Lubrication System: Lubrication System Diagram OIL Pressure Check Service Information Oil Pump Trouble Shooting

5 .
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM .........m

5-2 OIL PRESSURE CHECK ..............................5-5
SERVICE INFORMATION ...........................5-3 OIL PUMP ...................................................5-6
TROUBLE SHOOTING ................................5-4 OIL COOLER .............................................5-12

LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
ROCKER ARM
--L
7
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
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.
a The crankcase must be separated to service the oil pump (page 5-6).
* When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
a If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
a For engine oil level check (page 4-1 1).
a For engine oil and filter change (page 4-1 1).
0 For final drive oil check and change (page 4-16).
a For oil pressure indicator inspection (page 22-14).
SPECIFICATIONS
- Unit: m m (in
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 2.6 liters (2.75 US qt, 2.29 Imp qt) -
After draininglfilter change 2.8 liters (2.96 US qt, 2.46 Imp qt) -
After disassembly 3.2 liters (3.38 US qt, 2.82 Imp qt)
Recommended engine oil Suggested oil: Honda "4-stroke motor- -
cycle oil" or equivalent
Oil recommendation:
API i .. . r
(except oils labeled as energy conserv-
ing on circular API service label)
Viscositv: SAE IOW-30
( JASO ~ 9 0 standard:3 MA
Oil pressure at oil pressure switch 1 568 kPa (5.8 kgf/cm2,82 psi) -
- - - ,- - - ..... . . . . .,. ,- - -. . . - . , l
Oil pump rotor Tip clearance 1 0.1 5 (0.006) 1 0.20 (0.008)

Bodv
- - - , clearance
- - - -- 1 0.1
. 5 .- 0.21 (0.006 - 0.008) . .- -, 1 0.35 (0.014)
1 Side clearance i 0.02 - 0.08 i0.001- 0.003) 1 0.10 i0.004'1
TORQUE VALUES
Oil pressure switch 12 N.m (1.2 kgf.m, 9 Ibf.ft) Apply sealant to the threads
Oil pressure switch terminal screw 1.9 N.m (0.2 kgfem, 1.4 Ibf-ft)
Oil cooler bolt 64 N.m (6.5 kgf.m, 47 Ibf.ft) Apply engine oil to the threads
Oil pump assembly bolt 13 N.m (1.3 kgfam, 9 Ibfaft) CT bolt
LUBRlCATlON SYSTEM
Oil pressure gauge set Oil pressure gauge attachment
or equivalent commercially avail- or equivalent commercially avail-

able able
TROUBLE SHOOTING
ctuaeu.00 l o w
Oil consumption
External oil leak
Worn piston rings
Improperly installed piston rings
Worn cylinders
Worn stem seals
Worn valve guide
Low oil pressure
Oil level low
Clogged oil strainer
Faulty oil pump
Internal oil leak
lncorrect oil being used
No oil pressure
Oil level too low
0 Oil pressure relief valve stuck open
. . drive chain
0 Broken oil DumD
Broken oil pump drive andlor driven sprocket
Damaged oil pump
Internal oil leak
High oil pressure
Oil pressure relief valve stuck closed
0 Clogged oil gallery or metering orifice
lncorrect oil being used
Oil contamination
0 Oil or filter not changed often enough
Worn piston rings
Oil emulsification
Blown cylinder head gasket
Leaky coolant passage
Entry of water
LUBRICATION SYSTEM
OIL PRESSURE CHECK
Remove the left crankcase rear cover (page 3-15).
If the engine is cold, the pressure reading will be
abnormally high. Warm up the engine to normal
operating temperature before starting this test.
Stop the engine.
Remove the rubber cap and disconnect the oil pres-
sure switch wire by removing the terminal screw.
Remove the oil pressure switch and connect an oil

pressure gauge attachment and gauge to the pres-
sure switch hole.
TOOLS:
icn pressure gauge set 07506-3000001
Oil pressure gauge attachment 075104220100
or equivalent commercially available
Check the oil level and add the recommended oil if
necessary (page 4-11).
Start the engine and check the oil pressure at 5,000
min-' (rpm).
OIL PRESSURE:
568 kPa (5.8 kgf/cm2, 82 psi) at 5,000 min.' (rpm)
Stop the engine.
head 3-4 mm (0.1-

0 2 ,l TORQUE: 12 N-m (1.2 kgf.m, 9 Ibf-ft)
Connect the oil pressure switch wire and tighten the

terminal screw.
TORQUE: 1.9 N.m (0.2 kgf-m, 1.4 Ibf-ft)
Install the rubber cap.
Start the engine.
Check that the oil pressure indicator turns off after 1
or 2 seconds. If the oil pressure indicator stays on,
stop the engine immediately and determine the
cause (page 22-14).
LUBRlCATlON SYSTEM
lmJaukw
REMOVAL
Separate the crankcase (page 13-91.
Remove the bolts, pressure relief valve cover and oil
pump assembly from the left crankcase.
Remove the dowel pin, collars and 0-rings.
DISASSEMBLY
OU- PUMP BODY
Remove the oil pipe, oil pipe seal and 0-ring.
Remove the pressure relief valve and 0-ring.

LUBRICATION SYSTEM
Hemove the oil strainer and 0-ring.
Remove the bolts and pump body from the pump

cover.
Remove the dowel pins.

Remove the washer, drive shaft, drive pin, inner
and outer rotors.
P R E S S U R E W VALVE
Check the operation of the pressure relief valve by
pushing on the piston.
The snap ring is Remove the snap ring, washer, spring and piston
under spring pres- from the pressure relief valve body.
sure. Use care
when removing it
and wear eye and
face protection. Be
careful not to lose
the disassembled
parts.
LUBRICATION SYSTEM
Check the piston for wear, sticking or damage.
Check the valve spring for wear or fatigue.
Check the relief valve body for clogging or damage.
Clean all parts and assemble the relief valve in the
reverse order of disassembly.
NOTE:
Install the snap ring with the chamfered edge
facing the thrust load side.
Do not reuse worn snap ring which could easily
spin in the groove.
Check that the snap ring is seated in the groove.
NOT_E:
Measure each clearance at several points and use
the largest reading to compare the service limit.
BODY CLEARANCE
Temporarily assemble the inner rotor, outer rotor,
drive pin and pump shaft into the pump body.
Measure the body clearance.
TIP CLEARANCE
Measure the tip clearance.
SERVICE LIMIT: 0.20 mm (0.008 in)
LUBRICATION SYSTEM
SIDE CLEARANCE
Measure the side clearance.
Install the outer and inner rotors to the pump body.

NOTE:
Install the inner rotor with the groove side facing
the pump cover.
LUBRICATION SYSTEM
Install the drive shaft and drive pin by aligning the
drive pin with the grooves in the inner rotor.
Place the washer into the inner rotor groove.
Install the dowel pins to the pump body.
TORQUE: 13 N-m (1.3 kgf-m, 9 Ibf-ft)
Clean the oil strainer.

LUBRICATION SYSTEM
NOTE:
Install an oil pipe seal with its tapered side facing
out.
Install the oil pipe to the oil pump securely.
Install the dowel pin and collars.

Coat new 0-rings with oil and install them.
Install the oil pump assembly into the crankcase

securely.
lnstall the pressure relierf valve cover and tighten

the bolts securely.
Assemble the crankcase (page 13-47).
Check the oil pressure lpage 5-51.
LUBRICATION SYSTEM
O I L E R
REMOVALIINSTALLATION
Remove the oil filter (page 4-12).
Drain the coolant from the cooling system (page 7-
6).
Loosen the band screws, then disconnect the water
hoses from the water pump.
Remove the bolt, spring washer and oil cooler from

the crankcase.
Installation is in the reverse order of removal.
At installation, align the stopper on oil cooler with
the tab on the crankcase.
ing oil cooler side. COOLER

Apply engine oil to the bolt threads and install it.
Tighten the bolt to the specified torque.
&l-m 16.547 Ihf.ft)
I SPRING WASHER MARK SIDE

"0"
6. FUEL SYSTEM (PGM-FI)
SYMPTOM TROUBLESHOOTING .............6-6 THROTTLE BODY .....................................6-65
PGM-FI TROUBLESHOOTING ECT SENSOR ............................................6-72

INFORMATION .........................................
6-14
CMP SENSOR ...........................................6-72
DTC INDEX ................................................6-18
BANK ANGLE SENSOR ...........................6-73
DTC TROUBLESHOOT~NG.......................6-19
FI/IGNITION RELAY .................................6-74
MIL TROUBLESHOOTING ........................ 6-38
ECM (ENGINE CONTROL MODULE).....S.6-75
MIL CIRCUIT lNSPECTlON.......................6-54
ENGINE IDLE SPEED................................6-77
FUEL LINE lNSPECTlON ..........................6-55
IACV (Idle Air Control Valve) 6-77
FUEL PUMP...............................................6-59
m. . . . . . . . . . . . . . . . .
SECONDARY AIR SUPPLY SYSTEM ...mm. 6-79

FUEL PUMP RELAY ..................................6-61
O2SENSOR ...............................................6-82
FUEL SYSTEM (PGM-FI)
COMPONENT LOCATION
FUEL SYSTEM (PGM-FIJ
SERVICE INFORMATION
Before disconnecting fuel feed hose, relieve pressure from the system by disconnecting the quick connect fitting in the
fuel Dump base 6-55).
endi in^
. . or.twkting
.. 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.
Uo not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incor-
rect 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.
Prevent dirt and debris from entering the throttle bore 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.
Uo not loosen or tighten the white painted bolts, nuts and screws of the throttle body.
Always replace the packing when the fuel pump is removed.
It is impossible to disassemble the fuel pump after removing it.
A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
The VS sensor sends digital pulse signal to the ECM and computation. Refer to procedures for VS sensor inspection
- DTC troubleshooting (page 6-19]
- MIL troubleshooting (page 6-38]
When disassembling the programmed fuel injection parts, note the location of the 0-rings. Replace them with new ones
upon reassembly.
Use a digital tester for PGM-t-I system inspection.
kor fuel level sensor inspection (page 22-11).
ITEM SPECIFICATIONS
Throttle bodv identification number GQ66A
Idle speed +
1,200 100 min.' (rpm)
Throttle grip free play 2 - 6 m m (1112 - 114 in)
IAT sensor resistance (2O0C168"F) 1-4kR
ECT sensor resistance (2O0C168"F) 2.32 - 2.59 kR
Fuel injector resistance (at 20°C 168°F) 10.0 - 14.0 R
CMP sensor peak voltage (at 20°C 168°F) 0.7 V minimum
CKP sensor peak voltage (at 20°C 168°F) 0.7 V minimum
Fuel pressure at idle 343 kPa (3.5 kgf/cm2, 50 psi)
Fuel pump flow (at 12 V) 200 cm3(6.8 US oz. 7.0 I ~ oz)
D minimum110 seconds
TOOLS
P-
Fuel pressure gauge Pressure gauge manifold Pressure gauge hose attachment C
07406-0040004 07ZAJ-S5A0110 07ZAJ-S7C01000
Pressure gauge hose attachment A Fuel attachment joint ECM test harness 33P
07ZAJ-SA5A0120 07ZAJ-S7C0200 070MZ-MCA0100
SCS connector Inspection test harness Test probe

07OPZ-ZY30100 07GMJ-ML80100 07ZAJ-RDJA110
lmrie diagnostic tester (model 625)
or Peak voltage adaptor
07HGJ-0020100
with commercially available digital

multimeter (impedance IOMWDCV
minimum)
SYMPTOM TROUBLESHOOTING
When the motorcycle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 6-18) and
begin the appropriate troubleshooting procedure. If there are no DTCIMIL blinking stored in the ECM memory, do the diag-
nostic procedure for the symptom, in sequence listed below, until you find cause.
Symptom Diagnosis procedure Also check for
Engine cranks but won't 1. Crank the starter for more than No fuel to injector
start ten seconds and check the DTC - Clogged fuel filter
n-rr p p
troubleshooting according to - Pinched or clogged fuel tank breather
the DTC. hose
2. lnspect the fuel supply system - Faulty fuel pump
(page 6-58). - Faulty fuel pump circuits
Contaminatedldeteriorated fuel
Faulty fuel injector
IACV stuck
Faulty ignition system
1. ECM powerlground circuits a Open circuit i n the power input andlor
malfunction (page 6-75) ground wire of the ECM
(No fuel pump operation 2. lnspect the fuel supply system 0 Faulty bank angle sensor or related circuit
sound when the turning the (page 6-58). Faultv FIIIGN relav or related circuit
ignition ON) 0 ~ a u l t \engine
j stob switch or related circuit
Blown STARTERIIGN fuse (10 A) -
1. Check the idle speed. Restricted fuel feed hose
rough idling 2. Check the IACV. Contaminatedldeteriorated fuel
3. lnspect the fuel supply system Intake air leak
(page 6-58). Faulty IACV
0 Restricted fuel tank breather hose
Faulty ignition system
Check the PAlR system (page 6-79). 0 Faulty pulse secondary air injection (PAIR)
braking is used system

- Faulty PAlR control solenoid valve
- Faulty PAlR check valve
- Clonned hose of the PAlR system
~aultyr~nitio system
n
Check the ignition system. Faulty ignition system
lnspect the fuel supply system a Pinched or clogged fuel feed hose
(driveability) and poor fuel (page 6-58). Faulty pressure regulator
economy Faultv iniector
~ a u l t \iinition
j system
stays ON but no DTCs Troubleshoot the MIL circuit (page Faulty MIL circuit
set, or MIL never comes ON 6-38).
at all
MIL stays ON at all Check the DLC circuit (Brown wire) 0 Short circuit in the DLC related wire
I (No DTC set) for short circuit.
EL SYS1 t M (PGM-FI)
PGM-FI SYSTEM I OCATION
PGM-FI SYSTEM DIAGRAM
lcirumm
SWITCH FUSE
m A z i d
BIN
IGP A51'
PAIR CONTROL SOLENOIDVALVE

A30 K-LINE
DLC
815 SSTAND
VS SENSOR
WIR fi
v
4
IMMOBILIZER
INDICATOR
BI: Black Br: Brown

Y: Yellow 0: Orange
Bu: Blue Lg: Light green
G: Green P: Pink
R: Red Gr: Gray
W: White
ECM 33P (Black) CONNECTOR 33P (Light gray) CONNECTOR
ECM side of the male terminals
ECTOR LOCATION
P
Note 1: Remove the screen inner cowl (page 3-14).
Note 1: Open and support the fuel tank (page 4-5).
IAT SENSOR 2P (NATURAL)

CONNECTOR (Note 11
Note 1: Remove the right middle cowl (page 3-11).
Note 2: Open and support the fuel tank (page 4-5).
ECT SENSOR 3P (GRAY)

CKP SENSOR 2P (NATURAL) CONNECTOR (Note 1)
CONNECTOR (Note 1)
MAP SENSOR 3P (BLACK)

CONNECTOR (Note 2)
MIDDLE SIDE LOCATION
IACV 4P (WHITE)CONNtCTOR
FRONT (#2) INJECTOR 2P

(GRAY) CONNECTOR (Note 1)
Note 1: Remove the left side coverlpivot cover (page 3-51.
Note 1: Remove the right side cover/pivot cover (page 3-5).
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 that of the troubleshooting. If the MIL was on,
but then went out, the original problem may be intermittent.
Opens and Shorts
"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all.
With ECMs this can something mean something work, but not the way it's supposed to.
If the MK has come on
Refer to DTC READOUT (page 6-15).
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 6-6).
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSEM
The PGM-FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system, the ECM
turns on the MIL and stores a DTC i n 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 pre-
programed value i n the simulated program map. When any abnormality is detected in the injectorb), crankshaft position
(CKP) sensor andtor camshaft position (CMP) 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 tCM 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.
l-or 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 ECM 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 ECM 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 ECM detects the output voltage is 0 V, then the DTC 8-1 (fP
sensor circuit low voltage) will be displayed.
5v
MAP SENSOR TP SENSOR
VOLTAGE
0 OUTPUT VOLTAGE
5v 5v
ECT SENSOR IAT SENSOR
-
a
OUTPUT VOLTAGE OUTPUT VOLTAGE
-
- -
-
- If the HDS pocket tester is not available, DTC can
be read from the ECM memory by the MIL blink
pattern.
The number of MIL blinks is the equivalent the
MIL
main code of the DTC (the sub code cannot be

displayed by the MIL).
e The MIL has two types of blinks, a long blink and
short blink. The long blinking lasts for 1.3 sec-
onds, the short blinking lasts for 0.5 seconds. l
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).
e When the ECM stores more than one DTC, the
MIL will indicate them by blinking in the order l
from the lowest number to highestnumber.
!!dmxz&
When the ignition switch is turned ON and engine stop switch " 0 ",the MIL will stay on for a few sec-
onds, then go off. If the MIL does not come on, troubleshoot the MIL circuit (page 6-38).
P
The DTC is indicated i n two ways according to the failure status.
r In case the ECM detects the problem at present, the MIL will come on and the MIL will start to blink
as its DTC when the side stand is lowered. It is possible to readout the MIL blink pattern as the cur-
rent DTC.
In case the ECM 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
r The HDS can readout the DTC, freeze data, current data and other ECM condition.
How t o connect the HDS Pocket Tester
Turn the ignition switch to OFF.
Remove the side cover/pivot 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 " 0",check the DTC and freeze data.
NOTE:
r Freeze data indicates the engine conditions when
the first malfunction was detected.
ECM reset
The HDS can reset the ECM data including the DTC,
freeze data and some learning memory.
DTC READOUT
Start the engine and check the MIL.
MIL
r If the engine will not start, turn the starter motor
for more than 10 seconds and check that the MIL
blinks.
r When the ignition switch is turned ON, the MIL
will stay on for a few seconds, then go off.
If the MIL stays on or blinks, connect the HDS Pocket
Tester to the DLC (page 6-15).
Read the DTC, freeze data and follow the trouble-
nl
To read the DTC with the MIL blinking, refer to the

following procedure.
Reading DTC w i t h the MIL
Remove the side cover/pivot cover (page 3-5).

