehicle does not accelerate • Excessive starting shock • Vehicle creeps (vehicle does not stop) when idling • Driving power falls off when accelerating (insufficient engine brake) • Engine stalls when accelerating Refer to the following symptom troubleshooting (page 14-9): • A/T does not shift • When shifting in the AUTO (automatic:) mode, excessive shift shock, engine rpm ( m i l ) ' rises or driving power falls off Refer to the following symptom troubleshooting (page 14-10): • A/T does not shift • Gear position indicator displays " - - " and drive mode indicator "ESP" stays on Check the DLC circuit (Brown/red wire) for short circuit. Also check for • Engine oil level (page 410) • Oil pressure (page 14-12) • Emergency valve • Engine oil level (page 410) • Oil pressure (page 14-12) • Combination meter circuit • Short circuit in the DLC related wire STARTING CONTROL FAILURE Vehicle Does Not Accelerate 1. A/T Clutch Pressure Control Solenoid Operation Sound Check Put the gear selector lever in the Drive or Reverse position. Check for a "click" sound from the A/T clutch pressure control solenoid when the ignition switch is ON. Is there sound? 14-6 NO - GO TO STEP 2. YES - G O TO STEP 3. A/T CLUTCH PRESSURE CONTROL SOLENOID DRIVETRAIN SYSTEM 2. A/T Clutch Pressure Control Solenoid Operation Check Remove the valve body cover (page 14-47). Disconnect the A/T clutch pressure control solenoid 2P (Black) connector. Connect a 12 V battery to the solenoid terminals. It should operate (sounds) when the battery is connected. 2P BLACK CONNECTOR Does the solenoid operate? NO - Faulty A/T clutch pressure control solenoid. YES - Test-ride the vehicle and check the gear position indicator (page 14-44). 3. Vehicle Test-riding Accelerate the vehicle with the mode select switch at ESP. Check the acceleration performance with the transmission in the 2nd and 3rd ranges. Does the vehicle accelerate with the transmission in 2nd and 3rd? YES - Faulty 1st shift clutch system (page I486) NO - Hydraulic circuit malfunction is the likely cause. Check the oil pressure (page 14-12). Excessive Acceleration Shock 1. Vehicle Test-riding Accelerate the vehicle with the mode select switch at ESP. Check for acceleration shock with the transmission in the 2nd and 3rd ranges. Is there acceleration shock with the transmission in 2nd and 3rd? NO - Faulty 1st shift clutch system (page 1466) YES - Hydraulic circuit malfunction is the likely cause. Check the oil pressure (page 14-12). 14-7 DRIVETRAIN SYSTEM Vehicle Creeps (vehicle does not stop) When Idling 1. Vehicle Test-riding NOTE: • Be sure the emergency valve is not active, that the stopper bolt is secured with the lock plate as shown. If it is turned all the way in (active), the transmission will be fixed in 2nd range and the vehicle creeps when idling. For emergency valve information (page 14-47). LOCK PLATE Start the engine and shift the sub-transmission in drive position with the mode select switch at ESP. Check the acceleration performance (creep) with the transmission in the 2nd and 3rd ranges. Does the vehicle creep with the transmission in 2nd and 3rd? NO - Faulty 1st shift clutch system (page I486) YES - Hydraulic circuit malfunction is the likely cause. Check the oil pressure (page 14-12). Driving Power Falls Off (insufficient engine brake) When STOPPER EiOLT Accelerating 1. A/T Clutch Pressure Control Solenoid Operation Sound Check Put the gear selector lever in the Drive or Reverse position. Check for a "click" sound from the A/T clutch pressure control solenoid when the ignition switch is ON. ATT CLUTCH PRESSURE CONTROL SOLENOID Is there sound? NO - GO TO STEP 2. YES - GO TO STEP 3. 2. A/T Clutch Pressure Control Solenoid Operation Check Remove the valve body cover (page 14-47). Disconnect the A/T clutch pressure control solenoid 2P (Black) connector. Connect a 12 V battery to the solenoid terminals. It should operate when the battery is connected. Does the solenoid operate? 14-8 NO - Faulty A/T clutch pressure control solenoid. YES - Test-ride the vehicle and check the gear position indicator (page 14-20). 2P (BLACK) CONNECTOR DRIVETRAIN SYSTEM 3. Vehicle Test-riding Test-ride the vehicle with the mode select switch at ESP. Check for engine braking with the transmission in the 2nd and 3rd ranges. Is there engine braking with the transmission in any range except 1st? YES - Faulty 1st shift clutch system (page I486) NO - Hydraulic circuit malfunction is the likely cause. Check the oil pressure (page 14-12). Engine Stalls When Accelerating 1. Vehicle Creep Check NOTE: • Perform this test after engine idle speed inspection (page 6-55). Start the engine. Shift the sub-transmission in drive position with the brake applied. Wait several seconds. Release the brake and check the vehicle condition. Does the vehicle creep? YES - Perform the inspection "Vehicle creeps when idling" on while applying the brake in the same manner as above (page 14-8). NO - Hydraulic circuit malfunction is the likely cause. Check the oil pressure (page 14-12). SHIFT CONTROL FAILURE A/T Does Not Shift 1. Vehicle Test-riding Test-ride the vehicle with the mode select switch at ESP. Check that it shifts to each range. Does the vehicle shift? YES - • Faulty throttle position sensor system. Check the installation condition (page 6-43). • Faulty VS sensor system. Check the installation condition (page 18-30). NO - GO TO STEP 2. 2. Shift Solenoid Valve Operation Check Disconnect the shift solenoid valve 2P (Black) and 2P (Brown) connectors. Connect a 12 V battery to each solenoid terminals. It should operate (sounds) when the battery is connected. Does the solenoid valves operate? NO - Faulty shift solenoid valve A and/or B. YES - Hydraulic circuit malfunction is likely cause. Check the oil pressure (page 1412). 14-9 DRIVETRAIN SYSTEM When Shifting in the AUTO (automatic) Mode, Excessive Shift Shock, Engine rpm (min') Rises or Driving Power Falls Off 1. Vehicle Test-riding Test-ride the vehicle with the mode select switch at ESP. Check above symptoms when shifting with the ESP shift switch. Are there repeated symptoms? YES - • Faulty throttle position sensor system. Check the installation condition (page 6-43). • Faulty VS sensor system. Check the installation condition (page 18-30). NO - Hydraulic circuit malfunction is likely cause. Check the oil pressure (page 1412). " - - " GEAR POSITION INDICATOR INDICATE BUT NO DTC SET A/T Does Not Shift 1. Shift Solenoid Valve Inspection When Shifting to " 1 " Put the gearshift lever in "D" (drive) and turn the drive mode select switch to "ESP". Shift the transmission into " 1 " (first gear) with the gearshift switch and check shift solenoid valve A. SHIFT SOLENOID VALVE B Does Shift Solenoid Valve A Operate? NO - Faulty shift solenoid valve A. YES - GO TO STEP 2. SHIFT SOLENOID VALVE A 2. Shift Solenoid Valve Inspection When Shifting to "2" Shift the transmission into " 2 " (second gear) with the gearshift switch and check shift solenoid valves A and B. Do Shift Solenoid Valves A or B Operate? NO - GO TO STEP 3. YES - • Faulty shift solenoid valve A. • Faulty shift solenoid valve B. 3. Shift Solenoid Valve Inspection When Shifting to "3" Shift the transmission into "3" (third gear) with the gearshift switch and check shift solenoid valve B. Does Shift Solenoid Valve B Operate? 14-10 NO - Faulty shift solenoid valve B. YES - No problem (Temporary Failure). t DRIVETRAIN SYSTEM GEAR POSITION INDICATOR DISPLAYS "- -" AND DRIVE MODE INDICATOR "ESP" STAYS ON 1. PCM Connector Inspection Turn the ignition switch OFF. Remove the steering cover (page 3-5). Seal the PCM connector with tape to prevent dirt and oil from entering the connector after disconnecting the 33P connector. Disconnect the PCM 33P connectors. Check the connector for loose contacts or corroded terminals. Is the connector in good condition? NO - Loose or poorly connected PCM 33P connectors. YES - GO TO STEP 2. 2. Combination Meter Connector Inspection Remove the combination meter 14P (Gray) connector and disconnect it. Check the connector for loose contacts or corroded terminals. Is the connector in good condition? NO - Loose or poorly connected combination meter 14P (Gray) connector. YES - GO TO STEP 3. 14P (GRAY) CONNECTOR 3. LCD Line Open Circuit Inspection Be careful not to bend the connector terminals. Check the LCD wires for continuity between the combination meter and PCM connectors terminals. COMBINATION METER 14P (GRAY) CONNECTOR (Wire side of male terminal) Is there continuity? NO YES - • • • • • Open circuit Open circuit Open circuit Open circuit Open circuit - GO TO STEP 4. in the in the in the in the in the Pink/blue wire. Blue/white wire. Light blue wire. Blue wire. Orange wire. PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) 14-11 DRIVETRAIN SYSTEM 4. LCD Short Circuit Inspection Check the LCD wires for continuity between the combination meter connector terminals of the wire harness side and ground. COMBINATION METER 14P (GRAY) CONNECTOR (Wire side of male terminal) Is there continuity? YES - • Short Short Short Short Short circuit circuit circuit circuit circuit NO - GO TO STEP 5. in the in the in the in the in the Pink/blue wire. Blue/white wire. Light blue wire. Blue wire. Orange wire. 5. Shift Solenoid Valve Inspection Connect the PCM 33P and combination meter 14P (Gray) connectors. Perform the troubleshooting of "A/T Does Not Shift" (page 14-10). When connecting the PCM 33P connectors, check that there is no dirt and oil in the connector. Are the shift solenoid valves in good condition? NO - Faulty shift solenoid valves A and/or B. YES - Faulty PCM. OIL PRESSURE CHECK NOTE: • After checking each oil pressure, perform the inspection and cleaning according to the troubleshooting chart (page 14-14). • Failure to warm the engine will cause very high oil pressure readings. External leaks will cause low oil pressure readings. Check the oil level and add the recommended engine oil if necessary (page 4-10). Also, warm the engine to normal operating temperature and check for external leaks. Be careful not touch the rotating wheels during inspection. Support the vehicle using a hoist or equivalent and raise all the wheels off the ground. For line pressure: Remove the sealing bolt and washer on the right side of the shift valve body. For 1st, 2nd and 3rd clutch pressure: 14-12 NOTE: • Clean around the sealing bolts with compressed air before removing the bolts, and be sure that no dirt is allowed to enter the oil gallery. Remove the following: - left engine side cover (page 3-17) left front mud guard (page 3-8) BOLTANDWASHER (LINE PRESSURE) DRIVETRAIN SYSTEM Remove the sealing bolts and washers on the bottom of the shift valve body. Connect the oil pressure gauge and adapter to each inspection hole (hole threads; M8 x 1.25). Line pressure: PRESSURE GAUGE TOOLS: Pressure gauge set 07406-0020005 or Oil pressure gauge 0-160 psi 07ZMJ-HN2A100 and Adapter, banjo 8 x 1.25 mm 07AMJ-HN8A100 (U.S.A. only) Start the engine and check the oil pressure as follows. For line pressure: Shift the sub-transmission into Neutral (set the selector lever in center position) and measure the oil pressure. LINE OIL PRESSURE (80°C/176°F): 785 kPa (8.0 kgf/cm2,114 psi) at 5,000 rpm (min ') For 1st, 2nd and 3rd Shift the sub-transmission in Drive position with the clutch pressure: mode select switch at "ESP". Shift to the respective transmission position (1st, 2nd and 3rd) with the ESP shift switch and measure the each clutch oil pressure. HOSE 1st/2nd/3rd pressure: PRESSURE GAUGE SET SHIFT CLUTCH OIL PRESSURE (80°C/176°F): 1st, 2nd, 3rd: 785 kPa (8.0 kgf/cm2,114 psi) at 5,000 rpm (min ') Stop the engine. Remove the pressure gauge and hose(s). Install the new sealing washer and bolt to the right side of the shift valve body, tighten the bolt securely. 14-13 DRIVETRAIN SYSTEM Remove the sealing bolts and washers on the bottom of the shift valve body. After the oil pressure check is completed, start the engine and make sure there are no oil leaks. TROUBLESHOOTING CHART OF HYDRAULIC CIRCUIT PRESSURE CHECK SECTION MEASUREMENT RESULT (•: Abnormal / Blank: Normal) Line pressure • 1st clutch pressure • 2nd clutch pressure 3rd clutch pressure 0 Emergency valve 0 2-3 shift valve 0 0 Shift solenoid valve A Probable Faulty Part (applied to 0) • • • A/T clutch pressure control solenoid 1-2 shift valve Shift solenoid valve B 0 0 0 0 Refer to page 0 14-48 0 2nd orifice control valve 3rd orifice control valve Shift valve body Orifice control valve body 1st clutch 3rd clutch 0 0 0 0 0 0 0 0 0 2nd clutch 14-66 0 0 Feed pipe A 0 Feed pipe B 0 0 0 Feed pipe C 0 0 0 14-56 Torque converter 0 14-60 Oil pump 0 5-5 Oil pipe setting collar 0 Oil filter 0 0 0 14-55 0 4-12 Oil strainer 0 13-7 Oil level 0 4-10 For function of each component (page 2-7). 14-14 • • • • I • • • • • • • DRIVETRAIN SYSTEM DRIVETRAIN SYSTEM LOCATION COMBINATION METER IGNITION SWITCH DRIVE MODE SELECT SWITCH PCM GEARSHIFT SWITCH 2WD/4WD SELECT SWITCH FRONT VS SENSOR SHIFT SOLENOID VALVE A TPSENSOR GEAR POSITION SWITCH FRONT FINAL CLUTCH REAR VS SENSOR A/T CLUTCH PRESSURE CONTROL SOLENOID SHIFT SOLENOID VALVE B BATTERY CKP SENSOR EOT SENSOR 14-15 DRIVETRAIN SYSTEM DRIVETRAIN SYSTEM DIAGRAM B^Bu I BANK ANGLE Bl MAIN Br - B3 VCC Y — B14 TH G/R - B2 SG SENSOR ENG STOP A4 SFT SOL A A2 — Y/BI - Y — B2S TOM SHIFT SOLENOID A SFT SOL A Lo A13 — Q/W — W/H - A3 A6 W/Bu- SelV u SelUP --(15) SHIFT SFT SOL B A12 — Y/G — SOLENOID B W/Y — A5 an - Sel DOWN LJ --(16) StopLamp A23 SW LINP A26 — Y/R — A/T CLUtCH PC SOLENOID LINM A27 — B u / R - Bu/O- A1B MODE SW PCM Br/BI — A7 G — Bl] Lb/W- ONDP A6 0NDM AS --(4) ONDSW LG FR FINAL CLUTCH A24 GPD L s f R - A17 GPN COMBINATON ONDIND A20 METER Gr — A2S GPR TWIND A19 G/BI - A28 StopSlg SW P/W — B4 FRVSP Bl/O — A15 SenVB2 LODI LCD2 LCD3 LCD4 LOD5 A22 A21 A32 A31 A30 LCD Lb CPU Bu RRVSP BS SenVBI A16 I ~ . G . Y| REAR VS SENSOR W --©in) B-11 Bl:BLACK Y : YELLOW Bu:BLUE G :GREEN B :RED W : WHITE 14-16 Br : BROWN 0 :ORANGE Lb : LIGHT BLUE Lg : LIGHT GREEN P :PINK Gr :GRAY A-23 A-33 B-23 B-33 DRIVETRAIN SYSTEM DRIVETRAIN CONNECTOR LOCATION FRONT CONNECTOR LOCATIONS Note 1: Note 2: Remove the steering cover (page 3-5). Remove the VS sensor cover (page 18-12). PCM 33P (BLACK) CONNECTOR (Note 1) PCM (Note 1) PCM 5P (BLACK) CONNECTOR (Note 1) PCM 33P (GRAY) CONNECTOR (Note 1) \ FINAL CLUTCH 2P (GREEN) CONNECTOR (Note 2) 14-17 DRIVETRAIN SYSTEM Note 1: Note 2: Note 3: Remove the fuel tank (page 6-39). Remove the left inner fender (page 3-9). Remove the right inner fender (page 3-9). LEFT HANDLEBAR SWITCH 10P (GREEN) (NoteD COMBINATION METER 14P (GRAY) CONNECTOR (NoteD COMBINATION METER 4P (BLACK) CONNECTOR (Note 1) COMBINATION METER 4P (NATURAL) CONNECTOR (Note!) FINAL CLUTCH 2P (GREEN) CONNECTOR (Note 2) SHIFT SOLENOID SUB-HARNESS 6P (NATURAL) CONNECTOR (Note 2) FRONT VS SENSOR 3P (BLUE) CONNECTOR (Note 2) REAR VS SENSOR 3P (YELLOW) CONNECTOR (Note 2) 14-18 4WD SWITCH 2P (BLACK) CONNECTOR (Note D MODE SELECT SWITCH 3P (BLACK) CONNECTOR (Note 3) DRIVETRAIN SYSTEM MIDDLE/REAR CONNECTOR LOCATIONS Note 1: Note 2: Remove the seat (page 3-4). Remove the fuel tank side cover (page 3-6). SHIFT SOLENOID 2P (BROWN) CONNECTOR A/T CLUTCH PRESSURE CONTROL SOLENOID 2P (BLACK) CONNECTOR MAP/TP SENSOR 5P (BLACK) CONNECTOR (Note 1) SHIFT SOLENOID 2P (BLACK) CONNECTOR GEAR POSITION SWITCH 3P (NATURAL) CONNECTOR (Note 2) 14-19 DRIVETRAIN SYSTEM DRIVETRAIN TROUBLESHOOTING INFORMATION Refer to "PGM-FI Troubleshooting Information" for the general troubleshooting information (page 613). SYSTEM DESCRIPTION SELF-DIAGNOSIS SYSTEM The PCM (Powertrain Control Module) integrates the ECM (Engine Control Module), the TCM (Transmission Control Module) and the selectable 4WD system control. Therefore some detection items are shared by the PGM-FI and drivetrain system and they may affect the system operation of both systems. And the drivetrain system is equipped with the selfdiagnostic system. When any abnormality occurs in the A/T or selectable 4WD system, the PCM turns on the indicators blinking and stores a DTC in its erasable memory for the relevant system failure. FA model shown: GEAR POSITION INDICATOR In case of a function failure in the A/T system (e.g.: Shift solenoid valve failure), the gear position indicator will blink "- -" to indicate the DTC. In case of a function failure in the both, A/T and selectable 4WD, system, both the indicators will blink at the same time to indicate the DTC. FAIL-SAFE FUNCTION The drivetrain 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 A/T system, the PCM stops the automatic shift function and anticreep function, and defaults the transmission into 2nd gear. Also, the gear position indicator blinks " - - " to indicate the DTC. When the PCM detects a problem in the selectable 4WD system, the PCM stops controlling the system and defaults into the 2WD mode. Also, the 4WD indicator blinks to indicate the DTC. DTC (Diagnostic Trouble Code) Refer to the DTC information in "Fuel system (PGMFI)" (page 6-13). 14-20 4WD INDICATOR DRIVETRAIN SYSTEM INDICATOR BLINK PATTERN • The number of indicator blinks is the equivalent the main code of the 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 lasts for 1.3 seconds, the short blink lasts for 0.5 seconds. One long blink is the equivalent of ten short blinks. For example, when one long blink is followed by five short blinks, the DTC is 15 (one long blink = 10 blinks, plus five short blinks). 3 sec. 1 sec. . 1 sec. 1 sec.. -"ON Pattern repeated OFF One Blink Blinking 3 times Blinking 8 times problem code (Example: Blinking 3 times = Problem code 3) • When the PCM stores more than one DTC, the indicator displays in the order from the lowest number to highest number. CURRENT DTC/FREEZE DTC The DTC is indicated in two ways according to the failure status. • If the PCM detects the problem at present, the gear position indicator and 4WD indicator will blink at all time. It is possible to readout the indicator blink pattern as the current DTC. • 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 freeze DTC by following the DTC readout procedure. HDS POCKET TESTER INFORMATION Refer to the "How to connect the HDS Pocket Tester" and "ECM Reset" information in "Fuel system (PGMFl)" (page 6-13). DTC READOUT Reading DTC with the indicator NOTE: • If the MIL blinks, refer to the "PGM-FI Troubleshooting Information" and troubleshoot the PGM-FI system first. Then recheck the Drivetrain system after clearing the PGM-FI DTC. • After performing diagnostic troubleshooting, erase the problem code(s) (page 14-22) and testdrive the vehicle to be sure that the problem(s) have been removed. Turn the ignition switch on and connect the HDS Pocket Tester to the DLC (page 6-14). Read the DTC, freeze data and follow the troubleshooting index (page 14-24). To read the DTC without the HDS pocket tester, refer to the following procedure. 14-21 DRIVETRAIN SYSTEM Turn the ignition switch ON, read the gear position indicator " — " or 4WD indicator blinks, the number of blinks indicates the current DTC. Refer to the troubleshooting index (page 14-24). When retrieving the Freeze DTC, refer to the following procedures. 1. Turn the ignition switch OFF and remove the steering cover (page 3-5). 2. Remove the dummy connector and short the DLC terminals using the special tool. TOOL: SCS connector 070PZ-ZY30100 CONNECTION: Brown/red - Green 3. Turn the ignition switch to ON, read the gear position indicator " — " or 4WD indicator blinks, the number of blinks indicates the freeze DTC. Refer to the troubleshooting index (page 14-24). CLEARING DTC Connect the HDS Pocket Tester to the DLC (page 614). Clear the DTC with the HDS while the engine is stopped. To clear the DTC without HDS, refer to the following procedure. How to clear the DTC without HDS NOTE: • When clearing the Drivetrain DTC as follows, the PGM-FI DTC would also be cleared at the same time, check the MIL blinks and troubleshoot the PGM-FI system before readout/clearing the Drivetrain DTC. 1. Turn the ignition switch OFF and remove the steering cover (page 3-5). 14-22 GEAR POSITION INDICATOR DRIVETRAIN SYSTEM 2. Remove the dummy connector and short the Brown/red and Green wire terminals of the DLC using the special tool. TOOL: SCS connector 070PZ-ZY30100 CONNECTION: Brown/red - Green 3. Turn the ignition switch ON. 4. Remove the special tool from the DLC. 5. The indicator will light for approximately 5 seconds. While the indicator lights, short the DLC terminals again with the special tool. The selfdiagnostic memory is erased if the malfunction indicator goes off and starts blinking. NOTE: • The DLC must be jumped while the indicator lights. If not, the indicator will not start blinking. • Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the indicator starts blinking. 14-23 DRIVETRAIN SYSTEM DRIVETRAIN DTC INDEX • When the gear position indicator"- -" is lighting constantly, but no problem code is indicated and retrievable, refer to the symptom troubleshooting (page 14-6). DTC (Refer to) 3-1 (14-26) 3-2 (14-27) 3-3 (14-26) 4-1 (14-28) 4-2 (14-30) 4-3 (14-28) 8-1 (6-23) 8-2 (6-24) 11-1 (6-27) Function Failure Front final clutch Low input • Loose or poor contact of the front final clutch related connector • Front final clutch or its circuit malfunction Front final clutch High input • Front final clutch or its circuit malfunction Front final clutch drive circuit • Front final clutch or its circuit malfunction A/T clutch pressure control solenoid valve Low input • Loose or poor contact of the A/T clutch pressure control solenoid valve related connector • A/T clutch pressure control solenoid valve or its circuit malfunction A/T clutch pressure control solenoid valve High input • A/T clutch pressure control solenoid valve or its circuit malfunction A/T clutch pressure control solenoid valve drive circuit • A/T clutch pressure control solenoid valve or its circuit malfunction TP sensor circuit Low voltage (less than 0.22 V) • TP sensor or its circuit malfunction TP sensor circuit High voltage (more than 4.93 V) • Loose or poor contact of the TP sensor connector • TP sensor or its circuit malfunction Rear VS sensor no signal • Loose or poor contact of the Rear VS sensor connector • Rear VS sensor or its circuit malfunction 12-1 (14-31) Front VS sensor no signal • Loose or poor contact of the Front VS sensor connector • Front VS sensor or its circuit malfunction 15-1 (14-32) Shift solenoid valve A (short) • Shift solenoid valve A or its circuit malfunction Shift solenoid valve A (open) • Shift solenoid valve A or its circuit malfunction 15-2 (14-33) 14-24 Symptom/Fail-safe Function • Selectable 4WD systerh does not work (2WD mode only) • Selectable 4WD systerh does not work (2WD mode only) • Selectable 4WD system does not work (2WD mode only) • A/T shift function and anti-creep function does not work (2nd gear only) Indicator Blinks 4WD A/T 3 PGMFIDTC 4 • A/T shift function and anti-creep function does not work (2nd gear only) • A/T shift function and anti-creep function does not work (2nd gear only) • Poor engine acceleration • Fail-safe value: 0° • A/T shift function and anti-creep function does not work (2nd gear orjly) • Poor engine acceleration • Fail-safe value: 0° • A/T shift function and anti-creep function ddes not work (2nd gear orlly) 8 8-1 • A/T shift function and anti-creep function ddes not work (2nd gear only) • Selectable 4WD system does not work (2WD mode only) • A/T shift function and anti-creep function ddes not work (2nd gear only) • Selectable 4WD system does not work (2WD mode only) • A/T shift function and anti-creep function dwes not work (2nd gear only) • A/T shift function and anti-creep function does not work (2nd gear only) 11 11 12 12 8-2 15 11-1 DRIVETRAIN SYSTEM DTC (Refer to) 16-1 (14-35) 16-2 (14-36) 31-1 (14-37) Function Failure Symptom/Fail-safe Function Shift solenoid valve B (short) • Shift solenoid valve B or its circuit malfunction Shift solenoid valve B (open) • Shift solenoid valve B or its circuit malfunction System voltage Low (less than 9.3 V) • PCM power input circuit malfunction • A/T shift function and anti-creep function does not work (2nd gear only) • A/T shift function and anti-creep function does not work (2nd gear only) • A/T shift function and anti-creep function does not work (2nd gear only) • Selectable 4WD system does not work (2WD mode only) • A/T shift function and anti-creep function does not work (2nd gear only) — 32-1 (14-38) Fail-safe relay circuit • Fail-safe relay circuit malfunction 33-2 (6-53) 41-1 (14-39) EEPROM malfunction 42-1 (14-40) 44-1 (14-41) 44-2 (14-42) Gear position switch circuit • Gear position switch circuit malfunction (Short) Shift (UP/DOWN) switch circuit • Shift (UP/DOWN) switch circuit malfunction (Short) EOT sensor circuit low voltage (less than 0.07 V) • EOT sensor or its circuit malfunction EOT sensor circuit high voltage (more than 4.85 V) • Loose or poor contact of the EOT sensor connector • EOT sensor or its circuit malfunction • A/T shift function and anti-creep function does not work (2nd gear only) • A/T shift function and anti-creep function does not work (2nd gear only) • A/T shift function and anti-creep function does not work (2nd gear only) • Cooling fan turns on • A/T shift function and anti-creep function does not work (2nd gear only) • Cooling fan turns on Indicator Blinks A/T 4WD 16 31 31 32 32 — — PGMFIDTC 33-2 41 42 44 44 14-25 DRIVETRAIN SYSTEM DRIVETRAIN DTC TROUBLESHOOTING NOTE: • The connector location and the necessary parts , to disconnect the connector (page 14-17). • Perform inspection with the ignition switch turned OFF, unless otherwise specified. • After troubleshooting, erase the problem code and test-ride the vehicle to be sure that the system is normal. DTC 3-1 (FRONT FINAL CLUTCH LOW INPUT), DTC 3-3 (FRONT FINAL CLUTCH DRIVE CIRCUIT) • Before starting the troubleshooting, check for loose or poor contact on the front final clutch 2P (Green) connector and PCM 33P (Black) connector and then recheck the DTC. 1. Recheck DTC Turn the ignition switch ON and test-ride the vehicle with 4WD, then recheck the current DTC. Is DTC 3-1 or 3-3 indicated? YES - GO TO STEP 2. NO - Intermittent failure 2. Front Final Clutch Inspection Turn the ignition switch OFF. Disconnect the front final clutch 2P (Green) connector. Measure the resistance between the front final' clutch 2P (Green) connector terminals of the clutch side. Connection: Orange/black - Pink/black fe the resistance within 5.1- 5.8 Cl (20°C/68°F)7 YES - GO TO STEP 3. NO - Faulty front final clutch. FRONT FINAL CLUTCH 2P (GREEN) CONNECTOR (Clutch side of male terminal) P/BI O/BI 3. Front Final Clutch Circuit Inspection Turn the ignition switch ON. Measure the voltage between the front final clutch 2P (Green) connector terminals of the wire harness side. Connection: Orange/black - Pink/black FRONT FINAL CLUTCH 2P (GREEN) CONNECTOR (Wire side of female terminal) Is the voltage about 11 V with the select switch into 4WD? 14-26 YES - GO TO STEP 6. NO - GO TO STEP 4. O/BI P/BI DRIVETRAIN SYSTEM 4. Front Final Clutch Line Open Circuit Inspection Be careful not to bend the connector terminals. Check for continuity between the PCM 33P (Black) and front final clutch 2P (Green) connector terminals. TOOL: Test probe 07ZAJ-RDJA110 FRONT FINAL CLUTCH 2P (GREEN) CONNECTOR (Wire side of female terminal) A9 A8 / Connection: A8 - Pink/black A9 - Orange/black Is there continuity? NO - • Open circuit in the Orange/black wire. • Open circuit in Pink/black wire. YES - GO TO STEP 5. PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) 5. Front Final Clutch Line Short Circuit Inspection Check for continuity between the front final clutch 2P (Green) connector terminals of the wire harness side and ground. Connection: Pink/black - Ground Orange/black - Ground FRONT FINAL CLUTCH 2P (GREEN) CONNECTOR (Wire side of female terminal) Is there continuity? YES - • Short circuit in the Orange/black wire. • Short circuit in Pink/black wire. NO - GO TO STEP 6. O/BI P/BI 6. Recheck DTC Turn the ignition switch ON and test-ride the vehicle with 4WD, then recheck the current DTC. te DTC 3-1 or 3-3 indicated? YES - Replace the PCM with a new one and recheck. NO - Intermittent failure DTC 3-2 (FRONT FINAL CLUTCH HIGH INPUT) 1. Recheck DTC Turn the ignition switch ON and test-ride the vehicle with 4WD, then recheck the current DTC. te DTC 3-2 indicated? YES - GO TO STEP 2. NO - Intermittent failure 14-27 DRIVETRAIN SYSTEM 2. Front Final Clutch Inspection Turn the ignition switch OFF. Disconnect the front final clutch 2P (Green) connector. Measure the resistance between the front final clutch 2P (Green) connector terminals of the clutch side. Connection: Orange/black - Pink/black Is the resistance within 5.1- 5.8 D (20°C/68°F)? YES - GO TO STEP 3. NO - Faulty front final clutch. FRONT FINAL CLUTCH 2P (GREEN) CONNECTOR (Clutch side of male terminal) IP/BI O/BI 3. Front Final Clutch Line Short Circuit Inspection Check the for continuity between the front final clutch 2P (Green) connector terminals of the wire harness side and ground. Connection: Pink/black - Ground Orange/black - Ground te there continuity? YES - • Short circuit in the Orange/black wire. • Short circuit in Pink/black wire. NO - GO TO STEP 4. 4. RecheckDTC Turn the ignition switch ON and test-ride the vehicle with 4WD, then recheck the current DTC. Is DTC 3-2 indicated? YES - Replace the PCM with a new one and recheck. NO - Intermittent failure DTC 4-1 (A/T CLUTCH PRESSURE CONTROL SOLENOID LOW INPUT), DTC 4-3 (A/T CLUTCH PRESSURE CONTROL SOLENOID DRIVE CIRCUIT) • Before starting the troubleshooting, check for loose or poor contact on the A/T clutch pressure control solenoid 2P (Black) connector, solenoid sub-harness 6P (Natural) connector and PCM 33P (Black) connector and then recheck the DTC. 1. RecheckDTC Turn the ignition switch ON and test-ride the vehicle, then recheck the current DTC. Is DTC 4-1 or 4-3 indicated? 14-28 YES - GO TO STEP 2. NO - Intermittent failure FRONT FINAL CLUTCH 2P (GREEN) CONNECTOR (Wire side of female terminal) O/BI P/BI DRIVETRAIN SYSTEM 2. A/T Clutch Pressure Control Solenoid Inspection Turn the ignition switch OFF. Disconnect the A/T clutch pressure control solenoid 2P (Black) connector. Measure the resistance between the A/T clutch pressure control solenoid 2P (Black) connector terminals of the solenoid side. A/T CLUTCH PC SOLENOID 2P (BLACK) CONNECTOR (Solenoid side of male terminal) V Y/R Bu/R Connection: Yellow/red - Blue/red fe the resistance within 4.5 - 10.0 D ? YES - GO TO STEP 3. NO - Faulty A/T clutch pressure control solenoid valve. 3. A/T Clutch Pressure Control Solenoid Circuit Inspection Turn the ignition switch ON. Measure the voltage between the A/T clutch pressure control solenoid 2P (Black) connector terminals of the wire harness side. Connection: Yellow/red - Blue/red A/T CLUTCH PC SOLENOID 2P (BLACK) CONNECTOR (Wire side of female terminal) Bu/R Y/R Is the voltage about 11 V with the ignition switch ON? YES - GO TO STEP 6. NO - GO TO STEP 4. 4. A/T Clutch Pressure Control Solenoid Line Open Circuit Inspection Be careful not to bend the connector terminals. Check for continuity between the PCM 33P (Black) and the A/T clutch pressure control solenoid 2P (Black) connector terminals. TOOL: Test probe 07ZAJ-RDJA110 Connection: B26 - Blue/red B27 - Yellow/red A/T CLUTCH PC SOLENOID 2P (BLACK) CONNECTOR (Wire side of female terminal) B27 i— r L i Is there continuity? NO - • Open circuit in the Blue/red wire. • Open circuit in Yellow/red wire. YES - GO TO STEP 5. B26 / "r\T i —i 1 i 1—~l \ / T . ftm I r 1 L / f—, J ' p. i/D -Y/R PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) 14-29 DRIVETRAIN SYSTEM 5. A/T Clutch Pressure Control Solenoid Line Short Circuit Inspection Check the for continuity between the A/T clutch pressure control solenoid 2P (Black) connector terminals of the wire harness side and ground. Connection: Blue/red - Ground Yellow/red - Ground ATT CLUTCH PC SOLENOID 2P (BLACK) CONNECTOR (Wire side of female terminal) Is there continuity? YES - • Short circuit in the Blue/red wire. • Short circuit in Yellow/red wire. NO - GO TO STEP 6. 6. RecheckDTC Turn the ignition switch ON and test-ride the vehicle, then recheck the current DTC. Is DTC 4-1 or 4-3 indicated? YES - Replace the PCM with a new one and recheck. NO - Intermittent failure DTC 4-2 (A/T CLUTCH PRESSURE CONTROL SOLENOID HIGH INPUT) 1. RecheckDTC Turn the ignition switch ON and test-ride the vehicle, then recheck the current DTC. te DTC 4-2 indicated? YES - GO TO STEP 2. NO - Intermittent failure 2. A/T Clutch Pressure Control Solenoid Inspection Turn the ignition switch OFF. Disconnect the A/T clutch pressure control solenoid 2P (Black) connector. Measure the resistance between the A/T clutch pressure control solenoid 2P (Black) connector terminals of the solenoid side. Connection: Yellow/red - Blue/red Is the resistance within 4.5 -10.0 £2 ? 