SM XR 190L (2017) Eng

Shop Manual
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XR190L
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1. General Information
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3. Frame & Chassis
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4. Electrical System
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This book is Specific Shop Manual.

Refer to “Basic Shop Manual” for basic and
common maintenance instructions.
XR190L-H (2017)
1. GENERAL INFORMATION
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A Few Words About Safety ···················· 1-2 SPECIAL TOOL LIST····························· 1-16
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How To Use This Manual························ 1-3 CABLE & HARNESS ROUTING ············ 1-17
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MODEL IDENTIFICATION ······················· 1-5 TECHNICAL FEATURES ······················· 1-24
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SPECIFICATIONS ···································· 1-6 MAINTENANCE SCHEDULE················· 1-25
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TORQUE VALUE···································· 1-12
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1-1
GENERAL INFORMATION
A Few Words About Safety

GENERAL INFORMATION
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
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Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
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This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
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procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
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that you do not use replacement parts of inferior quality.
For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
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servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
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Improper service or repairs can create an unsafe
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condition that can cause your customer to be
seriously hurt or killed.
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Follow the procedures and precautions in this
manual and other service materials carefully.
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For Your Safety R

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
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of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
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Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
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Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
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killed.
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Follow the procedures and precautions in this

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manual carefully.
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Important Safety Precautions

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Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
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• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
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• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
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burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
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Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
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• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
1-2
GENERAL INFORMATION
How To Use This Manual

This manual is "Spec (Specific)" Service Manual. The service and repair information for this model is described in this
manual as specific information. Refer to “Basic" Service Manual for basic/common service information and
instructions.
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Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.
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Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the
break-in period.
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Your safety, and the safety of others, is very important. To help you make informed decisions we have provided
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safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
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You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,
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or CAUTION. These signal words mean:
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You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
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You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
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You CAN be HURT if you don’t follow instructions.
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• Instructions – how to service this vehicle correctly and safely.
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As you read this manual, you will find information that is preceded by a symbol. The purpose of this message
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is to help prevent damage to your vehicle, other property, or the environment.

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ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS

PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF
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APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY
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TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR
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PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,

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MOTOR SCOOTERS OR ATVS.

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© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
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Date of Issue: July, 2016

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1-3
GENERAL INFORMATION
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required
pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.
INSTRUCTION SYMBOL
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Removal or Disassembly procedure. Installation or Assembly procedure.
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Disconnect the connector. Connect the connector.
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Order of installation/assembly with a point of
Order of removal/disassembly with a point of note.
note.
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Tighten specified torque. Replace with a new one before assembly.
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Check the part for an inspection. Measure the part for an inspection.
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Turn ignition switch to OFF. Turn ignition switch to ON.
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Start the engine. Measure a resistance or check continuity.
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Measure a voltage. Measure an ampere.
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Refer to “Basic” Service Manual for the instruc-

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Use the Honda special tool.

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LUBRICATION AND SEAL SYMBOL

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Apply molybdenum oil solution (mixture of an

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Use the recommend engine oil. engine oil and molybdenum grease in a ration of
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1:1).
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Apply a specified grease. Use a multi-purpose

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Apply a liquid sealant.

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grease unless otherwise specified.

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Apply a locking agent. Use a medium strength

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Use DOT 3 or DOT 4 brake fluid.

one unless otherwise specified.
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Use a specified fork oil or suspension fluid.