Remove the dummy connector and short DLC termi-
nals using the special tool.
TOOL:
SCS connector 070PZ-ZY30100
CONNECTION: Brown - Green
Turn the ignition switch to ON, read, note the MIL
blinks and refer to the troubleshooting index (page
6-18).
NOTE:
If the ECM has any DTC i n its memory, the MIL will
start blinking.
CLEARING DTC
Connect the HDS Pocket Tester t o the DLC (page 6-15).
Clear the DTC with the HDS while the engine is stopped.
To clear the DTC without HDS, refer to the following procedure.
How t o clear the DTC with SCS service connector
ve the slde covedplvot cover Cpage 3-51.
Turn the ignition switch to OFF.
Make sure the Remove the dummy connector and short the
-
engine stop switch
"L
,,A ,
,,
\ .
Brown and Green wire terminals of the DLC
TOOL:
SCS connector 070PZ-ZY30100
CONNECTION: Brown - Green
Turn the ignition switch to ON.
Remove the special tool wire from the DLC.
The MIL will light for approximately 5 seconds.
- - short the DLC terminals
While the MIL lights,
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.
CIRCUIT INSPECTION
INSPECTION AT ECM CONNECTOR
rial away from the ECM connector before discon-

necting it.
A faulty PGM-FI system is often related to poorly
connected or corroded connections. Check those
connemons b ~ h proceedmg.
e
0 In testing at ECM connector (wire harness side)
terminal, always use the test prove. Insert the
test prove into the connector terminal, then
attach the digital multimeter probe to the test
probe.
TOOL:
Test probe 07ZAJ-RDJA110
TEST HARNESS CONNECTION
Remove the left side coverlpivot cover (page 3-5).
Connect the battery cable.
Disconnect the ECM 33P connectors from the mod-
ule.
I
I
wire harness and the ECM. ECM TEST HARNESS

\
TOOL:
ECM test harness 33P 070MZ-MCA0100
TEST HARNESS TERMINAL LAYOUT
shown in this illustration. ECM 33P (BLACK) CONNECTOR

(ECM side of male terminal)
ECM 3 3 (LIGHT
~ GRAY) CONNECTOR
(ECM side of male terminal)
a5
for the ECM connector terminals as shown. TEST HARNESS PIN BOX
(A TERMINALS)
TEST HARNESS PIN BOX

(B TERMINALS)
FUEL SYS 'EM (PGM-FIJ
INDEX
--
DTC
(MIL blinks) Function Failure Symptom/Fail-safe function
1-1 (1) MAP sensor circuit low voltage (less than 0.2 V) Engine operates normally
r MAP sensor or its circuit malfunction
MAP sensor circuit high voltage (more than 3.9 V) Engine operates normally
r Loose or poor contact of the MAP sensor connec-
tor
r MAP sensor or its circuit malfunction
MAP sensor performance problem Engine operates normally
r Loose or poor connection of the MAP sensor vac-
uum nose
MAP sensor malfunction
ECT sensor circuit low voltage (less than 0.07 V) r Hard start at a low tempera-
r ECT sensor or its circuit malfunction ture
Fail-safe value: 90°C/1940F
Cooling fan turns on
ECT sensor circuit high voltage (more than 4.93 V) r Hard start at a low tempera-
r Loose or poor contact of the ECT sensor connec- ture
tor Fail-safe value: 90°C/1940F
0 ECT sensor or its circuit malfunction Cooling fan turns on
TP sensor circuit low voltage (less than 0.3 V) Poor engine acceleration
0 TP sensor or its circuit malfunction
TP sensor circuit high voltage (more than 4.93 V) Poor engine acceleration
r Loose or Door contact of the TP sensor connector Fail-safe value: 0"
0 TP senso; or its circuit malfunction
IAT sensor circuit low voltage (less than 0.07 V) Engine operates normally
r IAT sensor or its circuit malfunction Pre-program value: 25OCff7OF
IAT sensor circuit high.voltage (more than 4.93 V) Engine operates normally
a Loose or poor contact of ihe IAT sensor connec- Fail-safe value: 25OCI77OF
tor
IAT sensor or its circuit malfunction
VS sensor no signal Engine operates normally
r Loose or poor contact of the VS sensor connector
r VS sensor or its circuit malfunction
No. 1 injector circuit malfunction tngine does not start
a Loose or poor contact of the injector connector r Injectors, fuel pump and igni-
r Injector or its circuit malfunction tion shut down
No. 2 injector circuit malfunction Engine does not start
0 Loose or poor contact of the injector connector Iniectors, fuel pump and igni-
Injector or its circuit malfunction tion shut down
CMP sensor no sianal Engine does not start
Loose or poor contact of the CMP sensor connec- r Injectors, fuel pump and igni-
tor tion shut down
r CMP sensor or its circuit malfunction
CKP sensor no signal Engine does not start
r Loose or poor contact of the CKP sensor connec- 0 Injectors, fuel pump and igni-
tor tion shut down
r CKP sensor or its circuit malfunction
0 2 sensor malfunction Engine operates normally
r Loose or poor contact of the 0 2 sensor connector
0 2 sensor or its circuit malfunction
O z sensor heater circuit malfunction Engine operates normally
Loose or poor contact of the 0 2 sensor heater
commr
r O z sensor heater or its circuit malfunction
IACV circuit malfunction r Engine stalls, hard t o start,
Loose or poor contact of the IACV connector rough idling
r IACV or its circuit malfunction
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW
VOLTAGE]
1. MAP Sensor System Inspection
Turn the ignition switch ON and engine stop
".
Check the MAP sensor with the HDS pocket
Is about 0 V or below indicated7

YFS - GOTOSTEP2.
NO - Intermittent failure
0 Loose or poor contact on the MAP
SenSOrcOnnector
. . .
MAP 3P (BLACK)
m e o; 3P (Black) connec-
tor. (Wire side of female terminal)

s w i t c h " 0 ".
Measure the voltage at the wire harness side.
Connection: Yellowlred (+) - Greenlorange (4
Is the voltage within 4.75 - 5.25V7
I I
G10 YIR
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. MAP Sensor Input Line Inspection

. . .
Turn the I-n SW.&& OFF
Disconnect the ECM 33P connectors. ECM 33P (BLACK) CONNECTOR
(Wire side of female terminal)
Check for continuity at the Yellowlred wire
between the MAP sensor 3P (Black) connector
terminal and the ECM 33P (Black) connector.
Connection: A9 - Yellowlred
TOOL:
Test probe
Is there continuity?
I
YES - Replace the ECM with a known good
MAP SENSOR 3~ (BLACK)CONNECTOR
one, and recheck. (Wire side of female terminal)
NO - Open circuit in Yellowlred wire
4. MAP Sensor Output Line Short Circuit Inspec-
tion
?P
(Black) connector terminal of the wire harness MAP SENSOR 3P (BLACK) CONNECTOR
side and ground. (Wire side of female terminal)
Connection: Light greenlyellow - ground
I
SYS I EM (PGM-FI)
5. MAP Sensor lnspection
Heplace the MAP sensor with a known good one
(page 6-75).
Reset the ECM (page 6-15).
switch " C) ".
Check the MAP sensor with the HDS.
Is DTC 1-1 indcatefl
YES - Replace the tCM with a known good
one, and recheck
NO - Faulty original MAP sensor
DTC 1-2 (MAP SENSOR HIGH

VOLTAGE)
r Before starting the inspection, check for loose or
poor contact on the MAP sensor 3P (Black) con-
nector and recheck the D1C.
1. MAP Sensor System lnspection 1
-
I'urn the ignition switch ON and engine stop
switch " C) ".
m
YES - I'O STtP 2.

0 Loose or poor contact on the MAP
Sensor Connector
MAP Sensor System lnspection 2
Turn the ignition switch OFF.
Disconnect the MAP sensor 3P (Black) connec- (Wire side of female terminal)
tor.
Connect the MAP sensor terminals at the wire
harness side with a jumper wire.
Connection: Light greenlyellow - Greenlorange JUMPER
switch " 0 ".
tester.
Is about 0 V indicated?
YES - Faulty MAP sensor
3. MAP Sensor Input Voltage lnspection

Remove the jumper wire. MAP SENSOR 3P (BLACK) CONNECTOR
switch " 0 ".
Connection: Yellowlred (+) - Greenlorange (-)
Is the voltage within 4.75 - 5.25V?
YES - GO TO STEP 4.
NO - Open circuit in Greenlorange wire
r Open circuit in Yellow/red wire
4. MAP Sensor Output Line Open Circuit Inspec-
tion
3"W c S.
Check for continuity at the Light greenlyellow ECM 33P (LIGHT GRAY) CONNECTOR
wire between the MAP sensor 3P (Black) connec- (Wire side of female terminal)
tor terminal and the ECM 33P (Light gray) con-
nector.
Connection: B9 - Light greenlyellow
TOOL:
one, and recheck MAP SENSOR 3~ (BLACK) CONNECTOR
NO - Open circuit in Light greenlyellow wire
DTC 2-1 (MAP SENSOR)

a Before starting the inspection, check for loose or
nector and recheck the DTC.
1. MAP Sensor System lnspection
switch " 0 ".
Start the engine and check the MAP sensor with
the HDS pocket tester at idle speed.
Is the voltage within 1.6 - 1.8 V?
YES - Intermittent failure
NO - GO TO STEP 2.
2. Manifold Absolute Pressure Test
Check for connection and installation of the MAP
sensor vacuum hose.
Is the MAP sensor vacuum hose connection cor-
rect?
YES - GO TO STEP 3.
NO - Correct the hose installation
3. MAP Sensor System lnspection

Replace the MAP sensor with a known good one
(page 6-75).
switch " n ".
Start the engine and check the MAP sensor with
the HDS pocket tester at idle speed.
YES - Faulty original MAP sensor
NO - Replace the ECM with a known good
one, and recheck.
D1 C 7-1 (ECT SENSOR LOW
VOLTAGE)
1. tCT Sensor System lnspection
-
switch "0".
Check the ECI' sensor with the HDS pocket
m
NO - Intermittent f a i l m
YES - TO STFP 2.
2. E€T Sensor lnspection
Remove t k m g h middle cowt
Disconnect the ECT sensor 3P (Gray) connector.
Check the ECT sensor with the HDS pocket

tester.
NO - GO TO STEP 3.
YES - GOTOSTEP4.
3. ECT Sensor Resistance lnspection
Measure the resistance at the ECT sensor termi-

nals.
CONNECTION: Pinklwhite - Greenlorange
-
STANDARD: 2.32 2.59 kR (20°C/68"F)
Is the resistance within 2.32 - 2.59 kn?
YES - Replace the ECM with a new one, and
recheck.
No - Faulty ECT sensor.
I ECT SENSOR (Sensor side of male terminal)
4. ECT Sensor Short Circuit lnspection

Disconnect the ECM 33P connector from the
module (page 6-65). ECT SENSOR 3P (GRAY) CONNECTOR
Check for continuity between the ECT sensor 3P
(Gray) connector of the wire harness side and
ground.
CONNECTION: Pinklwhite Ground -
YES - Short circuit in P i n w h i t e wire.
NO - Replace the ECM with a new one, and
recheck.
DTC 7-2 (ECT SENSOR HIGH
VOLTAGE
poor contact on the ECT sensor 3P (Gray) con-
1. ECT Sensor System lnspection
Turn the ignitio-
switch "0".
tester.
NO - Intermittent failure.
a Loose or poor contact on the ECT
sensor 3P (Gray) connector.
YES - TOLSTFP 7
2. ECT Sensor lnspection
Remove the right middle cowl (page 3-11).
Turn the ignition switch OFF. WW
-iu-
/
Connect the ECT sensor terminals with a jumper
wire.
CONNECTION: Pinklwhite - Greenlorange
switch "0".
tester.
l -\- \
Is about 0 V indicated? ECT SENSOR 3P (GRAY) CONNECTOR
YES - Faulty ECT sensor. (Wire side of female terminal)
NO - GO TO STEP 3.
3. ECT Sensor Open Circuit lnspection
Disconnect the jumper wire. ECT SENSOR 3P ECM 33P (LIGHT
(GRAY) GRAY) CONNECTOR
Disconnect the ECM 33P connectors (page 6-65). CONNECTOR (Wire (Wire side of female
Check for continuity between the ECM connector side of female terminal)
and ECT sensor connector of the wire harness terminal) \
side.
CONNECTION: B13 - Pinklwhite
A18 - Greenlorange
TOOL:
Is there continuity7
recheck.
NO - Open circuit i n Pinklwhite wire.
a Open circuit in Greenlorange wire.
ECM 3 3 (BLACK)
~
CONNECTOR (Wire
side of female
terminal)
DTC 8-1 (TP SENSOR LOW VOLTAGEJ
poor contact on the TP sensor 3P (Blue) connec-
P
l . TP Sensor System lnspection
-
switch " ".
Check the TP sensor with the HDS pocket tester
when the throttle fully closed.

r Loose or poor contact on the TP sen-
SOrcOnnector
NO - 1'0STI-P 2.
2. TP Sensor Input Voltage lnspection
Remove the air cleaner housing (page 6-63). TP SENSOR 3P (BLUE) CONNECTOR
Disconnect the TP sensor 3P (Blue) connector. (Wire side of f m ~ a l eterminal)
switch " 0 ".
-
Connection: Yellowlred (+) Greenlorange (-1
-
NO - GO TO STEP 3.
3. TP Sensor Circuit lnspection

015 .
Check for continuity at the Yellowlred wire ECM 33P (BLACK) CONNECTOR
between the TP sensor 3P (Blue) connector ter- (Wire side of female terminal)
minal and the ECM 33P (Black) connector.
TOOL:
Test probe
one, and recheck
TP SENSOR 3~ (BLUE) CONNECTOR
NO - Open circuit in Yellowlred wire (Wire side of female terminal)
4. TP Sensor Output Line Open Circuit lnspection

Check for continuity at the Redlyellow wire
ECM 33P (LIGHT GRAY) CONNECTOR
between the TP sensor 3P (Blue) connector ter-
minal and the ECM 33P (Light gray) connector. , terminal)
(Wire side of female
-
Connection: B31 Redlyellow I \
TOOL:
Test probe
C@TO STEP 5
NO - Open circuit in Redlyellow wire

TP SENSOR 3~ (BLUE) CONNECTOR
5. TP Sensor Output Line Short Circuit lnspection
Disconnect the TP sensor 3P (Blue) connector.
TP SENSOR 3P (BLUE) CONNECTOR
Check for continuity between the TP sensor 3P (Wire side of female terminal)
connector terminal of the wire harness side and
ground.
-
Connection: Redlyellow Ground
YES - Short circuit i n Redlyellow wire
NO - GO TO STEP 6.
6. TP Sensor lnspection
Heplace the f P sensor with a known good one.
H i a g e 6-15).
Turn the i g n i t i 6 K G i t c h ON and engine stop
switch " 0 ".
Check the TP sensor with the HDS pocket tester.
1s DTC8-1- i
YtS - Replace the tCM with a known good
one, and recheck
80 - Faulty original TP sensor
DTC 8-2(TP SENSOR HIGH VOLTAGE1

1. TP Sensor System lnspection
switch " 0 ".
Check the TP sensor with the HDS pocket tester.
YES - GO TO STEP 2.
Loose or poor contact on the TP sen-
sotconnector
TP Sensor Resistance lnspection
Disconnect the TP sensor 3P (Blue) connector
I TP SENSOR (Sensor side of male terminal)
Measure the resistance at the TP sensor side.

Connection: Redlyellow - Greedorange
Is the resistance within 0.5 - 1.5 &R?
YES - GO TO STEP 3.
NO - Faulty TP sensor
~
3. TP Sensor Input Voltage lnspection
. ..
Measure the voltage at the wire harness side. .