14-30 YES - GO TO STEP 3. NO - Faulty A/T clutch pressure control solenoid valve. A/T CLUTCH PC SOLENOID 2P (BLACK) CONNECTOR (Solenoid side of male terminal) Y/R V Bu/R DRIVETRAIN SYSTEM 3. A/T Clutch Pressure Control Solenoid Line Short Circuit Inspection Check for continuity between the A/T clutch pressure control solenoid 2P (Black) connector terminals of the wire harness side and ground. Connection: Blue/red - Ground Yellow/red - Ground A/T CLUTCH PC SOLENOID 2P (BLACK) CONNECTOR (Wire side of female terminal) Is there continuity? YES - • Short circuit in the Blue/red wire. • Short circuit in Yellow/red wire. NO - GO TO STEP 4. 4. RecheckDTC Turn the ignition switch ON and test-ride the vehicle, then recheck the current DTC. Is DTC 4-2 indicated? YES - Replace the PCM with a new one and recheck. NO - Intermittent failure DTC 12-1 (FRONT VS SENSOR) • Before starting the troubleshooting, check for loose or poor contact on the front VS sensor 3P (Blue) connector and PCM 33P (Gray) connector and then recheck the DTC. 1. Front VS Sensor System Check Clear the DTC, test-ride and check the front VS sensor signal with the HDS pocket tester. Is the front VS sensor signal indicated normally? YES - I nte rm itte nt fa i I u re NO - GO TO STEP 2. 2. Front VS Sensor Ground Line Inspection Turn the ignition switch OFF. Disconnect the front VS sensor 3P (Blue) connector. Turn the ignition switch ON, measure the voltage between the front VS sensor 3P (Blue) connector terminals of the wire harness side. FRONT VS SENSOR 3P (BLUE) CONNECTOR (Wire side of male terminal) Connection: Black/orange {+) - Green (-) Is there battery voltage? NO - • Open or short circuit in the Black/ orange wire. • Open circuit in the Green wire. YES Bl/O - GO TO STEP 3. 14-31 DRIVETRAIN SYSTEM Front VS Sensor Output Line Inspection Measure the voltage between the front VS sensor 3P (Blue) connector terminals of the wire harness side. Connection: Pink/white (+) - Green (-) Is the voltage about 5 V? NO - Open or short circuit in the Pink/white wire. YES - GO TO STEP 4. FRONT VS SENSOR 3P (BLUE) CONNECTOR (Wire side of male terminal) 1 4-4J P/W 4. Front VS Sensor Inspection Turn the ignition switch OFF. Replace the front VS sensor with a new one (page 18-12). Clear the DTC, test ride the vehicle and recheck the DTC. Is the DTC 12-1 indicated? YES - Replace the PCM with a new one, and recheck. NO - Faulty original front VS sensor. DTC 15-1 (SHIFT SOLENOID "A" SHORT) 1. Recheck DTC Turn the ignition switch ON and test-ride the vehicle, then recheck the DTC. Is DTC 15-1 indicated (or can not shift)? YES - GO TO STEP 2. NO - Intermittent failure 2. Shift Solenoid Valve "A" Inspection Turn the ignition switch OFF. Disconnect the shift solenoid "A" 2P (Black) connector. Measure the resistance between the shift solenoid valve "A" 2P (Black) connector terminals of the solenoid side. Is the resistance within 14.6 - 16.2 ii 68T)? YES - GO TO STEP 3. NO - Faulty shift solenoid valve A. (20C/ 2P BLACK CONNECTOR 14-32 DRIVETRAIN SYSTEM 3. Shift Solenoid "A" Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the shift solenoid "A" 2P (Black) connector. Check for continuity between the shift solenoid "A" 2P (Black) connector terminals of the wire harness side and ground. Connection: Green/white - Ground Yellow/black- Ground SHIFT SOLENOID "A" 2P (BLACK) CONNECTOR (Wire side of male terminal) Is there continuity? YES - • Short circuit in the Yellow/black wire. • Short circuit in the Green/white wire. NO - G O TO STEP 4. 4. Failure Reproduction Connect the shift solenoid "A" 2P (Black) connector. Turn the ignition switch ON. Test-ride the vehicle for several minutes under the same conditions as those indicated by the freeze data. Is DTC 15-1 indicated ? NO - Intermittent failure YES - Replace the PCM with a new one and recheck. DTC 15-2 (SHIFT SOLENOID "A" OPEN) • Before starting the troubleshooting, check for loose or poor contact on the shift solenoid 2P (Black) connector and PCM 33P (Black) connector and then recheck the DTC. 1. Recheck DTC Turn the ignition switch ON and test-ride the vehicle, then recheck the DTC. fe DTC 15-2 indicated ? YES - GO TO STEP 2. NO - Intermittent failure 14-33 DRIVETRAIN SYSTEM 2. Shift Solenoid Valve "A" Inspection Turn the ignition switch OFF. Disconnect the shift solenoid "A" 2P (Black) connector. Measure the resistance between the shift solenoid valve 2P (Black) connector terminals of the solenoid side. Is the resistance within 14.6 - 16.2 Q (20 C/ 68W YES - GO TO STEP 3. NO - Faulty shift solenoid valve "A". 2P BLACK) CONNECTOR 3. Shift Solenoid Valve "A" Line Open Circuit Inspection Be careful not to bend the connector terminals. Connect the shift solenoid "A" 2P (Black) connector. Disconnect the PCM 33P (Black) connector. Measure the resistance at the PCM connector terminals. TOOL: Test probe 07ZAJ-RDJA110 Connection: A2 - A13 Is the resistance within 14.6 - 16.2 n (20 C/ 68°F)? NO - • Open circuit in the Yellow/black wire. • Open circuit in the Green/white wire. YES A13 PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) - GO TO STEP 4. 4. Shift Solenoid "A" Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the shift solenoid "A" 2P (Black) connector. Check for continuity between the shift solenoid "A" 2P (Black) connector terminals of the wire harness side and ground. Connection: Green/white - Ground Yellow/black- Ground Is there continuity? 14-34 YES - • Short circuit in the Yellow/black wire. • Short circuit in the Green/white wire. NO - GO TO STEP 5. SHIFT SOLENOID "A" 2P (BLACK) CONNECTOR (Wire side of male terminal) DRIVETRAIN SYSTEM 5. Failure Reproduction Connect the shift solenoid "A" 2P (Black) connector and PCM 33P (Black) connector. Turn the ignition switch ON. Test-ride the vehicle for several minutes under the same conditions as those indicated by the freeze data. Is DTC 15-2 indicated ? NO - Intermittent failure YES - Replace the PCM with a new one and recheck. DTC 16-1 (SHIFT SOLENOID "B " SHORT) 1. Recheck DTC Turn the ignition switch ON and test-ride the vehicle, then recheck the DTC. Is DTC 16-1 indicated ? YES - GO TO STEP 2. NO - Intermittent failure 2. Shift Solenoid Valve "B" Inspection Turn the ignition switch OFF. Disconnect the shift solenoid "B" 2P (Brown) connector. Measure the resistance between the shift solenoid valve "B" 2P (Brown) connector terminals of the solenoid side. Is the resistance within 14.6 - 16.2 Q (20°C/ 68°F)? YES - GO TO STEP 3. NO - Faulty shift solenoid valve "B". 2P (BROWN) CONNECTOR 3. Shift Solenoid "B" Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the shift solenoid "B" 2P (Brown) connector. Check for continuity between the both shift solenoid "B" 2P (Brown) connector terminals of the wire harness side and ground. Connection: Yellow/green - Ground Green - Ground SHIFT SOLENOID "B" 2P (BROWN) CONNECTOR (Wire side of male terminal) Is there continuity? YES - • Short circuit in the Yellow/green wire. • Short circuit in the Green wire. NO - GO TO STEP 4. 14-35 DRIVETRAIN SYSTEM 4. Failure Reproduction Connect the shift solenoid "B" 2P (Brown) connector. Turn the ignition switch ON. Test-ride the vehicle for several minutes under the same conditions as those indicated by the freeze data. Is DTC 16-1 indicated ? NO - Intermittent failure YES - Replace the PCM with a new one and recheck. DTC 16-2 (SHIFT SOLENOID "B" OPEN) • Before starting the troubleshooting, check for loose or poor contact on the shift solenoid "B" 2P (Brown) connector and PCM 33P (Black) connector and then recheck the DTC. 1. Recheck DTC Turn the ignition switch ON and test-ride the vehicle, then recheck the DTC. Is DTC 16-2 indicated ? YES - GO TO STEP 2. NO - Intermittent failure 2. Shift Solenoid Valve "B" Inspection Turn the ignition switch OFF. Disconnect the shift solenoid "B" 2P (Brown) connector. Measure the resistance between the shift solenoid valve "B" 2P (Brown) connector terminals of the solenoid side. Is the resistance within 14.6 - 16.2 ii (20 C/ 68°F)7 YES - GO TO STEP 3. NO - Faulty shift solenoid valve B. 2P (BROWN) CONNECTOR 3. Shift Solenoid Valve "B" Line Open Circuit Inspection Be careful not to bend the connector terminals. Connect the shift solenoid "B" 2P (Brown) connector. Disconnect the PCM 33P (Black) connector and 5P (Black) connector. Measure the resistance at the PCM connectors terminals. TOOL: Test probe 07ZAJ-RDJA110 PCM 5P (BLACK) CONNECTOR (Wire side of female terminal) A12 Connection: A12 - Green te the resistance within 14.6 - 16.2 Q (20 C/ 68 F)? 14-36 NO - • Open circuit in the Yellow/green wire. • Open circuit in the Green wire. YES - GO TO STEP 4. PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) DRIVETRAIN SYSTEM 4. Shift Solenoid "B" Line Short Circuit Inspection Turn the ignition switch OFF. Disconnect the shift solenoid "B" 2P (Brown) connector. Check for continuity between the shift solenoid "B" 2P (Brown) connector terminals of the wire harness side and ground. Connection: Yellow/green - Ground Green - Ground SHIFT SOLENOID "B" 2P (BROWN) CONNECTOR (Wire side of male terminal) te there continuity? YES - • Short circuit in the Yellow/green wire. • Short circuit in the Green wire. IMO - GO TO STEP 5. 5. Failure Reproduction Connect the shift solenoid "B" 2P (Brown) connector, PCM 33P (Black) and 5P (Black) connector. Turn the ignition switch ON. Test-ride the vehicle for several minutes under the same conditions as those indicated by the freeze data. te DTC 16-2 indicated ? NO - Intermittent failure YES - Replace the PCM with a new one and recheck. DTC 31-1 (SYSTEM VOLTAGE LOW) • Before starting the troubleshooting, check the combination meter function or starter motor function. If these have malfunction, inspect the battery, fuses or ignition switch. • Before starting the troubleshooting, check for loose or poor contact on the PCM 33P connectors and then recheck the DTC. 1. PCM System Voltage Inspection Turn the ignition switch ON. Check the battery voltage in the Data List menu of HDS pocket tester. te the voltage less than 9.3 V? YES - GO TO STEP 2. NO - Intermittent failure. 14-37 DRIVETRAIN SYSTEM 2. PCM Power Input Line Inspection Be careful not to bend the connector terminals. Turn the ignition switch OFF. Disconnect the PCM 33P (Gray) connector. Turn the ignition switch ON. Measure the voltage between the wire harness side connector terminal and ground. TOOL: Test probe B1 \ m 1\ 1 \ —(3 07ZAJ-RDJA110 Connection: B1 (+) - Ground {-) \ i _—i i 1 i 1 Is there battery voltage? NO - • Inspect the battery/charging system (page 20-7). • Open or short circuit in the Black/ blue wire. • Blown IGN fuse. YES - GO TO STEP 3. 3. Failure Reproduction Clear the DTC, test-ride or check the vehicle under the conditions indicated as the freeze data and recheckthe DTC. te the DTC 31-1 indicated ? NO - Intermittent failure YES - Replace the PCM with a new one and recheck. DTC 32-1 (FAIL SAFE RELAY CIRCUIT) 1. Recheck DTC Clear the DTC, turn the ignition switch ON and recheck the current DTC. Is the DTC 32-1 indicated? 14-38 NO - Intermittent failure. YES - Replace the PCM with a new one and recheck. PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) — / ^ DRIVETRAIN SYSTEM DTC 41-1 (GEAR POSITION SWITCH CIRCUIT) • Before starting the troubleshooting, check for loose or poor contact on the gear position switch 3P (Natural) connector and PCM 33P (Black) connector and then recheck the DTC. 1. Gear Position Switch Line Inspection at PCM Connector Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector. Be careful not to bend the connector terminals. Perform the gear position switch inspection (page 14-44). Also check for the short circuit between each gear position switch terminals. Is there normal continuity? NO - GO TO STEP 2. YES - GO TO STEP 3. 2. Gear Position Switch Line Inspection at the Connector Disconnect the gear position switch connector. Check for continuity between the gear position switch 3P (Natural) connector of the switch side and ground (page 14-44). Also check for the short circuit between each gear position switch terminals. Connection: Light green/red - Ground' Gray - Ground Light blue/white - Ground GEAR POSITION SWITCH 3P (NATURAL) CONNECTOR (Switch side of female terminal) U if U Lb/W Gr Lg/R Is there normal continuity? NO - Faulty gear position switch. YES - • Open or short circuit in the Light green/red wire. • Open or short circuit in the Light blue/white wire. • Open or short circuit in the Gray wire. 3. Failure Reproduction When connecting the PCM 33.P connectors, check that there is no dirt and oil in the connector. Connect the PCM and gear position switch connectors. Clear the DTC, turn the ignition switch ON, select the gear position "D", "R" and check the current DTC. fe the DTC 41-1 indicated? NO - Intermittent failure. YES - Replace the PCM with a new one and recheck. 14-39 DRIVETRAIN SYSTEM DTC 42-1 (SHIFT UP/DOWN SWITCH CIRCUIT) • Before starting the troubleshooting, check for loose or poor contact on the handlebar switch 10R (Green) connector and PCM 33P (Black) connector and then recheck the DTC. 1. Shift Switch Status Inspection Turn the ignition switch ON. Check the shift switch status and voltage in the Data List Menu of HDS as follows: UP DOWN "Up" ON 3.64 - 4.08 V 1.76-2.09 V "Down" ON 1.76-2.09 V 3.64 - 4.08 V Both ON 4.0 - 4.99 V 4.0 - 4.99 V Both OFF 0 - 0.99 V 0 - 0.99 V Is the shift switch status normal? YES - Intermittent failure NO - GO TO STEP 2. 2. Shift Switch Line Inspection (PCM side) Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector. Check for continuity between the PCM 33P (Black) connector terminals in each switch position (page 14-45). TOOL: Test probe 07ZAJ-RDJA110 PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) Connection: A 3 - A 6 A3-A5 Is there normal continuity? NO - GO TO STEP 3. YES - GO TO STEP 4. A5 3. Gearshift Switch Inspection (Handlebar Switch Side) Remove the left handlebar switch 10P (Green) connector from the frame and disconnect it. Check for continuity at the switch side 10P (Green) connector terminals in each switch position (page 14-45). Connection: White/red - White/blue White/red - White/yellow Is there normal continuity? 14-40 NO - Check the shift switch condition or replace the shift switch with a new one and recheck. YES - • Open or short circuit in the wires between the PCM 33P (Black) and handlebar switch 10P (Green) connector. - White/red wire. - White/yellow wire. - White/blue wire. HANDLEBAR SWITCH 10P (GREEN) CONNECTOR (Switch side of male terminal) DRIVETRAIN SYSTEM 4. Failure Reproduction Connect the PCM and gearshift switch connectors. Clear the DTC, turn the ignition switch ON and recheck the current DTC. Is the DTC 42-1 indicated? NO - Intermittent failure. YES - Replace the PCM with a new one and recheck. DTC 44-1 (EOT SENSOR LOW VOLTAGE) 1. EOT Sensor System Inspection Turn the ignition switch ON and engine stop switch "o"Check the EOT sensor with the HDS. Is about 0 V indicated? NO - • Intermittent failure. • Loose or poor connection on the ECT sensor 2P (Black) connector. YES - GO TO STEP 2. 2. EOT Sensor Inspection Turn the ignition switch OFF. Disconnect the EOT sensor 2P (Black) connector. 2P (BLACK) CONNECTOR Turn the ignition switch ON and engine stop switch "O". Check the EOT sensor with the DTC pocket tester. Is about 0 V indicated? NO - G O TO STEP 3. YES - GO TO STEP 4. 3. EOT Sensor Resistance Inspection Turn the ignition switch OFF. Measure the resistance at the EOT sensor terminals. Connection: Yellow - Green/red Standard: 2.3 - 2.6 kii (20°C/68°F) EOT SENSOR 2P (BLACK) CONNECTOR (Sensor side of male terminal) Is the resistance within 2.3 - 2.6 kQ? YES No - Replace the PCM with a new one, and recheck. G/R - Faulty EOT sensor. 14-41 DRIVETRAIN SYSTEM 4. EOT Sensor Short Circuit Inspection Disconnect the PCM 33P (Gray) connector from the PCM (page 6-54). Check for continuity between the EOT sensor 2P (Black) connector terminal of the wire harness side and ground. EOT SENSOR 2P (BLACK) CONNECTOR (Wire side of female terminal) Connection: Yellow - Ground Is there continuity? YES - Short circuit in Yellow wire. NO - Replace the PCM with a new one, and recheck. DTC 44-2 (EOT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the EOT sensor 2P (Black) connector and recheck the HDS. 1. EOT Sensor System Inspection Turn the ignition switch ON and engine stop switch "O". Check the EOT sensor with the HDS pocket tester. Is about 5 V indicated? NO - • Intermittent failure. • Loose or poor contact on the EOT sensor 2P (Black) connector. YES - GO TO STEP 2. 2. EOT Sensor Inspection Turn the ignition switch OFF. Disconnect the EOT sensor 2P (Black) connector. Jump the EOT sensor terminals with a jumper wire. Connection: Yellow - Green/red EOT SENSOR 2P (BLACK) CONNECTOR (Wire side fof female terminal) \ V-fnr-inU Turn the ignition switch ON and engine stop switch "o". Check the EOT sensor with the HDS pocket in < % < tester. Is about 0 V indicated? 14-42 YES - Faulty EOT sensor. NO - GO TO STEP 3. G/R Y \ JUMPER WIRE DRIVETRAIN SYSTEM 3. EOT Sensor Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wire. EOT SENSOR 2P (BLACK) CONNECTOR (Wire side of female terminal) Disconnect the PCM 33P (Gray) connector (page B2 6-54). Check for continuity between the PCM 33P (Gray) connector terminals and ECT sensor 2P (Black) connector terminals of the wire harness side. TOOL: Test probe 07ZAJ-RDJA110 Connection: B28-Yellow B2 - Green/red B28 7 PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) Is there continuity? YES - Replace the PCM with a new one, and recheck. NO - • Open circuit in Yellow wire. • Open circuit in Green/red wire. 14-43 DRIVETRAIN SYSTEM GEAR POSITION SWITCH INSPECTION Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector (page 216). Check for continuity between each gear position switch wire terminal of the PCM connector and ground. PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) A16 A25 A24 There should be continuity only at the terminals that correspond to the gearshift lever positions shown below, and there should be no continuity at the other terminals. You must test each of the three wires in each gearshift lever position. Therefore, you need to make 9 tests, between each gear position switch wire terminal and ground. If the test result is abnormal, disconnect the gear position switch 3P (Natural) connector. Perform the continuity test at the 3P (Natural) connector in the same manner (page 14-44). Color Position Light blue/ white DRIVE NEUTRAL REVERSE o- Light green o Gray GND -o -o If the test result at the PCM is abnormal and the one at the 3P connector is normal, check for open or short circuit, or loose or poor connector contact. If the both test results are abnormal, replace the gear position switch. 3P(NATURAL CONNECTOR REPLACEMENT Remove the following: - seat (page 3-4) - right side cover (page 3-5) - left fuel tank side cover (page 3-7) Disconnect the gear position switch 3P (Natural) connector. Release the gear position switch wire from the clamps. 3P(NATURAL CONNECTOR 14-44 DRIVETRAIN SYSTEM Shift the sub-transmission into neutral. Remove the two bolts and the gear position switch from the crankcase cover. GEAR POSITION SWITCH Coat a new O-ring with engine oil and install it onto a new gear position switch. Align the long end of the switch pin with the " N " mark. Install the gear position switch by aligning the switch pin with the slot in the crankcase cover being careful not to damage the switch pin. Install the bolts and tighten them. Route the gear position switch wire properly (page 1-20). GEARSHIFT SWITCH NOTE. • The A/T can shift and the meter indicates the shift position (1 through 3) with the following conditions: - Mode select switch at ESP (Electric Shift Program) - Gearshift lever in D range - Ignition switch turned ON INSPECTION Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector (page 216). NOTE: • When reconnecting the PCM 33P connector, check that there is no dirt and oil in the connector. Check for continuity between the PCM connector terminals in each switch position. PCI\/I33P(B LACK) corsINECTOR (Wire sicie jrminal) off P A6 r-@A3 \ \ " i [ i Continuity should exist between the color coded wires as follows: Perform the continuity test at the 10P (Green) connector in the same manner (page 14-45). 1 y J ] / / A5 If the test result is abnormal, remove the right inner fender (page 3-9). Disconnect the left handlebar switch 10P (Green) connector. v DOWN ^\Color White/ White/ White/ White/ yellow red Positioft\ blue red Up Free Down o - -o o- —o 14-45 DRIVETRAIN SYSTEM If the test result at the PCM is abnormal and the one at the 10P (Green) connector is normal, check for open or short circuit, or loose or poor connector contact. If the both test results are abnormal, replace the handlebar switch (gearshift switch). DRIVE MODE SELECT SWITCH INSPECTION Turn the ignition switch OFF. Disconnect the PCM 33P (Black) connector (page 216). PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) Green Black/blue NOTE: • When reconnecting the PCM 33P connector, check that there is no dirt and oil in the connector. Check for continuity between the PCM connector terminals in each switch position. TOOL: Test probe 07ZAJ-RDJA110 Continuity should exist between the color coded wires as follows: A18 PCM 5P (BLACK) CONNECTOR (Wire side of female terminal) If the test result is abnormal, remove the right inner fender (page 3-9). Disconnect the drive mode select switch 3P (Black) connector. Perform the continuity test at the 3P (Black) connector in the same manner (page 14-46). Color Blue/ Black/ Green Position \ orange green ESP o •o D If the test result at the PCM is abnormal and the one at the 3P (Black) connector is normal, check for open or short circuit, or loose or poor connector contact. If the both test results are abnormal, replace the drive mode select switch. 3P BLACK CONNECTOR 14-46 DRIVETRAIN SYSTEM SHIFT VALVE BODY NOTICE Do not drop or strike the solenoid valves when servicing. 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 A/T clutch pressure control solenoid (stuck; mechanical lock), and the vehicle is hindered from running. Open the bypass oil circuit manually to supply hydraulic pressure (In this case, the transmission will be fixed in the 2nd range and the vehicle creeps during idling.) • The stopper bolt that operates the emergency valve is secured with the lock plate. When trouble occurs, remove the lock plate and turn the stopper bolt all the way in to activate the emergency valve. STOPPER BOLT REMOVAL Remove the following: - Clean around the valve body with compressed air to remove dust, dirt and foreign material. left engine side cover (page 3-17) left front mud guard (page 3-8) left inner fender (page 3-9) wire clip two setting bolts valve body cover shift solenoid valve 2P (Black and Brown) con- ' nectors A/T clutch pressure control 2P (Black) connector SHIFT SOLENOID CONNECTORS A/T CLUTCH PC SOLENOID CONNECTOR 14-47 DRIVETRAIN SYSTEM six bolts (small head) shift valve body assembly If the valve body will be disassembled, loosen the six solenoid valve bolts and four sealing bolts (large head; gold). Place a shop towel under the valve body. - gasket four oil joint collars O-rings JOINT COLL4RS/O-RINGS DISASSEMBLY/INSPECTION NOTE: • Keep dust and dirt away from all the parts. • Take care not to damage the mating surfaces of the valve bodies. The emergency SOLENOID AND EMERGENCY VALVES valve is built in the Remove the following from the valve body cover: A/T clutch pressure control solenoid. - bolts - shift solenoid valve A and B (by pulling out of the body cover) screw and lock plate four bolts and A/T clutch pressure control solenoid assembly rubber seal (from the valve body) A/T clutch pressure control solenoid Use a hand- Connect a pressure pump to the input port (filter operated air pump side) of the shift solenoid valve. only. Do not use a high pressure air Connect a 12 V battery to the solenoid valve short the positive terminals and check for air flow conditions (do not and negative use a thin wire because a large amount of current terminals. flows). - valve A: Yellow/black (+) - Green/white (-) valve B: Yellow/green (+) - Green (-) Air should not flow (the pressure should maintained) while the battery is connected, and should flow out of the output ports that goes to the shift valve when the battery is disconnected. 14-48 SCREW AND LOCK PLATE 11 J T OUTLET PORTS INLET PORT DRIVETRAIN SYSTEM Be careful not to Connect the 12 V battery positive terminal to the short the positive Yellow/red terminal and negative terminal to the and negative Blue/red terminal of the A/T clutch pressure control terminals. solenoid 2P (Black) connector, and check the spool valve through the oil passages for operation. The valve should move to away from the solenoid side when the battery is connected, and should return by spring force when the battery is disconnected. SPOOL VALVE Remove the following from the linear solenoid assembly: - valve stopper bolt emergency valve valve spring Blow through all the oil passages Wash all the parts with a high flash point or nonthoroughly flammable solvent and blow dry them with com(including solenoid pressed air to clean completely. valves). Check the emergency valve and valve bore for scoring, scratch or abnormal wear. SPRING EMERGENCY VALVE STOPPER BOLT ORIFICE CONTROL AND SHIFT VALVES Remove the following: - four bolts orifice control valve body ORIFICE CONTROL VALVE BODY - separator plate shift valve body SHIFT VALVE BODY 14-49 DRIVETRAIN SYSTEM - separator plate two dowel pins four sealing bolts and washers PLATE BOLTS AND WASHERS DOWEL PINS Remove the following from the orifice control valve body: - spring seats valve springs orifice control valves (2nd and 3rd) ORIFICE CONTROL VALVE (2nd) \ SPRING SPRING SEAT Remove the following from the shift valve body: - ORIFICE CONTROL VALVE (3rd) SHIFT VALVE (1-2) spring seats valve springs shift valves (1-2 and 2-3) Blow through all the Wash all the parts with a high flash point or nono/7passages flammable solvent and blow dry them with comthoroughly. pressed air to clean completely. Check the spool valves (orifice control and shift valves) and valve bores for scoring, scratch or abnormal wear. SPRING SEAT 14-50 SHIFT VALVE (2-3) DRIVETRAIN SYSTEM ASSEMBLY NOTE: • Before assembly, clean all the parts with compressed air. Make sure that there is no dust or lint on any parts. A/T clutch pressure control solenoid VALVE SPRING EMERGENCY VALVE STOPPER BOLT SCREW LOCK PLATE VALVE BODY COVER SHIFT VALVE BODY SHIFT SOLENOID VALVE B \ ~ SHIFT SOLENOID VALVE A SHIFT VALVE (1-2) VALVE SPRING SPRING SEAT ORIFICE CONTROL VALVE (2nd) VALVE SPRING ORIFICE CONTROL VALVE BODY SPRING SEAT ORIFICE CONTROL VALVE (3rd) SHIFT AND ORIFICE CONTROL VALVES Apply engine oil to the outer surface of the spool (shift and orifice control) valves. SHIFT VALVE/SPRING Install the spring Insert each shift valve (1-2 and 2-3) and spring into seats with the slit the shift valve body and secure it with the spring facing away from seat. the orifice control valve body (page 14-51). SHIFT VALVE BODY 14-51 DRIVETRAIN SYSTEM Install the spring Insert each orifice control valve (2nd and 3rd) and seats with the slit spring into the shift valve body and secure it with facing away from the spring seat. the shift valve body (page 14-51). ORIFICE CONTROL VALVE BODY CONTROL VALVE/ SPRING SPRING SEAT Install the four sealing bolts with new sealing washers. VALVE BODY PLATE Install the following onto the valve body cover: - dowel pins separator plate shift valve body BOLTS AND WASHERS BODY COVER Install the following onto the shift valve body: - separator plate orifice control valve body PLATE Install the four valve body bolts and tighten them securely. Tighten the four sealing bolts. 14-52 SEALING BOLTS DRIVETRAIN SYSTEM SOLENOID AND EMERGENCY VALVES Coat a new O-ring with engine oil and install it into the stopper bolt groove. Apply engine oil to the emergency valve. SCREW LOCK PLATE STOPPER BOLT Install the spring and emergency valve into the A/T clutch pressure control solenoid body with the concave head end portion of valve facing in. Install the valve stopper bolt and screw it in until the groove edge is aligned with the valve body surface. Install the lock plate and screw as shown. Coat a new rubber seal with engine oil and install it into the groove in the A/T clutch pressure control solenoid body. Install the A/T clutch pressure control solenoid assembly with the four bolts. A/T CLUTCH PRESSURE CONTROL SOLENOID BOLTS Coat new O-rings with engine oil and install them into the grooves in each shift solenoid valve. Do not interchange A and B. B (Brown) A (Black) Install the shift solenoid valve A and B with the bolts. Tighten the six solenoid valve bolts and lock plate screw securely. SCREW INSTALLATION Clean the mating surface of the valve body assembly and front crankcase cover. Coat new O-rings with engine oil and install them into the grooves in the oil joint collars. Install the four joint collars and a new gasket. JOINT COLLARS/O-RINGS , *W' 14-53 DRIVETRAIN SYSTEM Install the shift valve body assembly with the six bolts and tighten them securely. BOLTS Connect the solenoid valve 2P (Black and Brown) ' connectors. Connect the A/T clutch pressure control 2P (Black) connector. SHIFT SOLENOID CONNECTORS A/T CLUTCH PC SOLENOID CONNECTOR (long wire) Install the valve body cover with the two setting bolts and tighten them. Install the wire clip over the wire harness and into the body cover. Perform the transmission oil pressure check, if necessary (page 14-12). Install the following: - inner fender (page 3-9) front mud guard (page 3-8) engine side cover (page 3-17) FRONT CRANKCASE COVER REMOVAL Remove the following: - front mud guards (page 3-8) inner fenders (page 3-9) front center grille (page 3-10) center mud guards (page 3-7) engine side covers (page 3-17) engine guard (page 3-17) front propeller shaft (page 8-6). water pump (page 7-14) shift valve body (page 14-47) OILPIPCS oil pipes (by removing each joint bolt) O-rings O-RINGS 14-54 DRIVETRAIN SYSTEM pipe setting cap and O-ring oil feed pipe C pipe setting collar (by pulling it out with a needle nose pliers) and O-rings SETTING COLLAR SETTING CAP - oil feed pipe B and O-ring CRANKCASE SETTING CAP SETTING COLLAR O-RING fourteen bolts side cover stays and hose guide front crankcase cover two oil joint pipes and O-rings oil orifice and O-rings two dowel pins 14-55 DRIVETRAIN SYSTEM CLEANING/INSPECTION Remove the following: OIL PIPE JOINT - oil filter (page 4-12) - dipstick - sealing bolts and washers - three bolts and oil pipe joint Wash the crankcase cover with solvent and blow through all the passages with compressed air to clean them thoroughly. DIPSTICK The feed pipes are supplying engine oil to each shift clutch; A: 1st, B: 2nd and C: 3rd. Check the feed pipe A, B and C for abnormal wear or damage. The hydraulic oil in the torque converter is supplied through the crankshaft. Check the crankshaft seal collar behind the bearing for abnormal wear or damage. BOLTS AND WASHERS For replacement, see page 14-56. BEARING REPLACEMENT Remove the crankshaft bearing using the special tools. TOOLS: Bearing remover, 17 mm Remover handle Remover weight CRANKSHAFT BEARING OIL SEAL BEARING PEMOVER OUTPUT SHAFT BEARING 07936-3710300 07936-3710100 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) Remove the output shaft oil seal. Drive the output shaft bearings out of the crankcase cover. 14-56 DRIVETRAIN SYSTEM Remove the snap ring and washer, and the seal collar. Coat a new O-ring with engine oil and install it into the groove in a new collar. Be careful not to Install the collar until it is seated. Install the washer damage the inner and the snap ring into the cover groove properly. surface of the collar. Drive a new bearing in with the marked side facing up. TOOLS: Crankshaft bearing: Driver Attachment, 42 x 47 mm Pilot, 17 mm 07749-0010000 07746-0010300 07746-0040400 Output shaft bearing: Driver Attachment, 42 x 47 mm Pilot, 25 mm 07749-0010000 07746-0010300 07746-0040600 ATTACHMENT/PILOT INSTALLATION Blow through the oil passage in the crankcase cover with compressed air. OIL PIPE JOINT Clean the crankcase and cover mating surfaces. Install the following if they were removed: - sealing bolts with new washers oil pipe joint with a new O-ring dip stick oil filter (page 4-12) BOLTS AND WASHERS Apply engine oil to the lips of a new oil seal, and install it into the crankcase cover until it is fully seated. 