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1-4
GENERAL INFORMATION
MODEL IDENTIFICATION
• Model name: XR190L-H
Code/Type Destination
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LA Latin America
PE Peru
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CL Chile
DK General KILO
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VEHICLE IDENTIFICATION NUMBER
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ENGINE SERIAL NUMBER

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COLOR LABEL
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1-5
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
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DIMENSIONS Overall length 2,075 mm
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Overall width 812 mm
Overall height 1,124 mm
Wheelbase 1,351 mm
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Seat height 835 mm
Footpeg height 300 mm
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Ground clearance 242 mm
Curb weight 133 kg
Maximum weight capacity 155 kg
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FRAME Frame type Semi double cradle type
Front suspension Telescopic fork
Front wheel travel 161.5 mm
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Rear suspension Swingarm
Rear wheel travel 147 mm
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Front tire size 90/90 -19M/C 52P
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Rear tire size 110/90 - 17M/C 60P
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Front tire brand C6559F (CHENG SHIN)
Rear tire brand C6559 (CHENG SHIN)
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Front brake Hydraulic single disc
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Rear brake Mechanical leading trailing
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Caster angle 26° 12’

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Trail length 95.9 mm

Fuel tank capacity 12.0 liter
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Fuel tank reserve capacity 3.9 liter

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ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical

Bore and stroke 61.000 x 63.096 mm
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Displacement 184.43 cm3

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Compression ratio 9.5 : 1

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Valve train Chain driven OHC with rocker arm

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Intake valve opens 10° BTDC at 1 mm lift

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closes 30° ABDC at 1 mm lift

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Exhaust valve opens 35° BBDC at 1 mm lift

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closes 0° ATDC at 1 mm lift

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Lubrication system Forced pressure and wet sump

Oil pump type Trochoid
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Cooling system Air cooled

Air filtration Viscous paper filter
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Engine dry weight 29.5 kg

Emission control system Crankcase emission control system
Three-way catalytic converter
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FUEL SYSTEM Type PGM-FI (Programmed Fuel Injection)

Throttle bore 30 mm
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1-6
GENERAL INFORMATION
ITEM SPECIFICATION
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission 5 speeds
Primary reduction 3.136 (69/22)
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Final reduction 3.000 (48/16)
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Gear ratio 1st 2.785 (39/14)
2nd 1.789 (34/19)
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3rd 1.368 (26/19)
4th 1.090 (24/22)
5th 0.928 (26/28)
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Gearshift pattern Left foot operated return system
1-N-2-3-4-5
ELECTRICAL Ignition system Full transistorized
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Starting system Electric starter motor
Charging system Single phase output alternator
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Regulator/rectifier SCR opened, single phase half-wave rectification
Lighting system Alternator
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FUEL & ENGINE SPECIFICATIONS n
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FUEL SYSTEM
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ITEM R SPECIFICATIONS
Throttle body identification number GQ1QA
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Idle speed 1,400 ± 100 rpm
Throttle grip freeplay 2 – 6 mm
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Fuel pressure at idle 294 kPa

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Fuel pump flow (at 12 V) 58.6 cm3 minimum/10 seconds

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LUBRICATION SYSTEM
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Unit: mm
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ITEM STANDARD LIMIT

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Engine oil capacity After draining 1.0 liter –

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After disassembly 1.2 liter –

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Recommended engine oil Honda “4-stroke motorcycle oil” or an

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equivalent motor oil.

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API service classification: SG or higher –

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JASO T903 standard: MA

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Viscosity: SAE 10W-30

Oil pump rotor Tip clearance 0.15 0.20
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1-7
GENERAL INFORMATION
CYLINDER HEAD
Unit: mm
ITEM STANDARD LIMIT
Cylinder compression 1,402 kPa at 650 rpm –
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Valve clearance IN 0.08 ± 0.02 –
EX 0.24 ± 0.02 –
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Camshaft Cam lobe height IN 34.249 – 34.489 34.219
EX 34.079 – 34.319 34.049
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Rocker arm, Rocker arm shaft O.D.
IN/EX 9.988 – 10.000 –
rocker arm shaft
Valve, Valve stem O.D. IN 4.975 – 4.990 4.965
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valve guide EX 4.955 – 4.970 4.945
Valve guide I.D. IN/EX 5.000 – 5.012 –
Valve guide projection
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IN/EX 16.8 – 17.0 –
above cylinder head
Valve seat width IN 1.2 – 1.4 1.8
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EX 1.0 – 1.2 1.6
Valve spring free length INNER 35.59 34.88
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OUTER 39.46 38.67
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Cylinder head warpage – 0.05
CYLINDER/PISTON
Unit: mm
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ITEM STANDARD LIMIT
Cylinder I.D. 61.00 – 61.01 61.10
Warpage – 0.10
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Piston Piston O.D. 60.981 – 60.997 at 13 mm from bottom of