-
Connection: Yellowlred (+) Greenlorange (-)
Is the voltage within 4.75 - 5.25 V7
one, and recheck
NO - Open circuit in Greentorange or wires
DTC 9-1 (IAT SENSOR LOW VOLTAGE)

1. IAT Sensor System lnspection
switch " 0 ".
Check the IAT sensor with the HDS pocket tester.
Is about 0 V indicated7
YES - GO TO STEP 2.
Loose or poor contact on the IAT
sensor connector
2. IAT Sensor lnspection
Upen and support the tuel tank (page 4-5).
Disconnect the IAT sensor 2P (Gray) connector.
switch " (I ".
Is about 0 V indicated7
YES - GO TO STEP 3.
NO - Faulty IAT sensor
3. IAT Sensor Output Line Short Circuit lnspection
(Gray) connector terminal of the wire harness

side and ground.
Connection: Graylblue - ground
YES - Short circuit in Graylblue wire

one, and recheck
/
IAT SENSOR 2P (GRAY) CONNECTOR
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)
poor contact on the IAT sensor connector and
recheck the DTC.

switch " 0 ".
YES - GO TO STFP 7
NO - Intermitlent failure
Loose or poor contact on the IAT
SenSOrcOnnector
2. IAT Sensor Inspection
Open and support the fuel tank (page 4-5). GrIBu JUMPER WIRE
Disconnect the IAT sensor 2P (Gray) connector.
Connect the IAT sensor terminals with a jumper
wire.
Connection: Graylblue - Greenlorange
switch " (-J ".
YES - Faulty IAT sensor IAT SENSOR i~ (GRAY) CONNECTOR
NO - GO TO STEP 3. (Wire side of female terminal)
3. IAT Sensor Output Line lnspection

Disconnect the ECM 33P connectors.
Check for continuity at the Graylblue and Green1
orange wire between the IAT sensor 2P (Gray) IAT SENSOR 2P ECM 33P (LIGHT
y) P-CTQR
tors. (Wire side of female CONNECTOR (Wire
CONNECTION: B29 - Graylblue terminal) side of female
A18 - Greenlorange l terminal)
TOOL:
one, and recheck.
NO - Open circuit in Graylblue wire
r Open circuit in Greenlorange wire
ECM 33P (BLACK) CONNECTOR

DTC 11-1 (VS SENSOR)
poor contact on the VS sensor 3P connector and
recheck the DTC.
1. VS Sensor System lnspection
Place the motorcycle on its center stand and rear
wheel off the ground.
Start the engine and operate the throttle grip.
Check the VS sensor with the HDS pocket tester.
Is the vehicle weed indicated normallv?
YES - GOTOSTEPZ.
NO - GO TO STEP 3.
2. Recheck the DTC
Reset the DTC (page 6-16).
Test ride the motorcycle.
Stop the engine.
switch "0".
Check the VS sensor with the HDS pocket tester.
Is the DTC 11-1 indicated?
YES - Replace the ECM with a new one and
recheck.
NO - Loose or poor contact on the ECM
connectors.
Intermittent failure.
3. Combination Meter lnspection
Does the combination meter operate normally?

NO - Inspect the combination meter (page
22-8).
4. VS Sensor Input Voltage lnspection

VS P-Ta
Disconnect the VS sensor 3P connector (page 22- (Wire side of female terminal)
9). \
switch "0".
Measure the voltage at the VS sensor connector
of the wire harness side.
CONNECTION: Black/brown(+) - Greenlblack
(-1
Does the battery voltage exist?
NO - Open or short circuit i n the Black/
brown wire.
r Open circuit i n the Greedblack wire. .
YES - GO TO STEP 5.
5. VS Sensor Pulse Line Open Circuit lnspection
Disconnect the ECM 33P connectors (page 6-65). (Wire side of female terminal)
Check for continuity between the ECM 33P (Light
green) connector and VS sensor 3P connector of
-
CONNECTION: B28 Pinklgreen
TOOL:
NO - Open circuit in Pinktgreen wire. VS SENSOR 3P CONNECTOR
YES - GO TO STEP 6.
6. VS Sensor Pulse Line Short Circuit lnspection
Disconnect combination meter connectors (page
22-7). VS SENSOR 3P CONNECTOR
Be sure to discon- (Wire side of female terminal)
Check for continuity between the VS sensor 3P
nett the 'On-
connector of the wire harness side and ground.
nector.
YES - Short circuit in the PinWgreen wire.
NO - VS sensor.
DTC 12-1
Before starting the inspection, check for loose or
poor contact o n the injector 2P (Gray) connector
and recheck the DTC.
DTC INJEC- POWER SIGNAL SIGNAL
TOR
- -
- INPUT LINE LINE AT ECM
12-1 N O . ~ Blacldwhite Pinldblue A17
Rear
13-1 No.2 Blacklwhite Pinklyellow A6
1. Injector System lnspection

switch "O", start the engine and check the injec-
tor with the HDS pocket tester.
Loose or poor contact on the injector
2P (Gray) connector.
YES - TO STEP 2.
m u t Voltage Inspection

NO - Open or short circuit i n Blackiwhite -
wire. -*
INJECTOR 2P (GRAY) CONNECTOR

YES - GOTOSTEPS. (Wire side of female terminal)
3. Injector Resistance lnspection
terminals.
STANDARD: 10.0 - 14.0 Cl (20°C/68"F)
Is the resistance within 10.0 - 14.0 L? (20°C/
NO - Faulty injector.
YES - GO TO STEP 4.
INJECTOR (lnjector side of male terminal)

4. Injector Signal Line Open Circuit lnspection
FRONT INJECTOR 2P
Disconnect the ECM 33P (Black) connector (page (GRAY) CONNECTOR
6-65). (Wire side of female
terminal)
Check for continuity between the ECM 33P
(Black) connector and injector 2P (Gray) connec-
tor of the wire harness side.
TOOL:
NO - Open circuit in SIGNAL line wire. '
YES - GOTOSTEP5.
H~AH mzr
CONNECTOR (GRAY) CONNECTOR
(Wire side of (Wire side of female
female terminal) terminal)
5. lnjector Signal Line Short Circuit lnspection

l-
UIS- b
connect the (Gray) connector and ground.

ECM CONNECTION: SIGNAL LINE -Ground
tor.
YES - Short circuit i n the SIGNAL line wire.
recheck.
A
\
INJECTOR 2P (GRAY) CONNECTOR
DTC 13-1 (No.2 FRONT INJECTOR)

See page 6-30
DTC 18-1 (CMP SENSOR)
poor contact o n the CMP sensor 2P (Black) con-
1. CMP Sensor Peak Voltage Inspection
Turn the ignition switch OkF.
Disconnect the CMP sensor 2P (Black) connector. CMP SENSOR 2P (BLACK)CONNECTOR
(Sensor side of male terminal)
switch " 0".
Crank the engine with the starter motor, and
measure the CMP sensor peak voltage at the
CMP sensor 2P (Black) connector.
Connection: Gray (4- Whitelyellow (-1
n
lmrie diagnosis tester (model 625) or

Peak voltage adaptor 07HGJ-0020100
with commerciallv available digital multimeter
(impedance 10 MRIDCV minimum)
Is the vottage more than 0.7 V (20 "U68 O F ) ?
G
YFS - TO STFP 7
NO - Faulty CMP sensor
2. CMP Sensor Circuit Inspection
Turn the ignition switch OH-.
Disconnect the ECM 33P connectors. CMP SENSOR ECM 33P (BLACK)
2P (BLACK) CONNECTOR (Wire side
Check for continuity at the Grey and Whitelyel- CONNECTOR of female terminal)
low wire between the CMP sensor 2P (Black)
connector terminals and the ECM 33P connec-
tors terminals.
(Wire side of
female terminal) I
Connection: B33 - Gray
1.
a -
TOOL:
I
YES - Short circuit in the Gray wire

NO - Open circuit i n the Whitelyellow wire
0 Open circuit i n the Gray wire

DTC 19-1 (CKP SENSOR)
poor contact on the CKP sensor connector and
recheck the DTC.
1. CKP Sensor Peak Voltage lnspection
. ..
Turn the I m o n switch OFF. I
Disconnect the CKP sensor 2P (Natural) connec- I CKP SENSOR 2P (NATURAL) CONNtCTOH
tor.
I (Sensor side of male terminal)
\
switch " (I ".

measure the CKP sensor peak voltage at the CKP
ensor 2P {Natural).mnne&r,
Connection: Yellow (+) - Whitelyellow (-)
TOOLS:
Peak voltage adaptor ' 07HGJ-0020100
with commercially available digital multimeter I 1
Is the voltage more than 0.7 V (20 "Cl68 "F)?
YES - GOTOSTEP2.
NO - Faulty CKP sensor
2. CKP Sensor Circuit lnspection
Disconnect the ECM 33P connectors. CKPSENSOR2P ECM33P(BLACK)
(NATURAL) CONNECTOR (Wire side
t bY W a dW W v d - n f f p m n l p b
low wire between the CKP sensor 2P (Natural)
connector terminals and the ECM connector ter-
minals.
(Wire side of
female terminal) I
Connection: B22 -Yellow
A32 - White/yellow
TOOL:
Test probe
YES - Short circuit in the Yellow wire
NO - Open circuit in the Yellow wire
r Open circuit in the White/yellow wire
ECM 3 3 (LIGHTGRAY)
~ CONNECTOR
DTC 21-1 (02 SENSOR)
8 Before starting the inspection, check for loose or
poor contact on the 0 2 sensor 4P (Black) connec-
tor and recheck the DTC.
1. 0 2 Sensor System lnspection
Start the engine and warm up the engine up to
coolant temperature is 80 "C (176 OF).
Test-ride the motorcycle.
Check the 0 2 sensor with the HDS pocket tester.
Is the DTC21-1 indicated?
NO - Check the fuel pressure (page 6-58).
8 If the system is correct, GO TO STEP
YES - GO TO STFP 7
2. 0 2 Sensor Open Circuit lnspection
Remove the right side covertpivot cover (page 3- 0 2SENSOR 4P ECM 33P (BLACK)
5). (BLACK) CONNECTOR (Wire side
CONNECTOR of female terminal)
Disconnect the ECM 33P connector and
sor 4P (Black) connector.
Check for continuity between the ECM 33P con-
0 2 sen-
(Wire side of
female terminal) I
nector of the wire harness side and 0 2 sensor 4P
(Black) connector of the wire harness side.
CONNECTION: A18 - Greenlorange
B20 - Whitelorange
TOOL:
Test probe
Are there continuities?
NO - Open circuit in Greenlorange wire.

r Open circuit in Whitetorange wire.
ECM 3 3 (LIGHT
~ GRAY)CONNECTOR
3. Oz Sensor Short Circuit lnspection
Disconnect the ECM 33P (Light gray) connector. ECM 33P (LIGHT GRAY) CONNECTOR
Check the continuity between the ECM 33P
(Light gray) connector of the wire harness side
and around.
CONNECTION: B20 - Ground
TOOL:
Test probe
YES - Short circuit i n Whitelorange wire
NO - GO TO STEP 4.
4. 0 2 Sensor lnspection
Replace the 0 2 sensor with a new one.
Reset the ECM.
coolant temperature is 80 "C (176 "F).
Test-ride the motorcycle.
Check the 0 2 sensor with the HDS pocket tester.
Is the DTC21-I indicated7
NO - Faulty original 0 2 sensor.
YES - Check the fuel supply system.
DTC 23-1 (02 SENSOR HEATER)

tor and recheck the DTC.
1. 0 2 Sensor Heater System lnspection
Start the engine and check the 0 2 sensor heater
with the HDS pocket tester.
Is the DTC 23- 1 indicated7
YES - GOTOSTEP2.
NO - 0 Loose or poor contact on the 0 2 sen-
sor 4P (Black) connector.
Intermittent failure.
2. 0 2 Sensor Heater Resistance lnspection
urn me lgnltlon s w ~ t c
kemove the right side ",p
:;viot cover (page 3-
5).
Disconnect the 0 2 sensor 4P (Black) connector.
Measure the resistance at the 0 2 sensor 4P
(Black) connector terminals of the sensor side.
CONNECTION: White - White
-
Is the resistance within 10 40 R (20°C/680F)?
YES - GOTOSTEPS.
NO - Faultyozsensor.
3. 0 2 Sensor Heater Power Input Line lnspection

. ..
fi
nector of the wire harness side and ground.
CONNECTION: Black/white (+) - Ground (-)
d . -
Does me oarrery voltage e m f
-.
YES - GO TO STEP 4.
NO - Open circuit in the BlacWwhite wire.
\
SENSOR 4P (BLACK) CONNECTOR
0 2
4. 0 2 Sensor Heater O ~ e circuit
n lns~ection
1.....+g
Disconnect the ECM 33P (Gray) connector.
y:..+-
Check for continuity between the ECM 33P
(Gray) connector and 0 2 sensor 4P (Black) con-
nector of the wire harness side. Q
............* ..........
1:
......
L 2.
i...... l..... i...........
. l.. .......
CONNECTION: Blacklgreen- B2 1. . 7... .:.. ...7 .
l':.. , : . : . I .:
TOOL:
YES - GO TO STEP 5. 0; SENSOR 4P (BLACK) CONNECTOR B2
NO - Open circuit i n BlacWgreen wire. (Wire side of female terminal)
5. 0 2 Sensor Heater Short circuit lnspection
Check for continuity between the 0 2 sensor 4P

(Black) connector of the wire harness side and
ground.
CONNECTION: Blacklgreen - Ground
YES - Short circuit in BlacWgreen wire.
NO - Replace the ECM with a new one,
recheck.
and
0 2
/
SENSOR 4P (BLACK)
CONNECTOR (Wire side of
female terminal) ..
DTC 29-1 (IACV)

poor contact on the IACV 4P (White) connector
and recheck the DTC.
1. Recheck DTC
Start the engine and recheck the DTC.
Loose or poor contact o n the IACV 4P
(White) connector.
YES - GO TO STEP 2.
2. IACV Short Circuit Inspection

Disconnect the IACV 4P (White) connector.
Check for continuities between the IACV 4P
I I
Bluelorange - Ground I I
Bu/G Bu/O Bu/BI Bu/R
Bluelblack - Ground
Bluelred - Ground
YES - Short circuit i n Bluelgreen or Blue/
orange wire.
m Short circuit in Bluelblack or Bluelred
wire.
-
@!!@
A _
-
_ _
-
.
-
-
NO - GO TO STEP 3.
3. IACV Circuit Continuity Inspection
Disconnect the €CM 33P (Black) connector.
ECM 33P (BLACK) CONNECTOR
Check for continuities between the ECM 33P (Wire side of female terminal)
(Black) connector terminals and the IACV 4P
(White) connector terminals.
-
CONNECTION: A19 Bluelgreen
A27 - Bluelorange
A16 - Bluelblack
A29 - Bluelred l
Test probe
Are there continuities? lACV4P (WHITE)CONNECTOR
YES - GO TO STEP 4.
NO - Open or loose contact in Bluelgreen
or Bluelorange wlre.
Open or loose contact in Blue/black
or Bludred wue.
4. IACV Resistance Inspection
Measure the resistance at the IACV 4P (White)
connector terminals. IACV 4P (WHITE)CONNECTOR
(IACV side of male terminal)
-
CONNECTION: Bluelgreen Bluelred
-
Bluelblack Bluelorange
STANDARD: 99 - 121 R (25"C/77"F)
Is the resistance within 99 - 121 a (25*C/77OF)?
recheck.
NO - Faulty IACV.
FUEL SYSTEM (PGM-F!)
MIL TROUBLESHOOTING
MIL 1 BLINK (MAP SENSOR)
nector and recheck the MIL blinking.
1. MAP Sensor Output Voltage inspection
Connect the ECM test harness to ECM connec-
tors (page 6-17). (A TERMINALS)
switch " Q ".
Measure the voltage at the test harness termi-
nals.
Connection: B9 (+) - A18 (-)
0 Loose or poor contact on the ECM
connectors TEST HARNESS PIN BOX
(B TERMINALS)
NO - About 5 V I
GO TO STEP 2
About 0 V
GO TO STEP 3.
2. MAP Sensor Output Line lnspection
Turn- t
. .. QFF.
Disconnect the MAP sensor 3P (Black) connec- MAP SENSOR 3P (BLACK) CONNECTOR
switch " Q ".
Measure the voltage at the wlre harness slde.
Connection: Light greenlyellow (+) - Green1
orange (-)
Is the voltage within 2.7 - 3,IV?
YES - Faulty MAP sensor
NO - Open circuit in Light greentorange
wire
r Open circuit i n Greentorange wire
3. MAP Sensor Input Voltage lnspection
L.
MAP SENSOR 3P (BLACK) CONNECTOR
Connection: Yellowlred (+) - Ground (-) (Wire side of female terminal)
YES - GOTOSTEP4.
NO - GO TO STEP 5.
4. MAP Sensor Output Line Short Circuit Inspec-
tion
(Black) connector terminal of the wire harness MAP SENSOR 3P (BLACK) CONNECTOR
side and ground. (Wire side of female terminal)
Connection: Light greenlyellow - Ground
YES - Short circuit in Light greenlyellow wire
NO - Faulty MAP sensor
5. MAP Sensor Input Line Inspection

nrr
Disconnect the ECM 33P connectors. TEST HARNESS PIN BOX

(A TERMINALS)
Check for continuity at the Yellowlred wire
between the MAP sensor 3P (Black) connector
terminal and the test harness terminal.
one, and recheck.
NO - Open circuit in Yellowlred wire
MAP SENSOR 3~ (BLACK) CONNECTOR
MIL 2 BLINKS (MAP SENSOR)

1. MAP Sensor Hose lnspection
Turn the ignition switch OFF
Check for connection and installation of the MAP
sensor vacuum hose.
Is the MAP sensor hose connection correct7
YES - GO TO STEP 2.
NO - Correct the hose connection or installa-
tion
2. MAP Sensor Output Voltage lnspection
tors (page 6-17). TEST HARNESS PIN BOX