14-57 DRIVETRAIN SYSTEM Coat new O-rings with engine oil and install them onto the joint pipe. Install the joint pipes into the oil pump. Apply liquid sealant (Three Bond 1215 or equivalent) to the mating surface of the crankcase cover. Blow the oil orifice with compressed air to clean the passage. Coat new O-rings with engine oil and install them into the orifice groove. Install the oil orifice with the stepped side facing out. Install the two dowel pins. 14-58 DRIVETRAIN SYSTEM Install the following: - CRANKCASE COVER front crankcase cover 14 bolts with the side cover stays and hose guide Make sure the mating surfaces Tighten the bolts in a crisscross pattern in several touch evenly, there steps securely. should be no clearance between the cover and crankcase. BOLTS STAYS Coat a new O-ring with engine oil and install it onto the flange of the feed pipe B. Apply engine oil to the outer surface of pipe B. Align the flange Carefully insert pipe B into the crankcase cover tabs with the while turning it slowly to avoid damaging the oil grooves in the seal in the crankcase. cover. Coat new O-rings with engine oil and install them into the setting collar grooves. Install the setting collar until it is seated. O-RINGS Apply engine oil to the outer surface of feed pipe C. Align the flange Insert pipe C while turning it slowly to avoid damagtabs with the ing the O-ring in the setting collar. grooves in the C o g t g n e w o . r j n g w j t h engine oil and install it into collar the setting cap groove. Install the setting cap and tighten it. TORQUE: 21 N-m (2.1 kgf-m, 15 Ibf-ft) PIPEC SETTING CAP 14-59 DRIVETRAIN SYSTEM Coat new O-rings with engine oil and install them into the oil pipe grooves. Connect the pipe B Connect the oil pipes with the bolts and tighten (flange lug) to the them securely. front side Install the following: - shift valve body (page 14-53) water pump (page 7-15) front propeller shaft (page 8-10) engine side covers (page 3-17) center mud guards (page 3-7) front center grille (page 3-10) inner fenders (page 3-9) front mud guards (page 3-8) TORQUE CONVERTER REMOVAL Remove the front crankcase cover (page 14-54). Be careful not to Unstake the lock nut. damage the Loosen the lock nut while holding the converter crankshaft threads. boss with an open end wrench (width across flats: 32 mm). Remove the lock nut and washer. Remove the torque converter assembly using the special tools. TOOL: Puller, 35 x 1.0 mm 07933-HA80000 or 07933-HB3000A (U.S.A. only) Remove the following: - stator shaft (while turning it counterclockwise) needle bearings | STATOR SHAFT 14-60 DRIVETRAIN SYSTEM washers inner collar needle bearings THRUSTNEEDLE BEARING TORQUE CONVERTER INSPECTION NOTE: • Replace the torque converter as an assembly (from converter to inner collar). Check the primary drive gear teeth for abnormal wear or damage. Hold the torque converter and turn the drive gear to check the one-way clutch in the torque converter. The gear should turn counterclockwise smoothly and should not turn clockwise. DRIVE GEAR Check the needle bearings for abnormal wear or damage. Check the one-way clutch sprag in the stator shaft for abnormal wear, damage or irregular movement. Check the sprag contacting surface for abnormal wear or damage. STATOR SHAFT INNER COLLAR 14-61 DRIVETRAIN SYSTEM Check the seal ring on the stator shaft for abnormal wear or damage. Assemble the stator shaft and inner collar. Hold the inner collar and turn the stator shaft. The shaft should turn counterclockwise smoothly and should not turn clockwise. SHIFT CLUTCH/MAINSHAFT DISASSEMBLY NOTE: • For 2nd/3rd shift clutch (countershaft) mainshaft removal (page 13-2). and 1st SHIFT CLUTCH REMOVAL Remove the torque converter (page 14-60). Be careful not to damage the mainshaft threads. Unstake the lock nut. Loosen the lock nut while holding the driven geai boss with an open end wrench (width across flats; 29 mm). Remove the following: - 14-62 lock nut washer 1st shift clutch assembly DRIVETRAIN SYSTEM - washer M1 gear guide O-rings 1st SHIFT CLUTCH DISASSEMBLY Remove the following from the clutch drum: - DRIVEN GEAR primary driven gear O-rings stopper ring end plate STOPPER RING END PLATE - three clutch discs and plates wave spring WAVE SPRING Remove the return spring and clutch piston (page 14-65). CLUTCH PLATES CLUTCH DISCS 14-63 DRIVETRAIN SYSTEM 2nd/3rd SHIFT CLUTCH AND MAINSHAFT DISASSEMBLY Remove the countershaft (2nd/3rd shift clutch) and mainshaft (page 13-7). C3GEAR C2 GEAR Remove the end washers with a screwdriver and disassemble the countershaft: - C1 gear thrust washer C2 gear bearing lock washer C3gear bearing thrust washer 2nd/3rd shift clutch assembly O-rings C1 GEAR SHIFT CLUTCH ASSEMBLY END WASHER LOCK WASHER THRUST WASHER i THRUST WASHER END WASHER BEARING Remove the following from each clutch drum: - stopper ring end plate END PLATE - three clutch discs and plates wave spring WAVE SPRING Remove the return spring and clutch piston (page 14-65). CLUTCH PLATES CLUTCH DISCS 14-64 DRIVETRAIN SYSTEM CLUTCH PISTON REMOVAL Install the following special tools onto the shift clutch. COMPRESSOR BOLT ATTACHMENTS (07LAE-PX40100) TOOLS: Clutch compressor attachment 07LAE-PX40100 (2 required) Compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A (U.S.A. only) If either support block end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. NOTE: • Be sure the special tool is adjusted to have full contact the stepped areas with the spring retainer. SUPPORT BLOCKS RETAINER To prevent loss of Compress the return spring by tightening the nut. spring tension, do Remove the snap ring from the boss. not compress more than necessary. Loosen the special tool and remove the following: - SNAP RING snap ring spring retainer return spring RETAINER SPRING 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 them with compressed air. 14-65 DRIVETRAIN SYSTEM MAINSHAFT DISASSEMBLY Remove the mainshaft (page 13-7). M3 GEAR Disassemble the mainshaft: - M2GEAR M1 gear bearing washer M3 gear snap rings M2 gear M1 GEAR SNAP RINGS WASHER BEARING INSPECTION MAINSHAFT The M1 gear Check each gear tooth and bearing for abnormal bearing has one wear or damage. roller missing from C h e c | < t h f i QJ| h o | e s j n t h e m a i n s h a f t f o r d M3GEAR M2 GEAR each cage by design. M1 GEAR SNAP RINGS WASHER / BEARING CLUTCH DRUM AND PISTON Check the clutch drum for nicks, indentations or abnormal wear made by the clutch plates. CHECK VALVE Check the oil holes in the drum boss and check valve in the piston for clogs. CLUTCH DRUM PISTON CLUTCH DISC AND PLATE Replace the clutch Check the linings of the clutch discs for wear (disc discs and plates as groove disappearance). a set. Check the clutch plates for discoloration. DISC 14-66 DRIVETRAIN SYSTEM CLUTCH RETURN SPRING Measure the spring free length. SERVICE LIMIT: 31.8 mm (1.25 in) SHIFT CLUTCH/MAINSHAFT ASSEMBLY MAINSHAFT ASSEMBLY Blow through the oil passages in the mainshaft with compressed air. I M2 GEAR Apply engine oil to the each gear teeth and bearing. Install the snap ring Install the following onto the mainshaft: and washer with - M2 gear the chamfered - snap rings (so that its end gap aligns with the (rolled) edge facing groove in the splines) away from the - M3 gear (with the ribs facing out) thrust load. M3 GEAR RIBS SNAP RINGS The Ml gear - washer bearing has one - bearing roller missing from - M1 gear each cage by Make sure the snap rings are fully seated in the design. shaft grooves. M1 GEAR Install the mainshaft assembly with the countershaft (2/3 shift clutch) (page 13-10). WASHER BEARING 14-67 DRIVETRAIN SYSTEM SHIFT CLUTCH ASSEMBLY 1st SHIFT CLUTCH CLUTCH PLATES (3 pcs) CLUTCH DISCS (3 pcs) END PLATE STOPPER RING RETURN SPRING PRIMARY DRIVEN GEAR SPRING RETAINER O-RINGS CLUTCH PISTON SNAP RING 2nd/3rd SHIFT CLUTCH CLUTCH DRUM O-RINGS CLUTCH PISTON WAVE SPRING CLUTCH PLATES (3 pcs) CLUTCH DISCS (3 pcs) END PLATE RETURN SPRING SPRING RETAINER SNAP RING STOPPER RING 14-68 DRIVETRAIN SYSTEM All shift clutches Clean the inner surface of the clutch drum thorDRUM (1st, 2ndand3rd) oughly and blow through the oil holes in the drum use the following boss and check valve in the piston. proce ure. ^pp|y e n g | n e o j | t 0 n e w O-rings and install them into the piston groove. Place the clutch piston into the clutch drum in the direction shown. Be careful not to Install the piston while turning it to ensure proper PISTON pinch the O-rings seating. with too much force. Place the following into the clutch drum. - SPECIAL TOOLS return spring spring retainer snap ring Install the special tools while adjusting their position carefully (page 14-65). To prevent loss of Compress the return spring by tightening the nut. spring tension, do not compress more than necessary. SPRING RETAINER SNAP RING Align the end gap Install the snap ring into the groove in the drum with the groove (3 boss properly. places) in the spring Loosen the special tools and remove them. retainer. SNAP RING 14-69 DRIVETRAIN SYSTEM Install the wave spring into the piston groove. WAVE SPRING Coat the clutch discs with clean engine oil. Install the three clutch plates and discs alternately, starting with the plate. Install the end plate with the stepped side facing out. STOPPER RING Install the stopper ring into the drum grooves properly. Perform the initial clearance inspection (page 1470). END PLATE CLUTCH INITIAL CLEARANCE CHECK Assemble the shift clutch. Measure the clearance between the end plate and top disc. Set a dial indicator on the end plate with the plate is lowered. Lift the end plate up against the stopper ring and read the clearance, and record it. Perform this inspection at the three points from 120° apart. STANDARD: 0.7 - 0.9 mm (0.03 - 0.04 in) If the clearance is not within the standard value, replace the end plate with a new one as follows. Remove the stopper 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 14-70 END PLATE DRIVETRAIN SYSTEM If the calculated Select the end plate, and install it and the stopper dimension is over ring drum grooves properly. the thickest plate 1st CLUTCH 2nd/3rd CLUTCH thickness, replace Mark Thickness Mark Thickness the clutch discs and plates as a set. 1 2.1 mm 1 2.3 mm 2 3 4 5 6 7 8 9 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 mm mm mm mm mm mm mm mm 2 3 4 5 11 12 13 14 15 16 2.6 mm 2.9 mm 3.2 mm 3.5 mm 2.15 mm 2.45 mm 2.75 mm 3.05 mm 3.35 mm 3.65 mm 2nd/3rd shift clutch: Install the countershaft and transmission gears (page 14-71). 1st shift clutch: Install the primary drive gear (page 14-72). COUNTERSHAFT ASSEMBLY (2nd/3rd Shift Clutch) Blow through the oil passages in the countershaft with compressed air. O-RINGS Coat new O-rings with engine oil and install them into the shaft grooves as shown. Install the countershaft into the shift clutch by aligning the splines. Apply engine oil to the gear teeth and the bearings and assemble the countershaft. NOTE: • Install the washer with the chamfered (rolled) edge facing away from the thrust load. • Align the lock washer groove with the tabs on the clutch drum boss. C2 GEAR LOCK WASHER THRUST WASHER C1 GEAR END WASHER END WASHER C3 GEAR NEEDLE BEARING THRUST WASHER 2nd/3rd SHIFT CLUTCH ASSEMBLY Install the countershaft assembly with the mainshaft (page 13-10). 14-71 DRIVETRAIN SYSTEM PRIMARY DRIVEN GEAR INSTALLATION (1st Shift Clutch) Blow through the oil holes in the driven gear boss with compressed air. DRIVEN GEAR Coat new O-rings with engine oil and install them into the boss grooves. Install the primary driven gear into the shift clutch until it is fully seated. Install the 1st shift clutch assembly (page 14-72). SHIFT CLUTCH 1st SHIFT CLUTCH INSTALLATION Install the following: - M1 gear guide (apply engine oil to the gear teeth) washer new O-rings (apply engine oil) Line up the tabs of the three clutch discs in the shift clutch. Align the disc tabs Carefully install the shift clutch assembly onto the with the gear guide mainshaft and onto the M1 gear guide until it is fully teeth, seated (the whole of the shaft threads are exposed). Apply engine oil to the threads of a new lock nut. Install the washer and lock nut. Tighten the lock nut while holding the driven gear boss with an open end wrench (width across flats: 29 mm). TORQUE: 108 N m (11.0 kgf-m, 80 Ibf-ft) Be careful not to Stake the lock nut into the shaft groove. damage the | n s t a | | t h e torque converter H(page 14-73). M a mainshaft threads. 14-72 DRIVETRAIN SYSTEM TORQUE CONVERTER INSTALLATION Apply engine oil to the bearings, gear teeth and clutch sprag. INNER COLLAR WASHERS STATOR SHAFT TORQUE CONVERTER Install the needle bearing into the inner collar. Install the inner collar and onto the crankshaft by aligning the cutout with the stopper pin. THRUSTNEEDLE BEARING Install the thrust needle bearing onto the inner collar with the needle roller side facing in. Install the washers. WASHER •mmmmmmi Install the three bearings onto the stator shaft. NEEDLE BEARINGS 14-73 DRIVETRAIN SYSTEM Install the stator shaft while turning it counterclockwise. Install the torque converter, aligning the splines P-TORQUE CONVERTER carefully. Install the washer. Apply engine oil to the threads of a new lock nut. Install the lock nut and tighten it while holding the converter boss with an open end wrench (width across flats: 32 mm). TORQUE: 108 N m (11.0 kgf m, 80 ibf-ft) Be careful not to Stake the lock nut into the crankshaft groove. damage the {nstM t h e f r o n t c r a n | < c a s e c o v e r ( p a g e 14.57) crankshaft threads. 14-74 a 15. FRONT WHEEL/SUSPENSION/STEERING SYSTEM COMPONENTS 15-2 SERVICE I N F O R M A T I O N ••••• 15-3 TIRES 15-11 WHEEL HUB AND KNUCKLE- •15-15 TROUBLESHOOTING 15-5 FRONT SHOCK ABSORBER •15-22 HANDLEBAR 15-6 SUSPENSION ARM- •15-23 •15-28 THROTTLE HOUSING 15-10 STEERING SHAFT FRONT WHEEL 15-11 TIE-ROD • 15-33 15-1 FRONT WHEEL/SUSPENSION/STEERING SYSTEM COMPONENTS 32 N-m (3.3 kgf-m, 24 44 N-m (4.5 kgf 34 N-m (3.5 kgf- 44 N-m (4.5 29 N-m (3.0 kgf-m 78 N-m (8.0 kgf-m, 58 Ibfft) 64 N-m (6.5 kgf-m, 47 Ibfft) 15-2 FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL • 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 4-23). Do not twist or bend the brake hose and pipe when serving. Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. For brake system information (page 17-2). For handlebar switch inspection (page 23-7). SPECIFICATIONS ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo Tie-rod distance between the ball joints Toe STANDARD 30 kPa (0.30 kgf/cm2, 4.4 psi) 26 kPa (0.26 kgf/cm2, 3.8 psi) 34 kPa (0.34 kgf/cm2, 5.0 psi) 30 kPa (0.30 kgf/cm2, 4.4 psi) 387.5 ± 1 mm (15.26+ 0.4 in) Toe-out: 10.9+15 mm (7/16 ±9/16 in) SERVICE LIMIT 4 mm (0.16 in) - TORQUE VALUES Handlebar lower holder nut Front wheel nut Front wheel hub nut 39 N-m (4.0 kgf-m, 29 Ibf-ft) 64 N-m (6.5 kgf-m, 47 Ibf-ft) 78 N-m (8.0 kgf-m, 58 Ibf-ft) Front brake caliper bracket flange bolt Front brake disc bolt Front brake splash guard flange bolt Shock absorber mounting nut Brake hose clamp flange bolt Upper arm pivot nut Lower arm pivot nut Upper and lower arm ball joint nut 44 N-m (4.5 kgf-m, 33 Ibf-ft) Tie-rod stud joint nut Combination meter stay mounting nut Steering shaft end nut Steering shaft holder bolt Parking lock lever screw Rear brake lever pivot bolt Rear brake lever pivot nut Parking stopper stay screw Brake light switch (left lever side) 42 N-m (4 3 kgf-m, 31 11 N-m(1 1 kgf-m, 8 44 N-m (4 ,5 kgf-m, 33 12 N-m (1 ,2 kgf-m, 9 34 N-m (3. 5 kgf-m, 25 44 N-m (4. 5 kgf-m, 33 29 N-m (3. 0 kgf-m. 21 Ibf-ft) Ibf-ft) Ibf-ft) Ibf-ft) Ibf-ft) Ibf-ft) Ibf-ft) 54 N-m (5.5 kgf-m, 40 Ibf-ft) 25 N-m (2.5 kgf-m, 18 Ibf-ft) 108 N-m (11.0 kgf-m, 80 Ibf-ft) 32 N-m (3.3 kgf-m, 24 Ibf-ft) 7 N-m (0.7 kgf-m, 5.1 Ibf-ft) 1 N-m (0.1 kgf-m, 0.7 Ibf-ft) 6 N-m (0.6 kgf-m, 4.3 Ibf-ft) 2 N-m (0.2 kgf-m, 1.4 Ibf-ft) 1 N-m (0.1 kgf-m, 0.7 Ibf-ft) Lock nut: replace with a new one. Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole. ALOC bolt: replace with a new one ALOC bolt: replace with a new one ALOC bolt: replace with a new one Lock nut: replace with a new one. Lock nut: replace with a new one. Lock nut: replace with a new one. Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole. Lock nut: replace with a new one. Apply locking agent 15-3 FRONT WHEEL/SUSPENSION/STEERING TOOLS Attachment, 42 x 47 mm 07746-0010300 Attachment, 52 x 55 mm 07746-0010400 Attachment, 22 x 24 mm 07746-0010800 Attachment, 20 mm I.D. 07746-0020400 Pilot, 30 mm 07746-0040700 Pilot, 16 mm 07746-0041300 Attachment, 28 x 30 mm 07946-1870100 Compressor bolt assembly 07GAE-PG40200 or 07746-0020300 or 07746-0020200 Driver 07749-0010000 or 07GAE-PG4020A (U.S.A. only) Oil seal driver 07JAD-PH80101 Clutch compressor attachment 07LAE-PX40100 Ball joint remover, 28 mm 07MAC-SL00201 07ilvlAC-SL0202 (U.S.A.only) or 07IV1AC-SL00200 and 07MAC-SL0A300 (U.S.A.only) 15-4 FRONT WHEEL/SUSPENSION/STEERING Ball joint remover/installer 07WMF-HN00100 ATV Bead Buster KLS379024 (U.S.A. only) TROUBLESHOOTING Hard steering • Steering shaft holder too tight • Damaged steering shaft bearing/bushing • Insufficient tire pressure Steers to 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 • Bent rim • Worn or damaged knuckle bearing • Faulty tire • Wheel hub nut not tightened properly Soft suspension • Weak shock absorber spring • Faulty shock absorber damper Hard suspension • Bent shock absorber damper rod • Improperly installed suspension arms • Faulty suspension arm bushings Front suspension noise • Loose front suspension fasteners • Damaged suspension components 15-5 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the meter covers (page 3-18). FGA model shown: • COMBINATION METER Remove the following: - two nuts combination meter/stay assembly brake hose (from the hose clamp) - three wire bands WIRE BANDS Keep the master cylinder upright to prevent air from entering the hydraulic system. - - AUSTRALIA type only: - - two screws throttle housing holder throttle housing connectors two bolts master cylinder holder brake master cylinder MASTER CYLINDER screw nut horn switch HORN SWITCH 15-6 THROTTLE HOUSING NUT FRONT WHEEL/SUSPENSION/STEERING two screws bracket holder rear brake lever bracket three screws handlebar switch HANDLEBAR SWITCH LEVER BRACKET bolts grip ends and collars handlebar grips GRIP BOLT/COLLAR/GRIP END four bolts upper holders handlebar INSTALLATION Align the punch mark on the handlebar with the with the top edge of the lower holder. Install the handlebar and upper holders with the punch marks facing forward. Tighten the front bolts first, then tighten the rear bolts. PUNCH MARKS HANDLEBAR 15-7 FRONT WHEEL/SUSPENSION/STEERING Apply Honda Bond A or Honda Hand Grip Cement (U.S.A only) to the inside surface of each handlebar grip and to the clean surfaces of the handlebar. Wait 3-5 minutes and install the grips. Rotate the grips for even application of the adhesive. GRIP Install the grip ends with the collars and tighten the bolts. BOLT/COLLAR/GRIP END Align the seam of Install the left handlebar switch, and tighten the the switch with the inside screw (1) first, then tighten the outside punch mark on the screws (2). handlebar. Align the locating pin on the bracket with the hole in the switch housing. Install the brake lever bracket and holder with the punch mark facing up. Tighten the upper screw first, then tighten the lower screw. AUSTRALIA type Install the horn switch and tighten the screw and only: nut. HORN SWITCH 15-8 " NUT FRONT WHEEL/SUSPENSION/STEERING Align the edge of the master cylinder with the punch mark on the handlebar. Install the brake master cylinder and holder with the "UP" mark facing up. Tighten the upper bolt first, then tighten the lower bolt. HOLDER TORQUE: 12 N m (1.2 kgf m, 9 Ibf-ft) Connect the connectors to the brake and brake light switches. CONNECTORS Align the lug on the Install the throttle housing and holder against the throttle housing master cylinder. Tighten the front screw first, then with the mating line tighten the rear screw. of the master cylinder. LUG THROTTLE HOUSING Align Secure the switch wires with the three wire bands. Route the wires Install the combination meter/stay and tighten the and hose properly two nuts. (page 1-20). COMBINATION METER TORQUE: 25 N-m (2.5 kgf m, 18 Ibf-ft) Install the brake hose into the clamp. 15-9 FRONT WHEEL/SUSPENSION/STEERING THROTTLE HOUSING DISASSEMBLY Remove the following: - three screws throttle housing cover gasket BOOT Slide the boot off the throttle cable adjuster. Loosen the lock nut and cable adjuster. Bend down the lock washer tab and remove the following: - pivot nut and lock washer throttle lever and washer return spring throttle arm (by disconnecting the throttle cable) dust seal (from the housing bottom) ASSEMBLY Coat a new dust seal lip with grease and install it into the throttle housing until it is fully seated. Apply grease to the throttle lever pivot in the housing and to the throttle cable end. Connect the cable to the throttle arm. Install the washer onto the throttle lever and insert the throttle lever into the throttle housing. Install the throttle arm with the spring over the lever pivot by aligning the flat surfaces as shown. Install a new lock washer and the pivot nut, and tighten it. Bend up the washer tab against the nut. 15-10 WASHER FRONT WHEEL/SUSPENSION/STEERING Install the throttle housing cover with a new gasket and tighten the three screws. COVER Adjust the throttle lever free play (page 4-4). FRONT WHEEL REMOVAL Loosen the wheel nuts. Support the vehicle using a hoist or equivalent and raise the front wheels off the ground. Remove the nuts and wheel. INSTALLATION NOTE: • Do not interchange the left and right tires. Install the wheel with the arrow mark facing in the normal rotating direction. Install the wheel nuts and tighten them. TORQUE: 64 N m (6.5 kgf-m, 47 Ibf-ft) TIRES REMOVAL (U.S.A. only) NOTE. • This service requires the ATV 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 to the proper rim size. Align the flat side of the support with the corresponding rim size indicator. Use only water as a lubricant when removing or mounting tires. Soap or some mounting lubricants may leave a slipperly residue which can cause the tire to shift on the rim and lose tire pressure during riding. Lube the bead area of the tire with water, pressing down on the tire sidewall/bead area in several places to allow the water to run into and around the bead. 15-11 FRONT WHEEL/SUSPENSION/STEERING Place the wheel assembly over the center shaft and use the correct size cone to keep the wheel centered during operation. Install the bottom hold down nut, bearing side down, and finger tighten it so the wheel can rotate freely during operation. Install the breaker arm assembly over the center shaft and adjust the upper rim supports to fit the outside rim diameter. Install the top hold down nut and tighten it finger tight. CENTER SHAFT BREAKER ARM ASSY. NUT NUT UPPER RIM SUPPORTS Failure to back out Pull the leverage bar down so the breaker shoe is the breaker shoe just below the rim lip. Turn the crank to fully push two turns will cause the breaker shoe between the tire bead and rim. the shoe to scratch Once the shoe contacts the rim, back the crank out the bead lock, two turns to allow the shoe to clear the rim's bead which may cause lock. LEVERAGE BAR the tire to leak. Push down on the leverage bar to push the tire bead over the bead lock. Use only short strokes on the handle. While the shoe 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 properly and break the other bead by following the above procedures. Remove the tire from the rim using a tire changing machine or tire irons and rim protectors. 15-12 LEVERAGE BAR FRONT WHEEL/SUSPENSION/STEERING 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 described below. Check the tire for puncturing objects. Chalk mark the punctured area and remove the puncturing objects. Inspect and measure the injury. Tire repairs for injuries larger than 15 mm (5/8 in) should be a section repair. Section repairs should be done by a professional tire repair shop. If the injury is smaller than 15 mm (5/8 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. Insert and center a rubber plug through the eye of the inserting needle. Apply cement to rubber plug. Push the inserting needle with plug into the injury until the plug is slightly above the tire. Be careful not to push the plug all the way into the tire to prevent from falling inside. Twist the needle and remove it from the tire; the plug will stay in the tire. 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 15-11) and apply a cold patch to the inside of the tire. 15-13 FRONT WHEEL/SUSPENSION/STEERING If a plug has been inserted, trim it even with the inner tire surface. Temporarily place a rubber patch that is at least 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 over the injury. 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 installation. Clean the rim bead seat and flanges. Use only water as a lubricant when removing or mounting tires. Soap or some mounting lubricants may leave a slippery residue which can cause the tire to shift on the rim and lose air pressure during riding. Apply clean water to the rim flanges, bead seat and base. Install the valve core in the valve stem. Install the tire with the arrow mark facing in the normal rotating direction. Inflate the tire to seat the tire bead. Deflate the tire. Wait 1 hour and inflate the tire to the specified pressure. RECOMMENDED TIRE PRESSURE: FRONT: Standard: 30 kPa (0.30 kgf/cm2, 4.4 psi) Minimum: 26 kPa (0.26 kgf/cm2, 3.8 psi) Maximum: 34 kPa (0.34 kgf/cm2, 5.0 psi) With cargo: 30 kPa (0.30 kgf/cm2, 4.4 psi) REAR: Standard: 25 kPa (0.25 kgf/cm2, 3.6 psi) Minimum: 22 kPa (0.22 kgf/cm2, 3.2 psi) Maximum: 28 kPa (0.28 kgf/cm2, 4.0 psi) With cargo: 25 kPa (0.25 kgf/cm2. 3.6 psi) Check for air leaks and install the valve cap. 15-14 FRONT WHEEL/SUSPENSION/STEERING WHEEL HUB AND KNUCKLE REMOVAL Remove the front wheel (page 15-11). BRAKE CALIPER Support the caliper Remove the following: so that it does not mounting bolts hang from the brake front brake caliper hose. Do not twist or bend the brake hose. - cotter pin hub nut wheel hub WHEEL HUB - socket bolts splash guard Remove the cotter pin from the tie-rod ball joint Stud. Remove the ball joint nut by holding the joint stud flat surfaces. 15-15 FRONT WHEEL/SUSPENSION/STEERING Remove the brake disc cover flange bolts and brake disc cover. Remove the cotter pins from the ball joint studs. Loosen the ball joint nuts, but do not remove them yet. FLANGE BOLTS DISC COVER COTTER PINS, BALL JOINT NUTS Release the ball joints, using the special tool according to the following instructions. TOOL: Ball joint remover, 28 mm 07MAC-SL00201 or 07MAC-SL0202 (U.S.A. only) or 07MAC-SL00200 and 07MAC-SL0A300 (U.S.A. only) BALL JOINT REMOVER Apply grease to the ball joint remover at the point shown. This will ease installation of the tool and prevent damage to the pressure bolt threads. Insert the jaws carefully, making sure that you do not damage the ball joint boot. If necessary, apply Adjust the jaw spacing by turning the pressure bolt. penetrating type lubricant to loosen the ball joint. 15-16 Apply grease here PRESSURE BOLT FRONT WHEEL/SUSPENSION/STEERING To prevent the tool from dropping, tie the strap on a neighboring solid part such as the lower arm, tierod, etc. before operation. STRAP • Do not tie the 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 as necessary to make the jaws parallel. Then hand-tighten the pressure bolt and recheck the jaws to make sure they are still parallel. PRESSURE BOLT Tighten the pressure bolt with a wrench until the ball joint stud pops loose. Remove the ball joint nuts and the knuckle from the upper and lower arms. ADJUSTING BOLT INSPECTION Turn the inner race of the bearing in the knuckle with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly knuckle. BEARING 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. BOOT BRAKE DISC REPLACEMENT Remove the four socket bolts and brake disc from the wheel hub. BRAKE DISC Install a new brake disc with new socket bolts and tighten the bolts. TORQUE: 42 N m (4.3 kgf-m, 31 Ibf-ft) BOLTS 15-17 FRONT WHEEL/SUSPENSION/STEERING BEARING REPLACEMENT Remove the dust seals from the knuckle. DUST SEALS Remove the snap ring and drive the bearings out of the knuckle. TOOLS: Driver Attachment, 42 x 47 mm Pilot, 30 mm 07749-0010000 07746-0010300 07746-0040700 Pack the cavities of a new bearings with grease. Drive in the bearing squarely with the marked side facing up until they are fully seated. TOOLS: Driver Attachment, 52 x 55 mm Pilot, 30 mm 07749-0010000 07746-0010400 07746-0040700 PILOT Install the snap ring into the knuckle groove with the chamfered side facing in. 15-18 ATTACHMENT/PILOT SNAP RING FRONT WHEEL/SUSPENSION/STEERING Apply grease to a new outer dust seal lip and install seal using the same tools until it is flush with the knuckle end. OUTER DUST SEAL Apply grease to the lips of a new inner dust seal and install seal until it is flush with the knuckle end, being careful not to damage the lip. TOOLS: Driver Oil seal driver 07749-0010000 07JAD-PH80101 OIL SEAL DRIVER INNER DUST SEAL BALL JOINT REPLACEMENT Remove the snap ring from the ball joint. SNAP RING Set the knuckle and special tools with "A" mark side of the remover/installer facing to the ball joint in the vise as shown. Press the ball joint out of the knuckle. TOOLS: Ball joint remover/installer Attachment, 28 x 30 mm 07WMF-HN00100 07946-1870100 15-19 FRONT WHEEL/SUSPENSION/STEERING Set the knuckle and special tools with "B" mark side of the remover/installer facing to the ball joint in the vise as shown. Press the ball joint into the knuckle until it is fully seated. TOOLS: Ball joint remover/installer Attachment, 20 mm I.D. 07WMF-HN00100 07746-0020400 NOTICE If you feel strong resistance when compressing the vise, stop. Reset the attachment of the tool so that the ball joint head can go into the hollow of the attachment and try again. Install the snap ring with the chamfered edge facing in. INSTALLATION Install the knuckle onto the drive shaft, and lower and upper arms with the ball joint nuts. COTTER PINS, BALL JOINT NUTS Install the tie-rod ball joint into the knuckle with a new nut. Tighten each arm ball joint nut to the specified torque and further tighten until its grooves align with the cotter pin hole. TORQUE: 29 N-m (3.0 kgf-m, 21 Ibf-ft) Install new cotter pins. Install the brake disc cover and tighten the brake disc cover flange bolts. 15-20 DISC COVER FRONT WHEEL/SUSPENSION/STEERING Tighten the tie-rod ball joint nut by holding the joint stud flat surfaces. TIF.DOD BALL JOINT TORQUE: 54 IMm (5.5 kgf-m, 40 Ibf-ft) Install a new cotter pin. COTTER PIN ^ S S i Apply molybdenum disulfide grease to the drive shaft splines. BALL JOINT NUT SOCKET BOLTS Install the splash guard with new bolts and tighten the bolts. TORQUE: 11 N m (1.1 kgf m, 8 Ibf-ft) SPLASH GUARD Install the wheel hub and hub nut. Tighten the nut to the specified torque and further tighten until its grooves align with the cotter pin hole. TORQUE: 78 N m (8.0 kgf-m, 58 Ibf-ft) Install a new cotter pin. WHEEL HUB Install the front brake caliper with new mounting bolts and tighten the bolts. MOUNTING BOLTS BRAKE CALIPER TORQUE: 44 N m (4.5 kgf m, 32 Ibf-ft) Install the front wheel (page 15-11). 15-21 FRONT WHEEL/SUSPENSION/STEERING FRONT SHOCK ABSORBER REMOVAL Support the vehicle using a hoist or equivalent and r raise the front wheel off the ground. Support the lower arm. Remove the mounting nuts, bolts and shock absorber. INSPECTION Check the upper pivot bushing for wear or damage. Check the damper unit for leaks or other damage. Replace the shock absorber assembly if necessary. BUSHING For lower pivot bearing inspection and replacement (page 15-26). INSTALLATION Install the shock absorber in the frame and over the r upper arm, and insert the mounting bolts from the front side. Install new mounting nuts and tighten them. TORQUE: 44 N m (4.5 kgf m, 33 Ibf-ft) NUT 15-22 FRONT WHEEL/SUSPENSION/STEERING SUSPENSION ARM REMOVAL Remove the front carry pipe (page 3-10) Remove the front wheel (page 15-11). 