60.900
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Piston pin bore I.D. 14.002 – 14.008 14.020
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Piston pin O.D. 13.994 – 14.000 13.980

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Piston rings Piston ring end gap Top 0.07 – 0.17 0.27
Second 0.17 – 0.32 0.42
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Oil (side rail) 0.10 – 0.35 0.55

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Piston ring-to-ring Top 0.015 – 0.045 –

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groove clearance Second 0.015 – 0.045 –

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CLUTCH/GEARSHIFT LINKAGE
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Unit: mm
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ITEM STANDARD LIMIT

Clutch lever freeplay 10 – 20 –
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Clutch Disc thickness 2.92 – 3.08 2.70

Plate warpage – 0.15
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Spring free length 40.5 39.5

Primary driven gear I.D. 23.000 – 23.021 –
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Clutch outer guide O.D. 22.959 – 22.980 –

I.D. 16.991 – 17.009 –
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Mainshaft O.D. at clutch outer guide 16.966 – 16.984 –

ALTERNATOR/STARTER CLUTCH
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Unit: mm
ITEM STANDARD LIMIT
Starter driven gear boss O.D. 45.660 – 45.673 –
Starter driven gear boss I.D. 29.000 – 29.021 –
1-8
GENERAL INFORMATION
CRANKSHAFT/TRANSMISSION/BALANCER
Unit: mm
ITEM STANDARD LIMIT
Connecting rod Side clearance 0.10 – 0.35 0.45
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Radial clearance 0 – 0.008 0.05
Connecting rod small end I.D. 14.010 – 14.028 14.038
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Crankshaft Runout – 0.03
Transmission Gear I.D. M4 20.000 – 20.018 –
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M5 17.000 – 17.018 –
C1 20.500 – 20.521 –
C2 23.020 – 23.041 –
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C3 20.020 – 20.038 –
Gear bushing O.D. C1 20.459 – 20.480 –
C2 22.984 – 23.005 –
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Gear bushing I.D. C1 17.000 – 17.018 –
C2 20.020 – 20.041 –
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Mainshaft O.D. at M4 19.968 – 19.980 –
at M5 16.968 – 16.980 –
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Countershaft O.D. at C1 16.966 – 16.984 –
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at C2 19.978 – 19.989 –
at C3 19.988 – 20.000 –
Shift fork, fork Fork I.D. 10.000 – 10.018 –
shaft Fork shaft O.D. 9.986 – 9.995 –
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Claw thickness 4.93 – 5.00 4.83
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FRAME & CHASSIS SPECIFICATIONS

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FRONT WHEEL/SUSPENSION/STEERING
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Unit: mm
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ITEM STANDARD LIMIT

Cold tire Driver only 150 kPa –
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pressure Driver and passenger 150 kPa –

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Axle runout – 0.2

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Wheel rim runout Radial – 1.0

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Axial – 1.0
Fork Recommended fork fluid CN10# –
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Fluid level 184 –

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Fluid capacity 183 ± 2.5 cm3 –

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REAR WHEEL/BRAKE/SUSPENSION
Unit: mm
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ITEM STANDARD LIMIT

Cold tire pres- Driver only 150 kPa –
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sure Driver and passenger 200 kPa –

Axle runout – 0.2
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Wheel rim runout Radial – 1.0