(A TERMINALS)
switch " 0 ".
\
nals.
Connection: B9 (+) -A18 (-)
YES - GO TO STEP 3.
NO - Faulty MAP sensor TEST HARNESSPIN BOX
(B TERMINALS)
3. MAP Sensor Output Voltage lnspection At Idle

lb.
Measure the voltage at the test harness termi- (ATERMINALS)
nals. \
Connection: B9 (+) -A18 (-)
Standard: 2.7 V maximum
Is the voltage less than 2.7 V?
one, and recheck
NO - Faulty MAP sensor c3
TEST HARNESSPIN BOX
(B TERMINALS)
MIL 7 BLINKS (ECT SENSOR)

poor contact on the ECT sensor 3P (Gray) con-
1. ECT Sensor Output voltage Inspection
F.
Connect the test harness to ECM 33P connectors TEST HARNESS PIN BOX
(page 6-17). (A TERMINALS)
\
Turn the ignition

- switch ON and engine
- stop I \
switch "0".
nals.
I l0
l
CONNECTION: B13 (+) - A18 (-1

STANDARD: 2.7 - 3.1 V (20°C/680F)
Is the voltage within 2.7 - 3.1 V? I \
YES - Loose or poor contact on the ECM TEST HARNESSPIN BOX
connectors. (B TERMINALS)
Intermittent failure. I
NO - GO TO STEP 2.
2. ECT Sensor Input Voltage lnspection
Disconnect the ECT sensor 3P (Gray) connector. TEST HARNESS PIN BOX
(B TERMINALS)
switch "0".
Measure the voltage at the test harness terminal
and ground.
CONNECTION: B13 (+) - ground (-)
recheck.
YES - GO TO STEP 3.
3. ECT Sensor Resistance lnspection

r
Measure the resistance at the ECT sensor termi-

nals.
CONNECTION: Pinklwhite - Greentorange
STANDARD: 2.32 - 2.59 kR (20°C/68"F)
Is the resistance within 2.32 - 2.59 ko?
No - Faulty ECT sensor.
YES - GO TO STEP 4.
( ECT SENSOR (Sensor side of male terminal)
4. ECT Sensor Open Circuit lnspection
terminals and ECT sensor connector of the wire TEST HARNESS PIN BOX (B TERMINALS)
harness side.
-
CONNECTION: B13 Pinklwhite
CONNECTION: A18 - Greentorange
NO - Open circuit in Pinklwhite wire.
Open circuit in Greenlorange wire.
YES - GO TO STEP 5.
l BOX (A TERMINALS)
ECTSENSOR 3~ (GRAY) CONNECTOR

5. ECT Sensor Short Circuit lnspection
ECT SENSOR 3P (GRAY) CONNECTOR

nectors disconnected.
Check for continuity between the ECT sensor
connector of the wire harness side and ground.
YES - Short circuit in Pinktwhite wire.
recheck.
MIL 8 BLINKS (TP SENSOR)
poor contact on the TP sensor 3P (Blue) connec-
tor and recheck the MIL blinking.
1. TP Sensor Output Voltage
. .. FF.
D r n e s s to ECM connec- TEST HARNESS PIN *OX
Measure the TP sensor output voltage at the test

harness terminals.
Standard: *0.4 - 0.6 V (throttle fully closed)
*4.3 - 4.9 V (throttle fully opened)
NOTE: TEST HARNESS PIN BOX

a A voltage marked * refers to the value of the (B TERMINALS)
ECM output voltage (STEP 3) when the volt- -
age reading shows 5 V.
When the ECM output voltage reading shows
other than 5 V, derive the TP sensor output
voltage at the test harness as follows:
In the case of the ECM output voltage is 4.75
v:
0.4 X 4.7515.0 = 0.38 V
0.6 X 4.7515.0 = 0.57 V
Thus, the solution is "0.38 - 0.57 V" with the
throttle fully closed.
Replace 0.4 and 0.6 with 4.3 and 4.9 respec-
tively, in the above equations to determine
the throttle fully opened range.
Is there standard voltage7
r Loose or poor contact on the ECM
connectors
NO - GO TO STEP 2.
2. TP Sensor Input Voltage Inspection
nrr
Disconnect the TP sensor 3P (Blue) connector. TP SENSOR 3P (BLUE)CONNECTOR

switch " 0".
Connection: Yellowlred (+) - Greenlorange (-)
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. TP Sensor Output Voltage Inspection
Turn the ignition switch OFF. Tr-T I I a nv
Connect the tCM test harness to tL34 connec-
\
switch " 0 ".
Measure the voltage at the test harness fermi-
nals.
Connection: A9 (+) -A18 (-1
Is the voltage within 4.75 - 5.25V7 I Q ~ O
YES - Open circuit i n Redlyellow wire
r Open circuit in Greenlorange wire
NO - Redace the ECM with a known nood I
4. TP Sensor Output Line lnspection
-rn
(Blue) connector terminal of the wire harness TEST HARNESS PIN BOX
side and the test harness terminal. (B TERMINALS)
Connection: Redlyellow - B31
l
YES - GO TO STEP 5.
NO - Open circuit in Redlyellow wire

5. TP Sensor Output Line Short Circuit lnspection
TP SENSOR 3P (BLUE)CONNECTOR
Check for continuity between the TP sensor 3P (Wire side of female terminal)
(Blue) connector terminal of the wire harness
side and ground.
YES - Short circuit in Redlyellow wire
NO - Faulty TP sensor
SYS [EM (PGM-FIJ
MIL 9 BLINKS (IAT SENSOR)
poor contact on the IAT sensor 2P (Natural) con-
1. IAT Sensor Output Voltage lnspection
Connect the ECM test harness t o ECM connec- TEST HARNESS PIN BOX
tors (page 6-17). (B TERMINALS)
switch " 0".
nals.
-
Standard: 2.7 3.1 V (20°C/680F)
-
Is the voltage within 2.7 3.1 V?
YES - Intermittent failure TEST HARNESS PIN BOX
r Loose or poor contact on the ECM (A TERMINALS)
connectors
NO - TO STFP 7
2. IAT Sensor Input Voltage lnspection
lurn the ignition switch OFF.
Disconnect the IAT sensor 2P (Natural) connec- IAT (NATURAL)
switch " 0".
Measure the voltage at the wire harness side of
IAT sensor connector.
Connection: Graylblue (+) - Greenlorange (-)
Is the voltage within 4.75 - 5.25V7
YES - GO TO STEP 3.
NO - GO TO STEP 4.
3. IAT Sensor Resistance lnspection

Disconnect the IAT sensor 2P (Natural) connec- IAT SENSOR
tor.
Measure the resistance at the IAT sensor termi-
nals (at 20 - 30°C/68 - 86°F).
Standard: 1- 4 kR (20 - 3O0C168- 86°F)
Is the resistance within 1 - 4 kR?
NO - Faulty IAT sensor.
YES - GO TO STEP 4.
4. IAT Sensor Open Circuit lnspection
Check for continuity at the Graylblue and Green/ TEST HARNESS PIN BOX
orange wires between the IAT sensor 2P (Natu- (B TERMINALS)
ral) connector terminal and the test harness ter-
minals.
Connection: Graylblue - B29
Greenlorange - A18
Are there continuity?
YES - GO TO STEP 5. G/O @I- TEST>ARNESS PIN BOX
NO - Open circuit i n Graylblue wire (A TERMINALS)
r Open circuit in Greenlorange wire IAT SENSOR 2P (NATURAL) CONNECTOR
5. IAT Sensor Output Line Short Circuit lnspection
(Natural) connector terminal of the wire harness

side and ground.
Connection: Graylblue - ground
YES - Short circuit in Graylblue wire

one, and recheck.
-
/ -
IAT SENSOR 2P (NATURAL) CONNECTOR
MIL 11 BLINKS (VS SENSOR)

poor contact on the VS sensor 3P connector and
recheck the MIL blinking.
1. Combination Meter lnspection
NO - Inspect the combination meter (page

22-8).
2. VS Sensor Pulse Inspection At ECM
Turn the ignition switch OW.
Connect the test harness t o the ECM 33P connec- (B TERMINALS)
tors (page 6-17). \
Place the motorcycle on its center stand and rear
wheel off the ground.
Measure the voltage between the test harness
terminal and ground with the ignition switch ON
and engine stop switch "0"while slowly turning
the rear wheel by hand.
-
B28 (+) ground (-)
STANDARD: Repeat 0 t o 5 V
- I
Is the voltage at the standard value?
I
YES - TO STEP 3.
NO - TO STFP 4.
Install the removed parts i n the reverse order of

removal. MIL
Reset the self diagnosis memory data from the
ECM (page 6-16).
coolant temperature is 80 "C (176 O F ) .
Test ride the motorcycle.
Stop the engine.
Retrieve the self diagnosis memory data (page 6-
15) and check that the MIL blinks.
Is the M11 blink I I times7
NO - Loose or poor contact on the ECM
connector.
termittent failure.
YES - Replace the ECM with a new one and
recheck.
4. VS Sensor Input Voltage Inspection
VS SENSOR 3P CONNECTOR
Disconnect the VS sensor 3P connector (page 22- (Wire side of female terminal)
10).
switch "0".
Measure the voltage at the VS sensor connector
of the wire harness side.
CONNECTION: Black/brown (+) - Greenlblack (-1
NO - Open or short circuit i n Black/brown

wire.
r Open circuit in Greenlblack wire.
Faulty combination meter.
YtS - TO STEP 5.
FUEL SYSf EM (PGM-FI)
5. VS Sensor Pulse Line Open Circuit lnspection
Turn the ignition switch O h .
Check for continuity between the test harness (B TERMINALS)
terminal and VS sensor connector of the wire 1
harness side.
CONNECTION: B28 - Pinklgreen
Is there cantinuitv7 I I
VS SENSOR 3P CONNECTOR
6. VS Sensor Pulse Line Short Circuit lnspection

Disconnect the test harness and ECM 33P con-
nectors disconnected. VS SENSOR 3P CONNECTOR
Disconnect combination meter 20P connector (Wire side of female terminal)
(page 22-7).
Check for contintrity between the vehicle speed PIG
sensor connector and ground. .
-
CONNECTION: Pinklgreen Ground
NO - Faulty VS sensor.
MIL 12 BLINKS (No.1 REAR INJECTOR)

e Before starting the inspection, check for loose or
poor contact on the injector 2P (Gray) connector
and recheck the MIL blinking.
Rear
Front
1. Injector Input Voltage lnspection
--Remove the air cleaner housing (page 6-63).
I
Disconnect the injector 2P (Gray) connector.
switch "0".
Measure the voltage between the injector 2P
ground.
-
CONNECTION: Blacklwhite (+) Ground (-)
-.
cc
NO - Open or short circuit in Blacklwhite INJECTOR 2P (GRAY)
wire. CONNECTOR (Wire side
YES - GO TO STEP 2. of female terminal)
2. lnjector Resistance lnspection
Turn the ignition switch OW.
Measure the resistance of the injector connector
terminals.
STANDARD: 10.0 - 14.0 R (20°C/6S0F)
Is the resistance within 10.0 - 14.0 R (20°C/
68"F)?
NO - Faulty injector.
YES - TO STFP 3.
I INJECTOR (Injector side of male terminal)
3. Injector Signal Line Open Circuit lnspection

Connect the test harness t o the €CM 33P (Black)
connector (page 6-17). FRONT INJECTOR 2P (GRAY) CONNECTOR
Check for continuity between the test harness
terminal and injector 2P (Gray) connector of the
TFST Pm M X
b.
-
CONNECTION: SIGNAL LlNE SIGNAL LlNE
(A TERMINALS) \
NO - Open circuit i n SIGNAL line wire.
YES - GOTOSTEPI.
REAR INJECTOR 2~ (GRAY)CONNECTOR

4. Injector Signal Line Short Circuit lnspection

Disconnect the test harness and ECM 33P (Black)
connectors disconnected.
Check for continuity between the injector 2P
ground.
CONNECTION: SIGNAL LlNE Ground-
YES - Short circuit in SIGNAL line wire.
recheck. ...,..,
INJECTOR 2~ (GRAY)CONNECTOR
MIL 13 BLINKS (No.2 FRONT (Wire side of female terminal)
INJECTOR)
See page 6-48.
MIL 18 BLINKS (CMP SENSOR)
poor contact on the CMP sensor connector and
recheck the MIL blinking.
1. CMP Sensor Peak Voltage lnspection at ECM
nectors (page 6-17).

switch " (I ".
measure the CMP sensor peak voltage at the test
harness terminals.
\ TEST HARNESS PIN BOX
(B TERMINALS)
J

TOOLS:
Peak voltage adaptor 07HGJ-0020100 U PEAK VOLTAGE ADAPTOR
with commercially available digital multimeter I
Is the voltage more than 0.7 V (20 "U68 "F)?
Loose or poor contact on the ECM
connectors
NO - GO TO STEP 2.
2. CMP Sensor Peak Voltage lnspection
Hemove the air cleaner houslng (page 6-63).
Disconnect the CMP sensor 2P (Black) connector. (Sensor side of male terminal)
switch " (I ".
measure the CMP sensor peak voltage at the

CMP sensor 2P (Black) connector.
Connection: Gray (+) - Whitelyellow (-)
Is the voltage more than 0.7 V (20 "W68 "F)?
YES - Open or short circuit in the Whitelyel- \
low wire or Gray wire PEAK VOLTAGE ADAPTOR
I
NO - Faulty CMP sensor
FUEL SYSTEM (PGM-F!)
MIL 19 BLINKS (CKP SENSOR]
0 Before starting the inspection, check for loose or
poor contact on the CKP sensor connector and
recheck the M L blinking.
1. CKP Sensor Peak Voltage Inspection at ECM
Turn the ignition switch Otp.
Connect the ECM test harness to the ECM con-
I TEST HARNESS PIN BOX (A TERMINALS)
switch " fi ".
l \ TEST HARNESS PIN BOX
(B TERMINALS)

measure the CKP sensor peak voltage at the test
harness terminals.
TOOLS:
PEAK VOLTAGE ADAPTOR
Peak voltage a d a ~ t o r 07HGJ-0020100 I l
with commercially available digital multimeter
Is the voltage more than 0.7 V (20 "C/68OF)?
YtS - Intermittent failure
r Loose or poor contact on the t C M
NO - TO ST?P 7
2. MP Sensor Peak Voltage lnspection
Turn the
. .. OFF.
Remove the right middle cowl (page 3-1 1). CKP SENSOR 2P (NATURAL) CONNECTOR
Disconnect the CKP sensor 2P (Natural) connec- (Sensor side of male terminal)
tor.
switch " 0 ".
measure the CKP sensor peak voltage at the CKP
sensor 2P (Natural) connector.
Connection: Yellow (+) - Whitelyellow (-)
Is the voltage more than 0.7 V (20 "U68"F)?
YES - Open or short circuit in the Yellow,
Whitelvellow wire
~- ~ -
NO - Faulty CKP sensor

MIL 21 BLINKS ( 0 2 SENSOR)
1. 0 2 Sensor System lnspection
ll-

coolant temperature is 80 "C (176 "F), then let it
idle.
Test-ride the motorcycle and recheck the MIL
blinking.
Is the MIL 21 blinks?
- Check the fuel \
/
NO pressure (page 6-58), if
the system is correct. TEST HARNESS PIN BOX
YES - GO TO STEP 2. (B TERMINALS)
TEST HARNESS PIN BOX (A TERMINALS)
2. Oz Sensor Open Circuit lnspection

N I -
I .
TEST HARNESS PIN BOX (B TERMINALS)
Disconnect the 0 sensor 4P (Black) connector.
I
2
Check for continuity between the test harness TEST HARNESS PIN BOX
terminals and the 0 2 sensor connector terminals (B TERMINALS)
cte.
CONNECTION: B20 - Whitelorange
A18 - Greenlorange
Is there continuities?
NO - Open circuit i n the White/orange
(Black) wire.
Open circuit in the Greenlorange o2SENSOR 4~ (BLACK)CONNECTOR
(Gray) wire. (Wire side of female terminal)
YES - GO TO STEP 3.
3. 0 2 Sensor Short Circuit lnspection
terminal and ground. (B TERMINALS)
IS mere conmmryc
,.
.. -, I \ 1
NO - GO TO STEP 4.
4. 0 2 Sensor lnspection
Replace the 0 2 sensor with a known good one.
Reset the ECM (page 6-15).
Turn the ignition switch ON.
Warm the engine until the coolant temperature
is 80 "C (176 "F), the let it idle.
Test-ride the motorcycle and recheck the MIL
blinking.
Is the MIL 21 blinks?
NO
YES
- Fautty original 0 2 sensor.
- Check the fuel supply system.
S- TEST HARNESS PIN BOX
(B TERMINALS)
MIL 23 BLINKS ( 0 2 SENSOR HEATER)

1. 0 2 Sensor Heater Resistance lnspection
Turn the lgnltlon sw~tchUtt.
Remove the right side coverlpivot cover (page 3-
5).
Disconnect the 0 2 sensor 4P (Black) connector.
Measure the resistance at the 0 2 sensor connec-
tor terminals.
CONNECTION: White -White
Is the resistance within 10 - 40 0 (2O0C/68"F)7
NO - Faulty 0 2 sensor.
YES - GO TO STEP 2.
2. Oz Sensor Heater Circuit lnspection

T u r n the ignition switch ON.
Measure the voltage at the 0 2 sensor 4P (Black)
connector of wire harness side.
-
CONNECTION: Blacklwhite (+) Ground (-1
... ......" ......"..," ,,,,,,,,..
Does the battery voltage exit?
BIN
NO - Open or short circuit in the BlacWwhite L J
wire.
YES - GO TO STEP 3.
\
0 2SENSOR 4P (BLACK)
- CONNECTOR (Wire side of
female terminal)
3. 0 2 Sensor Heater Open circuit lnspection 2
nrr
Connect the ECM test harness to the ECM con- (B TERMINALS)
\
Check for continuity between the test harness
terminal and 0 2 sensor 4P (Black) connector of
the wire harness side.
CONNECTION: B2 - Black/green
NO
YES
- Open circuit in Blacklgreen wire.
- GOTOSTEP4.
I \
0 2 SENSOR 4P (BLACK) CONNECTOR
4. Oz Sensor Heater Short circuit lnspection
terminal and ground.