1 COTTER PINS, BALL JOINT NUTS Remove the cotter pins from the ball joint studs. Loosen the ball joint nuts, but do not remove them yet. Release the ball joints, using the special tool according to the instructions (page 15-16). TOOL: Ball joint remover, 28 mm 07MAC-SL00201 or 07MAC-SL0202 (U.S.A. only) or 07MAC-SL00200 and 07MAC-SL0A300 (U.S.A. only) Support the wheel hub/knuckle assembly securely. BALL JOINT REMOVER Remove the following: - pivot nut, bolt and lower arm LOWER ARM Remove the two brake hose clamp bolts. BOLT/NUT I Remove the following: - shock absorber lower mounting nut and bolt pivot nuts, bolts and upper arm UPPER ARM BOLTS 15-23 FRONT WHEEL/SUSPENSION/STEERING INSPECTION Remove the seal caps and pivot collar from the upper arm. DUST SEAL CAPS BOOT For ball joint Inspect the ball joint boot for tears or other damage replacement by moving the ball joint stud. (page 15-25) It should moves freely and smoothly. PIVOT COLLAR Check the pivot bushings in the upper arm for wear or damage. BUSHINGS Remove the shock absorber lower pivot collar. NEEDLE BEARING Forbearing Check the pivot bearing for wear or damage. replacement (page 15-26) PIVOT COLLAR Remove the two flange bolts and lower arm guard if necessary. BUSHINGS Check the pivot bushings in the lower arm for wear or damage. ARM GUARD 15-24 FRONT WHEEL/SUSPENSION/STEERING BALL JOINT REPLACEMENT Remove the snap ring from the ball joint. BALL JOINT SNAP RING Set the upper arm and special tools with "A" mark side of the remover/installer facing to the ball joint as shown. Press the ball joint out of the upper arm. TOOLS: Ball joint remover/installer Attachment 28 x 30 mm ATTACHMENT 07WMF-HN00100 07946-1870100 Set the upper arm and special tools with " B " mark side of the remover/installer facing to the ball joint as shown. Press the ball joint into the upper arm until it is fully seated. TOOLS: Ball joint remover/installer Attachment, 20 mm I.D. Attachment, 17 mm I.D. Attachment, 15 mm I.D. 07WMF-HN00100 07746-0020400 or 07746-0020300 or 07746-0020200 NOTICE If you feel strong resistance when lowering the press, stop. Reset the attachment of the tool so the ball joint head can go into the hollow of the attachment and try again. Failure to reset the attachment will damage the ball joint and/or the upper arm. Install the snap ring with the chamfered edge facing in. SNAP RING 15-25 FRONT WHEEL/SUSPENSION/STEERING SHOCK ABSORBER LOWER PIVOT BEARING REPLACEMENT Remove the dust seals. NEEDLE BEARING Press the bearing out of the upper arm using the special tools. TOOLS: Driver Attachment, 22 x 24 mm Pilot, 16 mm 07749-0010000 07746-0010800 07746-0041300 Press the bearing Carefully press in a new bearing until it is flush with with the marked the pivot edge (until the press stops). side facing up. TOOLS: Driver Attachment, 22 x 24 mm Pilot, 16 mm 07749-0010000 07746-0010800 07746-0041300 Install new dust seals with the flat side facing in until the depth from the pivot outer surface is 1 mm (0.04 in). Apply grease to the dust seal lips and the needle rollers of the bearing. Install the pivot collar. PIVOT COLLAR 15-26 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Apply grease to the pivot collar outer surface and install the collar into the upper arm. Apply molybdenum disulfide grease to the dust seal lips and install the dust seal caps onto the upper arm. g—JifitM.1^ DUST SEAL CAPS Install the upper arm into the frame with the pivot bolt and a new nut, and tighten the nut to the specified torque. TORQUE: 34 N m (3.5 kgf-m, 25 Ibf-ft) Install the shock absorber lower mount to the upper arm with the mounting bolt and a new nut, and tighten the nut to the specified torque. TORQUE: 44 N m (4.5 kgfm, 32 Ibf-ft) Install and tighten the two new brake hose clamp bolts to the specified torque. TORQUE: 12 N m (1.2 kgf m, 9 Ibf-ft) Install the lower arm into the frame with the pivot bolts and new nuts, and loosely tighten the nuts. BOLTS AND ^ f e NUTS LOWER ARM Install the wheel hub/knuckle assembly onto the upper and lower arms and install the ball joint nuts. Tighten each nut to the specified torque and further tighten until its grooves align with the cotter pin hole. BALL INLJ I o/ COTTER PINS TORQUE: 29 N-m (3.0 kgf m, 21 Ibf-ft) Install new cotter pins. 15-27 FRONT WHEEL/SUSPENSION/STEERING Install the front wheel (page 15-11). Place the vehicle on level ground and tighten the lower arm pivot nuts. TORQUE: 44 N m (4.5 kgf m, 32 Ibf-ft) Install the front carrier pipe (page 3-10). STEERING SHAFT REMOVAL Remove the following: - front wheels (page 15-11) inner fenders (page 3-9) front fender (page 3-12) lower meter covers (page 3-18) - brake hose (from the clamp) wires (from the clip) CLIP | CLAMP two nuts combination meter/stay assembly brake hose (from the hose clamp) IFGA model shown METER/STAY IBRAKE HOSE I CLAMP ^ ^ ^ ^ H Keep the master cylinder reservoir upright. 15-28 handlebar lower holder nuts and washers handlebar assembly (from the steering shaft) NUTS I HANDLEBAR ASSEMBLY FRONT WHEEL/SUSPENSION/STEERING cotter pins tie-rod ball joint nuts (while holding the joint stud flats with an open end wrench) tie-rods (from the steering shaft arm) cotter pin shaft end nut and washer shaft arm brake hose (release from clamp) two holder bolts shaft holder steering shaft (from the shaft bearing) shaft bushing 15-29 FRONT WHEEL/SUSPENSION/STEERING INSPECTION Check the steering shaft bushing for wear or damage. Check the steering shaft for distortion or damage. Turn the inner race of the steering shaft bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the frame. BEARING REPLACEMENT Remove the upper and lower dust seals. Remove the snap ring. [DUST SEALS* 15-30 FRONT WHEEL/SUSPENSION/STEERING Assemble the special tools onto the steering shaft bearing. COMPRESSOR ATTACHMENT Remove the bearing from the frame by tightening the nut. TOOLS: Clutch compressor attachment 07LAE-PX40100 Compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A (U.S.A. only) Attachment, 28 x 30 mm 07946-1870100 10 mm washer Common hardware COMPRESSOR BOLT ATTACHMENT WASHER NUT Draw a new bearing into the frame with the marked side facing up until it is fully seated. TOOLS: Clutch compressor attachment 07LAE-PX40100 Compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A (U.S.A. only) Attachment, 42 x 47 mm 07746-0010300 10 mm washer Common hardware NUT fly COMPRESSOR BOLT ATTACHMENT Install the snap ring into the groove properly with the chamfered edge facing up. WASHER * JS. COMPRESSOR ATTACHMENT The upper seal is Coat new dust seal lips with grease and install flush with the frame edge and the lower seal is seated onto the bearing. them. INSTALLATION NOTE: • Route the wires, hose and cables properly (page 1-20). Apply grease to the shaft bushing inner surface. PTTrrjTTr^1 Install the shaft bushing onto the steering shaft with ' the arrow mark facing up. Install the steering shaft into the shaft bearing. 15-31 FRONT WHEEL/SUSPENSION/STEERING Install the shaft holder with the hose clamp facing the right side and tighten the two bolts alternately, then tighten to the specified torque. TORQUE: 32 N-m (3.3 kgf m, 24 Ibfft) Install the brake hose to the hose clamp. CLAMP Apply molybdenum disulfide grease to the steering shaft splines. WASHER • Align Install the shaft arm over the steering shaft by aligning the wide tooth with the wide groove. Install the washer and end nut, and tighten it. TORQUE: 108 N m (11.0 kgf-m, 80 Ibf-ft) Install a new cotter pin. Install the tie-rods into the steering shaft arm. Install new joint nuts and tighten them by holding the ball joint stud flats with an open end wrench. TORQUE: 54 N-m (5.5 kgf-m, 40 Ibfft) Install new cotter pins. Install the handlebar assembly onto the steering shaft with the washers and new lower holder nuts. Tighten the nuts. TORQUE: 39 N-m (4.0 kgf-m, 29 Ibf ft) 15-32 HANDLEBAR ASSEMBLY FRONT WHEEL/SUSPENSION/STEERING Route the wires Install the combination meter/stay and tighten the , model shown: wm and hose properly t w o nuts. (page 1-20). I BRAKE HOSE TORQUE: 25 IMm (2.5 kgf-m, 18 Ibf-ft) Install the brake hose into the clamps on the steering shaft and shaft holder (see below). Make sure all the Secure the wires with the wire clip. wires and hose are | n s t a | | t h e b r a k e h o s e j n t Q t h e d a properly routed i n g s h a f t h o | d e r . on the steer. a (page 1-20). Install the following: - lower meter covers (page 3-18) front fender (page 3-12) inner fenders (page 3-9) front wheels (page 15-11) TIE-ROD REMOVAL Remove the following: - front wheel (page 15-11) - inner fender (page 3-9) Remove the cotter pins. Remove the tie-rod ball joint nuts while holding the joint stud flats with an open end wrench. Remove the tie-rod from the knuckle and steering shaft arm. INSPECTION Inspect the tie-rod for distortion or damage. Inspect the ball joint boots for tears or other damage by moving the ball joint studs. They should move freely and smoothly. BALL JOINT BOOTS Replace the ball joint if necessary. 15-33 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY/ASSEMBLY Loosen the lock nuts and remove the ball joints and lock nuts from the tie-rod. NUTS Install the unmarked ball joint and gold colored nut on the flat (wrench holding area) side of the tie-rod, and the "L" marked ball joint and silver nut on the opposite side. &-4^0— FLATS The ball joint positions are 180° from each other. Tighten these nuts after installing the tierod. Hand-tighten the lock nuts and measure the distance between the lock nut and thread end. STANDARD DISTANCE: A/B: 8.3 mm (0.33 in) The difference between distance A and B should be 3 mm (0.1 in) or less. INSTALLATION Install the tie-rod with the flat side of the rod toward the knuckle. Install new joint nuts and adjust the toe-out (page 4-23). Tighten the joint nuts by holding the ball joint stud flats with an open end wrench. TORQUE: 54 N m (5.5 kgf-m, 40 Ibf-ft) Install new cotter pins. Install the following: - inner fender (page 3-9) front wheel (page 15-11) Adjust the toe and ball joint angle (page 4-23) 15-34 "L" MARK A 16. REAR WHEEL/SUSPENSION SYSTEM COMPONENTS 16-2 REAR WHEEL 16-6 SERVICE INFORMATION- 16-3 WHEEL HUB/KNUCKLE 16-6 TROUBLESHOOTING 16-5 REAR SHOCK ABSORBER/ SUSPENSION ARM 16-10 16-1 REAR WHEEL/SUSPENSION SYSTEM COMPONENTS 34 N-m (3.5 kgf-m, 25 Ibf-ft) 34 N-m (!3.5 kgf-m, 25 Ibf-ft) m (5.5 kgf-m, 40 Ibf-ft) 34 N-m (3.5 kgf-m, 2 5 Ibf-ft) 137 N-m (14.0 kgf-m, 101 Ibf-ft) 64 N-m (6.5 kgf-m, 47 Ibf-ft) 16-2 REAR WHEEL/SUSPENSION SERVICE INFORMATION GENERAL This section covers service of the rear wheel and rear suspension. For tire information (page 15-11). For brake system service (page 17-2). For rear driving mechanism service (page 19-2). A jack or other support is required to support the vehicle. Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. SPECIFICATIONS ITEM Minimum tire tread depth Cold tire pressure Standard Minimum Maximum With cargo 25 kPa (0.25 22 kPa (0.22 28 kPa (0.28 25 kPa (0.25 STANDARD kgf/cm2, 3.6 psi) kgf/cm2, 3.2 psi) kgf/cm2, 4.0 psi) kgf/cm2, 3.6 psi) SERVICE LIMIT • 4 mm (0.16 in) - TORQUE VALUES Rear wheel nut Rear wheel hub nut 64 N-m (6.5 kgf-m, 47 Ibf-ft) 137 N-m (14.0 kgf-m, 101 Ibf-ft) Upper arm pivot nut (frame side) Upper arm pivot nut (knuckle side) Lower arm pivot nut 34 N-m (3.5 kgf-m, 25 Ibf-ft) 54 N-m (5.5 kgf-m, 40 Ibf-ft) 34 N-m (3.5 kgf-m, 25 Ibf-ft) Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole. Lock nut: replace with a new one. Lock nut: replace with a new one. Lock nut: replace with a new one. 16-3 REAR WHEEL/SUSPENSION TOOLS Driver 07749-0010000 Fork seal driver body 07947-KA50100 Spherical bearing driver 0~/HMF-HC00100 not available in U.S.A., use a suitable collar. Oil seal driver 07JAD-PH80101 16-4 Oil seal driver 07LAD-SM40100 REAR WHEEL/SUSPENSION TROUBLESHOOTING Rear wheel wobbling • Bent rim • Worn or damaged knuckle bearing • Faulty tire • Wheel hub nut not tightened properly • Loose rear suspension fasteners Steers to one side or does not track straight • Unequal tire pressure • Bent suspension arm or frame • Worn or damaged knuckle bearing • Weak shock absorber Soft suspension • Weak shock absorber spring • Faulty shock absorber damper Stiff suspension • Bent shock absorber damper rod • Improperly installed suspension arms • Faulty suspension bushings or bearings Rear suspension noise • Loose rear suspension fasteners • Damaged suspension components 16-5 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Loosen the wheel nuts. Support the vehicle using a hoist or equivalent and raise the rear wheels off the ground. Remove the nuts and wheel. For tire removal/installation and repair (page 15-11). INSTALLATION NOTE: • Do not interchange the left and right tires. Install the wheel with the arrow mark facing in the normal rotating direction. Install the wheel nuts and tighten them. TORQUE: 64 N m (6.5 kgf-m, 47 Ibf-ft) WHEEL HUB/KNUCKLE REMOVAL Remove the rear wheel (page 16-6). Remove the following: - cotter pin hub nut wheel hub COTTE R PIN 16-6 REAR WHEEL/SUSPENSION lower arm pivot nut and bolt upper arm pivot nut and bolt seal caps (from the knuckle) BOLTS NUT pivot collar (to disconnect the shock absorber) knuckle (from the drive shaft) COLLAR KNUCKLE INSPECTION Remove the dust seals. BEARING Turn the inner race of the bearing in the knuckle with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the knuckle. Inspect the knuckle for damage or cracks. For suspension pivot inspection (page 16-13). DUST SEALS BEARING REPLACEMENT Remove the snap ring. SNAP RING Press the bearing out of the knuckle using a suitable collar. 16-7 REAR WHEEL/SUSPENSION Pack the cavities of a new bearing with grease. Carefully press the bearing in the knuckle with the marking side facing up until it is fully seated. TOOLS: Driver Oil seal driver DRIVER 07749-0010000 07JAD-PH80101 Install the snap ring into the knuckle groove with the chamfered edge facing in. When installing the dust seals, be careful not to damage the seal lip. Support the knuckle with the driver weight to avoid damaging the outer dust seal. Coat the lips of new dust seals with grease and install them until they are flush with the knuckle surface. Install the outer seal first, then install the inner seal. TOOLS: OUTER SEAL: Driver Oil seal driver 07749-0010000 07LAD-SM40100 INNER SEAL: Driver Oil seal driver Fork seal driver body 07749-0010000 07LAD-SM40100 07947-KA50100 SEAL DRIVER INSTALLATION KNUCKLE Apply grease to the pivot bushings and dust seal lips on the knuckle. Apply molybdenum disulfide paste to the pivot bushing in the shock absorber. Install the knuckle onto the shock absorber with the pivot collar. Pack the lip cavities of the inner dust seal with 2.5 3 g of grease and set the knuckle over the drive shaft. Install the seal caps onto the dust seals on the knuckle. Coat new O-rings with molybdenum disulfide grease and install them into the pivot bolt grooves. Apply molybdenum disulfide grease to each bolt head (between the O-rings). Connect the upper and lower arms to the knuckle with the pivot bolts. 16-8 REAR WHEEL/SUSPENSION Install new nuts and tighten them. TORQUE: Upper arm: 54 N-m (5.5 kgfm, 40 Ibf-ft) Lower arm: 34 N-m (3.5 kgf-m, 25 Ibfft) WHEEL HUB Install a new dust seal into the hub with the metal side facing out until it is flush with the hub surface. j HUB S* ' DUST SEAL M s -—^-4 » Apply molybdenum disulfide grease to the drive shaft splines. Pack the lip cavities of the outer dust seal with 2.5 3 g of grease. Apply molybdenum disulfide grease to the dust seal and install the wheel hub. HUB 16-9 REAR WHEEL/SUSPENSION Install the hub nut and tighten it to the specified torque and further tighten until its grooves align with the cotter pin hole. TORQUE: 137 N m (14.0 kgf m, 101 Ibf-ft) Install a new cotter pin. Install the wheel (page 16-6). COTTER PIN REAR SHOCK ABSORBER/ SUSPENSION ARM SHOCK ABSORBER REMOVAL Remove the rear wheel (page 16-6). Remove the seat (page 3-4). Support the knuckle with a support block. Remove the following: - upper arm pivot nut and bolt (to disconnect the upper arm) seal caps NUT - pivot collar (to disconnect the knuckle) mounting nut and bolt shock absorber 16-10 SHOCK ABSORBER~1 REAR WHEEL/SUSPENSION SUSPENSION ARM REMOVAL UPPER ARM Remove the pivot collar (page 16-10). Right upper arm: Left upper arm: Remove the right side cover (page 3-5). Remove the oil filler lid (page 3-8). Remove the following: - stabilizer link nut (to disconnect the link) two pivot nuts and bolts upper arm UPPER ARM PIVOT BOLT/NUT/COLLAR LOWER ARM Remove the following: - lower arm pivot nut and bolt (to disconnect the knuckle) - PIVOT BOLT lower arm pivot nut and bolt lower arm LOWER ARM STABILIZER ARM AND LINK Remove the following: - link nuts stabilizer links LINK NUT 16-11 REAR WHEEL/SUSPENSION - four bolts and arm holders stabilizer arm stabilizer bushings INSPECTION SUPENSION ARMS Check the stabilizer bushings for wear or damage. Check the stabilizer arm for distortion or damage. Inspect the ball joint boot of the link for tears or other damage. Replace the nuts Remove the seal caps and pivot collars from the with new ones, lower arm. Remove the four nuts, bolts and arm guard if necessary. Check the pivot bushings for wear or damage. JOINT BOOTS CAPS COLLAR 16-12 ARM GUARD REAR WHEEL/SUSPENSION Remove the pivot collars and the dust seals from the upper arm. Check the pivot bearings for wear or damage. For bearing replacement (page 16-13). COLLARS Check the pivot bushings in the knuckle for wear or damage. BUSHINGS SHOCK ABSORBER Remove the upper pivot collar. Check the pivot bushings for wear or damage. Check the damper unit for leaks or other damage. BUSHING PIVOT BEARING REPLACEMENT Clean any grease from the upper arm pivot thoroughly. Remove the stopper rings from the pivot. BEARING DRIVER Press the bearing out of the upper arm using the special tool. TOOL: Spherical bearing driver 07HMF-HC00100 (not available in U.S.A., use a suitable collar) STOPPER RINGS 16-13 REAR WHEEL/SUSPENSION Install a new stopper ring into the inner groove in the pivot securely. Carefully press in a new bearing until it contacts the stopper ring (the depth from the outer surface is 12.8 mm), using the same tool. Install a new stopper ring. Pack each pivot (between bearing and dust seals) with 3 g of grease. Apply grease to the new dust seal lips and install them until they are flush with the outer surface. Install the pivot collars. SHOCK ABSORBER INSTALLATION Install new dust seals into the pivots with the lip side facing out until they are seated. Apply molybdenum disulfide paste to the pivot bushings and dust seal lips. COLLAR Install the seal caps and pivot collar. CAPS Install the shock absorber into the frame with the mounting bolt. Install a new nut. Connect the shock absorber to the knuckle and upper arm (page 16-16). Install the seat (page 3-4). 16-14 REAR WHEEL/SUSPENSION SUSPENSION ARM INSTALLATION STABILIZER ARM AND LINK Install the stabilizer arm and bushings with the arm holders so the rounded side of the bushings are toward the frame. Tighten the four holder bolts alternately. Install with the Install the stabilizer links with new nuts and tighten short threads into the stabilizer arm. them. LINK NUT LOWER ARM Install new dust seals with the lip side facing out until the depth from the bushing end is 0.5 mm (0.02 in). COLLAR BUSHINGS 0.5 mm Apply grease to the pivot bushings in the lower arm and install the pivot collar. Apply grease to the seal lips and install the seal caps over the dust seals securely. DUST SEAL DUST SEALS CAPS Install the lower arm into the frame. Align the bolt holes in the frame and arm, and insert the pivot bolt from the rear side. Install a new pivot nut. LOWER ARM 16-15 REAR WHEEL/SUSPENSION Coat new O-rings with molybdenum disulfide grease and install them into the pivot bolt groove. Apply molybdenum disulfide grease to the bolt head (between the O-rings) and insert the pivot bolt through the knuckle and lower arm. Install a new pivot nut and tighten each pivot nut. TORQUE: 34 N m (3.5 kgf m, 25 Ibf ft) UPPER ARM Insert the pivot Install the upper arm into the frame with the pivot bolts from the bolts and new nuts. inside. PIVOT BOLT/NUT/COLLAR Install new inner dust seals with the lip side facing the seated. Install new outer dust seals out until the depth from the (0.02 in). into the knuckle pivots bushing until they are with the lip side facing bushing end is 0.5 mm Apply grease to the pivot bushings and dust seal lips. 16-16 REAR WHEEL/SUSPENSION Apply molybdenum disulfide paste to the pivot bushing in the shock absorber. SHOCK ABSORBER! Connect the knuckle to the shock absorber with the pivot collar and install the seal caps over the dust seals. Coat new O-rings with molybdenum disulfide grease and install them into the pivot bolt grooves. Apply molybdenum disulfide grease to the bolt head (between the O-rings). Connect the knuckle to the upper arm with the pivot bolt. Install a new pivot nut. Tighten the each pivot nut. PIVOT BOLT TORQUE: Frame side: 34 N-m (3.5 kgf-m, 25 Ibfft) Knuckle side: 54 N-m (5.5 kgf-m, 40 Ibfft) Connect the stabilizer link with a new nut and tighten it. Flight side: Install the right side cover (page 3-5). Leftside: Install the oil filler lid (page 3-8). Install the rear wheel (page 16-6). 16-17 17. BRAKE SYSTEM SYSTEM COMPONENTS 17.-2 FRONT MASTER CYLINDER 17-13 17-4 FRONT BRAKE CALIPER 17-17 TROUBLESHOOTING 17-6 REAR BRAKE MASTER CYLINDER/ BRAKE FLUID REPLACEMENT/ AIR BLEEDING 17-7 SERVICE INFORMATION BRAKE PAD/DISC • • BRAKE PEDAL • 17-21 REAR BRAKE CALIPER 17-27 REAR BRAKE DISC 17-34 17-10 17-1 BRAKE SYSTEM SYSTEM COMPONENTS 34 N-m (3.5 kgf-m, 25 Ibf-ft) 12 NTn (1.2 kgfm, 9 Ibf-ft) 44 N-m (4.5 kgfm, 32 Ibf-ft) 42 N-m (4.3 kgfm, 31 Ibf-ft) 11 N-m (1.1 kgfm, 8 Ibf-ft) 34 N-m (3.5 kgfm, 25 Ibf-ft) 78 N-m (8.0 kgf-m, 58 Ibf-ft) 17-2 BRAKE SYSTEM 30 N-m (3.1 kgfm, 22 Ibf-ft) 2 N-m (0.2 kgfm, 1.4 Ibf-ft) 34 N-m (3.5 kgfm, 25 Ibf-ft) 34 N-m (3.5 kgfm, 25 Ibf-ft) 32 N-m (3.3 kgfm, 24 Ibf-ft) 17-3 BRAKE SYSTEM SERVICE INFORMATION GENERAL ACAUTION Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approve)d vacuum cleaner. A contaminated brake disc or pad reduces stopping power. Discard contaminated pads, and clean a contaminated disc with a high quality brake degreasing agent. Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make silre the reservoir is horizontal first. Never allow contaminates (dirt, water, etc.) to get into an open reservoir. Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled. Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible. Always check brake operation before riding the vehicle. SPECIFICATIONS ITEM Recommended brake fluid Front brake Brake disc thickness Brake disc runout Master cylinder I.D. Master piston O.D. Caliper cylinder I.D. Caliper piston O.D. Rear brake Brake disc thickness Brake disc runout Master cylinder I.D. Master piston O.D. Caliper cylinder I.D. Caliper piston O.D. Rear (parking) brake lever free play STANDARD DOT 4 brake fluid 4.0(0.16) 14.000 - 14.043 (0.5512 - 0.5529) 13.957 - 13.984 (0.5495 - 0.5506) 33.960 - 34.010 (1.3370 - 1.3390) 33.878 - 33.928 (1.3338 - 1.3357) 7.5 (0.30) 15.870 - 15.913 (0.6248 - 0.6265) 15.827 - 15.854 (0.6231 -• 0.6242) 30.230 - 30.280 (1.1902 - 1.1921) 30.165 - 30.198 (1.1876 - 1.1889) 25-30(1-1-3/16) Unit: mm (in) SERVICE LIMIT 3.0(0.12) 0.30 (0.012) 14.055 (0.5533) 13.945 (0.5490) 34.02 (1.340) 33.87 (1.333) 6(0.2) 0.5 (0.02) 15.925 (0.6270) 15.815(0.6226) 30.29(1.193) 30.14(1.187) - TORQUE VALUES Brake hose oil bolt Front caliper bleed valve Front caliper slider pin flange bolt Front brake pipe Front Brake lever pivot bolt Front brake lever pivot nut Front master cylinder holder bolt Rear brake caliper bleed valve Rear brake reservoir hose joint screw Rear brake caliper parking nut Rear brake caliper bracket pin bolt Rear brake caliper pin retaining bolt Rear brake caliper mounting bolt Rear brake disc bolt 17-4 34 N-m (3.5 kgf-m, 25 Ibf-ft) 5.4 N-m (0.55 kgf-m, 4.0 Ibf-ft) 23 N-m (2.3 kgf-m, 17 Ibf-ft) 17 N-m (1.7 kgf-m, 12 Ibf-ft) 1 N-m (0.1 kgf-m, 0.7 Ibf-ft) 5.9 N-m (0.6 kgf-m, 4.3 Ibf-ft) 12 N-m (1.2 kgf-m, 9 Ibf-ft) 5.4 N-m (0.55 kgf-m, 4.0 Ibf-ft) 2 N-m (0.2 kgf-m, 1.4 Ibf-ft) 27 N-m (2.8 kgf-m, 20 Ibf-ft) 32 N-m (3.3 kgf-m, 24 Ibf-ft) 23 N-m (2.3 kgf-m, 17 Ibf-ft) 30 N-m (3.1 kgf-m, 22 Ibf-ft) 20 N-m (2.0 kgf-m, 14 Ibf-ft) Apply locking agent to the threads. ALdC bolt: replace with a new one. ALOC bolt: replace with a new one. BRAKE SYSTEM TOOLS Lock nut wrench 07716-0020100 Snap ring pliers 07914-SA50001 w or 07914-3230001 17-5 BRAKE SYSTEM TROUBLESHOOTING FRONT DISC BRAKE Brake lever soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pad/disc Worn caliper piston seal Worn master cylinder piston cups Worn brake pad/disc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped/deformed brake disc Sticking/worn caliper piston Sticking/worn master cylinder piston Bent brake lever Brake lever hard Clogged/restricted brake system Sticking/worn caliper piston Sticking/worn master cylinder piston Caliper not sliding properly Bent brake lever Brake drags Contaminated brake pad/disc Badly worn brake pad/disc Warped/deformed brake disc Caliper not sliding properly Clogged/restricted fluid passage Sticking caliper piston REAR DISC BRAKE Rear brake pedal soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pad/disc Worn caliper piston seal Worn master cylinder piston cups Worn brake pad/disc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped/deformed brake disc Sticking/worn caliper piston Sticking/worn master piston Bent brake pedal Rear brake pedal hard Clogged/restricted hydraulic system Sticking/worn caliper piston Sticking/worn master piston Caliper not sliding properly Bent brake pedal Brake drags Contaminated brake pad/disc Badly worn brake pad/disc Warped/deformed brake disc Caliper not sliding properly Clogged/restricted fluid passage Sticking caliper piston Misaligned disc 17-6 BRAKE SYSTEM BRAKE FLUID REPLACEMENT/AIR BLEEDING NOTICE Do not allow foreign material to enter the system when filling the reservoir. Foreign material can cause brake system failure. Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced. Brake fluid will damage these types of materials. Use only DOT 4 brake fluid from a sealed container. Do not mix different types of fluid. They are not compatible. Mixed fluid types can cause brake system failure. BRAKE FLUID DRAINING FRONT BRAKE Turn the handlebar to the left side so that the reservoir is level before removing the reservoir cap. SCREWS RESERVOIR CAP Remove the screws, reservoir cap, set plate and diaphragm from the front master cylinder. Connect the bleed hose to the wheel cylinder bleed valve. Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve. Perform above procedure for other side bleed valve. 17-7 BRAKE SYSTEM REAR BRAKE Remove the right side cover (page 3-5). Remove the rear brake reservoir cap, set plate and diaphragm. Connect the bleed hose to the rear brake caliper bleed valve. Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve. BRAKE FLUID FILLING/BLEEDING FRONT BRAKE Close the front brake caliper bleed valve. Fill the front master cylinder reservoir with DOT 4 brake fluid from a sealed container. Follow the manu- Connect a commercially available brake bleeder to facturer's operating the bleed valve. instructions. Check the fluid level Operate the brake bleeder and loosen the bleed often while bleed- valve. ing the brake to.pre- , f a n vent air trom being w h e n automatjc refiM s y s t e m is not used, add fluid |ow t h e f | u j d |ev(j| jn t h e r e s e r v o j r js pumped into the system. If air enters the Perform the bleeding procedure until the system is bleeder from completely flushed/bled. around the bleed -,-. , . ., , . , . , Tighten the bleed valve. valve threads, seal the threads with TORQUE: 5.4 N m (0.55 kgf-m, 4.0 Ibf-ft) teflon tape. Perform air bleeding for the other side bleed valve. 17-8 BLEED VALVE M S I BLEED HOSE BRAKE SYSTEM If the brake bleeder is not available, perform the following procedure: Pump up the system pressure with the front brake lever until the lever resistance is felt. Connect a bleed hose to the front brake caliper bleed valve and bleed the system as follows: Do not release the 1. Squeeze the brake lever all the way and loosen the bleed valve 1/2 of a turn. Wait several seconds and then close the bleed valve. brake lever until the bleed valve has 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 (0.55 kgfm, 4.0 Ibf-ft) Perform air bleeding for the other side bleed valve. After bleeding air, operate the front brake lever. If it still feels spongy, bleed the system again. Fill the front master cylinder reservoir to the casting ledge with DOT 4 brake fluid from a sealed container. Install the diaphragm, set plate and reservoir cap, and tighten the screws. TORQUE: 1.5 N-m (0.2 kgfm, 1.1 Ibf-ft) REAR BRAKE Close the caliper bleed valve. Fill the rear brake reservoir with DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed valve. Operate the brake bleeder and loosen the bleed valve. If not using an automatic refill system, add brake fluid when the fluid level in the reservoir is low. NOTE: • Check the fluid level often while bleeding the brake to prevent air from being pumped into the system. • When using a brake bleeding tool, follow the manufacturer's operating instructions. Perform the bleeding procedure until the system is completely flushed/bled. NOTE: • If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape. Close the bleed valve and operate the brake pedal. If it is still feels spongy, bleed the system again. 17-9 BRAKE SYSTEM If a brake bleeder is not available, use the following procedure: Pump up the system pressure with the rear brake pedal until the pedal resistance is felt. Connect a plastic hose to the bleed valve and bleed the system as follows: 1. Depress the rear brake pedal, open the bleed valve 1/4 turn and then close it. NOTE: • Do not release the brake pedal until the bleed valve has been closed. 2. Release the brake pedal slowly and wait several seconds after it reaches the end of its travel. Repeat the steps 1 and 2 until air bubbles do not appear in the bleed hose. Tighten the bleed valve. TORQUE: 5.4 N m (0.55 kgf m, 4.0 Ibf ft) Fill the reservoir to the "UPPER" level with DOT 4 brake fluid from a sealed container. Install the diaphragm, set plate and reservoir cap. Install the right side cover (page 3-5). BRAKE PAD/DISC FRONT BRAKE PAD REPLACEMENT Remove the front wheel (page 15-11). CALIPER BODY Check the fluid level Push the caliper piston all the way in by pushing the in the master cylin- caliper body against the disc to allow installation of der reservoir as this new brake pads. ° P r T w ':aUS,eS Remove the caliper pin bolt. the fluid level to rise. SLIDE PIN BOLT 17-10 BRAKE SYSTEM Pivot the caliper body up and remove the brake pads from the caliper bracket. BRAKE PADS Always replace the Install new brake pads into the caliper bracket propbrake pads in pairs erly as s h o w n . to ensure even disc pressure. Lower the caliper body, install the caliper pin bolt and tighten it. CALIPER BODY TORQUE: 23 IM m (2.3 kgf-m, 17 Ibf-ft) Squeeze the front brake lever to seat the caliper piston against the pad. SLIDE PIN BOLT REAR BRAKE PAD REPLACEMENT Remove the right rear wheel (page 16-6). Remove the bracket pin retaining bolt and bracket pin bolt. Remove the caliper body from the caliper bracket. RETAINING BOLT Remove the brake pads from the caliper bracket. BRAKE PADS Always replace the Install new pad onto the caliper bracket properly so brake pads in pairs that the pin on the pad is facing to the piston. to ensure even disc pressure. 17-11 BRAKE SYSTEM Rotate the caliper piston clockwise using the special tool or equivalent to retract it and align the piston groove with the index mark on the caliper body. INDEX MARK TOOL: Lock nut wrench, 20 x 24 mm 07716-0020100 GROOVE Install the caliper body over the pads and caliper I BRACKET PIN BOLT bracket, aligning the groove in the piston with the pin on the pad. Install the bracket pin bolt and bracket pin retaining bolt, and tighten them. TORQUE: Bracket pin bolt: 32 N m (3.3 kgf m, 24 Ibf ft) Retaining bolt: 23 N m (2.3 kgf m, 17 Ibf ft) Install the right rear wheel (page 16-6). Operate the brake pedal to seat the caliper piston against the pad. FRONT BRAKE DISC INSPECTION Remove the front wheel (page 15-11). Remove the caliper body (page 17-17). Visually inspect the brake disc for damage or crack. Measure the brake disc thickness at several points. SERVICE LIMIT: 3.0 mm (0.12 in) Replace the brake disc if the smallest measurement is less than service limit. Check the brake disc for warpage. SERVICE LIMIT: 0.30 mm (0.012 in) Check the front wheel hub bearings or rear axle bearings for excessive play, if the warpage exceeds the service limit. Replace the brake disc if the bearings are normal. 