Axial – 1.0
Drive chain slack 20 – 30 60
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Drive chain size/link 428V/128LE –
1-9
GENERAL INFORMATION
BRAKE SYSTEM
Unit: mm
ITEM STANDARD LIMIT
Front Specified brake fluid DOT 3 or DOT 4 –
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Brake disc thickness 3.8 – 4.2 3.5
Brake disc warpage – 0.3
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Master cylinder I.D. 12.700 – 12.743 –
Master piston O.D. 12.657 – 12.684 –
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Caliper cylinder I.D. 27.000 – 27.050 –
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Caliper piston O.D. 26.918 – 26.968 –
Rear Pedal freeplay 20 – 30 –
Drum I.D. 110 111
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ELECTRICAL SYSTEM SPECIFICATIONS
PGM-FI SYSTEM
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ITEM SPECIFICATIONS
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EOT sensor resistance (20°C) 2.5 – 2.8 kΩ
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Fuel injector resistance (24°C) 11 – 13 Ω
IGNITION SYSTEM
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ITEM R SPECIFICATION
Spark plug CPR8EA-9 (NGK)
Spark plug gap 0.80 – 0.90 mm
Ignition coil peak voltage 100 V minimum
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CKP sensor peak voltage 0.7 V minimum

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Ignition timing ("F" mark) 8° BTDC at idle

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BATTERY/CHARGING SYSTEM
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ITEM SPECIFICATIONS
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Battery Type YTX7L-BS

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Capacity 12 V – 6 Ah (10HR)/6.3 Ah (20HR)

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Current leakage 0 mA
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Voltage Fully charged 12.8 V minimum

(20°C) Needs charging Below 12.3 V
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Charging current Normal 0.6 A/5 – 10 h

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Quick 3 A/1 h
Alternator Capacity 0.165 kW/5,000 rpm
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Charging coil resistance (20°C) 0.2 – 1.0 Ω

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1-10
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES
ITEM SPECIFICATIONS
Bulbs Headlight Hi/Lo 12 V – 35/35 W
Brake/tail light 12 V – 21/5 W
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Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
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Position light 12 V – 5 W
License light 12 V – 5 W
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Instrument light 1 12 V – 2 W
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Instrument light 2 12 V – 1.7 W
High beam indicator 12 V – 1.7 W
Neutral indicator 12 V – 3.4 W
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Turn signal indicator 12 V – 3.4 W
MIL 12 V – 3.4 W
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Fuse Main fuse 15 A
Sub fuse 10 A x 2
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Fuel level sensor resistance Full 6 – 10 Ω
Empty 90 – 100 Ω
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1-11
GENERAL INFORMATION
TORQUE VALUE
• Each fastener should be tightened to the standard torque value except the fasteners specified torque value.
• Q’TY: Quantity, DIA: Thread diameter (mm), TRQ: Tightening torque (N·m)
STANDARD TIGHTENING TORQUE
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FASTENER TYPE TRQ FASTENER TYPE TRQ
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5 mm hex bolt and nut 5.2 5 mm screw 4.2
6 mm hex bolt and nut 10 6 mm screw 9.0
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8 mm hex bolt and nut 22 6 mm flange bolt 12
10 mm hex bolt and nut 34 8 mm flange bolt and nut 27
12 mm hex bolt and nut 54 10 mm flange bolt and nut 39
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FUEL PUMP UNIT
ITEM Q'TY DIA TRQ REMARKS
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Fuel pump setting plate nut 4 6 12 2-4
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AIR CLEANER
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Air cleaner cover screw 4 5 1.0
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Air cleaner element screw 4 5 1.0
Air cleaner cover separate screw 5 n 5 1.0
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THROTTLE BODY
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ITEM Q'TY DIA
R TRQ REMARKS
Throttle cable A lock nut (throttle body side) 1 6 4.5
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Throttle cable B lock nut (throttle body side) 1 6 4.5
Insulator band screw 1 5 2.5
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Insulator bolt 2 6 12
Sensor unit torx screw 3 5 3.4
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IACV mounting torx screw 2 4 2.1

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Throttle cable stay screw 2 5 3.4

Injector joint bolt 2 5 5.1
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LUBRICATION SYSTEM
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Oil drain bolt 1 12 30

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Oil pump cover screw 1 4 3.0

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CYLINDER HEAD
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Crankshaft hole cap 1 32 15 Apply grease.