Connection: B2 - Ground
YES - Short circuit in the Blacklgreen wire.
recheck.

(B TERMINALS)
MlL 29 BLINKS (IACV)

m Before starting the inspection, check for loose or
poor contact on the IACV 4P (White) connector
1. IACV Short Circuit lnspection
Remove the air cleaner housing (page 6-63).
Disconnect the IACV 4P (White) connector.
Check for continuities between the IACV 4P
(White) connector and ground.
Connection: Blue/green - Ground
Blue/orange - Ground
Blue/black - Ground
Blue/red - Ground
YES - Short circuit in Bluelblack or Blue/
orange wire.
Short circuit in Bluelred or Blue1
green wire.
NO - GO TO STEP 2.
t L SYSTEM (PGM-F4
2. IACV Circuit Continuity Inspection
Connect the ECM test harness to ECM connec-
tors (page 6-17). I TEST HARNESS PIN BOX (A TERMINALS)
Check for continuities between the test harness
and the IACV 4P (White) connector.
Connection: A16 - Bluelgreen
A27 - Bluelorange
A29 - Bluelblack
A19 - Bluelred
Are there continuities7
YES - GO TO STEP 3. I
NO - Open or loose contact i n Bluelblack IACV $ (WHITE) CONNECTOR

or Bluetorange wire. (Wire side of female terminal)
a Open or loose contact in Bluelred or '
tlluetgreen wrre.
3. IACV Resistance lnspection
Disconnect the test harness from the tCM.
Connect the IACV 4P (White) connector. TEST HARNESS PIN BOX
Measure the resistance at the test harness termi- (A TERMINALS)
nals.
CONNECTION: A19 - A29
A I 6 A27 -
-
STANDARD: 99 121 R (25OCI77"F)
Is the resistance within 99 - 121 l2 (25%/77OF)?
-
recheck.
NO - Faulty IACV.
MIL CIRCUIT INSPECTION

tf m e engine can be started but t h r M t L does not
come on when the ignition switch ON and engine
stop switch "O",check the follows:
Check for operation of the combination meter func-
tion properly.
- If they do not function, check the combination
meter power input line (page 22-8).
- If they function properly, check the follows:
Ground the A20 terminal of the wire harness side

connector with a jumper wire. ECM 33P (BLACK) CONNECTOR
TOOL:
Turn the ignition switch ON and engine stop switch
"o",the MIL should come on.
- If the MIL come on, replace the ECM.
- If the MIL does not come on, check for open cir-
cult In m e Whltelblue wlre between m e combma-
tion meter and ECM.
If the wire is OK, replace the combination meter.
FUEL LINE I N S P E C m N
FUEL PRESSURE RELIEVINGIQUICK
CONNECT FITTING REMOVAL
Before disconnecting fuel feed hose, relieve pres-
sure from the system as following procedures.
1. Turn the ignition switch OFF.
Open and support the fuel tank (page 4-5).
2. Release the wire from the clamp and disconnect

the fuel pump 3P (Black) connector.
3. Start the engine, and let it idle until the engine
stalls.
4. Turn the ignition switch OFF.
5. Disconnect the battery cable (page 19-6).
8. Hold the connector with one hand and squeeze

the retainer tabs with the other hand release
them from the locking pawls.
S Prevent the remaining fuel i n the fuel feed hose

from following out with a shop towel.
S Be careful not t o damage the hose, pipe or other
parts.
Do not use tools.
S If the connector does not move, keep the retainer
tabs pressed down, and alternately pull and push
the connector until it comes of easily. LOCKING PAWL
FUEL SYSTEM (PGM-F11
cover the disconnected connector and pipe end

with the plastic bags.
QUICK CONNECT FITTING

INSTALLATION
a Always replace the retainer of the quick connect
fitting when the fuel feed hose is disconnected.
r If any damage or cut-out on the rubber cap,
replace i t with a new one.
a Do not bent or twist fuel feedhose
I
align the retainer locking pawls with the connec-

tor grooves.
Then press the quick connect fitting onto the
pipe until both retainer pawls lock with a
UP, L T V U
If i t is hard t o connect, put a small amount of

engine oil on the pipe end.
3. Make sure the connection is secure and that the
pawls are firmly locked into place; check visually RUBBER CAP RETAINER
and by pulling the connector.
4. Set the rubber cap between the retainer tab and
stopper on pipe.
CONNECTOR STOPPER
5. C c and
clamp the wire.
6. Set the fuel hose to the clamp.

7. Connect the positive cable and negative cable to
the battery.
Donotstart the 8. Turn the ignition switch ON and engine stop

engine, switch "0".
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
--P
connect fitting (page 6-55). PRESSURE GAUGE
\
Attach the fuel pressure gauge, attachment and
manifold. HOSE ATTACHMENT C
TOOLS:
L
I
I GREEN RETAINER
Fuel pressure gauge 07406-0040004
Pressure gauge manifold 07ZAJ-S5A0110
Pressure gauge hose attachment C 07ZAJ-S7C0100
Pressure gauge hose attachment A 07ZAJ-S5A0120
Fuel attachment joint 07ZAJ-S7C0200
Temporally connect the positive cable and negative
cable to the battery.
Start the engine and let it idle.
Read the fuel pressure.
STANDARD: 343 kPa (3.5 kgf/cm4, 50 psQ
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:
- Fuel line leaking
- Pinched or clogged fuel feed hose or fuel tank
BROWN
RETAINER
I
GREEN RETAINER
breather hose
- Fuel pump (page 6-59)
- Clogged fuel filter (Assembly of the fuel
HOSE ATTACHMENT A
pump:page 6-60)
around the attach- ing the engine and let it idle until it stalls.
QUICK CONNECT FITTING
ment to soak up
Remove the fuel pressure gauge, attachment and
any spilled fuel.
manifold from the fuel pump.
FUEL FLOW INSPECTION

Relieve the fuel pressure and disconnect the quick
connect fitting (page 6-55).
Remove the saddle bag body (page 3-7).
Remove the fuel pump relay (page 6-61).
Remove the relay connector cover from the rear
fender B.
the wire harness side using a jumper wire. RELAY CONNECTOR (BLUE)
BlNV (Wire side of female terminal)
..
' * / HOSE ATTACHMENT ,
TOOLS:
Pressure gauge hose attachment 07ZAJ-S7C0100
_Wipespilledgaso- Place the end of the hose into an approved gasoline

line out of the con- container.
tainer.
Temporally connect the positive cable and negative
cable to the battery.
Turn the ignition switch ON, engine stop switch "0"
for 10 seconds.
Measure the amount of fuel flow.
Amount of fuel flow:
200 cm3 (6.8 US oz, 7.0' Imp oz) minimum
110 seconds at 12 V
If the fuel flow is less than specified, inspect the fol-
lowing:
- Fuel pump (page 6-59).
- Clogged fuel filter (Assembly of the fuel
pump:page 6-60)
Connect the quick connect fitting (page 6-56).
FUEL PUMP
INSPECTION
and confirm that the fuel pump operates for a few
seconds.
If the fuel pump does not operate, inspect as fol-
lows:
Release the wire from the clamp.
Disconnect the fuel pump 3P (Black) connector.
I
and measure the voltage between the terminals.
CONNECTION: Brown (+) - Green (-)
There should be battery voltage for a few seconds.
If there is battery voltage, replace the fuel pump.
If there is no battery voltage, inspect the following:
- Open circuit in Brown wire andlor Green wire
- Fuse 20A
- Fuel pump relay (page 6-61)
- Fllignition relay (page 6-74)
- Engine stop switch (page 22-16)
- Bank angle sensor (page 6-73)
- ECM (page 6-75)
REMOVAL
0 Do not disassemble the tuel pump assembly.
Afrer disconnect Remove the fuel tank (page 6-62).
the 3P Remove the following:
(Black)connector.
b e sure to relieve - Nuts
the fuelpressure by - Fuel pump assembly
starting the engine - Packing
and let it idle until it
stalls.
Check the fuel pump for damage.

Replace the fuel pump if it necessary.
Clean the fuel strainer screen.
INSTALLATION
When instalfing the fuel pump assembly, put the
mating surface of the fuel tank on a level surface.
Clean the mating surface of the fuel tank and fuel
~nstde.
Always replace
packing with a new
one.
Be careful not to mage the pipe end when
pinch the dirt and
debris between the
fuel pump and
packing.
Tighten the fuel pump mounting nuts in the

sequence.
Install the fuel tank (page 6-62).
FUEL PUMP RELAY

INSPECTION
fender B
from the cover.
Disconnect the fuel pump relay from the relay con-

nector.
CONNECTION: A - B
-
Connect the 12V battery to the following fuel pump

relay connector terminals.
CONNECTION: C - D
There should be continuity only when the 12V bat-
tery is connected.
If there is no continuity when the 12V battery is con-
nected, redace the fuel pump relay.
FUEL TANK
Disconnect the fuel tank drain hose! and breather
hose.
Relieve the fuel pressure and remove the quick con-
remove the wire from the clamp.
- Bolt
- Nut
- Clamp
- Fuel tank assembly
While installing the fuel tank, route the wire harness
properly (page 1-35).
Route the fuel tank drain hose and breather hose
properly do not to be kinked or bound.
Set the fuel hose to the clamp.
AIR CLEANER HOUSING

Be careful not to damage the hoses and pipe
GG
ix
Remove the air cleaner element (page 4-7).
Disconnect the MAP sensor 3P (Black) connector.
Disconnect the MAP sensor vacuum hose.
Disconnect the IAT sensor 2P (Natural) connector
Disconnect the breather hoses from the air cleaner

housing.
Remove the PAIR solenoid valve from the air
cleaner housing.
Remove the air cleaner housing.
Replace the 0-rings if necessary.
Install the air cleaner housing.

Install the air funnel and tighten the screws
securely.
Install the PAIR solenoid valve from the air cleaner

housing.
Connect the breather hose to the air cleaner hous-
ing.
THROTTLE BODY
FEMOVAL
m o m
Bending or twisting the control cables will impair
smooth operation and could cause the cables to
stick or bind, resulting in loss of vehicle control.
S Before disconnecting the fuel hose, release the
fuel pressure (page 6-55).
Relleve the fuel pressure and disconnect the quick
Loosen the throttle cable lock nuts and adjusting
throttle drum and cable bracket.

Remove the throttle body from the insulators.
Disconnect the rear injector (#l) 2P (Gray) connec-

tor.
Remove the sub-harness from the clamp of the
throttle body.
- Front injector (#2) 2P (Gray)

- TP sensor 3P (Blue)
- IACV 4P (White)
I NOTICE I
a The throttle body is factory pre-set. Do not disas-
semble in a way other than shown in this man-
ual. I
Do not snap the throttle valve from fun open to
fuU dose after the throttle cable has been
removed. It may cause incorrect idle operation.
Do not damage the throttle body. It may cause
morrect throttle valve.
Do not loosen or tighten the white painted bolts,
nuts and screws of the throttle body. Loosening
or tightening them can cause throttle and idle
valve synchronization failure.
-Check rhe insula- Check the insulator band angle.

tors wirh its marked
Apply oil to the insulator inside surfaces for ease of
side facing to thror-
the throttle body installation.
rle body.
- Front injector (#2) 2P (Gray)

- TP sensor 3P (Blue)
- IACV 4P (White)
Install the sub-harness to the clamp of the throttle

body securely.
Connect the rear injector ( # l ) 2P (Gray) connector.
lnstati the throttle body to the insulator and tighten

the screws securely.
Check the insulator band distance is 12 f 1 m m (0.5

+0.04 in).
cable bracket.
Tighten the lock nuts securely.
Adjust the throttle grip free play (page 4-61.
Install the air cleaner housing (page 6-63).
REMOVAL
Before disconnecting fuel feed hose, relieve pres-

sure from the system (page 6-55).
The fuel feed hose IS made of the resin Be care-
ful not to bend or fold the fuel feed hose.
Helleve the fuel pressure and disconnect the quick
Remove the throttle body (page 6-65).
Clean around the injector base and fuel hose quick
connector with compressed air before removing the
injector, and be sure that no debris is allowed to
enter into the throttle body.
Disconnect the vacuum hoses from the joints of the

throttle body.
p - P -
Remove the bolts and fuel feed hose from the injec-
tor.
Remove the injector from the throttle body.

Remove the 0-ring and seal ring.
INSTALLATION
Install the injector into the throttle body, being care-

ful not to damage the seal ring.
ful not to damage the 0-ring.

Install and tighten the bolts to the specified torque.
TORQUE: 5.4 N-m (0.6 kgf-m, 4.0 Ibf-ft)
-Adjust the injector installation angle as shown.

FUEL FEED HOSE
Install the throttle body (page 6-65).
- REMOVALIINSTALLATION
Remove the screw and MAP sensor from the air
cleaner housing.
Installation is i n the reverse order of removal.
I INJECTOR
IAT SENSOR
Open and support the fuel tank (page 4-51.
Disconnect the IAT sensor 2P (Natural) connector.
Remove the screws and IAT sensor from the air
cleaner housing.
Instanation is in the reverse order of removai.
.-
t L SYSTEM IPGM-F11
- -.
ECT SENSOR
Drain the coolant (page 7-6).
Replace the ECT Disconnect the ECT sensor 3P (Gray) connector
sensor while the from the sensor.
engine is cold. Remove the ECT sensor and sealing washer.
Always replace a Install the new sealing washer and ECT sensor.
sealing washer with Tighten the ECT sensor t o the specified torque.
a new one.
TORQUE: 24.5 N-m (2.5 kgf-m,18 Ibf-ft)
Connect the ECT sensor 3P (Gray) connector.
Install the right middle cowl (page 3-11).
Fill the cooling system with recommended coolant
(page 7-6).
CMP SENSOR
Remove the throttle body (page 6-65). 2P (BLACK)CONNECTOR
Disconnect the CMP sensor 2P (Black) connector.
Apply oil to the new 0-ring and install it onto the
CMP sensor.
Install the CMP sensor into the rear cylinder head.
Install and tighten the bolt securely.
cormemor.
lnstall the right middle cowl (page 3-11).
BANK ANGLE SENSOR

INSPECTION
Place the motorcycle on its center stand on a level
surface.
UL
Disconnect the bank angle sensor 3P (Black) con-
nector and connect the inspection test harness.
TOOL:
Inspectiontest harness 07GMJ-ML80100
Turn the ignition switch ON and engine stop switch
"0".
Measure the voltage between the test harness ter-
minals.
CONNECT

Do not disconnect Remove the two screws and bank angle sensor.
the bank angle sen-
Connect the bank angle sensor 3P (Black) connector.
sor connector dur-
ing inspection
test, theignition shown, and ignition switch ON and engine stop 60" BANK ANGLE POSITION
switch " F P , then switch "0" then bank angle sensor is normal if the
turn the ignition engine stop relay clicks and power supply is closed.
'witch "ON"and
Incline the bank angle sensor approximately 60" to
the left or right with keep the ignition switch ON and
engine stop switch "0" then bank angle sensor is
normal if the engine stop relay clicks and power
supply is open. NORMAL
POSITION
60" (approximately)
Disconnect the bank angle sensor 3P (Black) con-

nector.
Remove the screws and bank angle sensor.
Route the sensor Instan the bank angle sensor with its "UP" mark fac-
wire correctly (page ing up.
1-35). Tighten the mounting screws securely.
Connect the bank angle sensor 3P (Black) connector.
FVIGNITION REI .AY

lNSPECTlON
Remove the s a d w ~ a body
g @age 3-7).
fender B
from the cover.

nector.
Connect the ohmmeter to the relay connector termi-

nals.
Connect the 12V battery to the following relay con-

nector terminals.
CONNECTION: C - D
tery is connected.
nected, replace the relay.
ECM (ENGINE CONTROL MODULE)