17-12 BRAKE SYSTEM REAR BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks. Measure the brake disc thickness at several points. SERVICE LIMIT: 6 mm (0.2 in) Replace the brake disc if the smallest measurement is less than the service limit. Check the brake disc for warpage. SERVICE LIMIT: 0.5 mm (0.02 in) Replace the brake disc if the warpage exceeds the service limit. FRONT MASTER CYLINDER DISASSEMBLY Drain the brake fluid from the front brake hydraulic system (page 17-7). SEALING WASHERS Disconnect the brake hose by removing the oil bolt and sealing washers. OIL BOLT Disconnect the front brake switch connectors. MASTER CYLINDER HOLDER Remove the master cylinder holder bolts, holder and master cylinder. BOLTS 17-13 BRAKE SYSTEM Remove the pivot nut, bolt and brake lever. Remove the screw and brake switches. PIVOT BOLT/NUT SWITCHES BRAKE LEVEIR SCREW Remove the boot from the master cylinder and master piston. BOOT Remove the snap ring using the special tool. TOOL: Snap ring pliers SNAP RING 07914-SA50001 or 07914-3230001 SNAP RING PLIERS Remove the master piston and spring. Remove the oil seal MASTER CYLINDER SPRING Clean the master cylinder, reservoir and master piston in clean brake fluid. PISTON CUPS OIL SEAL 17-14 MASTER PISTON BRAKE SYSTEM INSPECTION Check the master cylinder and master piston for scoring, scratches or damage. Check the piston cups and oil seal for wear, deterioration or damage. Measure the master cylinder I.D. SERVICE LIMIT: 14.055 mm (0.5333 in) Measure the master cylinder piston O.D. SERVICE LIMIT: 13.945 mm (0.5490 in) ASSEMBLY Coat the master piston, piston cups and oil seal with clean DOT 4 brake fluid. Install the oil seal into the master cylinder. MASTER CYLINDER SPRING Install the spring onto the piston end. Do not allow the piston cup lips to turn inside out. Install the spring and master piston into the master cylinder. PISTON CUPS MASTER PISTON Be certain the snap Install the snap ring into the groove in the master ring is firmly seated cylinder with the chamfered edge facing in using in the groove, the special tool. TOOL: Snap ring pliers SNAP RING 07914-SA50001 or 07914-3230001 SNAP RING PLIERS Install a new boot into the master cylinder and the groove in the piston Apply silicone grease to the brake lever pivot-tomaster piston contact area. BOOT 17-15 BRAKE SYSTEM Apply silicone grease to the brake lever pivot bolt sliding surface. PIVOT BOLT SWITCHES Install the pivot bolt and tighten it. TORQUE: 1 N m (0.1 kgfm, 0.7 Ibf ft) Install the pivot nut and tighten it. TORQUE: 5.9 N m (0.6 kgf m, 4.3 Ibf ft) Install the brake light switch and tighten the screw. TORQUE: 1.2 N m (0.12 kgf m, 0.9 Ibfft) PIVOT NUT Install the front brake master cylinder and holder with the "UP" mark facing up, and install the bolts. MASTER CYLINDER Connect the front brake light switch connectors. Align the end of the master cylinder with the lug on the throttle housing, and tighten the upper bolt first, then tighten the lower bolt. TORQUE: 12 N m (1.2 kgf m, 9 Ibfft) BOLTS Rest the brake hose joint between the stoppers on the master cylinder. Connect the brake hose with the oil bolt and new sealing washers, and tighten the oil bolt. SEALING WASHERS TORQUE: 34 N-m (3.5 kgfm, 25 Ibf ft) Fill and bleed the front brake hydraulic system (page 17-7). OIL BOLT 17-16 HOSE JOINT BRAKE SYSTEM FRONT BRAKE CALIPER DISASSEMBLY Drain the brake fluid from the front brake hydraulic system (page 17-7). BOLTS Remove the two bolts and guard plate. Disconnect the brake hose from the brake caliper by removing the oil bolt and sealing washer. T SEALING WASHERS Loosen the two caliper pin bolts. Remove the two mounting bolts and brake caliper assembly. CALIPER PIN BOLTS MOUNTING BOLTS Remove the two caliper pin bolts and separate the caliper bracket from the caliper body. CALIPER ASSEMBLY CALIPER PIN BOLTS Remove the brake pads. CALIPER BODY CALIPER BRACKET BRAKE PADS 17-17 BRAKE SYSTEM Remove the bracket pin, boot and pad springs from the caliper bracket. BRACKET PIN AND BOOT PAD SPRINGS Remove the caliper pin and boot from the caliper body. CALIPER PIN AND BOOT Place a shop towel over the piston. Do not use high Position the caliper body with the piston down and pressure air or bring apply small squirts of air pressure to the fluid inlet the nozzle too close to remove the piston. to the inlet. R e m o v e t h e c a | j p e r p j s ton boot. Be careful not to Push the piston seal in and lift it out. damage the piston C | e g n t h g b o Q t g n d s e g | caliper cylinder, 0 sliding surface. and piston with clean brake fluid. PISTON SEAL INSPECTION Check the caliper cylinder and piston for scoring, scratches or damage. CALIPER CYLINDER PISTON BOOT PISTON SEAL CALIPER PISTON 17-18 BRAKE SYSTEM Measure the caliper cylinder I.D. SERVICE LIMIT: 34.020 mm (1.3394 in) Measure the caliper cylinder piston O.D. SERVICE LIMIT: 33.870 mm (1.3335 in) ASSEMBLY CALIPER PIN PAD SPRINGS BRAKE PADS CALIPER BRACKET PISTON SEAL CALIPER PIN BOOT CALIPER BODY BRACKET PIN PISTON BOOT BRACKET PIN BOOT Coat new piston seal with clean brake fluid and install it into the seal groove in the caliper cylinder. CALIPER PISTON CALIPER CYLINDER Apply silicone grease to the inside of a new piston boot and install it into the caliper cylinder groove properly. Coat the caliper piston with clean brake fluid and install them into the caliper cylinder with the open side toward the pads, and install the piston boot into the piston groove properly. PISTON SEAL CALIPER PISTON 17-19 BRAKE SYSTEM Install the pad springs onto the caliper body as shown. Apply silicone grease to the insides of new pin boots. Install the caliper pin boot and pin into the caliper body. Install the bracket pin boot and pin into the caliper bracket. BRACKET p N A N D B 0 0 T PAD SPRINGS CALIPER PIN AND BOOT Install the brake pads onto the caliper bracket. Install the caliper body onto the bracket. Loosely install the caliper pin bolts. CALIPER PIN BOLTS CALIPER BODY CALIPER BRACKET Install the brake caliper assembly onto the knuckle with new mounting bolts, and tighten the bolts. BRAKE PADS CALIPER PIN BOLTS TORQUE: 44 N m (4.5 kgf m, 32 Ibf-ft) Tighten the caliper pin bolts. TORQUE: 23 N-m (2.3 kgf m, 17 Ibf-ft) CALIPER ASSEMBLY Connect the brake hose with the oil bolt and new sealing washers while inserting the stopper pin into the hole in the caliper body. Tighten the oil bolt. TORQUE: 34 N m (3.5 kgf m, 25 Ibf-ft) SEALING WASHERS 17-20 BRAKE SYSTEM Install the guard plate with new bolts and tighten the bolts securely. BOLTS Fill and bleed the front brake hydraulic system (page 17-7). REAR BRAKE MASTER CYLINDER/ BRAKE PEDAL DISASSEMBLY Drain the brake fluid from the rear brake hydraulic system (page 17-8). Remove the right center mud guard (page 3-7). Remove the screw and reservoir hose joint from the master cylinder. Remove the O-ring. Disconnect the brake hose from the master cylinder by removing the oil bolt and sealing washers. Remove the master cylinder mounting bolts while holding the brake pedal. 17-21 BRAKE SYSTEM Remove the brake pedal pivot bolt and dust seals. Unhook the brake switch spring from the return spring. Unhook the return spring from the pedal and frame. PIVOT BOLT Separate the master cylinder from the brake pedal by removing the cotter pin and joint pin. MASTER CYLINDER COTTER PIN Remove the boot from the master cylinder. BOOT Remove the snap ring using the special tool. TOOL: Snap ring pliers Remove the push rod. 17-22 07914-SA50001 or 07914-3230001 SNAP RING BRAKE SYSTEM Remove the master piston, primary cup and spring. SPRING Clean the master cylinder, spring and master piston in clean brake fluid. MASTER PISTON PRIMARY CUP INSPECTION Check the piston cups and boot for wear, deterioration or damage. SPRING Check the spring for damage. MASTER PISTON PRIMARY CUP Check the master cylinder and piston for scoring, scratches or damage. Measure the master cylinder I.D. SERVICE LIMIT: 14.055 mm (0.5533 in) Measure the master piston O.D. SERVICE LIMIT: 13.945 mm (0.5490 in) 17-23 BRAKE SYSTEM ASSEMBLY MASTER CYLINDER MASTER PISTON SNAP RING SPRING BOOT PRIMARY CUP PUSH ROD Coat the master piston and piston cups and with clean brake fluid. SPRING Install the primary cup onto the spring. Do not allow the Install the spring, primary cup and master piston piston cup lips to into the master cylinder. turn inside out. A p p | y s i | i c o n e g r e a s e t 0 t h e p u s h roc j cont act area of the master piston. Install the push rod into the master cylinder. Be certain the snap ring is firmly seated in the groove, SNAP RING PLIERS Install the snap ring into the groove in the master cylinder with the chamfered edge facing in using the special tool. TOOL: Snap ring pliers 07914-SA50001 or 07914-3230001 SNAP RING 17-24 BRAKE SYSTEM Install the boot into the master cylinder. BOOT If the push rod joint is reinstalled, adjust the push rod length so that the distance between the centers of the master cylinder lower mounting bolt hole and the centers of the joint pin hole is 80 ± 1 mm (3.15 ± 0.04 in). After adjustment, tighten the joint nut. TORQUE: 18 N m (1.8 kgf m, 13 Ibf-ft) 80 ± 1 mm (3.15 ±0.04 in) Connect the master cylinder to the brake pedal with the joint pin and a new cotter pin. BRAKE PEDAL COTTER PIN Apply grease to new dust seal lips. Install the dust seals into the brake pedal. I RETURN SPRING MASTER CYLINDER JOINT PIN SwiTcH SPRING Hook the return spring to the pedal and frame as shown. Connect the brake switch spring to the return spring. Install and tighten the brake pedal pivot bolt. 17-25 BRAKE SYSTEM Install the master cylinder onto the frame and tighten the mounting bolts securely. Connect the brake hose to the master cylinder with the oil bolt and new sealing washers. Rest the hose joint pin against the stopper and tighten the oil bolt. TORQUE: 34 N m (3.5 kgf m, 25 Ibf-fft) Coat a new O-ring with brake fluid and install it into the master cylinder. Install the reservoir hose joint onto the master cylinder. Route the wires Apply locking agent to the hose joint screw threads. and hose properly Install and tighten the hose joint screw. (page 1-20). T O R Q U E . 2 N m {Q2 kgfm •, 4 | b f f t ) Fill and bleed the rear brake hydraulic system (page 17-7). Install the right center mud guard (page 3-7). 17-26 BRAKE SYSTEM REAR BRAKE CALIPER DISASSEMBLY Remove the right rear wheel (page 16-6). Drain the brake fluid from the rear brake hydraulic system (page 17-8). Remove the rear brake adjusting nut and disconnect the brake cable from the brake arm. Remove the brake cable from the caliper body. Disconnect the brake hose from the caliper body by removing the oil bolt and sealing washers. SEALING ! WASHERS '. Loosen the bracket pin bolt. Remove the two mounting bolts and the brake caliper from the frame. Remove the bracket pin bolt and pivot the caliper body. CALIPER BODY BRACKET PIN BOLT 17-27 BRAKE SYSTEM Remove the brake pads and pad spring. BRAKE PADS PAD SPRING Separate the caliper body from the caliper bracket. CALIPER BODY CALIPER BRACKET Remove the boots and collar from the caliper bracket. COLLAR BOOT Remove the caliper piston by turning it counterclockwise. Remove the piston dust cover. Be careful not to Push the piston seal in and lift it out. damage the piston sliding surface. 17-28 BOOT DUST COVER BRAKE SYSTEM Remove the snap ring using the snap ring pliers. TOOL: Snap ring pliers qrviAP RINC 07914-SA50001 or 07914-3230001 SNAP RING PLIERS Remove the following: - spring guide adjusting spring B spacer bearing A adjusting bolt cup sleeve piston rod O-ring ROD PISTON BOLT SPACER - return spring parking nut spring washer brake arm - brake cam dust cover GUIDE BRAKE ARM Clean the disassembled parts in clean brake fluid. BRAKE CAM DUST COVER 17-29 BRAKE SYSTEM INSPECTION Check the caliper cylinder and piston for scoring or other damage. Measure the caliper cylinder I.D. SERVICE LIMIT: 30.29 mm (1.193 in) Measure the caliper piston O.D. SERVICE LIMIT: 30.14 mm (1.187 in) ASSEMBLY/INSTALLATION PAD SPRING BOOTS CALIPER BRACKET COLLAR ROD CALIPER BODY DUST COVER BRAKE CAM SPRING GUIDE PIST0N SEAL BRAKE ARM CUP RETURN SPRING WASHER CALIPER PISTON ADJUSTING BOLT SPACER ADJUSTING SPRING Ei PARKING NUT SNAP RING DUST COVER Apply silicone grease to the dust cover lips and install it into the caliper body. Apply silicone grease to the brake cam groove and install it into the caliper body with the groove facing the caliper cylinder. / BRAKE CAM 17-30 DUST COVER BRAKE SYSTEM Install the brake arm, washer and parking nut. Tighten the parking nut. BRAKE ARM TORQUE: 27 N m (2.8 kgf m, 20 Ibf ft) Install the return spring as shown. Coat a new O-ring with silicone grease and install it into the sleeve piston groove. Coat a new cup with silicone grease and install it onto the adjusting bolt. Install the adjusting bolt into the sleeve piston. Coat the rod with silicone grease and install it into the sleeve piston. Install the piston assembly in the caliper cylinder by aligning the pins of the piston with the holes in the caliper. Install bearing A, spacer, adjusting spring B and spring guide onto the adjusting bolt. ROD PISTON BOLT SPACER Install the snap ring using the snap ring pliers. TOOL: Snap ring pliers GUIDE SNAP RING 07914-SA50001 or 07914-3230001 SNAP RING PLIERS Coat a new piston seal with clean brake fluid and install it into the seal groove in the caliper. Coat the caliper piston with clean brake fluid. Apply silicone grease to the lips of a new dust cover. Install the dust cover onto the caliper piston. Install the dust cover into the groove in the caliper. Install the caliper piston into the caliper cylinder and onto the adjusting bolt by turning it clockwise. Install the dust cover into the groove in the caliper piston. DUST COVER CALIPER PISTON 17-31 BRAKE SYSTEM Apply silicone grease to the lips of new boots and install them into the caliper bracket. Coat the collar with silicone grease and install it into the caliper bracket. Coat the caliper pin of the caliper body with silicone grease and install it into the caliper bracket. Install the pad spring in the caliper body as shown. Install the brake pads onto the caliper bracket. PAD SPRING Pivot the caliper body over the pads and bracket. CALIPER BODY Temporarily install the bracket pin bolt. BRACKET PIN BOLT Install the brake caliper with new mounting bolts and tighten the bolts. TORQUE: 30 N m (3.1 kgf m, 22 Ibf ft) Tighten the bracket pin bolt. TORQUE: 32 IM m (3.3 kgf m, 24 Ibf ft) 17-32 MOUNTING BOLTS BRACKET PIN BOLT BRAKE SYSTEM Connect the brake hose to the brake caliper with the oil bolt and new sealing washers, and tighten the oil bolt. TORQUE: 34 N m (3.5 kgf m, 25 Ibf-ft) Install the rear brake cable into the caliper body and connect it to the brake arm with the joint pin. Install the rear brake adjusting nut. Fill and bleed the rear brake hydraulic system (page 17-7). Adjust the rear (parking) brake lever free play (page 4-20). Install the right rear wheel (page 16-6). 17-33 BRAKE SYSTEM REAR BRAKE DISC REMOVAL Remove the following: - oil filler lid right side cover (page 3-5) engine guard (page 3-17) both rear wheels (page 16-6) bolt and rear brake hose clamp two rear brake caliper mounting bolts two link nuts four rear upper arm bolts and nuts rear shock absorber upper mounting bolts. Lift the rear of the frame and place a jack or stand under the sub-frame at the final gear case. Disconnect the breather hose from the final gear case. Remove the following: - four sub-frame joint nuts and bolts two final gear case upper mounting nuts and bolts Remove the final drive assembly from the frame by moving it rearward. UPPER ARM BOLTS SHOCK ABSORBER UPPER MOUNTING BOLTS UPPER ARM BOLTS GEAR CASE UPPER MOUNTING BOLTS BRAKE HOSE CLAM'P BOLT LINK NUTS SUB-FRAMEJOINT BOLTS BRAKE CALIPER MOUNTING BOLTS 17-34 FINAL DRIVE ASSEMBLY BRAKE SYSTEM Remove the following: - boot band boot (off the pinion joint) propeller shaft spring - five disc bolts brake disc BOOT PROPELLER SHAFT INSTALLATION Install the brake disc with the stamp facing to the engine side. Install new disc bolts and tighten them in a crisscross pattern in several steps. BRAKE DISC TORQUE: 20 N m (2.0 kgf m, 14 Ibf ft) Apply 5 - 8 g of molybdenum disulfide grease to the pinion joint splines. Install the spring into the propeller shaft. Set the propeller shaft into the pinion joint while compressing the spring, then install the boot over the pinion joint groove securely and secure it with the boot band. Be sure the propeller shaft is installed properly by pulling on the shaft lightly. BOOT 17-35 BRAKE SYSTEM Coat a new O-ring with molybdenum disulfide grease and install it into the propeller shaft groove. Put the final drive assembly on a floor jack or other adjustable support and place the assembly under the main frame. While adjusting the jack height, move the final drive assembly forward and connect the propeller shaft into the universal joint. Be careful not to disconnect the propeller shaft and universal joint. Set the final drive assembly into the main frame and seat the propeller shaft securely to align the bolt holes, then insert the mounting bolts from the left side. Install new mounting nuts but do not tighten them yet. Route the breather hoses properly (page 1-20) and connect them. BOLTS AND «S» NUTS Insert the sub-frame joint bolt bolts from the inside. Install new joint nuts. Tighten the four mounting nuts and joint nuts alternately. TORQUE: Joint nut: 34 N-m Mounting 34 N-m Mounting 39 N-m (3.5 kgf-m, 25 Ibfft) bolt (main frame): (3.5 kgf-m, 25 Ibfft) bolt (sub-frame): (4.0 kgf m, 29 Ibfft) Install the rear shock absorber upper mounting bolts and nuts, and tighten them. 17-36 UPPER MOUNTING BOLTS BRAKE SYSTEM Insert the pivot Install the upper arm into the frame with the pivot bolts from the bolts and new nuts, and tighten the nuts. inside. Connect the stabilizer links to the stabilizer arms with new nuts and tighten them. Install the rear brake caliper onto the final gear case, and install and tighten the mounting bolts. TORQUE: 30 N m (3.1 kgf m, 22 Ibf-ft) Align the shapes of the brake hose clamp and grommet properly. Install the rear brake hose clamp onto the sub-frame and tighten the bolt securely. Install the following: - both rear wheels (page 16-6) engine guard (page 3-17) right side cover (page 3-5) oil filler lid CLAMP BOLT 17-37 18. FRONT DRIVING MECHANISM SYSTEM COMPONENTS SERVICE INFORMATION 18-2 18-14 CASE BEARING REPLACEMENT 18-22 DIFFERENTIAL ASSEMBLY 18-25 DIFFERENTIAL INSTALLATION 18-30 18-3 TROUBLESHOOTING 18-6 FRONT DRIVE SHAFT 18-7 DIFFERENTIAL REMOVAL DIFFERENTIAL DISASSEMBLY/ INSPECTION 18-12 18-1 FRONT DRIVING MECHANISM SYSTEM COMPONENTS 44 N-m (4.5 kgf m, 33 7 N-m (0.7 10 N-m (1 7 Ibf-ft) 22 N-m (2.2 kgf 18-2 FRONT DRIVING MECHANISM SERVICE INFORMATION GENERAL • Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The extension lines from the gear engagement surfaces should intersect at one point. • Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage the gear case. • Replace the ring and pinion gears as a set. • Replace the cam followers (12 pieces) as a set, and the cam followers, face cams, differential housing and cap as an assembly if the face cam, differential housing or cap is faulty. SPECIFICATIONS Unit: mm (in) Front differential Recommended oil Gear backlash Backlash difference Slip torque STANDARD 175 cm 3 (5.9 US oz, 6.2 Imp oz) 220 cm 3 (7.4 US oz, 7.7 Imp oz) Hypoid gear oil SAE #80 0.05-0.25(0.002-0.010) 14-17N-m(1.45-1.75kgf-m, Face cam-to-housing distance Differential ring gear depth Cone spring height 10-13 Ibfft) 3.3-3.7(0.13-0.15) 6.55-6.65(0.2579-0.2618) 2.8(0.11) ITEM Oil capacity At draining At disassembly SERVICE LIMIT 0.4(0.02) 0.2(0.01) 12 N-m (1.2 kgf-m, 9 Ibfft) 3.3(0.13) 6.55 (0.2579) 2.6(0.10) TORQUE VALUES Differential ring gear bolt Differential case cover 10-mm bolt Differential case cover 8-mm bolt Differential final clutch bolt Differential mounting bolt Differential 10-mm mounting nut Differential 8-mm mounting nut Front vehicle speed sensor bolt Rear vehicle speed sensor bolt Speed sensor cover stay bolt Rear vehicle speed sensor cover bolt 49 N-m (5.0 kgf-m 36 Ibfft) 49 N-m (5.0 kgf-m 36 Ibfft) 25 N-m (2.6 kgf-m 19 Ibfft) 25 N-m (2.6 kgf-m 19 Ibfft) 44 N-m (4.5 kgf-m ,33 Ibfft) 44 N-m (4.5 kgf-m , 33 Ibfft) 22 N-m (2.2 kgf-m 16 Ibfft) 10 N-m (1.0 kgf-m,, 7 Ibfft) 10 N-m (1.0 kgf-m,, 7 Ibfft) 10 N-m (1.0 kgf-m,, 7 Ibfft) 7 N-m (0.7 kgf-m, 5.1 Ibfft) Special bolt: replace with a new one. Apply locking agent to the threads. Lock nut: replace with a new one. 18-3 FRONT DRIVING MECHANISM TOOLS Universal bearing puller 07631-0010000 Remover weight 07741-0010201 or equivalent commercially available in U.S.A. or 07936-371020A or 07936-3710200 (U.S.A. only) Attachment, 22 x 24 mm 07746-0010800 Attachment, 20 mm I.D. 07746-0020400 Driver, 40 mm I.D. 07746-0030100 Attachment, 30 mm I.D. 07746-0030300 Pilot, 15 mm 07746-0040300 Pilot, 28 mm CI7746-0041100 Driver 07749-0010000 Remover handle 07936-3710100 Rearing remover set, 30 mm 07936-8890300 18-4 Attachment, 52 x 55 mm 07746-0010400 FRONT DRIVING MECHANISM Bearing remover shaft 07936-KC10100 Bearing remover head, 15 mm 07936-KC10200 or 07936-KC10500 (U.S.A. only) or 07936-KC10500 (U.S.A. only) Bearing clip compressor, 25 mm 070ME-HN8A100 Differential inspection tool 07KMK-HC50101 Driver 07949-3710001 Press attachment 07LME-GE20100 or 07KMK-HC5010A (U.S.A. only) 18-5 FRONT DRIVING MECHANISM TROUBLESHOOTING Consistent noise during cruising • Oil level too low • Foreign matter contaminating gear oil • Worn or damaged bearing • Worn or damaged ring gear and pinion gear • Deformed ring gear or differential case • Improper tooth contact between ring gear and pinion gear Gear noises while running • Oil level too low • Foreign matter contaminating gear oil • Chipped or damaged gears • Improper tooth contact between ring gear and pinion gear Gear noise 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 18-6 FRONT DRIVING MECHANISM FRONT DRIVE SHAFT REMOVAL It is not necessary to remove the splash guard. To prevent damage to the differential oil seal, hold the inboard joint horizontal until the drive shaft is clear of the differential. Remove the knuckle (page 15-15) Hold the inboard joint of the drive shaft and tug firmly to force the stopper ring on the inboard joint end past the groove while prying with a screwdriver. Remove the stopper ring from the inboard joint. INBOARD JOINT DISASSEMBLY/INSPECTION Check the boots for cuts or other damage. Check the drive shaft joints for excessive play or noise by moving the joints in a circular direction. If the outboard joint seems to be worn or damaged, the drive shaft must be replaced. INBOARD JOINT BOOTS NOTE. • To replace the outboard boot, first remove the inboard boot as described in the following steps. Then remove the bands and outboard boot from the inboard end of the shaft. • The outboard joint cannot be disassembled. OUTBOARD JOINT Replace the band with new ones whenever removing them. Bend up the lock tabs and raise the band ends to loosen the bands on the inboard side. Remove band B. Remove the boot from the inboard joint. BAND END BAND A TABS BAND B 18-7 FRONT DRIVING MECHANISM Remove the following: - stopper ring inboard joint - snap ring bearing inboard boot inboard band A STOPPER RING INBOARD JOINT SNAP RING BOOT Replace the compo- Check the following for wear or damage: nentsasanassem- _ b e a r i n g c a g e y ' - race steel balls inboard joint Remove the following: - INBOARD JOINT BEARING OUTBOARD BOOT BAND shaft boot band outboard boot band outboard boot SHAFT BOOT BAND 18-8 BOOT FRONT DRIVING MECHANISM ASSEMBLY DRIVESHAFT INBOARD JOINT SHAFT BOOT BAND OUTBOARD BOOT OUTBOARD JOINT SNAP RING BEARING STOPPER RING BEARING RACE BANDB OUTBOARD BOOT BAND INBOARD BOOT BEARING CAGE Each boot has an identification mark; "BJ71" for the outboard and "UJ68" for inboard. Inboard: UJ68 Outboard: BJ71 BAND A BJ71 UJ68 Vfl/n flVMYi Nl 1 INBOARD BOOT \ OUTBOARD BOOT Note the installation direction of the boot bands. Forward rotation direction BAND 18-9 FRONT DRIVING MECHANISM Pack the outboard joint with 55 - 75 g of specified grease. OUTBOARD BOOT BAND A Specified grease: NKG106 (KYODO YUSHI) INBOARD BOOT Install the following: - outboard boot - new shaft boot band - new inboard band A - inboard boot Do not tighten the bands at this time. 58S SHAFT BOOT BAND Install the bearing with the small O.D. facing the drive shaft. Install the snap ring with the chamfered side facing the bearing. BEARING SNAP RING BOOT Pack the inboard joint with 40 - 60 g of specified grease. Specified grease: NKG205 (KYODO YUSHI) Install the inboard joint over the bearing. Install the stopper ring into the groove in the inboard joint properly. Adjust the length of the drive shaft to the figure given below. DRIVE SHAFT LENGTH: Left: 363.3 mm (14.30 in) Right: 383.1 mm (15.08 in) 18-10 STOPPER RING FRONT DRIVING MECHANISM For band installs- Install inboard band A and a new inboard band B. tlon direction Bend down the band end and secure it with the lock See page 18-9. tabs. Tap the lock tabs with a plastic hammer. BAND END BAND A Install the shaft boot band and a new outboard boot band onto the outboard boot. Bend down the band end and secure it with the lock tabs. Tap the lock tabs with a plastic hammer. OUTBOARD BOOT BAND TABS SHAFT BOOT BAND INSTALLATION Install a new stopper ring into the groove in the inboard joint spline. STOPPER RING INBOARD JOINT Be careful not to damage the oil seal in the differential gear case. Install the drive shaft by holding the inboard joint until the stopper ring seats in the groove of the differential. I INBOARD JOINT; Make sure that the stopper ring is seated properly by pulling on the inboard joint lightly. Install the knuckle (page 15-20). 18-11 FRONT DRIVING MECHANISM DIFFERENTIAL REMOVAL Drain the differential oil (page 4-16). Remove the following: - left front mud guard (page 3-8) both inner fenders (page 3-9) front grille (page 3-10) left drive shaft (page 18-7) two bolts, guard plate and front Vehicle Speed Sensor (VS sensor). - two bolts and VS sensor cover Remove the rear VS sensor wire and front final clutch wire from the clamp. Remove the three bolts, VS sensor cover stay and rear VS sensor. Disconnect the front final clutch 2P (Green) connector. Remove the following: - 8 mm mounting nut and bolt two 8 mm bolts and mounting bracket 10 mm mounting nut, bolt and spacer 2P (GREEN)CONNECTOR REAR VS SliNSOR 10 mm NUT AND BOLT 8 mm NUT AND BOLT | MOUNTING BRACKET | 18-12 FRONT DRIVING MECHANISM breather tube 10 mm mounting bolt Move the differential forward for maximum clearance between the propeller shaft joint and engine. PROPELLER SHAFT JOINT Pull the propeller shaft joint out of the output shaft of the engine. Remove the O-ring. Remove the boot band and propeller shaft boot from the pinion joint. PROPELLER SHAFT BOOT Pull the propeller shaft to force the stopper ring past the groove in the pinion joint and remove the propeller shaft. Remove the stopper ring from the propeller shaft end. 18-13 FRONT DRIVING MECHANISM Separate the other drive shaft from the differential as you remove it. Remove the differential assembly from the frame. DIFFERENTIAL DISASSEMBLY/ INSPECTION PROPELLER SHAFT INSPECTION Remove the boot band and boot from the propeller shaft joint, and remove the propeller shaft joint and spring. BOOT BAND PROPELLER SHAFT BOOT PROPELLER SHAFT JOINT Check the splines of the propeller shaft and joint for wear or damage. If damaged, check the output shaft and the pinion joint also. Check the seal rubbers for fatigue or damage. Check the boots for cuts, deterioration or damage. BOOTS SEAL RUBBERS SPRING OPERATION CHECK Install a 8 mm nut onto the pinion gear. PINION GEAR 8 mm NUT 18-14 FRONT DRIVING MECHANISM Turn the 8 mm nut and check the pinion gear turns smoothly and quietly without binding. If the pinion gear does not turn smoothly or quietly, the pinion gear, ring gear and/or bearing may be damaged or faulty. They must be checked after disassembly; replace them if necessary. BACKLASH INSPECTION Hold the pinion gear with the 8 mm nut. Set the differential case into a jig or vise with soft jaws. Install the differential inspection tool into the right side of the differential. TOOL: Differential inspection tool 07KMK-HC50101 or 07KMK-HC5010A (U.S.A. only) Remove the oil filler cap and 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. 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 squarely, or the case is deformed. Inspect the bearings and case. 18-15 FRONT DRIVING MECHANISM If the backlash is excessive, replace the ring gear left side shim 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) when the thickness of the shim is changed by 0.10 mm (0.004 in). NOTE: • Twenty-three different thickness shims are available from the thinnest (0.50 mm) shim to the thickest (1.60 mm) shim in increments of 0.05 mm. 1 A ^ " ^ - - - R I G H T SHIM J Im LEFT SHIM gP^ 1 i "-• 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 an equal thickness and opposite amount of what the left side shim was changed; If the left shim was replaced with a 0.10 mm (0.004 in) thicker shim, replace the right shim with one that is 0.10 mm (0.004 in) thinner. DIFFERENTIAL REMOVAL Loosen the six cover bolts in a crisscross pattern in several steps and remove them. PRYING POINTS Pry the case cover at the points as shown by using a screwdriver and remove the cover. CASE COVER BOLTS Remove the differential assembly and shims. SHIMS DIFFERENTIAL ASSEMBLY 18-16 FRONT DRIVING MECHANISM BEARING INSPECTION Turn the inner race of each bearing in the gear case and cover with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the case or cover. BEARING GEAR TOOTH CONTACT PATTERN CHECK Keep dust and dirt Clean sealing material off the mating surfaces of the out of the case and differential case and cover, being careful not to cover. damage them. LEFT SHIM Apply thin coat of Prussian Blue to the pinion gear teeth for a tooth contact pattern check. Install the ring gear shims onto the differential assembly. Apply Prussian Blue Install the differential assembly into the gear case. RIGHT SHIM DIFFERENTIAL ASSEMBLY It is important to Install the case cover and tighten the bolts in several turn the pinion gear steps until the cover evenly touches the gear case. while tightening the Then, while rotating the pinion gear, tighten the bolts. If the ring bolts to the specified torque in a crisscross pattern gear shim is too in several steps. thick, the gears will lock after only light TORQUE: 10 mm bolt: 49 N m (5.0 kgf m, 36 Ibf-ft) 8 mm bolt: 25 N m (2.6 kgf-m, 19 Ibf-ft) tightening. 10 mm BOLTS 8 mm BOLTS 18-17 FRONT DRIVING MECHANISM Remove the oil filler cap. NORMAL: Rotate the ring gear several times in both directions of rotation. HEEL Check the gear tooth contact pattern through the oil filler hole. TOE FACE The pattern is indicated by the Prussian Blue applied to the pinion. Contact is normal if the Prussian Blue is transferred to the approximate center of each tooth, but slightly to the heel side and to the flank side. FLANK FLANK Drive side Coast side If the patterns are not correct, remove and change the pinion shim with one of an alternate thickness. Replace the pinion shim with a thicker one if the contact pattern is too high, toward the face. TOO HIGH: FACE Drive side Replace the pinion shim with a thinner one if the contact pattern is too low, toward the flank. TOO LOW: PINION SHIM FACE Coast side PINION SHIM The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in) when the thickness of the shim is changed by 0.12 mm (0.005). NOTE: • Fifteen different thickness shims are available from the thinnest (1.64 mm) shim to the thickest (2.18 mm) shim in intervals of 0.06 mm. Ring gear shims: A: (thinnest): 1.64 mm (0.064 in) G: (standard): 2.00 mm (0.079 in) J: (thickest): 2.18 mm (0.086 in) For pinion shim replacement (page 18-21) 18-18 FACE FLANK Drive side FLANK Coast side FRONT DRIVING MECHANISM DIFFERENTIAL INSPECTION Install the inspection tools into both sides of the differential. TOOL: Differential inspection tool 07KMK-HC50101 or 07KMK-HC5010A (U.S.A. only) Hold the flat surface of the tool with a vise. Attach a torque wrench to the other tool and measure the limited slip torque. STANDARD: 14 - 17 N m (14.5 - 17.5 kgfm, 10 - 13 Ibf-ft) SERVICE LIMIT: 12 N m (1.2 kgf m, 9 Ibf-ft) If the slip torque is out of specification, disassemble the differential and perform the components inspection (page 18-20) since the differential may be faulty. DIFFERENTIAL DISASSEMBLY Remove the ten bolts, then place the differential assembly with the ring gear side up. BOLTS RING GEAR Remove the following: - SIDE CONE SPRING ring gear side cone spring shim SHIM RING GEAR 18-19 FRONT DRIVING MECHANISM - face cam six cam followers A and six cam followers B face cam CAM FACE CAM FOLLOWERS A AND B 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. SERVICE LIMIT: 6.55 mm (0.2568 in) DIFFERENTIAL HOUSING/FACE CAM/CAM FOLLOWERS Check the sliding surface and grooves of the housing for damage or discoloration. 