Timing hole cap 1 14 10
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Cam chain tensioner lifter plug 1 6 4.0

Cam sprocket bolt 2 5 9.0
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Cylinder head nut 4 9 30 Apply engine oil.

Camshaft stopper bolt 1 6 12 Apply engine oil.
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Rocker arm shaft stopper bolt 2 5 5.0

Valve adjusting screw lock nut 2 6 18 Apply engine oil.
Cylinder stud bolt 4 9 9.0
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1-12
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE/BALANCER GEAR
Clutch center lock nut 1 14 83 Apply engine oil.
Shift drum stopper arm bolt 1 6 12 Apply locking agent.
Shift drum stopper plate bolt 1 6 12 Apply locking agent.
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Gearshift return spring pin 1 8 22 Apply locking agent.
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Clutch lifter plate bolt 4 6 12
Oil filter rotor lock nut 1 14 83 Apply engine oil.
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Oil filter rotor cover screw 3 5 4.0
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Starter clutch socket bolt 6 6 16 Apply locking agent.
Stator mounting bolt 3 6 12
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Flywheel lock nut 1 14 74 Apply engine oil.
CKP sensor mounting bolt 2 6 12 Apply locking agent.
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Alternator harness stay bolt 1 6 12 Apply locking agent.
CRANKCASE/CRANKSHAFT/BALANCER
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Mainshaft bearing setting plate bolt 2 6 12 Apply locking agent.
Push plug bolt 1 6 10 Apply locking agent.
Balancer driven gear lock nut 1 14 64 Apply engine oil.
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Balancer nut R 1 12 55 Apply engine oil.

ENGINE UNIT
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Front engine hanger nut 3 8 35

Front lower engine hanger nut 1 8 35
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Rear upper engine hanger nut 1 10 60

Rear lower engine hanger nut 1 10 60
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Upper engine hanger nut 2 8 35

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Drive sprocket bolt 2 6 12

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SIDESTAND
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Sidestand pivot bolt 1 10 10 3-12
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Sidestand pivot nut 1 10 39 Self lock nut 3-12

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EXHAUST PIPE/MUFFLER
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Exhaust pipe stud bolt 2 8 11 3-13
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Exhaust pipe joint cap nut 2 8 18

Muffler front protector bolt 3 6 14
Muffler protector socket bolt 1 6 10
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Muffler band bolt 1 8 20

Exhaust pipe protector socket bolt 1 6 10
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FRONT WHEEL
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Front axle nut 1 12 44 Self lock nut

Front brake disc nut 5 6 15
1-13
GENERAL INFORMATION
FORK
Top bridge pinch bolt 2 8 22
Bottom bridge pinch bolt 4 8 32
Brake hose clamper bolt 2 6 12
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Fork bolt 2 27 22
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Fork socket bolt 2 8 20 Apply locking agent.
HANDLEBAR
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Handlebar upper holder bolt 4 8 26
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Clutch lever pivot bolt 1 6 1.0
Clutch lever pivot nut 1 6 5.9
Throttle cable A adjusting nut (grip side) 1 7 3.8
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Throttle cable A lock nut (grip side) 1 10 3.0
Throttle cable B lock nut (grip side) 1 12 3.0
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STEERING STEM
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Steering stem nut 1 24 103
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Steering stem adjusting nut 1 26 – 3-19
REAR WHEEL
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ITEM R Q'TY DIA TRQ REMARKS
Rear axle nut 1 16 93 Self lock nut
Driven sprocket nut 6 8 32 Self lock nut
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REAR SUSPENSION
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Shock absorber upper bolt 1 10 44

Shock absorber lower nut 1 10 44 Self lock nut
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Swingarm pivot nut 1 14 88 Self lock nut

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Drive chain slider screw 1 5 6.0

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FRONT BRAKE
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Front master cylinder reservoir cap screw 2 4 1.5
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Front brake master cylinder holder bolt 2 6 12

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Front brake hose oil bolt 2 10 34

Brake lever pivot bolt 1 6 1.0
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Brake lever pivot nut 1 6 5.9

Front brake light switch screw 1 4 1.2
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Front brake pad hanger pin 1 10 17

Front brake pad pin plug 1 10 2.5
Front brake caliper bolt 2 8 30 Pre-coated (ALOC) bolt,
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replace with a new one.