ECM POWERIGROUND LINE
INSPECTION
Engine does not start (MIL no blinks)
1. ECM Power Input Voltage Inspection
r Before starting the inspection, check for loose
or poor contact on the ECM 33P connectors
aw
tors (page 6-17). TEST HARNESS PIN BOX
(A TERMINALS)
switch "0".
Measure the voltage between the test harness
terminal and ground.
CONNECTION: A5 (+) - Ground (-)
YES - GO TO STEP 2.
NO - GO TO STEP 3.
2. ECM Ground Line lnspection
rr
terminal and ground. (A TERMINALS)
CONNECTION: A23 - Ground
Is there continuities?
recheck.
NO - Open circuit i n the Green wire.
1 \ _L
......
TEST HARNESS PIN BOX """
(B TERMINALS)
3. Flllgnition Relay lnspection 1

r Ie.
I
Disconnect the Fllignition relay from the relay RELAY CONNECTOR (BROWN)
connector (page 6-74). (Wire side of female terminal)
switch "0".
Measure the voltage at the Fllignition relay con-
nector of the wire harness side.
CONNECTION: Black (+) - Red/orange (-)
NO - Faulty subfuse.
Open circuit in the Black or Red1
orange wire.
L RIO
YES - GOTOSTEPA
4. Engine Stop Relay lnspection 2
Jump the Fllignition relay connector terminals. RELAY CONNECTOR (BROWN)
FCTION: Bbcklwhite - Redlwhite (Wire side of female terminal)
Turn the ignition switch ON and engine stop WIRE

switch "0".
Measure the voltage at the ECM 33P connector
wire harness side terminal and ground.
CONNECTION: A5 (+l - Ground (-1
YES - Inspect the FI ignition relay (page 6-
74).
m Inspect the bank angle sensor (page
6-73).
NO - Open circuit i n Blacktwhite wire
between the encline stop relay and the
ECM.
TEST'HARNESS PIN BOX

(A TERMINALS)
FUEL SYSTM(PGM-FIJ
BEMOVAL/INSTALLATION

Release the tabs and remove the ECM.
ENGINE IDLE SZFH5

IDLE SPEED INSPECTION
m
r Inspect the idle speed after all other engine main-
tenance items have been performed and are
within specifications.
r Before checking the idle speed, inspect following
items.
- No DTC and MIL blkking.
-Spark plug condition (page 4-7).
- Air cleaner condition (page 4-7).
The engine must be warm for accurate speed
inspection.
r This system eliminates the need for manual idle
speed adjustment from the previous designs.
Start the engine and warm it up to coolant tempera-
ture is 80 "C (176 "F).
Start the engine and let it idle. Check the idle speed.
ENGINE IDLE SPEED: 1,200 k 100 min" (rpm)
If the idle speed is out of the specification, check the
following:
Throttle operation and throttle grip free play
(page 4-6).
s Intake air leak or engine top-end problem (page
9-5).
lACV operation (page 6-77).
IACV (Idle Air Control Valve)

IACV INSPECTION
nn
operated by the step motor. When the ignition
switch is turned ON, the IACV operates for a few
seconds.
Check the step motor operating (beep) sound with
the ignition switch turned ON.
NOT E:
The lACV operation can be checked visually as fol-
lowing:
S Remove the IACV from the throttle body with its
4P (White) connector in place, then turn the igni-
tion switch ON.
REMOVALANSTALLATION
r Do not remove the IACV cover unless it is neces-
sary to replace it with a new one.
r If the lACV cover is removed be careful so that
Install a new 0-ring to the IACV cover groove
securely.
lnstall the IACV and tighten the screws to the speci-

fied torque.
TORQUE: 3.4 N-m (0.3 kgf-m, 2.5 Ibf-ftl
SECONDARY AIR SUPPLY SYSTEM

SYSTEM INSPECTION
Start the enaine and warm i t up to coolant tempera-
ture is 80 "C (176 "F).
Stop the engine.
Open and support the fuel tank (page 4-51.
D~sconnecttne alr supply noses trom the air cleaner
housing.
Check that the secondary air intake port is clean and
free of carbon deposits.
Check the pulse secondary air injection (PAIR) check
valve if the port is carbon fouled (page 6-81).
Start the engine and open the throttle snghtly to be
certain that air is sucked in through the air supply PAlR SOLENOID VALVE
hose.
If the air is not drawn in, check the air supply hoses
for clogs and the PAlR solenoid valve (page 6-80).
AIR SUPPLY HOSES
PAlR SOLENOID VALVE

INSPFCTION
01 1 I
SOLENOID VALVE
Check air flow from input side to output side hose.
Air should flow out.
Connect the 12V battery to the solenoid valve side
2P connector terminals.
CONNECTION: Blacklwhite (+) - Orangelblack (4
Air should not flow when the battery is connected.
OUT - OUT
IN
Measure the resistance between the connector ter-

minals. SOLENOID VALVE
STANDARD: 23 - 27 R (20°C/68"F)
If it is out of the standard, replace the PAlR solenoid
valve.

Disconnect the air suction hoses from the solenoid
valve.
Disconnect the solenoid valve 2P (Black) connector.
Remove the solenoid valve from the air cleaner
housing.
PAlR CHECK VALVE INSPECTION

INSPECTION
Remove the cylinder head cover protector (page 9-
6).
Disconnect the air suction hose from the PAlR check
r
Remove the bolts and PAlR check valve cover.
Remove the reed valve from the cylinder head

cover.
Check the reed for damage or fatigue. Replaceif

necessary.
Replace the PAIR check reed valve if the rubber seat
is cracked, deteriorated or damaged, or if there is
clearance between the reed and seat.
have the following means.

- FF: Front
- RR: Rear
lnstall the PAIR check reed valve cover with its hose
connect direction aligning the direction mark on the
cylinder head cover.
Install and tighten the bolts securely.
Connect the air suction hose to the PAIR check reed
valve cover securely.
Install the air cleaner housing (page 6-63).
Install the cylinder head cover protector (page 9-33).
0 2 SENSOR
REMOVAL
Handle the 0 2 sensor with care.
Do not get grease, oil or other materials in the 0 2
sensor air hole.
0 Do not use an impact wrench while removing or
installing the 0 2 sensor.
Be careful not to damage the sensor wire.
Do not serv~ceme
sensor while it is
0 2
Remove the 0 2 sensor using the special tool.
hot.
TOOL:
0 2 sensor wrench
I NOTICE (
0 Be careful not to damage the sensor wire.
0 Do not use an impact wrench while removing
installing the 0 2 sensor
INSTALLATION
Install the 0 2 sensor and tighten it securely.
TOOL:
02 sensor wrench 07LAA-PT50101
Install the exhaust system (page 3-17).
7. COOLING SYSTEM
SYSTEM FLOW PATTERN .........................7-2 THERMOSTAT HOUSING.......................... 7-9
SERVICE INFORMATION ...........................7-3 RADIATOR/COOLING FAN...................... 7-10
T L H TIN ................................. 7-14
SYSTEM TESTING ......................................7-5 WATER PUMP ..........................................7-15
COOLANT REPLACEMENT ........................7-6 RADIATOR RESERVE TANK..... ...............7-18
MOSTAT ............................................
7-8
RADIATOR RESERVE TANK
WATER PUMP
LOOLING SYSTEM
SERVICE INFORMATION
GENERAL
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.
Radiator coolant is toxic. Keep it away from eyes, mouth and skin.
* If any coolant gets in your eyes, rinse them with water and consult a physician immediately.
a If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
0 If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.
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.
r Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
0 All cooling system service can be done with the engine in the frame.
a Avoid spilling coolant on painted surfaces.
0 After servicing the system, check for leaks with a cooling system tester.
SPEClFlCATlONS
ITEM SPECIFICATIONS
1 . 8 8 s (1.99 US qt, 1.65 Imp qt)
Reserve tank 0.4 liter(0.42 US qt, 0.35 Imp qt)
Radiator cap relief pressure 108 - 137 kPa (1.1 - 1.4 kgf/cm2, 16 - 20 psi)
Thermostat Begin to open 80 - 84 "C (176 - 183 "F)
Fully open 95 "C (203 "F)
Valve lift 8 m m (0.3 in) minimum at 95 "C (203 "F)
Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion
protection inhibitors
Standard coolant concentration 1:l mixture with distilled water
TORQUE VALUES
Water pump cover bolt CT bolt
Thermostat housing cover bolt
COOLING SYSTEM
ROUBLESHOOTING
Engine temperature too high
Faulty temperature indicator
Thermostat stuck closed
Faulty radiator cap
insufficient coolant
Passages blocked in radiator, hoses or water jacket
Air in system
Faulty cooling fan motor
Faulty water pump
Engine temperature too low
Thermostat stuck open
Faulty fan motor switch
Coolantleaks
Faulty water pump mechanical seal
Deteriorated 0-rings
Faulty radiator cap
Damaged or deteriorated cylinder head gasket
a Loose hose connection or clamp
Damaged or deteriorated hoses
LOOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
Remove the right middle cowl @age 3-11).
Remove the radiator cap.
the con.l
. Rnta h y b
ter.
STANDARD COOLANT CONCENTRATION:
1:l (distilled water and the recommended
Look for contamination and replace the coolant if

necessary.
COO1 ANT GRAVll Y CHART

COOLING SYSTEM
R A D l A T O R l S Y S T E M PRESSURE
INSPECTION
Remove the radiator cap (page 7-5).
Wet the sealing surfaces of the cap, then install the
cap onto the tester.
the radiator cap if i t 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)
Pressurize the radiator, engine and hoses using the

tester, and check for leaks.
txcessive pressure can damage the coolmg system

components. Do not exceed 737 kPa (7.4 kgf/cm2, 20
psi).
Repair or replace components if the system will not
Remove the tester and install the radiator cap.

Install the right middle cowl (page 3-11).
COOLANT REPLACEMENT
PREPARATION
I NOTICE 1
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 speci-
fied in the maintenance schedule.
I
ommended antifreeze.
ANTIFREEZE
RECOMMENDED ANTIFREEZE: SOLUTION
High quality ethylene glycol antifreeze containing
,'
(ETHYLENE
RECOMMENDED MIXTURE: GLYCOL BASE
1:l (distilled water and the recommended SOLUTION) OR DISTILLED
antifreeze)
EOOLING SYSTEM
~ - - - -
REPLACEMENT/AIR BLEEDING
NOTE:
When filling the system or reserve tank with cool-
ant, or checking the coolant level, hold the motorcy-
cle in an upright position.
Remove the radiator cap.
Drain the coolant from the system by removing the

crankcase drain bolt and sealing washer.
Reinstall the drain bolt with a new sealing washer.

Drain the coolant from the system by removing the
drain bolt and sealing washer.
Reinstall the drain bott wifn a newseating washer.
Remove the bolts and drain the reserve coolant.

Empty the coolant and rinse the inside of the
reserve tank with water.
instan and tighten the bolts securely.
Fill the reserve tank to the upper level line and
install the tank cap.
Fill the system with the recommended coolant
through the filler opening up to the filler neck.
Bleed air from the system as follows:
1. Shift the transmission into neutral.
Start the engine and let i t idle for 2 - 3 minutes.
2. Snap the throttle three to four times to bleed air
from the system.
3. Stop the engine and add coolant up to the filler
neck.
4. Install the radiator cap.
Install the right middle cowl (page 3-1 1).
FRMOSTAT
REMOVAL
Drain the coolant from the system (page 7-7).
Place a shop towel under the thermostat housing.
Loosen the band screw and disconnect the radiator
upper water hose.
Remove the thermostat.
E
TH R M D S T A T l N S P E C T l O N -
room temperature.
LOOLING SYSTEM
I
gloves andade- element for 5 minutes. THERMOMETER

quateeyeprotec- Suspend the thermostat in the heated water to
tion. check its operation.
Keep flammable
THERMOSTAT BEGINS TO OPEN:
80 - 84 'C (176 - 183 'F)
heating element.
Do not let the ther- VALVE LIFT:
mostat or ther- 8 mm (0.3 in) minimum a t 95 'C (203 'F)
mometer touch the
Replace the thermostat if the valve opens at a tem-
pan' Or you perature other than those specified.
false readings.
INSTALLATION
stat housing slot.
Install and tighten the bolt securely.

Install the thermostat housing to the cover and
tighten the bolts to the specified torque.
TORQUE: 9.8 N-m (1.0 kgf-m, 7 Ibf-ft)
Connect the radiator upper water hose and tighten
the band screw securely.
Fill and bleed the cooling system (page 7-7).
THERMOSTAT HOUSING
Remove the thermostat (page 7-8).
hoses.
Loosen the band screw and disconnect the water
hose.
Remove the thermostat housing assembly.
Route the hoses Install the thermostat housing assembly in the
and wires properly reverse order of removal.
(page 7-35).
RADIATOR/COOLING FAN
REMOVAL
Be careful nor to Drain the coolant from the system (page 7-71.
damage the radiator Remove the middle cowl (page 3-1 1).
fins while sewicing Remove the inner lower cowl (page 3-14).
the radiator and fan Remove the radiator under cover (page 3-14).
motor.
Remove the tabs on the radiator from the grooves
on the front cylinder head cover protector.
Remove the bolts.

lower water hose.
Remove the grommet on the radiator from the tab
on the frame.
the shroud.
Remove the bolts and fan motor assembly.
Remove the nut and cooling fan.
Hemove the nuts and fan motor from the shroud.

COOLING SYSTEM
ASSEMBLY
RADIATOR
FAN MOTOR
Install the fan motor on the shroud in the direction

as shown.
Install and tighten the bolts to the specified torque.

Install the cooling fan onto the motor shaft, aligning
the flat surfaces.
Instan and tighten the nut securely.
tighten the bolts to the specified torque.
--Route the wire Connect the fan motor 2P (Black) connector.

properly (page 1-
35).
COOLING SYSTEM
tab of the frame.

Connect the radiator lower water hose to the radia-
tor.
Tighten the band screw securely.
" , . . U . a , .
lnsra~lane r lgnren m e Bolrs securely.
Connect the radiator upper water hose to the radia-
tor.
- . . .
Instan the grooves on the front cylinder head cover
protector to the tabs on the radiator.
Install the middle cowl (page 3-1 1).
Install the inner lower cowl (page 3-14).
FAN CONTRO-

fender B.
Connect the 12V battery to the following fuel pump
relay connector terminals.
CONNECTION: C - D
tery is connected.
nected, replace the fan control relay.
WATER PUMP
MECHANICAL SEAL INSPECTION
!F
If there is leakage, the water pump mechanical seal
is defective and the water pump should be replaced.
COOLING SYSTEM
REMOVAL
Loosen the band screw and disconnect the follow-
ing hose:
- radiator lower water
- water hose (to thermostat case).
- oil cooler hoses
Remove the bolts, sealing washer and water pump

cover.
hose (to front cylinder).

Remove the 0-ring from the water pump groove.
Remove the water pump and 0-ring

LOOLING SYSTEM
INSTALLATION
Coat a new 0-ring with oil and install it onto the
stepped section of the water pump.
Install the water pump while aligning its groove
with the projection of the oil pump shaft.
Connect the water hose (to front cylinder).

Install a new 0-ring into the groove in the water
pump groove.
Align the bolt holes in the pump and crankcase, and

install the water pump cover with the bolts and a
new sealing washer.
Tighten the bolts in a crisscross pattern in several
steps.
TORQUE: 13 N.m (1.3 kgfem, 9 Ibfsft)
lowing hoses and tighten the band

m
COOLING SYSTEM
RADIATOR RESERVE TANK
Remove the middle cowl (page 3-1 1).

Disconnect the siphon hose and overflow hose from
the reserve tank and drain the reserve coolant.
Remove the bolt and reserve tank.
Route the hoses Installation is in the reverse order of removal.
properly @age 7-
35).
8. ENGINE REMOVALIINSTALLATION
COMPONENTS ...........................8-2 ENGINE REMOVAL ....................................

ENGINE REMOVALIINSTALLATION
SYSTEM COMPONENTS
39 N-m(4.0kgf-m,
29 Ibfeft)
ERVICE INFORMATION
GENERAL
a A hoist or equivalent is required to support the motorcycle when removing and installing the engine.
a A floor jack or other adjustable support is required to support and maneuver the engine.
a When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified
sequence. If you make a mistake with the tightening torque or sequence, loosen all mounting fasteners, then tighten
them again to the specified torque in the correct sequence.
I NOTICE I
Uo not support the engine using the engine oil filter or it win be damaged
When removinglinstalling the engine, tape the frame around the engine beforehand for frame protection.
I he following components require engine removal for servicing.
- Cylinder head (page 9-14)
- Cylinderlpiston (page 10-4)
- Crankshaft (page 13-111
- Transmission (Including gearshift drumlshift fork: page 13-19)
- Output gear case (page 13-27)
- Oil pump (page 5-6)
The following components can be serviced with the engine i n the frame.
- Camshaft (page 9-8)
- Throttle body (page 6-65)
- Water pump (page 7-15]
- Clutchlgearshift linkage (page 11-6)
- Alternatorlstarter clutch (page 12-41
- Electric starter (page 21-6)
SPECIFICATIONS
ITEM I SPECIFICATIONS I
Engine dry weight 65.2 kg (144 Ibs)
Engine oil capacity at disassembly 3.2 liters (3.38 US qt, 2.82 Imp qt)
Coolant capacity (radiator and engine) 1.88 liters (1.99 US qt, 1.65 Imp qt)
tngine hanger bolt (Front low; A) 39 N-m (4.0 kgfam, 29 Ibf-ftl

tngine hanger cross plate bolt 27 N m (2.8 kgfam, 20 1bf.f-t)
tngine hanger cross plate nut 27 N-m (2.8 kgfvm, 20 Ibf.ft)
tngine hanger bolt (Rear up; C) 39 Nsm (4.0 kgfam, 29 lbf.ft) Apply engine oil to the threads and
flange surface
tngine hanger bolt (Rear low; D) 39 N.m (4.0 kgfem, 29 IbfW Apply engine oil to the threads and
flange surface
Starter motor cable terminal nut 10 N.m (1.0 kgfsm, 7 Ibf-ftf
ENGINE REMOVAL
Drain the engine oil (page 4-12).
Drain the coolant from the cooling system (page 7-7).
Remove the following:
- Both side covers (page 3-5)
- Fuel tank (page 6-62)
- Spark plug caps (page 4-7)
- Left crankcase rear cover (page 3-15)
- Exhaust system (page 3-17)
- Radiator (page 7-10)
Disconnect the CMP sensor 2P (Black) connector.
, 3-..
2P (BLACK) CONNECTOR
- Neutralloil pressure switch 2P (Black)
- VS sensor 3P
- Side stand 3P (Green)
3P CONNECTOR 3P (GREEN) CONNECTOR

Disconnect the alternator 3P (Natural) connector.