18-20 DIFFERENTIAL HOUSING CAM FACE FRONT DRIVING MECHANISM Replace the cam Check the shim, face cams and followers for damfollowers as a set age. 112 pieces). FACE CAM CAM FOLLOWERS Temporarily assemble the differential housing, face cams and cam followers (page 18-27). Measure the height of the 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. SERVICE LIMIT: 3.3 mm (0.13 in) If the height is smaller than the service limit, replace the differential as an assembly. SIDE CONE SPRING Check the cone spring for damage. Measure the height of the cone spring. SERVICE LIMIT: 2.6 mm (0.10 in) PINION GEAR REMOVAL Remove the three bolts and front final clutch assembly from the differential. BOLTS Remove the O-ring from the final clutch assembly. FINAL CLUTCH ASSEMBLY 18-21 FRONT DRIVING MECHANISM Press the pinion gear out of the final clutch assembly using the special tools. TOOLS: Driver Pilot, 15 mm Be sure to wear heavy gloves to avoid burns when handling the heated final clutch. Using a torch to heat the final clutch may damage the clutch. DRIVER ATTACHMENT 07749-0010000 07746-0040300 Heat the final clutch to about 100°C (212°F). REMOVER WEIGHT Remove the pinion gear bearing from the final clutch using the special tools. TOOLS: Bearing remover, 30 mm Remover handle Remover weight 07936-8890300 07936-3710100 07936-371020A or 07936-3710200 REMOVER HANDLE BEARING REMOVER CASE BEARING REPLACEMENT DIFFERENTIAL BEARING Remove the oil seals from the differential case and cover. Drive the differential bearing out of the case and cover. Drive new bearings into the differential case and cover. TOOLS: Driver Attachment, 52 x 55 mm Pilot, 28 mm 07749-0010000 07746-0010400 07746-0041100 ATTACHMENT/PILOT 18-22 FRONT DRIVING MECHANISM Apply grease to new oil seal lips and install them into the differential case and cover. TOOL: Attachment, 20 mm I.D. ATTACHMENT 07746-0020400 PINION NEEDLE BEARING Rotate the stopper ring until the end of the stopper ring appears in the access hole. Strike gently near the end of the ring with a punch to bent the end upward. Grasp the end of the ring with needle-nosed pliers and pull the stopper ring out through the access hole. Be sure to wear heavy gloves to avoid burns when handling the heated gear case. Using a torch to heat the gear case may cause warpage. Heat the gear case to about 80°C (176°F) and remove the needle bearing by using the special tools. TOOLS: Remover head, 15 mm Bearing remover shaft Bearing remover, 15 mm Remover weight 07936-KC10200 07936-KC10100 or 07936-KC10500 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) Install a new stopper ring into the groove in a new bearing. 18-23 FRONT DRIVING MECHANISM Install the bearing into the compressor until it is flush with the end of the tool. TOOL: Bearing clip compressor, 25 mm 070ME-HN8A100 Place the driver, attachment and pilot on the top of the bearing and tape the driver to the compressor. TOOLS: Driver Attachment, 22 x 24 mm Pilot, 15 mm 07949-3710001 07746-0010800 07746-0040300 Place the bearing and tool assembly into a freezer for at least 30 minutes. COMPRESSOR NEEDLE BEARING Heat the gear case to 80°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 ring may slip out of the groove. If this happens, remove the ring and bearing, and install a new ring. 1 s = 5 ^ DRIVER COMPRESSOR PILOT ^ Make sure that the stopper ring is securely set in the groove of the gear case. (O'l STOPPER RING 18-24 FRONT DRIVING MECHANISM DIFFERENTIAL ASSEMBLY PINION BEARING CONE SPRING PINION SHIM RING GEAR SHIM \ RING GEAR DIFFERENTIAL BEARING STOPPER RING 10 mm BOLT NEEDLE BEARING GEAR CASE OIL SEAL FRONT FINAL CLUTCH 8 mm BOLT / GEAR CASE COVER DIFFERENTIAL BEARING DIFFERENTIAL SHIM LEFT FACE CAM DIFFERENTIAL CASE CAM FOLLOWERS I RIGHT FACE CAM DIFFERENTIAL BEARING, 2 9 x 5 2 x 1 2 mm PINION BEARING, 6006 C5 DIFFERENTIAL BEARING, 29 x 52 x 12 mm NEEDLE BEARING 15 x 25 x 16 mm 18-25 FRONT DRIVING MECHANISM PINION GEAR INSTALLATION Install the shim and bearing onto the pinion gear. NOTE: • When the gear set, differential bearing, differential housing and/or gear case has been replaced, use a 2.00 mm (0.079 in) thick shim for initial reference. PINION BEARING PINION GEAR PINION SHIM Press the pinion bearing onto the pinion gear. TOOLS: Driver, 40 mm I.D. Attachment, 30 mm I.D. DRIVER 07746-0030100 07746-0030300 ATTACHMENT BEARING PINION GEAR Be careful not to Press the pinion gear/bearing assembly into the damage the oil seal front final clutch using the special tools. lips in the final clutch. TOOLS: Press attachment Universal bearing puller Be sure to wear heavy gloves to avoid burns when handling the heated final clutch case. UNIVERSAL BEARING PULLER ATTACHMENT N. 07LME-GE20100 07631-0010000 or equivalent commercially available in U.S.A. U.S.A. only: Heat the final clutch case to about 100°C (212°F). Drop the pinion gear assembly into the warm final clutch case. PINION GEAR/BEARING Coat a new O-ring with grease and install it into the groove in the front final clutch assembly. FINAL CLUTCH ASSEMBLY 18-26 FRONT DRIVING MECHANISM Install the final clutch assembly onto the differential. Install and tighten the three bolts. BOLTS TORQUE: 25 N m (2.6 kgf-m, 19 Ibfft) FINAL CLUTCH ASSEMBLY Keep dust and dirt out of the differential housing. DIFFERENTIAL ASSEMBLY Install the face cam into the differential housing. Install the six cam followers A (rib) and six cam followers B (flat) into the specified grooves in the housing by two and two as shown. CAM FOLLOWERS HOUSING Install the face cam onto the cam followers. CAM FACE Measure the depth of the ring gear and record it (page 18-20). Measure the height of the housing-to-cam and record it (page 18-20). 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 face cam height Select the shim and install it onto the face cam. Differential shims: A: 1.3 mm (0.051 in) B: 1.4 mm (0.055 in) C: 1.5 mm (0.059 in) D: 1.6 mm (0.063 in) SIDE CONE SPRING E: 1.7 mm (0.067 in) F: 1.8 mm (0.071 in) G: 1.9 mm (0.075 in) Install the cone spring with the concaved side facing up (ring gear side). Install the ring gear. SHIM RING GEAR 18-27 FRONT DRIVING MECHANISM Install new ring gear bolts and tighten them in a crisscross pattern in several steps. BOLTS TORQUE: 49 N m (5.0 kgf m, 36 Ibf ft) Inspect the slip torque (page 18-19). If the slip torque is out of specification, perform the shim adjustment. Replace the differential assembly when the replacement shim is changed by 0.3 mm or more from the selected shim (page 18-27). RING GEAR DIFFERENTIAL CASE ASSEMBLY NOTE: • When the gear set, bearing, differential housing and/or gear case has been replaced, check the tooth contact pattern (page 18-17). Check the gear backlash (page 18-15). Keep dust and dirt Clean the mating surface of the gear case and cover, out of the case and being careful not to damage them. cover. g | o w c o m p r e s S e d air through the breather hole in the case cover. Install the proper ring gear shims onto the differential assembly and install the assembly into the gear case. 18-28 SHIMS FRONT DRIVING MECHANISM Coat a new O-ring with grease and install it into the gear case cover groove. GEAR CASE CASE COVER Install the case cover over the gear case. DIFFERENTIAL ASSEMBLY It is important to Apply locking agent to the threads of the two 10 mm turn the pinion gear bolts. while tightening the Install the bolts and tighten them in several steps bolts. If the ring until the cover evenly touches the gear case. Then, gear shim is too while rotating the pinion gear, tighten the bolts to thick, the gears will the specified torque in a crisscross pattern in sevlock after only light eral steps. tightening. TORQUE: 10 mm bolt: 49 N m (5.0 kgfm, 36 Ibf-ft) 8 mm bolt: 25 IM m (2.6 kgfm, 19 Ibf-ft) Make sure that the gear assembly rotates smoothly without binding. PROPELLER SHAFT ASSEMBLY PINION JOINT e ^ i SEAL RUBBER SEAL RUBBER (5-8g) Apply molybdenum disulfide grease to the seal rubbers. Apply 5 - 8 g of molybdenum disulfide grease to the propeller shaft joint splines. PROPELLER SHAFT JOINT SEAL RUBBERS Set the spring and propeller shaft joint onto the propeller shaft. SPRING PROPELLER SHAFT JOINT 18-29 FRONT DRIVING MECHANISM Install the boot over the propeller shaft joint while compressing the spring. Install the boot band into the boot groove. PROPELLER SHAFT BOOT BOOT BAND PROPELLER SHAFT JOINT DIFFERENTIAL INSTALLATION Place the differential into the frame. Install the right drive shaft onto the differential in the same manner as on (page 18-11). Install a new stopper ring into the groove in the propeller shaft. Apply 5 - 8 g of molybdenum disulfide grease to the propeller shaft joint splines. Install the propeller shaft assembly into the differential until the stopper ring seats in the pinion joint groove. Make sure that the stopper ring is seated properly by pulling on the pinion joint lightly. Install the propeller shaft boot over the pinion joint securely and the boot band into the boot groove. PROPELLER SHAFT BOOT 18-30 FRONT DRIVING MECHANISM Coat a new O-ring with molybdenum disulfide grease and install it into the groove in the output shaft. Apply molybdenum disulfide grease to the output shaft splines. PROPELLER SHAFT JOINT Apply molybdenum disulfide grease to the propeller shaft joint splines. Move the differential forward for maximum clearance between the propeller shaft joint and output shaft. Install the propeller shaft joint over the output shaft. OUTPUT SHAFT Align the bolt holes in the differential and frame, and install the 10 mm mounting bolt. BREATHER HOSE '. Connect the breather hose. Install the spacer, 10 mm mounting bolt and nut. Install the mounting bracket, 8 mm bolts, 8 mm mounting bolt and nut. Tighten the all mounting fasteners. TORQUE: 10 mm: 44 N-m (4.5 kgf-m, 33 Ibfft) 8 mm: 22 N-m (2.2 kgf-m, 16 Ibfft) 8 mm NUT AND BOLT • MOUNTING BRACKET i Connect the front final clutch 2P (Green) connector and install it onto the sensor cover stay. Install the rear VS sensor, VS sensor cover stay and three bolts, and tighten the bolts. 2P(GREEN) CONNECTOR MUM REAR VS SENSOR TORQUE: 10 N-m (1.0 kgfm, 7 Ibfft) Clamp the rear VS sensor wire and front final clutch wire. 18-31 FRONT DRIVING MECHANISM Install the VS sensor cover while hooking it on the boss on the case, and install and tighten the two bolts. TORQUE: 7 N m (0.7 kgf m, 5.1 Ibf-ft) Install the front VS sensor, guard plate and two bolts, and tighten the bolts. TORQUE: 10 N m (1.0 kgf m, 7 Ibf-ft) Install the following: - left drive shaft (page 18-7) front grille (page 3-10) inner fenders (page 3-9) left front mud guard (page 3-8) Fill the differential with the recommended oil (page 4-16). 18-32 19. REAR DRIVING MECHANISM SYSTEM COMPONENTS 19-2 UNIVERSAL JOINT 19-15 SERVICE INFORMATION 19-3 FINAL DRIVE DISASSEMBLY/ TROUBLESHOOTING 19-5 INSPECTION 19-16 REAR DRIVE SHAFT • 19-6 CASE BEARING REPLACEMENT 19-21 FINAL DRIVE REMOVAL 19-12 FINAL DRIVE ASSEMBLY 19-23 FINAL DRIVE INSPECTION 19-14 FINAL DRIVE INSTALLATION 19-27 19-1 REAR DRIVING MECHANISM SYSTEM COMPONENTS 34 N-m (3.5 kgf m, 25 Ibf ft) 34 N-m (3.5 kgf m, 25 Ibf ft) 34 N-m (3.5 kgf m, 25 Ibfft) 30 N-m (3.1 kdf-m, 22 Ibfft) 39 N-m (4.0 kgfm, 29 Ibfft) 19-2 REAR DRIVING MECHANISM SERVICE INFORMATION GENERAL • Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The extension lines from the gear engagement surfaces should intersect at one point. • Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage the gear case. • When using the lock nut wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench. Do not overtighten the lock nut. The specification later in the text gives both actual and indicated. • Replace the ring and pinion gears as a set. • For bearing replacement in the knuckle (page 16-7). SPECIFICATIONS Final drive ITEM Oil capacity At draining At disassembly Recommended oil Gear backlash Backlash difference Ring gear-to-stop pin clearance STANDARD 78 cm3 (2.6 US oz, 2.7 Imp oz) 90 cm 3 (3.0 US oz, 3.2 Imp oz) Hypoid gear oil SAE #80 0.05-0.25(0.002-0.010) 0.3-0.6(0.01-0.02) Unit: mm (in) SERVICE LIMIT 0.4(0.02) 0.2(0.01) - TORQUE VALUES Final gear case pinion bearing lock nut Pinion joint nut Final gear case cover bolt (10 mm) Final gear case cover bolt (8 mm) Final gear case mounting nut (main frame) Final gear case mounting nut (sub frame) Sub-frame joint nut Rear brake disc bolt 98 N-m (10.0 kgf-m, 72 Ibf-ft) Lock nut: replace with a new one. Stake. 108 N-m (11.0 kgfm, 80 Ibf-ft) Apply locking agent to the threads. 49 N-m (5.0 kgf-m, 36 Ibf-ft) Apply locking agent to the threads. 25 N-m (2.6 kgf-m, 19 Ibf-ft) 34 N-m (3.5 kgf-m, 25 Ibf-ft) Lock nut: replace with a new one. 39 N-m (4.0 kgf-m, 29 Ibf-ft) Lock nut: replace with a new one. 34 N-m (3.5 kgf-m, 25 Ibf-ft) 20 N-m (2.0 kgf-m, 14 Ibf-ft) ALOC bolt: replace with a new one. 19-3 REAR DRIVING MECHANISM TOOLS Attachment, 52 x 55 mm 07746-0010400 Attachment, 62 x 68 mm 07746-0010500 Driver, 40 mm I.D. 07746-0030100 Attachment, 25 mm I.D. 07746-0030200 Attachment, 35 mm I.D. 07746-0030400 Pilot, 30 mm 07746-0040700 Driver 07749-0010000 Lock nut wrench, 30 x 64 mm 07916-MB00002 Puller shaft 07931-ME40000 Remover handle 07936-3710100 Bearing remover set, 17 mm 07936-3710300 Remover weight 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) or 07931-ME4010B and 07931HB3020A (U.S.A. only) 19-4 REAR DRIVING MECHANISM Oil seal driver 07965-KE80200 Bearing clip compressor, 28 mm 070ME-HN8A200 not available in U.S.A. Driver attachment 07LAD-PW50500 Pinion puller base 07HMC-MM80110 or 07HMC-MM8011A (U.S.A. only) Pinion holder 07SMB-HM70200 Puller attachment 07YMC-GCS0100 (not available in U.S.A.) or 079493710001, 07746-0010700 and 077460040400 TROUBLESHOOTING Excessive noise • Worn or damaged bearing • Worn or scored splines • Worn or damaged drive shaft, propeller shaft or universal joint • Worn pinion and ring gears • Excessive backlash between pinion and ring gears • Oil level too low Wobble or vibration in vehicle • Axle not tightened properly • Bent axle Oil leak • Oil level too high • Clogged breather • Damaged seals • Loose case cover 19-5 REAR DRIVING MECHANISM REAR DRIVE SHAFT REMOVAL Remove the following. - wheel hub (page 16-6) seat (page 3-4) Flight drive shaft: Remove the right side cover (page 3-5). Left drive shaft: Remove the oil filler lid (page 3-8). Support the lower arm with a support block. Remove the following: - stabilizer link nut (to disconnect the link) two upper arm pivot nuts and bolts - shock absorber upper mounting nut and bolt Remove the shock absorber and upper arm off the frame, and pivot the knuckle outward to release it from the drive shaft. KNUCKLE To prevent damage Hold the inboard joint of the drive shaft and tug I INBOARD JOINT to>the thegear gearcase caseoiloil firmly firmlytotoforce forcethe thestopper stopperring ringat, the drive shaft end U ^ ^ ^ a . . seal, hold the past the groove while prying with a screwdriver. inboard joint horiRemove the stopper ring. zontal until the drive shaft is clear of the gear case. 19-6 REAR DRIVING MECHANISM DISASSEMBLY/INSPECTION Check the boots for cuts or other damage. Check the drive shaft joints for excessive play or noise by moving the joints in a circular direction. If the outboard joint seems to be worn or damaged, the drive shaft must be replaced. OUTBOARD JOINT BOOTS NOTE: • To replace the outboard boot, first remove the inboard boot as described in the following steps. Then remove the bands and outboard boot from the inboard end of the shaft. • The outboard joint cannot be disassembled. INBOARD JOINT Replace the band with new ones whenever removing them. Bend up the lock tabs and raise the band ends to loosen the boot bands on the inboard side. Remove the inboard boot band. TABS BAND END Remove the boot from the inboard joint. INBOARD BOOT BAND BAND B Remove the following: - stopper ring inboard joint STOPPER RING snap ring bearing inboard boot boot band B BOOT SNAP RING BEARING 19-7 REAR DRIVING MECHANISM Replace their com- Check the following for wear or damage: ponentsasan _ b e a r j assembly. - INBOARD JOINT steel balls inboard joint BEARING Remove the following: - BOOT shaft boot band outboard boot band outboard boot SHAFT BOOT BAND OUTBOARD BOOT BAND ASSEMBLY DRIVE SHAFT SHAFT BOOT BAND INBOARD JOINT OUTBO/SRDBOOT OUTBOARD JOINT SNAP RING BEARING STOPPER RING INBOARD BOOT BAND BEARING RACE INBOARD BOOT BEARING CAGE 19-8 BANDB OUTBOARD BOOT BAND REAR DRIVING MECHANISM Each boot has an identification mark; "85-71L" for the outboard and "BJ75" for inboard. "85-71L" OUTBOARD BOOT "BJ75" INBOARD BOOT Note the installation direction of the boot bands. Pack the outboard joint with 45 - 65 g of specified grease. -,, ,-ronADn D/~>I-VT OUTBOARD BOOT Specified grease: NKG106 (KYODO YUSHI) BANDB Install the following: - outboard boot new shaft boot band new boot band B inboard boot Do not tighten the bands at this time. INBOARD BOOT Install the bearing with the small O.D. facing the drive shaft. Install the snap ring with the chamfered side facing to the bearing. SNAP RING BEARING 19-9 REAR DRIVING MECHANISM Pack the inboard joint with 60 - 80 g of specified grease. Specified grease: NKG205 (KYODO YUSHI) Install the inboard joint over the bearing. Install the stopper ring into the groove in the inboard joint properly. Install the inboard boot over the inboard joint securely. STOPPER RING Pack 60 - 8C Be sure the length of the drive shaft to be set the figure given below. DRIVE SHAFT LENGTH: 425.2 mm (16.74 in) For band Install the shaft boot band and a new outboard boot installation direction band onto the outboard boot. (page 19-9). Bend down each band end and secure it with the lock tabs. Tap the lock tabs with a plastic hammer. TABS \ SHAFT BOOT BAND Install the boot band B and a new inboard boot band onto the inboard boot. Bend down each band end and secure it with the lock tabs. Tap the lock tabs with a plastic hammer. OUTBOARD BOOT BAND INBOARD BOOT BAND BANDB INBOARD JOINT 19-10 REAR DRIVING MECHANISM INSTALLATION Install a new stopper ring into the groove in the inboard joint splines. STOPPER RING Be careful not to Install the drive shaft by holding the inboard joint damage the oil seal until the stopper ring seats in the groove. e gear case. ^a^Q s u r e t n e s ^ O pp e r r j n g j s seated properly by pulling on the inboard joint lightly. Pack the lip cavities of the inner dust seal with 2.5 3 g of grease. Set the upper arm and shock absorber into the frame properly to fit the knuckle over the drive shaft. Insert the pivot Install the upper arm pivot bolts and new nuts, and bolts from the tighten them. inside. TORQUE: 34 IM-m (3.5 kgfm, 25 Ibf-ft) Connect the stabilizer link into the upper arm with a new nut and tighten it securely. UPPER ARM 19-11 REAR DRIVING MECHANISM Install the shock absorber upper mounting bolt and a new nut, and tighten it securely. Install the following: - wheel hub (page 16-9). Right side: - right side cover (page 3-5) Leftside: - oil filler lid (page 3-8) - seat (page 3-4). FINAL DRIVE REMOVAL Drain the final gear case oil (page 4-15). Remove the following: - engine guard (page 3-17) rear brake caliper without disconnecting the brake hose (page 17-27) drive shafts (page 19-6) Remove the following from the frame: - pivot nuts and bolts suspension arm/shock absorber assemblies Remove the brake hose clamp bolt. BOLT Place a floor jack or other adjustable support under the sub-frame. sub-frame joint nuts and bolts SUB-FRAME 19-12 BOLTS AND NUTS REAR DRIVING MECHANISM breather hose upper mounting nuts and bolts Lower the jack slightly and move it rearward to dis- I O-R|"N<~ connect the propeller shaft. Remove the final drive assembly out of the vehicle. Remove the following: - universal joint O-rings (from the propeller shaft and output shaft of the engine) boot band joint boot (off the pinion joint) propeller shaft spring disc bolts brake disc DISC mounting nuts and bolts final drive assembly ! FINAL DRIVE ASSEMBLY i 19-13 REAR DRIVING MECHANISM FINAL DRIVE INSPECTION PROPELLER SHAFT For boot and seal Check the splines for wear or damage. replacement (page If damaged, check the universal joint and output shaft also. Check the seal rubber for fatigue or damage. Check the boot for cuts or damage. SEAL RUBBER BOOT UNIVERSAL JOINT Check the boot for cuts or other damage. Check that the joint moves smoothly without binding or noise. FINAL DRIVE OPRRATION Turn the pinion joint and check that the gear turns smoothly and quietly without binding. If the gears They faulty 19-14 gears do not turn smoothly or quietly, the and/or bearing may be damaged or faulty. must be checked after disassembly; replace parts/assemblies as required. REAR DRIVING MECHANISM UNIVERSAL JOINT UNIVERSAL JOINT DISASSEMBLY/ ASSEMBLY Bend up the lock tabs and raise the band ends to loosen the boot bands. Remove the joint boot. Apply molybdenum disulfide grease to the joint bearing. BAND END Install the boot and set it onto the universal joint properly. TABS Install new boot bands so the band ends are facing opposite the forward direction. Bend down each band end and secure it with the lock tabs. Tap the lock tabs with a plastic hammer. BOOT Viewed from the rear side: AI T — ^ Forward direction // f . — TABS \ / s \ END f BAND 19-15 REAR DRIVING MECHANISM FINAL DRIVE DISASSEMBLY/ INSPECTION BACKLASH INSPECTION Remove the oil filler cap. PINION HOLDER Install the special tool into the pinion joint, and set the final drive assembly and tool in a vise. TOOL: Pinion holder 07SMB-HM70200 Install the drive shaft into the final drive assembly and hold it. Set a horizontal type dial indicator on the ring gear through the filler hole. Turn the ring gear back and forth with the drive shaft to read backlash. RING GEAR 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. 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 squarely, or the case is deformed. Inspect the bearings and case. LEFT SHIM If the backlash is excessive, replace the ring gear right shim with a thinner one. If the backlash is too small, replace the ring gear right shim with a thicker one. Backlash is changed by about 0.06 mm (0.002 in) when thickness of the spacer is changed by 0.12 mm (0.005 in). NOTE: • Ten different shims (from A to J) are available in thickness increments of 0.06 mm (0.002 in). Ring gear shims: A: 1.64 mm (0.064 in) B: 1.70 mm (0.067 in) C: 1.76 mm (0.069 in) D: 1.82 mm (0.072 in) E: 1.88 mm (0.074 in) F: 1.94 mm (0.076 in) G: 2.00 mm (0.079 in) H: 2.06 mm (0.081 in) I: 2.12 mm (0.083 in) J: 2.18 mm (0.086 in) Change the left shim thickness in an opposite amount of what the right shim was changed; If the right shim was replaced with a 0.12 mm (0.005 in) thicker one, replace the left shim with a 0.12 mm (0.005 in) thinner one. 19-16 RIGHT SHIM REAR DRIVING MECHANISM FINAL GEAR CASE DISASSEMBLY Loosen the cover bolts in a crisscross pattern in several steps and remove them. Pry the cover at the prying points using a screwdriver and remove the case cover. Remove the O-ring. PRYING POINTS Remove the ring gear and shims. BEARING RING GEAR SHIMS BEARING INSPECTION 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 that the bearing outer race fits tightly in the case and cover. BEARING BEARING For ring gear bearing replacement (page 19-21). 19-17 REAR DRIVING MECHANISM GEAR TOOTH CONTACT PATTERN CHECK Keep dust and dirt Clean the mating surfaces of the gear case and out of the case and cover. cover. thin coat of Prussian Blue to the pinion gear teeth for a tooth contact pattern check. RING GEAR Apply Prussian Blue Install the ring gear shims onto the ring gear. Install the ring gear with the shims into the gear case. LEFT SHIM Align the bolt holes and install the case cover. It is important to turn the pinion while tightening the bolts. If the ring gear shims is too thick, the gears will lock after only light tightening. 10 mm BOLTS COVER Install the cover bolts and tighten them in several steps until the cover evenly touches the gear case. Then, while rotating the pinion gear, tighten the bolts to the specified torque in a crisscross pattern in several steps. TORQUE: 10 mm bolt: 49 N m (5.0 kgf m, 36 Ibfft) 8 mm bolt: 25 N m (2.6 kgf m, 19 Ibfft) mm BOLTS Remove the oil filler cap. NORMAL: Rotate the ring gear several times in both directions of rotation. Check the gear tooth contact pattern through the oil filler hole. The pattern is indicated by the Prussian Blue applied to the pinion. Contact is normal if the Prussian Blue is transferred to the approximate center of each tooth, but slightly to the heel side and to the flank side. If the pattern are not correct, remove and change the pinion shim with one of an alternate thickness. 19-18 FACE FLANK DRIVE SIDE FLANK COAST SIDE REAR DRIVING MECHANISM Replace the pinion shim with a thicker one if the contact pattern is too high, toward the face. TOO HIGH: DRIVE SIDE Replace the pinion shim with a thinner one if the contact pattern is too low, toward the flank. COAST SIDE TOO LOW: The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in) when the thickness of the shim is changed by 0.12 mm (0.005 in). Pinion gear shims: A: 1.82 mm (0.072 in) B: 1.88 mm (0.074 in) C: 1.94 mm (0.076 in) D: 2.00 mm (0.079 in) E: 2.06 mm (0.081 in) F: 2.12 mm (0.083 in) G: 2.18 mm (0.086 in) FLANK For pinion shim replacement (page 19-20). DRIVE SIDE FLANK COAST SIDE PINION GEAR REMOVAL Install the special tool into the pinion joint, and set the final drive assembly and tool in a vise. TOOL: Pinion holder 07SMB-HM70200 Take care not to Loosen the pinion joint nut, and remove the joint drop the final drive nut and pinion joint. assembly from the vise. PINION HOLDER Remove the oil seals and O-ring. OIL SEALS 19-19 REAR DRIVING MECHANISM Be careful that Unstake the pinion bearing lock nut with a drill or metal particles do grinder. Unstake LOCK NUT not enter the bearing and the threads of the case are not damaged. Remove the lock nut using the special tool. TOOL: Lock nut wrench, 30 x 64 mm _ LUCK NUI WRENCH 07916-MB00002 Install the special tools onto the pinion gear shaft and gear case. TOOLS: Pinion puller base Puller shaft 07HMC-MM80110 or 07HMC-MM8011A (U.S.A. only) 07931-ME40000 or 07931-ME4010B and 07931-HB3020A (U.S.A. only) Pull the pinion gear assembly out from the gear case. PINION GEAR BEARING/SHIM REPLACEMENT Pull the pinion bearing from the shaft with a commercially available bearing puller. Remove the pinion shim. 19-20 PULLER BASE • REAR DRIVING MECHANISM Install the shim and bearing onto the pinion gear. SHIM NOTE: • When the gear set, ring gear bearing, and/or gear case has been replaced, use a 2.00 mm (0.79 in) thick shim for initial reference. BEARING PINION GEAR Press the pinion gear in the bearing until it is seated by supporting the bearing with the special tool. TOOL: Attachment 25 mm I.D. 07746-0030200 CASE BEARING REPLACEMENT RING GEAR BEARING Remove the oil seals from the case and cover. OIL SEAL BEARING Drive the bearings out of the case and cover. \ Drive each new bearing using the special tools. TOOLS: Case cover: Driver Attachment, 62 x 68 mm Pilot, 30 mm Gear case: Driver Attachment, 52 x 55 mm Pilot, 30 m m DRIVER 07749-0010000 07746-0010500 07746-0040700 07749-0010000 07746-0010400 07746-0040700 ATTACHMENT/PILOT 19-21 REAR DRIVING MECHANISM Apply grease to new oil seal lips. Install each oil seal with the metal side facing out so the exposed height is 4 mm (0.16 in) evenly (the rubber edge flush with the cover). TOOLS: Attachment, 35 mm I.D. Driver, 40 mm I.D. DRIVER 07746-0030400 07746-0030100 \: IACHMENT PINION NEEDLE BEARING Remove the stopper ring by rotating it until the end of the stopper ring appears in the access hole. Strike gently near the end of the ring with a punch to bend the end upward. Grasp the end of the ring with needle-nosed pliers and pull the stopper ring out through the access hole. Be sure to wear heavy gloves to avoid burns when handling the heated gear case. Using a torch to heat the gear case may cause warpage. Heat the gear case to 80°C (176°F) and remove the needle bearing by using the special tool. TOOLS: Bearing remover, 17 mm Remover handle Remover weight 07936-3710300 07936-3710100 07741-0010201 or 07936-371020A or 07936-3710200 (U.S.A. only) Remove the bearing cage and bearings from the inside of the pinion bearing to allow the special tool to grip the bearing. STOPPER RING Install the stopper ring into the groove in the bearing. Install the bearing into the special tool until the bearing is flush with the end of the tool. TOOL: Bearing clip compressor, 28 mm 070ME-HN8A200 Freeze the pinion bearing with the tool on ice or in a freezer. Heat the gear case to 80 C (176°F). COMPRESSOR Tape the clip com- Drive the pinion bearing into the gear case using the pressor to the special tools as follows. driver for bearing installation. TOOLS: Puller attachment Driver Attachment, 24 x 26 mm Pilot, 17 mm 07YMC-GCS0100 (not available in U.S.A.) or 07949-3710001 07746-0010700 07746-0040400 Only strike the driver once. If you strike it more than once, the stopper ring may slip out of the groove. If this happens, remove the ring and bearing, and install a new one again. Make sure that the stopper ring is securely set in the groove of the gear case. 19-22 DRIVER REAR DRIVING MECHANISM FINAL DRIVE ASSEMBLY GEAR CASE OIL SEAL RING GEAR BEARING STOPPER RING SHIM PINION NEEDLE BEARING RING GEAR PINION GEAR SHIM SHIM RING GEAR BEARING PINION BEARING V) STOP PIN INNER OIL SEAL SHIM OIL SEAL OUTER OIL SEAL GEAR CASE COVER PINION JOINT BRAKE DISC PINION GEAR INSTALLATION Keep the driver Drive the pinion gear assembly into the gear case. centered with the bearing outer race TOOL: during installation. Oil seal driver OIL SEAL DRIVER 07965-KE80200 (not available in U.S.A.) 19-23 REAR DRIVING MECHANISM Be sure to wear heavy gloves to avoid burns when handling the heated gear case. Using a torch to heat the gear case may cause warpage. U.S.A. only: Freeze the pinion gear and bearing. Heat the gear case to 80°C (176°F). Drop the cold pinion assembly into the warm gear case. Install a new lock nut and tighten it using the special tool. TOOL: Lock nut wrench, 30 x 64 mm LOCK NUT WRENCH 07916-MB00002 Refer to torque TORQUE: wrench reading Actual: 98 N m (10.0 kgfm, 72 Ibfft) information on Indicated: 89 N m (9.1 kgfm, 66 Ibf ft) "Service Information" (page 19-3). Be careful not to damage the threads of the case. Stake the lock nut into the case groove. Coat a new O-ring with grease and install it onto the pinion gear shaft. Apply grease to the lips of new oil seals Install the inner oil seal (70 mm O.D.) into the gear case until it is flush with the stepped edge. TOOL: Driver attachment 19-24 07LAD-PW50500 Stake LOCK NUT REAR DRIVING MECHANISM Install the outer oil seal (75 mm O.D.) into the gear case until it is flush with the gear case outer surface, using the same tool. OIL SEAL Clean the threads of the pinion gear shaft thoroughly. Install the pinion joint onto the pinion gear shaft, being careful not to damage the oil seal lips. Apply locking agent to the threads of the pinion joint nut and screw it in by hand as far as it goes. Hold the pinion joint with the special tool and tighten the joint nut. TOOL: Pinion holder 07SMB-HM70200 TORQUE: 108 N m (11.0 kgf-m, 80 Ibfft) RING GEAR CLEARANCE INSPECTION Install the ring gear with the shim into the case cover. RING GEAR Measure the clearance between the ring gear and stop pin with a feeler gauge. CLEARANCE: 0.3 - 0.6 mm (0.01 - 0.02 in) CASE COVER STOP PIN Remove the ring gear. Be sure to wear heavy gloves to avoid burns when handling the heated case cover. Using a torch to heat the case cover may cause warpage. If the clearance is not within specification, heat the case cover to approximately 80°C (176°F) and remove the stop pin by tapping the cover. Install a stop pin shim to obtain the correct clearance. STOP PIN SHIMS: A: 0.10 mm (0.004 in) B: 0.15 mm (0.006 in) Drive the stop pin into the case cover. STOP PIN SHIM 19-25 REAR DRIVING MECHANISM FINAL GEAR CASE ASSEMBLY NOTE: • When the gear set, bearing, and/or gear case has been replaced, check the tooth contact pattern check (page 19-18). Check the gear backlash (page 19-16). Keep dust and dirt Clean the mating surface of the gear case and cover, out of the case and being careful not to damage them. cover. g | o w compressed air through the breather holes in the gear case and cover. Install the proper ring gear shims onto the ring gear and install them into the gear case. Coat a new O-ring with grease and install it into the cover groove. Install the case cover onto the gear case. O-RING Apply locking agent to the threads of the two 10mm bolts. It is important to turn the pinion while tightening the bolts. If the ring gear shim is too thick, the gears will lock after only light tightening. 1 TE33 10 mm BOLTS COVER Install the cover bolts and tighten them in several steps until the cover evenly touches the case. Then, while rotating the pinion gear, tighten the bolts to the specified torque in a crisscross pattern in several steps. TORQUE: 10 mm bolt: 49 N m (5.0 kgf m, 36 Ibf-ft) 8 mm bolt: 25 N m (2.6 kgf m, 19 Ibf ft) Check that the gear assembly turns smoothly without binding. 8 mm BOLTS 19-26 REAR DRIVING MECHANISM FINAL DRIVE INSTALLATION Install the final drive assembly onto the sub-frame by inserting the mounting bolts from the left side. Install new mounting nuts but do not tighten them yet. FINAL DRIVE ASSEMBLY i BOLTS AND +3* Install the brake disc with the stamp facing the engine side. Install new disc bolts and tighten them in a crisscross pattern in several steps. NUTS BOLTS TORQUE: 20 N-m (2.0 kgf-m, 14 Ibf-ft) Install a new seal rubber onto the seal groove in the propeller shaft in the direction as shown. Install the joint boot onto the boot groove and the boot band into the band groove in the boot. Apply molybdenum disulfide grease to the seal rubber outer surface. Apply 5 - 8 g of molybdenum disulfide grease to the pinion joint splines. Install the spring into the propeller shaft. Set the propeller shaft into the pinion joint while compressing the spring, then install the boot over the pinion joint groove securely and secure it with the boot band. Be sure the propeller shaft is installed properly by pulling on the shaft lightly. BOOT 19-27 REAR DRIVING MECHANISM Coat a new O-ring with molybdenum disulfide grease and install it into the groove in the output shaft. Apply molybdenum disulfide grease to the splines of the both sides in the universal joint and install it onto the output shaft until it is fully seated. Coat a new O-ring with molybdenum disulfide grease and install it into the propeller shaft groove. Put the final drive assembly on a floor jack or other adjustable support and place the assembly under the main frame. While adjusting the jack height, move the final drive assembly forward and connect the propeller shaft into the universal joint. Be careful not to disconnect the propeller shaft and universal joint. Set the final drive assembly into the main frame and seat the propeller shaft securely to align the bolt holes, then insert the mounting bolts from the left side. Install new mounting nuts but do not tighten them yet. Route the breather hoses properly (page 1-20) and connect them. Insert the sub-frame joint bolt bolts from the inside. Install new joint nuts. Tighten the four mounting nuts and joint nuts alternately. TORQUE: Joint nut: 34 N m Mounting 34 N m Mounting 39 N m (3.5 kgf-m, 25 Ibf-ft) bolt (main frame): (3.5 kgf-m, 25 Ibf-ft) bolt (sub-frame): (4.0 kgf-m, 29 Ibf-ft) NUTS 19-28 REAR DRIVING MECHANISM Install the brake hose clamp and tighten the brake house clamp bolt securely. BOLT Install each lower arm of the suspension arm/shock absorber assemblies into the frame and insert each pivot bolt from the rear side. Install new pivot nuts and tighten them. TORQUE: 34 N m (3.5 kgf-m, 25 Ibfft) Install the following: - drive shafts (page 19-11) brake caliper (page 17-32) engine guard (page 3-17) Fill the gear case with the recommended oil (page 415). 19-29 20. BATTERY/CHARGING SYSTEM COMPONENT LOCATION 20-2 BATTERY •• 20-6 SYSTEM DIAGRAM 20-2 CHARGING SYSTEM INSPECTION 20-7 SERVICE INFORMATION 20-3 ALTERNATOR CHARGING COIL 20-8 TROUBLESHOOTING 20-5 REGULATOR/RECTIFIER 20-9 20-1 BATTERY/CHARGING SYSTEM COMPONENT LOCATION FUSE (30 A) ALTERNATOR REGULATOR/ RECTIFIER BATTERY SYSTEM DIAGRAM MAIN FUSE 30A JZL Y Y Y R G e e BATTERY REGULATOR/RECTIFIER ALTERNATOR G R Y 20-2 GREEN RED YELLOW BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL ikWARNING • 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. • • • • • • Always turn the ignition switch to OFF before disconnecting any electrical component. Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For a battery remaining in a stored vehicle, disconnect the negative battery cable from the battery. The maintenance free battery must be replaced when it reaches the end of its service life. The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions 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 voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under heavy load, such as having the headlight and taillight on for long periods of time without riding the vehicle. The battery will self-discharge when the vehicle is not in use. For this reason, charge the battery every two weeks to prevent sulfation from occurring. Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge the battery. Also, the battery life is lengthened when it is initially charged. When checking the charging system, always follow the steps in the troubleshooting (page 20-5). For alternator removal/installation (page 11-9). BATTERY CHARGING • Turn power ON/OFF at the charger, not at the battery terminal. • For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery. • Quick charging should only be done in an emergency; slow charging is preferred. BATTERY 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: BM-210-AH (U.S.A. only), BM-210, BATTERY MATE (MTP08-0192, U.S.A. only) or equivalent 20-3 BATTERY/CHARGING SYSTEM SPECIFICATIONS Battery (YTX20L-BS) Alternator ITEM Capacity Current leakage Voltage Fully charged (20°C/68°F) Needs charging Charging curNormal rent Quick Capacity Charging coil resistance (20°C/68°F) SPECIFICATIONS 12V- 18 Ah 1 mA maximum 13.0-13.2 V Below 12.3 V l.8A/5-10h 9.0 A/1 .Oh 360W/5,000rpm(min-1) 0.1-1.0 Q TOOLS Battery tester BM-210-AH (U.S.A. only) 20-4 Christie battery charger MC1012/2 (U.S.A. only) Battery Mate tester/charger MTP08-0192 (U.S.A only) BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. Battery Test Remove the battery (page 20-6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH (U.S.A. only), BM-210, BATTERY MATE (MTP08-0192, U.S.A. only) or equivalent Is the battery in good condition? No - Faulty battery YES - GO TO STEP 2. 2. Current Leakage Test Install the battery (page 20-6). Check the battery current leakage test (Leak test: page 20-7). Is the current leakage below 1 mA? YES - G O TO STEP 4. NO - GO TO STEP 3. 3. Current Leakage Test With Regulator/Rectifier Connector Disconnected Disconnect the regulator/rectifier connector and recheck the battery current leakage. Is the current leakage below 1 mA? YES - Faulty regulator/rectifier NO - • Shorted wire harness • Faulty ignition switch 4. Alternator Charging Coil Inspection Check the alternator charging coil (page 20-8). fe the alternator charging coil resistance within 0.1 - 1.0Q (20°C/68°F)? YES - GO TO STEP 5. NO - Faulty charging coil 5. Charging Voltage Inspection Measure and record the battery voltage using a digital multimeter (page 20-6). Start the engine. Measure the charging voltage (page 20-8). Compare the measurements to the results of the following calculation. STANDARD: Measured BV < Measured CV < 15.5 V • BV = Battery voltage • CV = Charging voltage Is the measured charging voltage within the standard voltage? YES - Faulty battery NO - GO TO STEP 6. 6. Regulator/Rectifier System Inspection Check the voltage and resistance at the regulator/rectifier connector (page 20-9). Are the measurements correct? YES - Faulty regulator/rectifier NO - • Open circuit in related wire • Loose or poor contacts of related terminal • Shorted wire harness 20-5 BATTERY/CHARGING SYSTEM BATTERY BATTERY REMOVAL/INSTALLATION Remove the two bolts and the battery cover. With the ignition switch OFF, disconnect the nega- j MFGATIVET-) CABLE tive (-) cable first, then disconnect the positive (+) cable by removing each terminal bolt. Remove the battery holder band. Remove the battery. Connect the posi- Install the battery in the reverse order of removal tive terminal first with the proper wiring as shown. and then the negaAfter installing the battery, coat the terminals with tive cable. clean dielectric grease. BATTERY CASE REMOVAL/INSTALLATION Remove the rear fender (page 3-14). ; BATTERY BOLTS Remove the starter relay switch from the battery case. I Remove the four bolts and battery case. Installation is the reverse order of removal. STARTER RELAY SWITCH VOLTAGE INSPECTION Remove the battery cover (page 20-6). Measure the battery voltage using a commercially available digital multimeter. VOLTAGE: Fully charged: 13.0 -13.2V Under charged: Below 12.3V 20-6 BATTERY/CHARGING SYSTEM BATTERY TESTING Remove the battery (page 20-6). Refer to the instructions that are appropriate to the battery testing equipment available to you. TOOL: Battery tester BM-210-AH (U.S.A. only), BM-210, BATTERY MATE (MTP08-0192, U.S.A. only) or equivalent BATTERY CHARGING (U.S.A. only) Remove the battery (page 20-6). Refer to the instructions that are appropriate to the battery charging equipment available to you. TOOL: Battery charger Christie battery charger (MC1012/ 2, U.S.A. only), BATTERY MATE (MTP08-0192, U.S.A. only) or equivalent CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the battery cover (page 20-6). Turn the ignition switch OFF and disconnect the negative (-) cable from the battery. Connect the ammeter (+) probe to the negative (-) cable and the ammeter (-) probe to the battery (-) terminal. With the ignition switch turned OFF, check for current leakage. NEGATIVE (-) TERMINAL • 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 blow out the fuse in the tester. • While measuring current, do not turn the ignition switch ON. A sudden surge of current may blow out the fuse in the tester. SPECIFIED CURRENT LEAKAGE: 1 mA 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. 20-7 BATTERY/CHARGING SYSTEM CHARGING VOLTAGE INSPECTION Remove the battery cover (page 20-6). 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. NOTICE • To prevent a short, make absolutely certain which are the positive (+) and negative (-) terminals or cables. • Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components. With the headlights on, measure the voltage on the multimeter when the engine runs at 5,000 rpm (min 1 ). STANDARD: Measured BV < Measured CV < 15.5 V BV = Battery voltage (page 20-6) CV = Charging voltage ALTERNATOR CHARGING COIL INSPECTION Remove the right side cover (page 3-5). Disconnect the alternator 5P (Natural) connector. Check the connector for loose contacts or corroded terminals. 5P (NATURAL) CONNECTOR Measure the resistance between the Yellow wire terminals of the alternator side connector. STANDARD: 0.1 - 1.0 U (at 20C/68 F) Check for continuity between each Yellow wire terminal of the alternator side connector and ground. There should be no continuity. Replace the alternator stator if resistance is out of specification, or if any wire has continuity to ground. Alternator stator replacement (page 11-9). 20-8 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the two bolts and regulator/rectifier. Disconnect the regulator/rectifier 3P (Gray) and 3P (Black) connectors. Check the connectors for loose contacts or corroded terminals. BATTERY LINE Measure the voltage between the Red wire terminal and ground. There should be battery voltage at all times. GROUND LINE Check the continuity between the Green wire terminal and ground. There should be continuity at all times. REGULATOR/RECTIFIER CHARGING COIL LINE Measure the resistance between the Yellow wire terminals. STANDARD: 0.1 - 1.0 Q (at 20°C/68°F) Check for continuity between each Yellow wire terminal and ground. There should be no continuity. 20-9 21. IGNITION SYSTEM COMPONENT LOCATION 21-2 IGNITION SYSTEM INSPECTION 21-5 SYSTEM DIAGRAM 21-2 IGNITION COIL 21-7 SERVICE INFORMATION 21-3 IGNITION TIMING 21-8 TROUBLESHOOTING 21-4 21-1 IGNITION SYSTEM COMPONENT LOCATION ENGINE STOP SWITCH IGNITION SWITCH PCM FUSE (10 A) CKP SENSOR BATTERY SYSTEM DIAGRAM PCM (ECM/TCM) 5PL • Bl/Y • 5P L IGNITION COIL CKP SENSOR FUSE 10A • Bl o^o R IGNITION SWITCH MAIN FUSE 30A © e BATTERY FUSE 10A ENGINE STOP RELAY Bl : BLACK Y : YELLOW Bu:BLUE G :GREEN H :RED W : WHITE 21-2 • Bl/Bu • - Bl/W • ENGINE STOP SWITCH To Bank Angle Sensor • • R/W - Bl/Y • — Bl/Bu- - BIW - - R/W — R/Y - IGNITION SYSTEM SERVICE INFORMATION GENERAL • 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 steps in the troubleshooting table on page 21-4. This ignition system is controlled by PCM. The ignition timing cannot be adjusted since the PCM is factory preset. 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 turn off the ignition switch before servicing. A faulty ignition system is often related to poor connections. Check those connections before proceeding. Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug. This vehicle's spark plug is equipped with iridium type electrode. Do not use any spark plug other than specified. For CKP sensor removal/installation (page 11-9). For ignition switch servicing (page 23-6). For engine stop switch inspection (page 23-7). For gear position switch servicing (page 14-44). SPECIFICATION Spark plug ITEM Standard For extended high speed riding Spark plug gap Ignition coil peak voltage CKP sensor peak voltage Ignition timing ("F" mark) SPECIFICATIONS IFR5L11 (NGK) VK16PRZ11 (DENSO) IFR6L11 (NGK) VK20PRZ11 (DENSO) 1.0 - 1.1 mm (0.039 - 0.043 in) 100 V minimum 0.7 V minimum 15°BTDCatidle TORQUE Spark plug Timing hole cap 22 N m (2.2 kgf-m, 16 Ibf-ft) 10 N-m (1.0 kgf-m, 7 Ibf-ft) TOOLS IgnitionMate peak voltage tester MTP07-0286 (U.S.A. only) Peak voltage adaptor 07HGJ-0020100 Test probe 07ZAJ-RDJA110 (not available in U.S.A.) with commercially available digital multimeter (impedance 10 Mii/DCV minimum) or Imrie diagnostic tester (model 625) (not available in U.S.A.) 21-3 IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system: - Faulty spark plug - Loose spark plug cap or spark plug wire connection - Water got into the spark plug cap (leaking the ignition coil secondary voltage) No spark at spark plug Ignition coil primary voltage UNUSUAL CONDITION Low peak voltage. No peak voltage. Peak voltage is normal, but no spark jumps at the plug. CKP sensor Low peak voltage. No peak voltage. 21-4 PROBABLE CAUSE! (Check in numerical order) 1. Incorrect peak voltage adapter connections. (System is normal if measured voltage is over the specifications with reverse connections.) 2. The multimeter impedance is too low. 3. Cranking speed is too slow (battery is under charged). 4. 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.) 5. Poorly connected connectors or an open circuit in the ignition system. 6. Faulty ignition coil. 7. Faulty Powertrain Control Module (PCM) (when above No.1 through 6 are normal). 1. Incorrect peak voltage adaptor connections. (System is normal if measured voltage is over the specifications with reverse connections.) 2. Battery is undercharged. (Large voltage drop when the engine is started.) 3. Faulty ignition switch or engine stop switch. 4. Loose or poorly connected PCM connectors. 5. No voltage at the Black/white (power source) wire of the PCM. 6. Open circuit or poor connection in the Green (ground) wire of the PCM. 7. Faulty peak voltage adaptor. 8. Faulty CKP sensor (Measure peak voltage) 9. Faulty PCM (when above No. 1 through 8 are normal). 1. Faulty spark plug or leaking ignition coil secondary current. 2. Faulty ignition coil. 1. The multimeter impedance is too low; below 10 Mfi/ DCV. 2. Cranking speed is too slow (battery is under charged). 3. The sampling timing of the tester and measured pulse were not synchronized. (System is normal if measured voltage is over the standard voltage at least once.) 4. Faulty CKP sensor (when above No. 1 through 3 are normal). 1. Faulty peak voltage adaptor. 2. Faulty CKP sensor IGNITION SYSTEM IGNITION SYSTEM INSPECTION PEAK VOLTAGE CONNECTION NOTE: • If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use the recommended digital multimeter or a commercially available digital multimeter with an impedance of 10 Mfi/DCV minimum. • The display value differs depending upon the internal impedance of the multimeter. Use the peak voltage tester or connect the peak voltage adaptor to the digital multimeter. DIGITAL MULTIMETER TOOLS: U.S.A. and Canada type: IgnitionMate peak voltage tester (U.S.A. only) or Peak voltage adaptor 07HGJ-0020100 (not available in U.S.A.) with commercially available digital multimeter (impedance 10 Mi2/DCV minimum) Imrie diagnostic tester (model 625) (not available in U.S.A.) PEAK VOLTAGE ADAPTOR IGNITION COIL PRIMARY PEAK VOLTAGE NOTE: • Check all system connections before this inspection. Poor connected connectors can cause incorrect readings. • Check the cylinder compression and check that the spark plug is installed correctly in the cylinder head. Remove the fuel tank (page 6-39). Disconnect the spark plug cap from the spark plug. Connect a known-good spark plug to the spark plug cap and ground the spark plug to the cylinder head as done in a spark test. KNOWN-GOOD SPARK PLUG 21-5 IGNITION SYSTEM With the connector connected, connect the peak voltage tester or adaptor probes to the ignition coil primary terminal and body ground. GREEN/RED WIRE TERMINAL CONNECTION: Green/red (-) - Body ground (+) Turn the ignition switch ON and the engine stop switch to the "O.". Shift the transmission into neutral. Avoid touching Crank the engine with the starter motor and read the spark plug the ignition coil primary peak voltage. or tester probes VOLTAGE: 100 V minimum to prevent electric shock. |f t n e p ea k voltage is lower than the standard value, follow the checks described in the troubleshooting chart (page 21-4). CKP SENSOR PEAK VOLTAGE NOTE: • Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Remove the steering cover (page 3-5). Seal the PCM connector with tape to prevent dirt and oil from entering the connector after disconnecting the 33P connector. Disconnect the 33P (Gray) connector Powertrain Control Module (PCM). from the NOTE: • When reconnecting the PCM 33P (Gray) connector, check that there is no dirt and oil in the connector. PCM 33P (GRAY) CONNECTOR Be careful not to Connect the peak voltage tester or adaptor probes bend the connector to the Blue/yellow and Green/white terminals of the terminals, wire harness side 33P (Gray) connector. TOOL: Test probe V. 1j I—' 1 07ZAJ-RDJA110 CONNECTION: B23 (+) - B12 (-) Shift the transmission into neutral. Turn the ignition switch ON. Crank the engine with the starter motor and read the CKP sensor peak voltage. PEAK VOLTAGE: 0.7 V minimum If the voltage measured at the PCM connector is abnormal, measure the peak voltage at the alternator connector. 21-6 PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) 1 - 1—' —r PEAK VOLTAGE ADAPTOR 4 i7 | B23 B12 IGNITION SYSTEM Remove the right side cover (page 3-5). Disconnect the alternator 5P (Natural) connector and connect the peak voltage tester or adaptor probes to the Blue/yellow and Green/white wire terminals of the alternator side connector. 5P NATURAL CONNECTOR In the same manner as at the PCM connector, measure the peak voltage and compare it to the voltage measured at the PCM connector. • If the peak voltage measured at the PCM connector is abnormal and the one measured at the alternator connector is normal, the Blue/ yellow or Green/white wire has an open or short circuit, or loose connection. • If both peak voltages are abnormal, follow the checks described in the troubleshooting chart (page 21-4). 5P (NATURAL) CONNECTOR (Alternator side of female terminal) PEAK VOLTAGE ADAPTOR G/W Bu/Y If the CKP sensor is faulty, replace the stator/CKP sensor assembly (page 11-11). IGNITION COIL REMOVAL/INSTALLATION Remove the left side cover (page 3-6). Disconnect the plug cap from the plug and free the spark plug wire from the clamps. Disconnect the ignition coil primary wire connector. Remove the two mounting bolts, ground terminal and the ignition coil. Installation is in the reverse order of removal. 21-7 IGNITION SYSTEM IGNITION TIMING Remove the right side cover (page 3-6). 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 timing light and tachometer. TIMING LIGHT I Start the engine, let it idle and check the ignition timing. The ignition timing is correct if the "F" mark on the flywheel aligns with the index mark on the rear crankcase cover at idle. INDEX VIARK \ Increase the engine speed and make sure the "F" mark begins to move. "F" MARK Coat a new O-ring with oil and install it onto the timing hole cap. Install the timing hole cap and tighten it to the specified torque. TORQUE: 10 N m (1.0 kgf-m, 7 Ibfft) Install the right side cover (page 3-6). 21-8 22. ELECTRIC STARTER COMPONENT LOCATION 22-2 STARTER MOTOR 22-6 SYSTEM DIAGRAM 22-2 STARTER RELAY SWITCH 22-12 SERVICE INFORMATION 22-3 DIODE 22-14 TROUBLESHOOTING 22-4 22-1 ELECTRIC STARTER COMPONENT LOCATION STARTER SWITCH IGNITION SWITCH GEAR POSITION (NEUTRAL) SWITCH STARTER MOTOR FUSE(IOA) STARTER RELAY SWITCH BATTERY SYSTEM DIAGRAM Bl/Bu • To BATTERY Bl:BLACK Y : YELLOW Bu:BLUE G :GREEN B :REO W : WHITE Lb : LIGHT BLUE Lg : LIGHT GREEN Gr : GRAY 22-2 r ELECTRIC STARTER SERVICE INFORMATION GENERAL • 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 22-4). A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. For starter clutch servicing (page 11-9). For ignition switch information (page 23-6). For engine stop switch and starter switch inspection (page 23-7). For front brake switch inspection (page 23-20). For gear position switch information (page 14-44). SPECIFICATIONS ITEM Starter motor brush length STANDARD 12.0-13.0(0.47-0.51) Unit: mm (in) SERVICE LIMIT 6.5 (0.26) 22-3 ELECTRIC STARTER TROUBLESHOOTING NOTE: • The starter motor should operate when the transmission is in heutral or when the transmission is in drive and the front brake lever is squeezed. • Make sure the engine stop switch is turned "O" before startirtg the engine. The starter motor does not operate with the engine stop switch turned OFF. Starter motor does not turn 1. Fuse Inspection Check for blown main fuse (30 A) or IGN fuse (10 A). Is the fuse blown? YES - Replace the fuse. NO - GO TO STEP 2. 2. Battery Inspection Check that the battery is fully charged and in good condition. Is the battery in good condition? YES - GO TO STEP 3. NO - Charge the battery (page 20-7). 3. Starter Relay Switch Operation Inspection Check the operation of the starter relay switch (page 22-12). Does the starter relay switch click? YES - GO TO STEP 4. NO - GO TO STEP 5. 4. Starter Motor Inspection Turn the ignition switch OFF. Apply battery voltage to the starter motor directly. Does the starter motor turn? YES - • Poorly connected starter motor cable. • Faulty starter relay switch (page 22-13). NO - Faulty starter motor (page 22-6). 5. Relay Coil Ground Line Inspection Turn the ignition switch OFF. Check the ground line of the starter relay switch (page 22-13). Is the ground line normal? NO - • • • • Faulty Faulty Faulty Loose gear position switch (page 14-44). diode (page 22-14). front brake switch (page 23-20). or poor contact of the related connector terminal. • Open circuit in the wire harness. YES - GO TO STEP 6. 6. Relay Coil Power Input Line Inspection Check the power input line of the starter relay switch (page 22-13). Is the power input line normal? YES 22-4 Faulty ignition switch (page 23-6). Faulty engine stop switch (page 23-7). Faulty starter switch (page 23-7). Loose or poor contact of the related connector terminal. Open circuit in the wire harness. - GO TO STEP 7. ELECTRIC STARTER 7. Starter Relay Switch Inspection Check the function of the starter relay switch (page 22-13). Does the starter relay switch function properly? NO - Faulty starter relay switch. YES - Loose or poor contact of the starter relay switch connector terminal. Starter motor turns engine slowly • Low battery voltage • Poorly connected battery cable • Poorly connected starter motor cable • Faulty starter motor • Poorly connected ground cable terminal Starter motor turns, but engine does not turn • Faulty starter clutch • Damaged starter gear train Starter relay switch clicks, but engine does not turn over • Crankshaft does not turn due to engine problems 22-5 ELECTRIC STARTER STARTER MOTOR REMOVAL Remove the following: - RIGHT ENGINE SIDE COVER right side cover (page 3-5) right center mud guard (page 3-7) Disconnect the negative (-) cable from the battery (page 20-6). Remove the three bolts and the right engine side cover. Slide the rubber cap off the starter motor cable ter­ minal and remove the terminal nut and starter motor cable. Remove the two mounting bolts and hose guide. Remove the bolt and ground cable from the engine. Pull out the starter motor. DISASSEMBLY/INSPECTION Remove the O-ring from the starter motor. 22-6 O-RING ELECTRIC STARTER Remove the starter motor case bolts. MOTOR CASE BOLTS Record the location Remove the following: and number of - front cover shims. - SHIMS lock washer insulated washer shims seal ring FRONT COVER INSULATED WASHER LOCK WASHER Record the location and number of shims. - rear cover shims seal ring armature REAR COVER SHIMS SEAL RING ARMATURE Check the oil seal and needle bearing in the front cover for deterioration, wear or damage. DUST SEAL BUSHING Check the bushing in the rear cover for wear or damage. NEEDLE BEARING 22-7 ELECTRIC STARTER Check the commutator bars of the armature for discoloration. COMMUTATOR BARS NOTE: • Do not use emery or sand paper on the commu­ tator. Check for continuity between pairs of commutator bars. There should be continuity. Check for continuity between each commutator bar and the armature shaft. There should be no continuity. Check for continuity between the insulated brush and cable terminal. There should be continuity. 22-8 prjNTINUITY­ NO CONTINUITY: CONTINUITY: INSULATED BRUSH ELECTRIC STARTER Check for continuity between the insulated brush and motor case. There should be no continuity. NO CONTINUITY: Measure the brush length. SERVICE LIMIT: 6.5 mm (0.26 in) Remove the following if necessary: - brush holder - nut washer insulator washers O-ring cable terminal insulated brush insulator CABLE TERMINAL INSULATED BRUSH INSULATOR WASHERS NUT WASHER INSULATOR 22-9 ELECTRIC STARTER ASSEMBLY SHIMS ARMATURE BOLTS FRONT COVER REAR COVER WASHER NUT O-RING »•# INSULATOR WASHERS MOTOR CASE Install the following: - insulator insulated brush cable terminal O-ring insulator washers washer nut CABLE TERMINAL O-RING INSULATED BRUSH INSULATOR WASHERS WASHER Install the brush holder, aligning the holder tab with the case groove, and the holder grooves with the insulated brush wires. INSULATOR BRUSH HOLDER Align 22-10 ELECTRIC STARTER Push and hold the brushes inside the brush holder, and install the armature through the motor case and brush holder. When installing the armature into the motor case, hold the armature tightly to keep the magnet of the case from pulling the armature against it. NOTICE The coil may be damaged if the magnet pulls the armature against the case. Install the same number of shims in the same loca­ tion as noted during removal. Install a new seal ring onto the motor case. Apply a thin coat of grease to the armature shaft end. Install the rear cover, aligning its groove with the brush holder tab. REAR COVER SHIMS SEAL RING ARMATURE Install the shims properly as noted during removal. Install the shims and insulated washer onto armature shaft. Install a new seal ring onto the motor case. Apply grease to the oil seal lip and needle bearing in the front cover. Install the lock washer onto the front cover. Install the front cover. SHIMS FRONT COVER INSULATED WASHER LOCK WASHER INSTALLATION Coat a new O-ring with oil and install it in the starter motor groove. O-RING 22-11 ELECTRIC STARTER Install the starter motor into the rear crankcase cover and onto the crankcase. Install the hose guide and mounting bolts, then tighten the bolts securely. Route the ground cable and tighten the bolt. Install the starter motor cable and terminal nut, and tighten the nut. Install the rubber cap over the cable terminal. Install the right engine side cover and tighten the three bolts securely. RIGHT ENGINE SIDE COVER Connect the battery negative (-) cable (page 20-6). Install the following: - right center mud guard lid (page 3-7) right side cover (page 3-5) STARTER RELAY SWITCH OPERATION INSPECTION Remove the battery cover (page 20-6). Shift the transmission into neutral. Make sure the engine stop switch is turned "O" Turn the ignition switch ON and push the starter switch. The coil is normal if the starter relay switch clicks. If you don't hear the switch click, and inspect the relay switch circuits (page 22-13). STARTER RELAY SWITCH 22-12 ELECTRIC STARTER CIRCUIT INSPECTION Remove the rear fender (page 3-14). Disconnect the starter relay switch 2P (Natural) con­ nector. GROUND LINE Check for continuity between the Green/black wire terminal of the wire harness side connector and ground. If there is continuity when the transmission is in neutral or when the transmission is in drive and the front brake lever is squeezed, the ground circuit is normal. POWER INPUT LINE 2P (NATURAL) CONNECTOR Turn the engine stop switch "O" and the ignition switch ON. Measure the voltage between the Yellow/red wire terminal (+) of the wire harness side connector and ground. If the battery voltage appears only when the starter switch is pushed, the circuit is normal. FUNCTION INSPECTION Remove the following: - rear fender (page 3-14) battery cover (page 20-6) STARTER RELAY SWITCH Disconnect the negative (-) cable from the battery (page 20-6). Disconnect the starter relay switch 2P (Natural) con­ nector. Remove the battery (+) cable and starter motor cable from the starter relay switch and ground (-). Connect the fully charged 12 V battery positive ter­ minal to the Yellow/red wire terminal and negative terminal to the Light green/red wire terminal of the starter relay switch. • BATTERY There should be continuity between the cable termi­ nals while the battery is connected, and no continu­ ity when the battery is disconnected. 22-13 ELECTRIC STARTER DIODE INSPECTION Remove the fuel tank (page 6-39). DIODE Remove the diode from the wire harness. Z Remove the seat (page 3-4). DIODE Remove the diode from the fuse box. <fc Check for continuity between the diode terminals. I When there is continuity, a small resistance value will register. If there is continuity in one direction, the diode is normal. 22-14 23. LIGHTS/METERS/SWITCHES COMPONENT LOCATION 23-2 FUEL GAUGE/FUEL LEVEL SENSOR 23-10 SERVICE INFORMATION 23-3 TEMPERATURE INDICATOR/ TEMPERATURE SENSOR 23-13 GPS RECEIVER (GPS model only) 23-16 BRAKE LIGHT SWITCH 23-19 FRONT BRAKE SWITCH 23-20 HEADLIGHT TAILLIGHT ACCESSORY SOCKET IGNITION SWITCH 23-4 23-4 23-5 23-6 HORN SWITCH (AUSTRALIA type only) 23-20 HANDLEBAR SWITCH 23-7 HORN (AUSTRALIA type only) COMBINATION METER/REAR VS SENSOR 23-20 23-8 23-1 LIGHTS/METERS/SWITCHES COMPONENT LOCATION FRONT EitRAKE (INHIBITOR) SWITCH IGNITION SWITCH FRONT BRAKE LIGHT SWITCH HANDLEBAR SWITCH ACCESSORY SOCKET REAR VS SENSOR EOT SENSOR 23-2 LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL • A continuity test can be made with the switches installed on the vehicle. • 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. • The following color codes are used throughout this section. Bu: Blue Bl: Black Br: Brown G: Green Gr: Gray Lb: Light Blue Lg: Light Green 0: Orange P: Pink R:Red W: White Y: Yellow SPECIFICATIONS Bulb Fuse ITEM Headlight Brake/taillight Neutral indicator Reverse indicator 4WD indicator Coolant/engine oil temperature indicator MIL (PGM-FI indicator) Meter light Main Sub-fuse SPECIFICATIONS 12V-40/40Wx2 12V-21/5Wx2 LED LED LED LED LED LED x 10 30 A x 2 1 5 A x 1 , 10 A x 4 TORQUE VALUES ECT sensor EOT sensor 12N-m(1.2kgfm, 9 Ibf-ft) 12N-m(1.2kgf-m,9lbf-ft) Apply sealant to the threads. TOOLS Inspection adaptor 07GMJ-ML80100 23-3 LIGHTS/METERS/SWITCHES HEADLIGHT BULB REPLACEMENT Remove the screw and the headlight cover by releasing the tab from the slit in the headlight case. Remove the dust cover. Remove the bulb socket by turning it counterclockwise. Remove the bulb from the headlight. HEADLIGHT COVER ADJUSTING SCREW SCREW Align the socket Install a new bulb in the reverse order of removal. tabs with the headlight grooves properly. ACCESS PLUG DUST COVER SOCKET BULB REMOVAL/INSTALLATION Remove the headlight bulb socket (page 23-4). HEADLIGHT Remove the two screws attaching the headlight wire clamps. Remove the two mounting bolts and the headlight. Install the headlight in the reverse order of removal. NOTE: • The headlight beam can be adjusted vertically by removing the access plug and turning the headlight beam adjusting screw. SCREWS BOLTS TAILLIGHT BULB REPLACEMENT Remove the screw and taillight cover cap. SCREW Turn the bulb socket counterclockwise and remove it. Turn the taillight bulb counterclockwise while pushing it in and remove it. Align the cover cap Install a new taillight bulb in the reverse order of tabs with the removal. grooves in the cover properly. SOCKET BULB 23-4 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the taillight bulb socket (page 23-4). TAILLIGHT Remove the trim clip, washer, three screws, protector and taillight cover. Remove the taillight from the cover. PROTECTOR Align the bosses Install the taillight in the reverse order of removal. and grommets properly. TRIM CLIP WASHER COVER SCREWS ACCESSORY SOCKET INSPECTION Remove the right inner fender (page 3-9). Remove the accessory socket 2P (White) connector from the frame and disconnect it. Measure the voltage between the White/black (+) and Green (-) wire terminals of the wire harness side connector. There should be battery voltage with the ignition switch turned to ON. If there is no voltage, check for brown fuse (10 A) and an open circuit in the wire harness. 