NOTE:
Wrap the intake manifold port with a shop towel or
cover them with a piece of tape to prevent any for-
eign material from dropping into the engine.
Loosen the band screws and disconnect the water
hoses (to thermostat case).
Remove the pinch bolt and gear shift arm.
Disconnect the air supply hoses from the PAIR

check valve covers.
Remove the clutch cable holder bolt and disconnect
the clutch cable end from the clutch lifter arm.
Remove the rubber cap and starter motor terminal
nut.
Disconnect the starter motor cable.
Remove the bolt and disconnect the ground cable.
must be continu- the engine.

ally adjusted to
Remove the bolts, nut and engine hanger cross
relieve stress for
plate.
bolt removal.
Remove the engine hanger nut, bolt and collars

(front, low; A).
Remove the rear engine hanger nut, washer, bolt

and collar (rear, low; D).
nui,
and collar (rear, up; C).
OUTPUT SHAFT
I BOOT UNIVERSAL JOINT
ENGINE INSTALLATION
m
0 All the engine mounting bolts and nuts loosely
install, t h e n g h t e n the bolts and nuts to the
specified torque in the specified sequence.
r Be sure to tighten an engine mounting fasteners
to the specified torque in the specified sequence.
If you make a mistake with the tightening torque
or sequence, loosen all mounting fasteners, then
tighten them again to the specified torque in the
correct sequence.
0 Route the wires, hoses and cables properly (page
1-35).
During engine Using a floor jack or other adjustable support, care-
installation, hold the fully place the engine into the frame and maneuver
engine securely and it into place.
be careful not to
damage the frame
and engine.
ENGINE REMOVAL/INSTALLATION
mountingpoints to the output shaft splines. Engage the output shaft

with the universal joint.
Temporarily install the all engine mounting fasten-

ers and collar.
Apply engine oil to the nut threads and flange sur-
faces.
Tighten the engine hanger nut (rear, up; C) to the
specified torque.
Apply engine oil to the nut threads and flange sur-

faces.
Tighten the engine hanger nut (rear, low; D) to the
specified torque.
TORQUE: 39 N.m (4.0 kgf-m, 29 Ibf-ft)
Tighten the engine hanger nut (front, low; A) to the

specified torque.
ENGINE REMOVALfINSTALLATION
Tighten the front engine hanger plate bolts and nuts
to the specified torque.
Connect the starter motor cable and tighten the ter-

minal nut to the specified torque.
Connect the ground cable and tighten the bolt
securely.
Connect the clutch cable end to the clutch lifter arm.
Install the clutch cable holder and bolt.
Tighten the bolt securely.
valve covers.
Instan the gearshift arm t o the gearshift spindle,

aligning with the punch mark and slit.
Tighten the gearshift arm pinch bolt securely.
tighten the band screws securely.
Connect the alternator 3P (Natural) connector.
2P (BLACK) CONNECTOR
- NeutraVoil pressure switch 2P (Black)
- VS sensor 3P
- Side stand 3P (Green) \ti / /l,(
I'
;
3P CONNECTOR 3P (GREEN) CONNECTOR

' 2P (NATURAL) CONNECTOR

lnstall the tollowmg:
- Throttle body (page 6-65)
- Exhaust system (page 3-18)
- Left crankcase rear cover (page 3-15)
- Spark plug cap (page 4-71
- Fuel tank (page 6-62)
- Both side covers (page 3-51
Fill the crankcase with engine oil (page 4-12).
Check the engine oil level (page 4-1 1).
9. CYLINDER HEADIVALVE
SYSTEM COMPONENTS ...........................9-2 CYLINDER HEAD DISASSEMBLY ---.-.----.

9-16
SERVICE INFORMATION ........................... 9-3 VALVE GUIDE REPLACEMENT.---------.----

9-19
TROUBLESHOOTING .................................9-5 VALVE SEAT INSPECTION1

REFACING.................................................9-20
CYLINDER COMPRESSION........................9-6
CYLINDER HEAD ASSEMBLY ..-------------.-
9-24
CYLINDER HEAD COVER REMOVAL---.-..-9-6
CYLNDER HEAD INSTALLATION--------..9-26
CAMSHAFT REMOVAL ..............................
W W t H HEAD RFMOVAL
CYLINDER HEAD COVER
CYLINDER HEADIVALVE
v
GENERAL
a This section covers service of the rocker arm, camshaft, cylinder head and valve.
a The rocker arm, camshaft and front cylinder head services can be done with the engine installed in the frame. The rear
cyltnder head servtce requlres englne removal.
a Be careful not to damage the mating surfaces when removing the cylinder head cover and cyfinder head. Do not strike
the cyfinder head cover and cylinder head too hard during removal.
a When disassembling, mark and store the disassembled parts to ensure that they are reinstaned in their original loca-
m
a Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
a Camshaft and rocker arm lubricating oil is fed through oil passages in the cylinder head and camshaft holder. Clean the
oil passages before assembling the cylinder head and cover.
I rocker arm I 1 11.983- 11.994(0.4718- 0.4722) 1 11.92(0.469) 1

shaft Rocker arm I.D. i INIEX i 12.006- 12.024(0.4726- 0.4734) 1 1 2.05(0.474)
Rocker arm-to-shaft clearance 1 0.012- 0.041 (0.0008- 0.0016) I 0.014(0.006)
Valve, Valve stem O.D. IN 5.475- 5.490 (0.2156 - 0.2161) 5.460(0.2150)
valve guide EX 5.460- 5.475 (0.2150- 0.2156) 5.455(0.2148)
Valve guide I.D. INIEX 5.500- 5.512(0.2165- 0.2170) 5.54(0.218)
Stem-to-guide clearance IN 0.010- 0.037 (0.0004- 0.0015) 0.07(0.003)
0.025- 0.052(0.0009- 0.0020)
I Valve guide projection
above cvlinder head
EX
IN
EX
1 12.5- 12.7(0.49- 0.50)
1 16.7- 16.9 (0.66- 0.67)
0.09 (0.004)
-
-
Valve seat width INIEX 0.90- 1.10(0.035- 0.043) 1.5 (0.06)
Valve spring Free length INIEX 44.91 (1.768) 43.9(1.73)
Cvlinder head w a r ~ a a e 0.10(0.004)
TORQUE VALUES
Spark plug 16 N.m (1.6kgf.m, 12 Ibf-ft)
Timing hole cap 10 N.m (1.0kgfem, 7 Ibf.ft) Apply engine oil to the threads and flange
surface
Crankshaft hole cap 15 N.m (1.5kgfem, 11 Ibf.ft) Apply engine oil to the threads and flange
surface
Valve adjusting screw lock nut 23 N m (2.3kgfmm, 17 Ibfeft) Apply engine oil to the threads and flange
surface
Cylinder head cover bolt 10 N.m (1.0kgf-m, 7 Ibf-ftl
Cylinder head bolt 23 N.m (2.3kgf.m, 17 Ibf-ft) Apply engine oil to the threads and seating
surface
Cylinder head nut 40 N.m (4.1kgfmm, 30 Ibfsft) Apply engine oil to the threads and seating
surface
Cam sprocket bolt 23 Nam (2.3kgf-m, 17 Ibfmft) Apply locking agent
Cam chain tensioner bolt 10 N - m (1.0kgfmm, 7 Ibf-ftj
Camshaft holder bolt 23 N.m (2.3kgfem, 17 Ibf-ft) Apply engine oil to the threads and seating
surface
Reed valve cover bolt 5.2 Nqm (0.5kgf-m, 3.7 Ibf-ft) C l bolt
Cylinder head sealing bolt 44 N.m (4.5kgfsm, 32 Ibfsft) Apply locking agent
TOOLS
-
Valve spring compressor Valve guide reamer, 5.510 m m Valve guide driver, 5.5 m m
07757-0010000 07984-2000001 07742-0010100
Valve seat cutter, 27.5 m m (45O IN) Valve seat cutter, 33 m m (45O EX) Flat cutter, 33 m m (32" IN)
07780-0010200 07780-0010800 07780-0012900
or equivalent commercially or equivalent commercially or equivalent commercially

available ava~lable available
Flat cutter, 27 m m (32" EX) lnterior cutter, 30 m m (60" IN) lnterior cutter, 26 m m (60" EX)
07780-0013300 07780-0014000 07780-0014500
or equivalent commercially or equivalent commercially or equivalent commercially

available available available
Cutter holder, 5.5 m m Valve guide driver
or equivalent commercially
available
CYLINDER HEADNALVE
UBLESHOOTING
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.
Compression too low, hard starting or poor performance at low speed
Valves
-- - - -
Incorrect valve adjustment

ned or bent valves
-Incorrect valve timing
-Broken valve spring
-Uneven valve seating
-Valve stuck open
Cylinder head
-Leaking or damaged cylinder head gasket
-Warped or cracked cylinder head
-
-Loose spark plug
Cylinderlpiston problem (page 10-31
Compression too high
Excessive carbon build-up on piston head or combustion chamber
Worn valve stem or valve guide

Damaged stem seal
Cylinderlpiston problem (page 10-3)
Excessive noise
lncorrect valve clearance
Sticking valve or broken valve spring
Fxcessive worn valve seat
Worn or damaged camshaft
r Worn or damaged rocker arm andlor shaft
r Worn rocker arm follower or valve stem end
Worn cam sprocket teeth
Worn cam chain
r Worn or damaged cam chain tensioner
Cylinderlpiston problem (page 10-3)
Rough idle
Low cvlinder com~ression
CYLINDER HEADIVALVE
LINDFR COMPRESSION
m
If the engine must be running to do some work,
make sure the area is well-ventilated, Never run the
engine rn an enclosed area.
To measure the cyl- Warm up the engine to normal operating tempera-
inder com~ression ture.
of each'cylinder, Stop the engine, disconnect
. . the spark plug caps and
remove only one remove one spark plug at a time.
plug at a time. S th . .vlto neutral.
.sslon
Install a compression gauge into the spark plug
hole.
Open the throttle all the way and crank the engine
with the starter motor until the gauge reading stop
rising.
Toavoiddischarging The maximum reading is usually reached within 4-7

the battery, do not seconds.
operate the starter
than seven sec- 1.0 kgf/cm2, 799 _+ 14 psil at
Low compression can be caused by:

- Blown
. - .. . . cvlinder head aasket
- Improper valve adjustment

- Valve leakage
- Worn piston ring or cynnder
High compression can be caused by:
- Carbon deposits in combustion chamber or on
piston head
CYLINDER HEAD COVER REMOVAL

FRONT
d r\
4-21.
Remove the front cylinder head cover protector.
CYUNDER HEADAIALVE
Remove the cylinder head cover bolts, washers and
rubber seals.
Disconnect the air supply hose to the PAIR valve
cover.
Be carefulnot to Remove the cylinder Read cover, dowel pm and gas-

damage the wire ket.
harness and mat- The dowel pin may leave on the cylinder head.
ing surfaces when
removing the cylin-
der head cover.
R
d
ttemove the tuel tank (page 6-621.

Remove the rear cylinder head cover protector.
Remove the cylinder head cover bolts, washers and

rubber seals.
Disconnect the air supply hose to the PAlR valve
cover.
CYLINDER HEADIVALVE
0 The dowel pin

n may leave on rne
the cyllnaer
cylinder neaa.
head.
der head cover
CAMSHAFT REMOVAL
NOTE:
r The camshaft can be serviced with the engine in
the frame.
r The front camshaft uses the same service proce-
dure as the rear camshaft.
Remove the rear cylinder head cover (page 9-1).
Remove the crankshaft hole cap, timing hole cap
and 0-rings from the left crankcase cover.
Turn the crankshaft counterclockwise and align the

"RT" mark (front cylinder: "FT" mark) with the-index
notch on the left crankcase cover.
Make sure the piston is at TDC (Top Dead Center) on
the exhaust stroke so the piston is at TDC on the
compression stroke when removing the camshaft
holder.
CYLINDER HEADIVALVE
Measure the cam chain tensioner wedge B length as I
shown. I WEDGE E
SERVICE LIMIT: 6 mm (0.2 in)
Replace the cam chain with a new one if the projec-
I
.....:
For the cam chain replacement, remove the follow-

mg:
Front:
- Front camshaft
- Flywheel (page 12-51
- Rear:
- Rear camshaft
- Primary drive gear (page 11-12]
the 2 mm pin fall wedge A hole while pulling the wedge A straight up
into the crankcase. and pushing down the wedge B.
Be careful not to let Remove the cam sprocket bolt, turn the crankshaft
the cam sprocket counterclockwise one full turn (360")and remove
bolts fall into the the other cam sprocket bolt.
crankcase.
Attach a piece of Remove the CMP sensor rotor (rear cylinder only)
wire to the cam cam sprocket from the camshaft flange surface.
chain to prevent it
from falling into the
crankcase.
CYLINDER HEADIVALVE
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
Loosen the bolts in a crisscross pattern in several
steps, then remove them and camshaft holder
assembly.
Remove the camshaft.
INSPECTION
CAMSHAFT RUNOUT
Support both end journals of the camshaft with V-
blocks and check the camshaft runout with a dial
SERVICE LIMIT 0.05 mm (0.002 in)
Check the cam lobe surfaces for scoring or evidence

of insufficient lubrication.
Measure each cam lobe height.
SERVICE LIMITS: IN: 40.58 m m (1.598 in)
EX: 40.67 mm (1.601 in)
NOTE:
Check the rocker arm if the cam lobe is worn or
damaged.
NOT E:
Check the oil passages and camshaft holder for
wear or damage if the journal surface is worn or
damaged.
Check the cam sprocket for wear or damage.
CYI INDER HFAD

Check the camshaft journal surfaces of cylinder
head for scoring, scratches or evidence of insuffi-
cient lubrication.
CAMSHAFT OIL CLFARANCE

Remove the cylinder head (page 9-14).
Clean off any oil from the journals of the camshaft
holders, cylinder head and camshaft.
Put the camshaft onto the cylinder head and lay a
strip of plastigauge lengthwise on each camshaft
journal.
NOTE:
r Do not block any oil holes with the plastigauge.
camshaft holder bolts t o the specified torque in a
crisscross pattern i n several steps.
TORQUE: 23 N-m (2.3 kgfm, 17 Ibf-ft)
Remove the camshaft holder and measure the

width of each plastigauge.
The widest thickness determines the oil clearance.
When the service limit is exceeded, replace the cam-
shaft and recheck the oil clearance.
Replace the cylinder head and camshaft holder if
the clearance still exceeds the service limit.
CAMSHiW I HOLDER DlSASStWlsLY

NOTE:
The front cylinder camshaft holder service uses the
same procedure as the rear cylinder camshaft
holder.
Remove the rocker arm shafts, intake and exhaust
rocker arms.
Remove the lock nut and valve adjusting screw.

CYLINDER HEADIVALVE
ROCKFR ARM/ROCKER ARM SHAFT UUSPtCTlON
Check the sliding surface of the rocker arms for
Measure the I.D. of each rocker arm.

SERVICE LIMIT 12.05 m m (0.474 in)
Check the shaft for wear or damaae.

Measure each rocker arm snatt u.u.
Calculate the rocker arm-to-shaft clearance.
Replace the rocker arm andtor shaft if necessary.
CAMSHAFT HOLDER INSPECTION

Check the camshaft journal surfaces of each cam-
shaft
. .-.holder
. . for
. . scoring,
. scratches or evidence of
CYLINDER HEADIVALVE
CYLINDER HEAD REMOVAL
NOT E:
a The engine must be removed from the frame
before servicing the rear cylinder head.
a The front cylinder head service can be done with
the engine in the frame.
The front cylinder head uses the same service
procedure as the rear cvlinder head.
Remove the following:
- Cylinder head cover (page 9-61
- Camshaft (page 9-8)
cylinder head Swing the radiator and remove the bolts, nuts and
only: engine hanger cross plate.
d . .- -
.
Remove the bolts, Intake manltold and U-rlng.
Remove the bolt and water hose jolnt from f i e cyl-

inder head.
Remove the cam chain tensioner mounting bolts
and sealing washers.
Loosen the bolts Remove the following cylinder head bolts and nuts:
_and nuts in a criss- - 8 m m bolts
cross pattern in -
10 m m nuts/washers
several steps.
Be careful not to Remove the cylinder head.
damage the mating
surface when
removing the cylin-
der head.
CYLINDER HEADIVALVE
HEAD DISASSEMBLY
Remove the spark plug.
Remove the CMP sensor (rear cylinder head only;
page 6-72).
Mark all parts dur- Remove the cotters using a special tool.
ing disassembly so
they can be placed TOOL:
back in their original Valve spring compressor 07757-0010000
position.
I NOTICE I
Compressing the valve spring more than necessary
will cause loss o f valve spring tension.
Do not reuse the Remove the valve spring compressor, then

removed stem seal. the retainer, spring and valve.
Avoiddamaging the Remove the carbon deposits from the combust~on
lNSPECTlON
meek the cynnder head for warpage wirh a srraighr

edge and feeler gauge.
VAI VF SPRING
Check the valve spring for fatigue or damage.
Measure the free length of each valve spring.
VALVE STEM, VALVE GUIDE
Measure each valve stem O.D. and record it.