2P (WHITE) CONNECTOR Remove the accessory socket cap. BOTTOM CENTER White/black Check for continuity between the White/black wire terminal of the socket side 2P connector and bottom center terminal of the socket, and between the Green wire terminal and side wall terminal. There should be continuity. If there is no continuity, replace the accessory socket. 23-5 LIGHTS/METERS/SWITCHES REPLACEMENT Remove the meter lower cover (page 3-18). Disconnect the accessory socket 2P (White) connector (page 23-5). Release the accessory socket wire from the wire clip on the steering shaft holder. Loosen the nut and remove the accessory socket from the meter lower cover. Install a new accessory socket by aligning the lug with the groove in the meter lower cover. Install the nut and tighten it securely. Route the acces- Install the removed parts in the reverse order of sory socket wire removal. properly (page 1-20). SOCKET COVER IGNITION SWITCH INSPECTION Remove the right inner fender (page 3-9). 4P NATURAL CONNECTOR Remove the ignition switch 4P (Natural) connector from the frame and disconnect it. Check for continuity between the switch side connector terminals in each switch position. Continuity should exist between the color coded wires as follows: ^\Color PositiorT\ ON OFF Red/ black Pink o- -o Red Black o- - o REPLACEMENT Remove the meter upper cover (page 3-18). Disconnect the ignition switch 4P (Natural) connector (page 23-6). IGNITION SWITCH STOPPERS Release the ignition switch wire from the wire clip on the steering shaft holder. Remove the ignition switch from the meter upper cover by pushing in the two stoppers. Install a new ignition switch by aligning the locating tab with the cover groove. Route the ignition Install the removed parts in the reverse order of switch wire prop- removal. erly (page 1-201. 23-6 COVER LOCATING TAB LIGHTS/METERS/SWITCHES HANDLEBAR SWITCH INSPECTION Remove the right inner fender (page 3-9). Remove the handlebar switch 10P (Light green) connector from the frame and disconnect it. LIGHT GREEN) CONNECTOR For gearshift Check for continuity between the switch side conswitch inspection nector terminals in each switch position. (page 14-45). Continuity should exist between the color coded wires as shown below: DIMMER SWITCH LIGHTING SWITCH GEARSHIFT SWITCH ENGINE STOP SWITCH LIGHTING SWITCH Color Bl/Br Position ON OFF DIMMER SWITCH Br ENGINE STOP SWITCH Color Bl/G Position OFF RUN OFF Color Position Low (N) High w Bu/BI O STARTER SWITCH Bl/W Bl/W Y/R FREE PUSH 23-7 LIGHTS/METERS/SWITCHES COMBINATION METER/REAR VS SENSOR POWER/GROUND LINE INSPECTION Remove the left inner fender (page 3-9). Remove the combination meter 14P (Gray) connector from the frame and disconnect it. Check the following at the wire harness side connector. POWER INPUT LINE Measure the voltage between the Black/blue wire terminal (+) and ground (-). There should be battery voltage with the ignition switch turned ON. If there is no voltage, check for an open circuit in the wire harness. BACK-UP VOLTAGE LINE 14P (GRAY) CONNECTOR Measure the voltage between the Red/black wire terminal (+) and ground (-). There should be battery voltage at all times. If there is no voltage, check for an open circuit in the wire harness. GROUND LINE Check for continuity between the Green wire terminal and ground. There should be continuity at all times. If there is no voltage, check for an open circuit in the wire harness. SPEEDOMETER/REAR VS SENSOR Check there is no DTC before the speedometer rear VS sensor inspection. If there is any DTC, refer to the PGM-FI troubleshooting (page 6-13). Check that the hour meter and odometer/trip meter function properly. • If they do not function, check the power/ground line (page 23-8). • If they function properly, check as follows: Remove the left inner fender (page 3-9). Remove the rear VS sensor 3P (Yellow) connector from the frame and disconnect it. Measure the voltage between the Black/pink (+) and Green (-) wire terminals of the wire harness side connector. There should be 10 V or more with the ignition switch turned ON. If there is no voltage, check for an open circuit in the wire harness. 23-8 ' 3P (YELLOW) CONNECTOR LIGHTS/METERS/SWITCHES Connect the inspection adaptor to the rear VS sensor 3P (Yellow) connectors. TOOL: Inspection adaptor WHITE CLIP i INSPECTION ADAPTOR 07GMJ-ML80100 Shift the transmission into neutral. Raise the wheels off the ground and support the vehicle securely with a hoist or equivalent. Turn the ignition switch ON. Measure the voltage between the Red clip (+) and White clip (-) while slowly turning the rear wheels by hand. There should be 0 to 5 V pulse voltage. • If the pulse voltage does not appear, replace the VS sensor. • If the pulse voltage appears, check as follows: Remove the left inner fender (page 3-9). Remove the combination meter 14P (Gray) connector from the frame and disconnect it. Check for an open or short circuit in the Pink/green wire between the rear VS sensor 3P (Yellow) connector and combination meter 14P (Gray) connector. If the Pink/green wire is OK, replace the combination meter. 14P (GRAY) CONNECTOR COMBINATION METER REMOVAL/ INSTALLATION Remove the left inner fender (page 3-9). Remove the combination meter 14P (Gray) connector and 4P (Natural) connector from the frame and disconnect it. 4P NATURAL CONNECTOR Release the meter wire from the wire clip on the steering shaft holder. Remove the meter cover (page 3-18). Route the acces- Installation is in the reverse order of removal. sory socket wire properly (page 1-20). 14P (GRAY) CONNECTOR REAR VS SENSOR REPLACEMENT Remove both inner fenders (page 3-9). Remove the rear VS sensor 3P (Yellow) connector from the frame and disconnect it. 3P (YELLOW) CONNECTOR 23-9 LIGHTS/METERS/SWITCHES Remove the two bolts and VS sensor cover. Remove the rear VS sensor wire from the clamp. Remove the three bolts, sensor cover stay and rear VS sensor. Coat a new O-ring with oil and install it onto a new rear VS sensor. Route the rear VS Install the rear VS sensor in the reverse order of sensor wire prop- removal. erly (page 1-20). FUEL GAUGE/FUEL LEVEL SENSOR SYSTEM INSPECTION Check that the speedometer and indicators function properly. • If they do not function, check the power/ground line (page 23-8). • If they function, check as follows: Remove the steering cover (page 3-5). Turn the ignition switch OFF and disconnect the fuel level sensor 2P (Natural) connector. Release the sensor wire from the wire clamp. 2P NATURAL) CONNECTOR 23-10 LIGHTS/METERS/SWITCHES Turn the ignition switch ON and check the fuel gauge. All segments should blink. FA model: Turn the ignition switch OFF. Connect the meter side connector terminals with a jumper wire. Turn the ignition switch ON and check the fuel gauge. All segments should blink. FGA model: ,..;„. If the fuel gauge does not function properly, replace the combination meter (page 23-9). 1 ? f T I ? Turn the ignition switch OFF. FUEL GAUGE SEGMENTS Remove the fuel tank cover (page 3-5). Remove the three bolts, retaining plate and fuel level sensor from the fuel tank. With the fuel level sensor float at the top (FULL) position, turn the ignition switch ON and check the fuel gauge. (FULL) BOTTOM (RESERVE) All segments up to segment "F" should come on. Turn the ignition switch OFF. FA model: FGA model: SEGMENT "F" 23-11 LIGHTS/METERS/SWITCHES Move the float to the bottom (RESERVE) position, turn the ignition switch to ON and check the fuel gauge. FA model: FGA model: LOW FUEL INDICATOR Segment "E" and low fuel indicator should blink. If the fuel gauge does not function properly, check the fuel level sensor (page 23-12). If the fuel level sensor is OK, replace the combination meter. If all segments blink during inspection, replace the combination meter. .irm Turn the ignition switch OFF. SEGMENT "E" Install a new seal rubber onto the fuel level sensor. Install the retainer plate onto the sensor by aligning the tab with the groove. Install the sensor into the fuel tank while aligning the groove in the plate with the boss on the fuel tank. Install and tighten the bolts securely. Install the removed parts in the reverse order of removal. FUEL LEVEL SENSOR INSPECTION Remove the fuel level sensor (page 23-10). Disconnect the fuel level sensor 2P (Natural) connector and connect the ohmmeter to the sensor side connector terminals. 2P (NATURAL) CONNECTOR 23-12 LIGHTS/METERS/SWITCHES Measure the fuel level sensor resistance with the float at the top (FULL) and bottom (RESERVE) positions. FLOAT POSITION TOP (FULL) BOTTOM (RESERVE) FLOAT RESISTANCE (20°C/68°) 5-7Q 204 - 210 n TOP (FULL) BOTTOM (RESERVE) TEMPERATURE INDICATOR/ TEMPERATURE SENSOR SYSTEM INSPECTION NOTE: • The coolant/engine oil temperature indicator should come on for a few seconds when the ignition switch is turned ON, and should extinguish shortly. FGA model shown: TEMPERATURE INDICATOR Check the neutral indicator and reverse indicator function properly. • If they do not function, check the power/ground line (page 23-8). • If they function, check as follows: Temperature indicator does not come on when the ignition switch turned to ON Seal the PCM con- Disconnect the Powertrain Control Module (PCM) nectors with tape to 33P connectors. prevent dirt and oil from entering the connector after disconnecting the 33P connectors. PCM 33P (BLACK) CONNECTOR (Wire side of female terminal) NOTE: • When reconnecting the PCM 33P connectors, check that there is no dirt and oil in the connector. Be careful not to Short the Blue/red and Green wire terminals with a bend the connec- jumper wire. tor terminals. Turn the ignition switch ON and check the tempera- ture indicator. • If the indicator comes on, replace the PCM. • If the indicator does not come on, check for an open circuit in the Blue/red and Green wire. If the wires are OK, replace the combination meter. I A19 I—I ) r 1 r _ -r ( A i ] I—I 1 I B13 11 Tu \ f PCM 33P (GRAY) CONNECTOR (Wire side of female terminal) 23-13 LIGHTS/METERS/SWITCHES Temperature indicator does not go off with the fan motor stops Remove the left engine side cover (page 3-17). Disconnect the ECT sensor 2P (Black) connector. (BLACK) CONNECTOR I Turn the ignition switch ON and check the temperature indicator. • If the indicator comes on, then goes off, check the ECT sensor (page 23-14). FGA model shown: TEMPERATURE INDICATOR If the indicator comes on and stays on, disconnect the connector from the EOT sensor and check the temperature indicator. - If the indicator goes off, check the EOT sensor (page 23-15). - If the indicator stays on, check for short circuit in the White and Green/red wire on ECT sensor wire or Yellow and Green/red wire on EOT sensor. 2P BLACK) CONNECTOR ECT SENSOR INSPECTION Drain the coolant from the engine (page 7-7). Remove the left engine side cover (page 3-17). Replace the ECT Disconnect the ECT sensor 2P (Black) connector sensor while the from the sensor. engine is cold. Remove the ECT sensor and O-ring. 2P (BLACK) CONNECTOR 23-14 LIGHTS/METERS/SWITCHES Suspend the ECT sensor in a pan of coolant (50 - 50 mixture) on an electric heating element and measure the resistance through the sensor as the coolant heats up. THERMOMETER NOTE: • Soak the element in coolant up to its threads with at least 40 mm (1.57 in) from the bottom of the pan to the bottom of the sensor. • Keep the temperature constant for 3 minutes before testing. A sudden change of temperature will result in incorrect readings. Do not let the thermometer or ECT sensor touch the pan. Resistance: 0.15 - 0.16 k£2 at 100C (212°F) 0.08 - 0.10 kti at 120°C (248F) ECTSENSOR Replace the ECT sensor if it is out of specifications by more than 10% at any temperature listed. Always replace the Install the new O-ring and ECT sensor. O-ring with a new Tighten the ECT sensor to the specified torque. °ne' TORQUE: 12 N m (1.2 kgf-m, 9 Ibf-ft) Connect the ECT sensor 2P (Black) connector. Install the removed parts in the reverse order of removal. Fill and bleed the cooling system (page 7-7). EOT SENSOR INSPECTION Drain the engine oil (page 4-11). Remove the left center mud guard (page 3-7). 2P BLACK CONNECTOR Disconnect the EOT sensor 2P (Black) connector and remove the EOT sensor. Suspend the EOT sensor in a pan of engine oil on an electric heating element and measure the resistance through the sensor as the oil heats up. THERMOMETER NOTE: • Soak the element in oil up to its threads with at least 40 mm (1.57 in) from the bottom of the pan to the bottom of the sensor. • Keep the temperature constant for 3 minutes before testing. A sudden change of temperature will result in incorrect readings. Do not let the thermometer or EOT sensor touch the pan. Resistance: 1.23 - 1.32 kQ at 40°C (104°F) Replace the EOT sensor if it is out of specifications by more than 10% at any temperature listed. EOT SENSOR 23-15 LIGHTS/METERS/SWITCHES Install the EOT sensor with a new sealing washer and tighten it. 2P BLACK CONNECTOR TORQUE: 12 N m (1.2 kgf m, 9 Ibfft) Connect the EOT sensor 2P (Black) connector. Install the removed parts in the reverse order of removal. Fill the recommended engine oil (page 4-11). GPS RECEIVER (GPS model only) INSPECTION If the GPS indicator is blinking and the antenna mark and all segments do not indicate at all, check the system by following the troubleshooting "GPS INDICATOR BLINKS" (page 23-17). If the GPS start-up time is too long every time the ignition switch is turned to ON despite of the hot start condition, check the system by following the troubleshooting "GPS START-UP TIME IS TOO LONG" (page 23-18). NOTE: The start-up time of the positioning varies as follows: • Hot start When the ignition switch is turned ON within 2 hours after it was turned OFF, the position fix will be completed in about 25 seconds. • Warm start When the ignition switch is turned ON more than 2 hours after it was turned OFF, the position fix will be completed in about 2 minutes. • 23-16 Cold start The position fix will be completed within about 8 minutes in the following situations; - When the ignition switch is turned ON more than 1 month after it was turned OFF - When the vehicle is transported for more than 100 km (62 miles) with the ignition switch turned OFF - When the battery is disconnected E S P B3H »••••!• INDICATOR »n_ rjnn IU C.UUmila ^ G psT.llJ ANTENNA MARK LIGHTS/METERS/SWITCHES GPS INDICATOR BLINKS (COMMUNICATION ERROR) 1. GPS Receiver Connector Check Remove the meter covers (page 3-18). Turn the ignition switch OFF. Remove the GPS receiver 6P (Natural) connector from the stay and disconnect it. Check for loose connection or poor contact of the GPS receiver connector. Connect the GPS receiver 6P (Natural) connector. Turn the ignition switch ON, wait for 8 minutes and check the GPS indicator. 6P (NATURAL) CONNECTOR Is the GPS indicator still blinking? YES - GO TO STEP 2. NO - No problem (Temporary failure). 2. GPS Receiver Input Voltage Line Inspection Turn the ignition switch OFF. Disconnect the GPS receiver 6P (Natural) connector. Turn the ignition switch ON. Measure the voltage between the meter side connector terminal and ground. Connection: Pink (+) - Ground (-) Is there about 5 V? YES - GO TO STEP 3. NO - • Open or short circuit in the Pink wire. • Inspect the power input line of the combination meter (page 23-8). METER SIDE 6P (NATURAL) CONNECTOR (Viewed from the terminal side) r~ p (i) 3. GPS Receiver Ground Line Inspection Turn the ignition switch OFF. Check for continuity between the meter side connector terminal and ground. Connection: White/green - Ground METER SIDE 6P (NATURAL) CONNECTOR (Viewed from the terminal side) fe there continuity? YES - GO TO STEP 4. NO - • Open circuit in the White/green wire • Inspect the ground line of the combination meter (page 23-8). W/G (Q) 23-17 LIGHTS/METERS/SWITCHES 4. GPS Receiver Replacement Replace the GPS receiver with a known good one. Turn the ignition switch ON, wait for 5 minutes and recheckthe GPS indicator. Is the GPS indicator still blinking? YES - Faulty combination meter. NO - Faulty original GPS receiver. INDICATOR GPS START-UP TIME IS TOO LONG 1. Recheck With the GPS System Reset Disconnect the battery negative (-) cable and reconnect it. Turn the ignition switch ON, wait until GPS system starts-up, and turn the ignition switch to OFF and ON. Does the GPS start-up within 30 seconds? YES - No problem (Temporary failure). NO - GO TO STEP 2. 2. GPS Receiver Back-up Voltage Inspection Remove the meter covers (page 3-18). Turn the ignition switch OFF. Remove the GPS receiver 6P (Natural) connector from the stay and disconnect it. Measure the voltage between the meter side connector terminal and ground. METER SIDE 6P (NATURAL) CONNECTOR (Viewed from the terminal side) Connection: Black/blue {+) - Ground (-) Is there about 5V? YES - Faulty GPS receiver. NO - • Open or short circuit in the Black/ blue wire. • Inspect the back-up voltage line of the combination meter (page 23-8). GPS receiver removal and installation (page 3-18). 23-18 Bl/Bu LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT BRAKE LEVER NOTE: • The lower switch is the front brake light switch. Disconnect the front brake lever switch connectors and check for continuity between the switch terminals. There should be continuity with the front brake lever squeezed and no continuity with the lever released. BRAKE LIGHT SWITCH CONNECTORS REAR BRAKE LEVER Disconnect the rear brake lever switch connectors and check for continuity between the switch terminals. There should be continuity with the rear brake lever squeezed and no continuity with the lever released. REAR BRAKE PEDAL Remove the right side cover (page 3-5). Disconnect the rear brake pedal switch 2P (Green) connector and check for continuity between the switch side connector terminals. There should be continuity with the rear brake pedal depressed and no continuity with the pedal released. 2P (GREEN) CONNECTOR 23-19 LIGHTS/METERS/SWITCHES FRONT BRAKE SWITCH NOTE: • The upper switch is the front brake (inhibitor) switch. Check the front brake lever free play and adjust it if necessary (page 4-19). Disconnect the front brake switch connectors and check for continuity between the switch terminals. There should be continuity with the front brake lever squeezed and no continuity with the lever released. BRAKE SWITCH CONNECTORS HORN SWITCH (AUSTRALIA type only) Disconnect the horn switch wire connectors. Check the continuity between the connector terminals. There should be continuity when the horn switch is pushed, and be no continuity when the switch is released. HORN (AUSTRALIA type only) Disconnect the wire connectors from the horn. Connect a 12 V battery to the horn terminals. CONNECTORS The horn is normal if it sounds when the 12V battery is connected across the horn terminals. HORN 23-20 24. WIRING DIAGRAM TRX680FA/FGA: 24-3 24-1 WIRING DIAGRAM TRX680FA/FGA: 0030Z-HN8-A600 24^3 25. TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT LOW AND HARD TO START 25-2 IDLE SPEED ENGINE LACKS POWER 25-3 POOR PERFORMANCE AT HIGH SPEED •25-6 POOR HANDLING 25-5 25-6 25-1 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 1. Spark Plug Inspection Remove and inspect spark plug. Is the spark plug in good condition? NO - • Incorrect spark plug heat range • Incorrect spark plug gap • Dirty air cleaner YES - GO TO STEP 2. 2. Spark Test Perform spark test. Is there weak or no spark? YES - • Loose or disconnected ignition system wire Faulty ignition coil Broken or shorted spark plug wire Loose or disconnected ignition system wires Faulty CKP sensor Faulty engine stop switch Faulty ignition switch Faulty PCM NO - GO TO STEP 3. 3. Fuel Pump Inspection Check for operation of the fuel pump and inspect the fuel flow. Is the fuel pump unit normal? NO - • Faulty fuel pump unit YES - G O TO STEP 4. 4. PGM-FI System Inspection Check the PGM-FI system. Is the PGM-FI system normal? NO - Faulty PGM-FI system Yes - GO TO STEP 5. 5. Cylinder Compression Test cylinder compression. Is the compression low? YES - • • • • • Valve clearance too small Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve NO - GO TO STEP 5. • Improper valve timing 6. Engine Start Condition Start by following normal procedure. Did the engine start but stops? YES 25-2 - • • • • Leaking intake manifold Leaking intake pipe Improper ignition timing (Faulty PCM or CKP sensor) Contaminated fuel TROUBLESHOOTING ENGINE LACKS POWER 1. Drivetrain Inspection Raise wheel off the ground and spin by hand. Does the wheel spin freely? NO - • Brake dragging • Worn or damaged wheel bearing • Damaged differential or final drive bearing • Faulty differential or final drive YES - GO TO STEP 2. 2. Tire Pressure Inspection Check tire pressure. Are the tire pressures correct? NO - • Faulty tire valve • Punctured tire YES - GO TO STEP 3. 3. Engine Condition Inspection Accelerate lightly. Does the engine speed increase? NO - • Clogged air cleaner • Restricted fuel flow • Clogged muffler • Restricted fuel fill cap breather YES - GO TO STEP 4. 4. Engine Condition Inspection Accelerate or run at high speed. Is there knocking? YES - • Worn piston and cylinder • Use of poor quality fuel • Excessive carbon build-up in combustion chamber • Ignition timing too advance (Faulty PCM) NO - GO TO STEP 7. 5. Spark Plug Inspection Remove and inspect spark plug. Is the spark plug fouled or discolored? YES - • Plug not serviced frequently enough • Incorrect spark plug used NO - GO TO STEP 6. 6. Engine Oil Inspection Check oil level and condition. Is there correct level and good condition? NO - • Oil level too high • Oil level too low YES - GO TO STEP 7. • Contaminated oil 7. Ignition Timing Inspection Check the ignition timing. Is the ignition timing correct? NO YES - • Faulty PCM • Faulty CKP sensor - GO TO STEP 8. 25-3 TROUBLESHOOTING 8. Cylinder Compression Inspection Test cylinder compression. Is the compression low? YES - • Valve clearance too small Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve Improper valve timing NO - GO TO STEP 9. 9. Fuel pump Inspection Inspect the fuel flow. Is the fuel pump unit normal? NO - Faulty fuel pump unit (page 6-36) YES - G O TO STEP 10. 10. PGM-FI System Inspection Check the PGM-FI system. Is the PGM-FI System normal? NO - Faulty PGM-FI system (page 6-13) YES - G O TO STEP 11. 11. lubrication Inspection Remove cylinder head cover and inspect lubrication. Is the valve train lubricated properly? 25-4 NO - • Clogged oil passage • Clogged oil orifice YES - • Faulty A/T system TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Spark Test Perform spark test. Is there weak or intermittent spark? YES - Faulty spark plug Fouled spark plug Loose or disconnected ignition system wires Broken or shorted spark plug wire Faulty ignition coil Faulty CKP sensor Faulty engine stop switch Faulty ignition switch Faulty PCM NO - GO TO STEP 2. 2. Fuel Pump Inspection Inspect the fuel flow. Is the fuel pump unit normal? NO - Faulty fuel pump unit (page 6-36) YES - GO TO STEP 3. 3. PGM-FI System Inspection Check the PGM-FI system. fe the PGM-FI system normal? NO - Faulty PGM-FI system (page 6-13) YES - G O TO STEP 4. 4. Intake Air Leak Inspection Check for leaks at the intake manifold pipes. Are there leaks? YES - • Loose insulator bands • Damaged insulator NO - GO TO STEP 5. 5. Ignition Timing Inspection Check the ignition timing. fe the ignition timing correct? NO YES - • Faulty PCM • Faulty CKP sensor - • Faulty A/T system 25-5 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1. Fuel Pump Inspection Inspect the fuel flow. Is the fuel pump unit operation normal? NO - Faulty fuel pump unit (page 6-36) YES - GO TO STEP 2. 2. PGM-FI System Inspection Check the PGM-FI system. te the PGM-FI system normal? NO - Faulty PGM-FI system (page 6-13) YES - GO TO STEP 3. 3. Ignition Timing Inspection Check ignition timing. te the ignition timing correct? NO - • Faulty PCM • Faulty CKP sensor YES - GO TO STEP 4. 4. Valve Timing Inspection Check valve timing. te the valve timing correct? NO - Camshaft not installed properly YES - GO TO STEP 5. 5. Valve Spring Inspection Check valve springs. Are the valve springs weak? YES - • Faulty valve spring NO - • Faulty A/T system POOR HANDLING Steering is heavy • Steering shaft nut or holder too tight • Damaged steering shaft bushing • Damaged steering shaft bearing Any wheel is wobbling • Excessive wheel bearing play • Bent rim • Improperly installed wheel hub • Loose suspension arm • Bent frame Vehicle pulls to one side • Tire air pressure incorrect • Faulty shock absorber I • Bent tie-rod • Incorrect tie-rod adjustment • Bent frame • Improper wheel alignment 25-6 26. INDEX ACCESSORY SOCKET 23-5 AIR CLEANER 4-5 AIR CLEANER HOUSING 6-41 AIR CLEANER HOUSING DRAIN PLUG 4-7 ALTERNATOR CHARGING COIL 20-8 ALTERNATOR STATOR/STARTER REDUCTION GEARS 11-9 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS 1-8 AUTOMATIC TRANSMISSION SYSTEM 2-7 : BANK ANGLE SENSOR 6-51 BATTERY -20-6 BATTERY/CHARGING SYSTEM SPECIFICATIONS 1-10 BODY PANEL LOCATIONS 3-3 BRAKE FLUID 4-17 BRAKE FLUID REPLACEMENT/AIR BLEEDING 17-7 BRAKE LIGHT SWITCH LIGHTS/METERS/SWITCHES 23-19 MAINTENANCE 4-19 BRAKE PAD/DISC 17-10 BRAKE PADS WEAR 4-18 BRAKE SYSTEM 4-19 BRAKE SYSTEM SPECIFICATIONS 1-10 CABLE & HARNESS ROUTING 1-20 CAMSHAFT 9-16 CASE BEARING REPLACEMENT 18-22 CENTER MUD GUARD 3-7 CHARGING SYSTEM INSPECTION 20-7 COMBINATION METER 23-8 COMPONENT LOCATION BATTERY/CHARGING SYSTEM 20-2 ELECTRIC STARTER 22-2 IGNITION SYSTEM 21-2 LIGHTS/METERS/SWITCHES 23-2 COOLANT REPLACEMENT 7-6 COOLING SYSTEM 4-13,7-5 COOLING SYSTEM SPECIFICATIONS• 1-7 CRANKCASE ASSEMBLY 13-12 CRANKCASE BEARING REPLACEMENT 13-10 CRANKCASE SEPARATION 13-6 CRANKCASE/CRANKSHAFT/BALANCER SPECIFICATIONS 1-9 CRANKSHAFT 13-7 CYLINDER COMPRESSION 9-6 CYLINDER HEAD ASSEMBLY 9-19 CYLINDER HEAD COVER ASSEMBLY/ INSTALLATION 9-22 CYLINDER HEAD COVER REMOVAL/ DISASSEMBLY 9-6 CYLINDER HEAD DISASSEMBLY 9-10 CYLINDER HEAD INSPECTION 9-11 CYLINDER HEAD INSTALLATION 9-20 CYLINDER HEAD REMOVAL 9-9 CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS 1-8 CYLINDER/PISTON INSPECTION 10-5 CYLINDER/PISTON INSTALLATION 10-8 CYLINDER/PISTON REMOVAL 10-4 CYLINDER/PISTON SPECIFICATIONS 1-8 DIFFERENTIAL ASSEMBLY 18-25 DIFFERENTIAL DISASSEMBLY/INSPECTION 18-14 DIFFERENTIAL INSTALLATION 18-30 DIFFERENTIAL REMOVAL 18-12 DIODE 22-14 DRIVE MODE SELECT SWITCH 14-46 DRIVE SHAFT BOOTS 4-14 DRIVETRAIN CONNECTOR LOCATION 14-17 DRIVETRAIN DTC INDEX 14-24 DRIVETRAIN DTC TROUBLESHOOTING 14-26 DRIVETRAIN SPECIFICATIONS DRIVETRAIN SYSTEM DIAGRAM DRIVETRAIN SYSTEM LOCATION DRIVETRAIN TROUBLESHOOTING INFORMATION DTC TROUBLESHOOTING ECT SENSOR ELECTRIC STARTER SPECIFICATIONS EMISSION CONTROL SYSTEMS ENGINE & FRAME TORQUE VALUES ENGINE GUARD ENGINE IDLE SPEED ENGINE INSTALLATION ENGINE OIL ENGINE OIL FILTER ENGINE REMOVAL ENGINE SIDE COVER ENGINE STOP RELAY EXHAUST SYSTEM FINAL DRIVE ASSEMBLY FINAL DRIVE DISASSEMBLY/INSPECTION FINAL DRIVE INSPECTION FINAL DRIVE INSTALLATION FINAL DRIVE REMOVAL FINAL GEAR CASE BEARING REPLACEMENT FLYWHEEL/STARTER CLUTCH FRONT BRAKE CALIPER FRONT BRAKE SWITCH FRONT CARRIER FRONT CARRY PIPE FRONT CRANKCASE COVER FRONT DRIVE SHAFT FRONT DRIVING MECHANISM SPECIFICATIONS FRONT FENDER • FRONT GRILLE FRONT MASTER CYLINDER FRONT MUD GUARD FRONT SHOCK ABSORBER FRONT WHEEL FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS FUEL GAUGE/FUEL LEVEL SENSOR FUEL LINE FUEL LINE INSPECTION FUEL PUMP RELAY FUEL SYSTEM (PGM-FI) FUEL SYSTEM SPECIFICATIONS FUEL TANK FUEL TANK COVER FUEL TANK SIDE COVER GEAR POSITION SWITCH GEAR SELECTOR LEVER LINKAGE GEARSHIFT SWITCH GENERAL SPECIFICATIONS GPS RECEIVER (GPS model only) HANDLEBAR HANDLEBAR SWITCH HEADLIGHT HORN (AUSTRALIA type only) HORN SWITCH (AUSTRALIA type only) IACV IACV (Idle Air Control Valve) IGNITION COIL IGNITION SWITCH IGNITION SYSTEM INSPECTION IGNITION SYSTEM SPECIFICATIONS IGNITION TIMING INJECTOR INNER FENDER 1-9 14-16 14-15 14-20 6-18 6-50 1-11 1-39 1-12 3-17 6-55 8-8 4-10 4-12 8-4 3-17 6-52 3-19 19-23 19-16 19-14 19-27 19-12 19-21 11-14 17-17 23-20 3-11 3-10 14-54 18-7 1-10 3-11 3-10 17-13 3-8 15-22 15-11 1-9 23-10 4-4 6-32 6-38 6-2 1-7 6-39 3-5 3-6 14-44 12-14 14-45 1-5 23-16 15-6 23-7 23-4 23-20 23-20 I 6-56 2-4 21-7 23-6 21-5 1-11 21-8 6-48 3-9 26-1 INDEX LIGHTS/METERS/SWITCHES SPECIFICATIONS 1-11 LUBRICATION & SEAL POINTS 1-17 LUBRICATION SYSTEM DIAGRAM 5-2 LUBRICATION SYSTEM SPECIFICATIONS 1-7 METER COVER 3-18 MIL CIRCUIT INSPECTION 6-31 MODEL IDENTIFICATION 1-3 MUFFLER PROTECTOR 3-12 NUTS, BOLTS, FASTENERS 4-22 OIL COOLER 5-12 OIL PRESSURE CHECK AUTOMATIC TRANSMISSION 14-12 LUBRICATION SYSTEM 5-5 OIL PUMP 5-5 OUTER FENDER 3-16 PCM (POWERTRAIN CONTROL MODULE) 2-2,6-53 PGM-FI CONNECTOR LOCATION 6-8 PGM-FI DTC INDEX 6-17 PGM-FI SYSTEM 2-3 PGM-FI SYSTEM DIAGRAM 6-7 PGM-FI SYSTEM LOCATION 6-6 PGM-FI TROUBLESHOOTING INFORMATION 6-13 RADIATOR COOLANT 4-12 RADIATOR RESERVE TANK 7-9 RADIATOR/COOLING FAN 7-10 REAR BRAKE CALIPER 17-27 REAR BRAKE DISC 17-34 REAR BRAKE MASTER CYLINDER/BRAKE PEDAL 17-21 REAR CARRIER/MUD GUARD 3-13 REAR CRANKCASE COVER 12-5 REAR DRIVE SHAFT 19-6 REAR DRIVING MECHANISM SPECIFICATIONS 1-10 REAR FENDER 3-14 REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL 4-15 REAR SHOCK ABSORBER/SUSPENSION ARM 16-10 REAR WHEEL 16-6 REAR WHEEL/SUSPENSION SPECIFICATIONS 1-9 RECOIL STARTER 11-5 REGULATOR/RECTIFIER 20-9 RIGHT SIDE COVER 3-5 SEAT 3-4 SELECTOR CABLE ADJUSTMENT 12-15 SERVICE INFORMATION • 4-3 ALTERNATOR/STARTER CLUTCH 11-3 BATTERY/CHARGING SYSTEM 20-3 BRAKE SYSTEM 17-4 COOLING SYSTEM 7-3 CRANKCASE/CRANKSHAFT/BALANCER 13-3 CYLINDER HEAD/VALVE/CAMSHAFT 9-3 CYLINDER/PISTON 10-3 DRIVETRAIN SYSTEM 14-3 ELECTRIC STARTER 22-3 ENGINE REMOVAL/INSTALLATION 8-3 FRAME/BODY PANELS/EXHAUST SYSTEM 3-2 FRONT DRIVING MECHANISM 18-3 FRONT WHEEL/SUSPENSION/STEERING 15-3 FUEL SYSTEM (PGM-FI) 6-3 IGNITION SYSTEM 21-3 LIGHTS/METERS/SWITCHES 23-3 LUBRICATION SYSTEM 5-3 MAINTENANCE 4-2 REAR DRIVING MECHANISM 19-3 REAR WHEEL/SUSPENSION 16-3 SUB-TRANSMISSION/GEARSHIFT LINKAGE 12-3 SERVICE RULES 1-2 SHIFT CLUTCH/MAINSHAFT ASSEMBLY 14-67 SHIFT CLUTCH/MAINSHAFT DISASSEMBLY 14-62 26-2 SHIFT VALVE BODY SKID PLATE, ENGINE GUARD SPARK ARRESTERSPARKPLUG STANDARD TORQUE VALUES STARTER MOTOR STARTER RELAY SWITCH STEERING COVER STEERING SHAFT STEERING SHAFT HOLDER BEARING STEERING SYSTEM SUB FUEL TANK/FUEL PUMP SUB-TRANSMISSION SUB-TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS SUSPENSION SUSPENSION ARM SYMPTOM TROUBLESHOOTING DRIVETRAIN SYSTEM FUEL SYSTEM (PGM-FI) SYSTEM COMPONENTS ALTERNATOR/STARTER CLUTCH BRAKE SYSTEM CRANKCASE/CRANKSHAFT/BALANCER CYLINDER HEADA/ALVE/CAMSHAFT CYLINDER/PISTON DRIVETRAIN SYSTEM ENGINE REMOVAL/INSTALLATION FRONT DRIVING MECHANISM FRONT WHEEL/SUSPENSION/STEERING FUEL SYSTEM (PGM-FI) REAR DRIVING MECHANISM REAR WHEEL/SUSPENSION SUB-TRANSMISSION/GEARSHIFT LINKAGE SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM ELECTRIC STARTER IGNITION SYSTEM SYSTEM FLOW PATTERN COOLING SYSTEM SYSTEM TESTING TAILUGHT TEMPERATURE INDICATOR/TEMPERATURE SENSOR THERMOSTAT THROTTLE BODY-THROTTLE HOUSING THROTTLE OPERATION TIE-ROD TIRES TORQUE CONVERTER INSPECTION TORQUE CONVERTER INSTALLATION TORQUE CONVERTER REMOVAL TRIM CLIP TROUBLESHOOTING ALTERNATOR/STARTER CLUTCH BATTERY/CHARGING SYSTEM BRAKE SYSTEM COOLING SYSTEM CRANKCASE/CRANKSHAFT/BALANCER CYLINDER HEADA/ALVE/CAMSHAFT CYLINDER/PISTON ELECTRIC STARTER ENGINE DOES NOT START OR IS HARD TO START ENGINE LACKS POWER FRAME/BODY PANELS/EXHAUST SYSTEM FRONT DRIVING MECHANISM FRONT WHEEL/SUSPENSION/STEERING 14-47 4-20 4-21 4-7 1-12 22-6 22-12 3-5 15-28 4-22 4-23 6-36 12-9 1-9 4-21 15-23 14-6 6-5 11-2 17-2 13-2 9-2 10-2 14-2 8-2 18-2 15-2 6-2 19-2 16-2 12-2 20-2 22-2 21-2 7-2 7-5 23-4 23-13 7-8 6-43 15-10 4-4 15-33 15-11 14-61 14-73 14-60 3-4 11-4 20-5 17-6 7-4 13-5 9-5 10-3 22-4 25-2 25-3 3-2 18-6 15-5 INDEX TROUBLESHOOTING IGNITION SYSTEM LUBRICATION SYSTEM POOR HANDLING POOR PERFORMANCE AT HIGH SPEED POOR PERFORMANCE AT LOW AND IDLE SPEED REAR DRIVING MECHANISM REAR WHEEL/SUSPENSION SUB-TRANSMISSION/GEARSHIFT LINKAGE 21-4 5-4 25-6 25-6 25-5 19-5 16-5 12-4 UNIVERSAL JOINT VALVE CLEARANCE VALVE GUIDE REPLACEMENT VALVE SEAT INSPECTION/REFACING WATER PUMP WHEEL HUB AND KNUCKLE WHEEL HUB/KNUCKLE(REAR) WHEELS/TIRES WIRING DIAGRAM 19-15 4-8 9-12 9-13 7-13 15-15 16-6 4-22 24-3 26-3
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Key Features
- 675cc engine provides plenty of power
- Fully automatic transmission makes it easy to operate
- Electric power steering provides precise control
- Independent suspension обеспечивает a smooth ride
- Four-wheel drive provides excellent traction
- Comfortable seat and handlebars provide a comfortable ride
Frequently Answers and Questions
What is the engine size of the Honda 2006 TRX680FA?
675cc
Does the Honda 2006 TRX680FA have a fully automatic transmission?
Yes
Does the Honda 2006 TRX680FA have electric power steering?
Yes
Does the Honda 2006 TRX680FA have independent suspension?
Yes
Does the Honda 2006 TRX680FA have four-wheel drive?
Yes
Is the Honda 2006 TRX680FA comfortable to ride?
Yes, it has a comfortable seat and handlebars