SERVICE LIMITS: IN: 5.460 mm (0.2150 in)
EX: 5.455 mm (0.2148 in)
CYLINDER HEADIVALVE
Ream the valve guide to remove any carbon build-
up before measuring the guide I.D.
NOTE:
Take care not to tilt or lean the reamer in the
guide while reaming. Otherwise, the valves
maybe installed slanted, causing oil leakage
from the stem seal and improper valve seat con-
tact. This may prevent valve seat refacinn.
a Insert the reamer from the combustion chamber
side of the head and always rotate the reamer
clockwise.
TOOL:
Valve guide reamer, 5.510 mm (INIEX)
07984-2000001
Measure each valve guide I.D. and record it.
EX: 5.54 mm (0.218 in)
Subtract each valve stem O.D. from the correspond-
ing guide I.D. to obtain the stem-to-guide clearance.
EX: 0.09 mm (0.004 in)
If the stem-to-guide clearance exceeds the service
limit, determine if a new guide with standard
dimensions would bring the clearance within toler-
ance.
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.
NOTE:
Inspect and reface the valve seats whenever the
valve guides are replaced (page 9-20).
CAM CHAIN GUIDt
Check the cam chain guide for wear or damage.
Replace the cam chain guide if necessary.
VALVE GUIDE REPLACEMENT
-
Emz
Hefinish the valve seats whenever the valve guides
are replaced to prevent uneven seating.
Chin new valve guides in a freezer section of refrig-
Heat the cylinder head to 130 - 140°C (275 - 290°Fj

with a hot plate or oven. Do not heat the cylinder
head beyond 150°C (300°F). Use temperature indica-
tor sticks, available from welding supply stores, to
be sure the cylinder head is heated to the proper
temperature.
To avoid burns, wear insulated gloves when han-
dling the heated cylinder head.
Using a torch to heat the cylinder head may cause
07742-0010100
CYLINDER HEADIVALVE
Adjust the valve guide driver to the valve guide
height.
TOOL:
Valve guide driver 07743-0020000
VALVE GUIDE PROJECTION ABOVE CYLINDER

HEAD:
- -
IN: 12.5 12.7 mm (0.49 0.50 in)
-
EX: 16.7 - 16.9 mm (0.66 0.67 in)
Drive new guides in from the camshaft side of the
cylinder head to the valve guide height while the
cylinder head is still heated.
Let the cylinder head cool to room temperature,

then ream the new valve guides.
TOOL:
Valve guide reamer, 5.510 mm (INIEX)
07984-2000001
NOTE:
a Take care not to tilt or lean the reamer in the
guide while reaming. Otherwise, the valves
maybe installed slanted, causing oil leakage
from the stem seal and improper valve seat con-
tact. This may prevent valve seat refacing.
a Insert the reamer from the combustion chamber
side of the head and always rotate the reamer
clockwise.
Clean the cylinder head thoroughly to remove any
metal particles after reaming.
Reface the valve seat (page 9-21).
VALVE SEAT INSPECTIONIREFACING
Clean all intake and exhaust valves thoroughly to

remove carbon deposits.
Apply a thin coat of Prussian Blue to each valve
face.
Tap the valve against the valve seat several times
using a hand-lapping tool, without rotating valve, to
make a clear pattern.
CYLINDER HtADIVALVE
Remove the valve and inspect the valve seat face.
NOTE:
I
r The valve cannot be ground. If the valve face is
burned or badly worn or if it contacts the seat
y
-
lnspect the valve seat face for:

Uneven seat width:
I
- Replace the valve and reface the valve seat.
a.
- Replace the valve and reface the valve seat.

DAMAGED FACE UNEVENSEAT
WIDTH
@ Contact area (too high or too low area):

- Reface the valve seat.
TOO LOW TOO HIGH
lnspect the width of the valve seat.

The valve seat contact should be within the speci-
fied width and even all around the circumference.
STANDARD: - -
0.90 1.10 mm (0.035 0.043 in)
If the valve seat width is not within specification,
reface the valve seat.
VALVE SEAT REFACING

m
koflow the refacer manufacturer's operating
instructions.
r Reface the valve seat whenever the valve guide
has been replaced.
r Be careful not to grind the seat more than neces-
sary.
CYLINDER HEADIVALVE
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.
0
CONTACT TOO LOW OLD SEAT
Using a 45" cutter, remove any roughness or irregu-

larities from the seat.
ROUGHNESS
TOOLS:
Seat cutter, 27.5 m m (IN) 07780-0010200
X) 0
7-
Cutter holder, 5.5 m m 07781-0010101

1
ing valve seat material.

TOOLS:
Flat cutter, 33 m m (IN) 07780-0012900
-Flat cutter, 27 m m (EX) 07780-0013300
Cutter holder, 5.5 m m 07781-0010101
seat.
TOOLS:
Interior cutter, 30 m m (IN) 07780-0014000
Interior cutter, 26 m m (EX) 07780-0014500
Cutter holder, 5.5 m m 07781-0010101

p
Using a 45" seat cutter, cut the seat to the proper

width.
Make sure that all pitting and irregularities are SEAT WIDTH
removed.
l I
r Excessive lapping pressure may deform or dam-

age the seat.
r Change the angle of lapping tool frequently to
prevent uneven seat wear.
r Lapping compound can cause damage if it enters
between the vaive stem and guide.
After cutting the seat, apply lapping compound to
the valve face, and lap the valve using light pres-
sure.
Atter lapp~ng,w a s h v d u a l compound3ff €he
cylinder head and valve.
Recheck the seat contact after lapping.
CYLINDER HEADIVALVE
CYLINDER HEAD ASSEMBLY
with compressed air.

Install the spring seat and new stem seal.
Lubricate valve stem and valve guide inner surfaces

with molybdenum disulfide oil.
Install the valve into the valve guide.
NOTE:
slowly when valve installing.

lnstall the valve spring with tightly wound coils fac-
ing the combustion chamber.
LI.
Grease the cotters Install the cotters using a speclal tool.
to ease installation.
TOOL:
. - more than neces-

Corn~ressinathe valve sorings d
sary 'will ca&e loss of valve spring tension.
the cylinder head so the valve heads

not contact anything and possibly get damaged.
Install the spark plug.

Install the CMP sensor (rear cylinder only; page 6-
72).
CYLINDER HEADIVALVE
CYLINDER HEAD INSTALLATION
NOTE:
r The front cylinder head uses the same service
procedure as the rear cylinder head.
r Be careful not to damage the mating surfaces
when cleaning the cylinder head mating surface.
r When cleaning the cylinder head mating surface,
place the shop towel over the cylinder opening to
prevent dust or dirt from entering the engine.
cylinder head thoroughly, being careful not to dam-

age them.
Install the cam chain guide by aligning the guide
end with the groove i n the crankcase and the bosses
with the groove i n the cylinder.
The cylinder heads are identified by marks on their

oil pockets.
"F": Front cylinder head
"R": Rear cylinder head
CYLINDER HEADNALVE
Install the cylinder head to the cylinder.
Apply oil to the each bolts and nuts threads and
seating surfaces.
Install and tighten the cylinder head bolts, nuts and
washer to the specified torque.
TORQUE:
10 mm nut: 40 N m (4.1 kgf-m, 30 Ibf-ft)
8 mm bolt: 23 N-m (2.3 kgf-m, 17 Ibf-ft)
NOTt:
0 Tighten all to hand-tight, then torque the larger
fasteners before tightening the smaller fasteners.
0 Tighten the bolts and nuts in a crisscross pattern
i n several steps.
the groove in the crankcase.
Install the tensioner bolts with new sealing washers

and tighten them alternately.
TORQUE: 10 Nqm (1.0 kgf-m, 7 Ibfsft)
Install a new 0-ring to the water hose joint.

CYLINDER HEADIVALVE
securely.
lnstall a new 0-ring to the intake manifold groove.
lnstall the intake manifold and tighten the bolts

securely.
lnstall the engine hanger cross plate, bolts and nuts.

Tighten the bolts and nuts to the specified torque.
lnstall the following:
- Camshaft (page 9-29]
- Cylinder head cover (page 9-33)
CYLINDER HEADNALVE
CAMSHAI-T INSTALLATION
CAMSHAFT HOLDER ASSEMBLY
EXHAUST ROCKER ARM
VALVE ADJUSTING SCREW EXHAUST ROCKER ARM SHAFT
Apply engine oil to the valve adjusting screw lock

nut threads and seating surface.
Install the valve adjusting screw and lock nut.
NOTE:
r The rocker arms are identified by the stamped
marks:
"IN": Intake rocker arm
"EX": Exhaust rocker arm
-0 The intake rocker arm shaft has two holes on
each end.
The exhaust rocker arm shaft has two grooves
o n each end.
Apply molybdenum disulfide oil solution to the slid-
ing surface of the shaft.
Install the rocker arms and shafts.
-
CYLINDER HEADIVALVE
Align the intake rocker arm shaft holes with the
holder holes.
Align the exhaust rocker arm shaft grooves with the
CAMSHAFT INSTALLATION
the camshaft position.
WONT CYLINDER TDC SETTING

If the rear cylinder Remove the rear cylinder head cover (page 9-7) and
has not been ser- check the rear cylinder camshaft position as follows:
viced, begin here.
"RT" mark on the flywheel with the index notch on
the left crankcase cover.
Then check the identification mark "R" on the rear

camshaft.
- If the "R" mark faces up, turn the crankshaft
counterclockwise 1-117 (412O) turn (align the "FT"
mark o n the flywheel with the index notch) and
begin installation of the front camshaft.
- If the "R" mark faces down (cannot be seen), turn
the crankshaft counterclockwise l / 7 (52")turn
(align the "FT" mark with the index notch) and
begin installation of the front camshaft.
Install the front camshaft (page 9-31).
CYLINDER HEADIVALVE
BOTH CYLINDER TDC SETTING
If both camshafts Align the "FT" mark on the flywheel with the index
have been serviced, notch on the left crankcase cover.
begin installation of
Install the front camshaft (page 9-31).
the front camshaft.
Set the rear cylinder at TDC (page 9-31).
Install the rear camshaft (page 9-31).
RtAR CYLINDkR TDC SETTING

If the front cylinder Remove the front cylinder head cover (page 9-6)
has not been ser- and check the front cylinder camshaft position as
viced, begin here. follows:
"FT" mark on the flywheel with the index notch on
the left crankcase cover.
Then check the identification mark " F on the front

camshaft.
- If the "F" mark faces up, turn the crankshaft coun-
terclockwise 617 (308") turn (align the "RT" mark
on the flywheel with the index notch) and begin
installation of the rear camshaft.
- If the "F" mark faces down (cannot be seen), turn
the crankshaft clockwise 1-6/7 (668") turn (align
the "RT mark with the index notch) and begin
installation of the rear camshaft.
Install the rear camshaft using the following proce-
-
dure.
SHAFT UUSTALl ATION
uses the same ser- with molybdenum disulfide oil.

vice procedure as
lnstall the camshaft with the camshaft identification
the rear camshaft.
mark (R: rear camshaft, F: front camshaft) facing up.
CYLINDER HEADIVALVE
molybdenum disulfide oil.

NOTE:
Before camshaft holder installation, loosen the
valve adjusting screw and lock nut fully.
Install the camshaft holder assembly.
seating surface.
Install the camshaft holder bolts.
Tighten the bolts to the specified torque in a criss-
cross pattern in several steps.
TORQUE: 23 N.m (2.3 kgfsm, 17 Ibf-ft)
lnstall the cam sprocket to the cam chain with the

timing mark facing outside.
Install the cam sprocket on the camshaft flange and
check that the timing marks align with the upper
surface of the cylinder head.
- .
Install m~mr
sensor rotor (rear cytinder only).
Be careful not to let Clean and apply a locking agent to the cam sprocket
the cam sprocket bolt threads.
bolts fall into the Ill
crankcase.
sprocket and camshaft.
Temporarily install the cam sprocket bolt.
Turn the crankshaft counterclockwise 360" and
tighten the other sprocket bolt to the specified
torque.
TORQUE: 23 N.m (2.3 kgf-m,17 Ibf-ft)
Turn the crankshaft counterclockwise 360" and
tighten the other sprocket bolt to the specified
torque.
tensioner wedge A and pushing down the wedge B.
NOTE:
r Be careful not to let the 2 m m pin fall into the
crankcase.
r Do not forget to remove the 2 mm pin before
installing the cylinder head cover.
Adjust the valve clearance (page 4-9).
UNDER HEAD COVF#R

lNSTALLATlON
Clean the gasket groove and cylinder head mating
surface of the cylinder head cover.
Install the gasket into the groove.
Clean the cylinder head cover mating surface of the

cylinder head.
Install the dowel pin to the front cylinder head
cover.
Install the front cylinder head cover on the front cyl-
inder head.
lnstall and tighten the cylinder head cover bolts to
the specified torque.
TORQUE: 10 N.m (1.0 kgf-m, 7 Ibf-ft)
Connect the air supply hose.
UI.
lnstall the throttle body (page 6-65).

Close the fuel tank (page 4-5).
cylinder head.
lnstall the dowel pin to the rear cylinder head cover.
Install the rear cylinder head cover on the rear cylin-
der.
Install and tighten the cylinder head cover bolts to

the specified torque.
TORQUE: 10 N-m (1.0 kgfmm, 7 Ibfaft)
Connect the crankcase breather hose.
CYLINDER HEADIVALVE

Lubrication System: Lubrication System Diagram OIL Pressure Check Service Information Oil Pump Trouble Shooting

Uploaded by

Copyright:

Available Formats

Lubrication System: Lubrication System Diagram OIL Pressure Check Service Information Oil Pump Trouble Shooting

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lubrication System: Lubrication System Diagram OIL Pressure Check Service Information Oil Pump Trouble Shooting

Uploaded by

Copyright:

Available Formats

5 .

LUBRICATION SYSTEM DIAGRAM .........m

SERVICE INFORMATION ...........................5-3 OIL PUMP ...................................................5-6

TROUBLE SHOOTING ................................5-4 OIL COOLER .............................................5-12

Oil pump rotor Tip clearance 1 0.1 5 (0.006) 1 0.20 (0.008)

Oil pressure gauge set Oil pressure gauge attachment

or equivalent commercially avail- or equivalent commercially avail-

Remove the oil pressure switch and connect an oil

Stop the engine.

head 3-4 mm (0.1-

Connect the oil pressure switch wire and tighten the

Remove the dowel pin, collars and 0-rings.

Remove the pressure relief valve and 0-ring.

Remove the bolts and pump body from the pump

Remove the dowel pins.

Install the outer and inner rotors to the pump body.

TORQUE: 13 N-m (1.3 kgf-m, 9 Ibf-ft)

Clean the oil strainer.

Install the dowel pin and collars.

Install the oil pump assembly into the crankcase

lnstall the pressure relierf valve cover and tighten

Remove the bolt, spring washer and oil cooler from

ing oil cooler side. COOLER

I SPRING WASHER MARK SIDE

SYMPTOM TROUBLESHOOTING .............6-6 THROTTLE BODY .....................................6-65

PGM-FI TROUBLESHOOTING ECT SENSOR ............................................6-72

SECONDARY AIR SUPPLY SYSTEM ...mm. 6-79

SCS connector Inspection test harness Test probe

with commercially available digital

braking is used system

PAIR CONTROL SOLENOIDVALVE

BI: Black Br: Brown

IAT SENSOR 2P (NATURAL)

ECT SENSOR 3P (GRAY)

MAP SENSOR 3P (BLACK)

FRONT (#2) INJECTOR 2P

ECT SENSOR IAT SENSOR

OUTPUT VOLTAGE OUTPUT VOLTAGE

main code of the DTC (the sub code cannot be

followed by five short blinks, the MIL is 25 (two

To read the DTC with the MIL blinking, refer to the

Remove the side cover/pivot cover (page 3-5).

rial away from the ECM connector before discon-

wire harness and the ECM. ECM TEST HARNESS

TEST HARNESS TERMINAL LAYOUT

shown in this illustration. ECM 33P (BLACK) CONNECTOR

TEST HARNESS PIN BOX

Is about 0 V or below indicated7

Turn the ignition switch ON and engine stop

3. MAP Sensor Input Line Inspection

DTC 1-2 (MAP SENSOR HIGH

YES - I'O STtP 2.

3. MAP Sensor Input Voltage lnspection

DTC 2-1 (MAP SENSOR)

3. MAP Sensor System lnspection

Check the ECT sensor with the HDS pocket

3. ECT Sensor Resistance lnspection

Measure the resistance at the ECT sensor termi-