Front brake caliper main slide pin 1 8 22 Apply locking agent.
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Front brake caliper bleed valve 1 8 5.4

REAR BRAKE
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Rear brake arm nut 1 6 10 Self lock nut
1-14
GENERAL INFORMATION
PGM-FI SYSTEM
EOT sensor 1 10 15 Apply engine oil.
O2 sensor 1 12 25
Bank angle sensor 2 6 5.8
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IGNITION SYSTEM
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Spark plug 1 10 16
LIGHTING SYSTEM
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Turn signal light mounting nut 4 10 19
SPEEDOMETER
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Meter screw 3 4 1.2
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GENERAL INFORMATION
SPECIAL TOOL LIST

TITLE TOOL No. TOOL NAME
07406-0040004 Fuel pressure gauge
070MJ-K260100 Fuel pressure gauge attachment
n
070MF-KVS0300 Fuel pump case remover
ió
070PZ-ZY30100 SCS short connector
07708-0030200 Locknut wrench, 10 x 12 mm
uc
07908-KE90000 Tappet adjusting wrench, 3 x 4 mm
070MG-0010100 Tensioner stopper
Fuel & Engine
07757-0010000 Valve spring compressor
rib
07984-MA60001 Valve guide reamer, 5.0 mm
07942-MA60000 Valve guide driver, 4.8 mm
07724-0010200 Gear holder
st
07GMB-KT70101 Clutch center holder
07725-0040001 Flywheel holder
Di
07933-KM10001 Flywheel puller
07746-0050300 Bearing remover head, 12 mm
o
07746-0050100 Bearing remover shaft
y
er
07746-0010200 Attachment, 37 x 40 mm
07746-0040200 Pilot, 12 mm
n
om
07749-0010000 Driver
07748-0010001 Oil seal remover
ió
07747-0010100
R
Fork seal driver weight
Frame & Chassis 07747-0010300 Fork seal driver attachment
cc
dy
07747-0010400 Fork seal driver attachment
07916-KA50100 Lock nut wrench
re
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07746-0050500 Bearing remover head, 17 mm

07746-0040400 Pilot, 17 mm
F
07953-MJ10000 Ball race remover set

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07746-0010300 Attachment 42 x 47 mm
07914-SA50001 Snap ring pliers
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hi
C
R
|
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a
Ch
id
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oh
Pr
1-16
GENERAL INFORMATION
CABLE & HARNESS ROUTING
COMBINATION
n
SWITCH WIRE
ió
uc
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RIGHT HEADLIGHT LEFT
st
HANDLEBAR WIRE HANDLEBAR
SWITCH WIRE SWITCH WIRE
Di
o
y
er
RIGHT
n
om
HANDLEBAR
LEFT
SWITCH WIRE
HANDLEBAR
ió
R SWITCH WIRE
TURN
SIGNAL
cc
dy
LIGHT
WIRE MAIN WIRE
re
HARNESS
du
INSIDE BOOT CONNECTORS:

F
· LEFT HANDLEBAR 9P
· LEFT HANDLEBAR SWITCH WIRE
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MAIN WIRE
HARNESS
le
ep
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MAIN WIRE
C
HARNESS
R
|

· RIGHT HANDLEBAR SWITCH 6P
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· LEFT FRONT TURN SIGNAL LIGHT WIRE 5 – 10 mm

· RIGHT FRONT TURN SIGNAL LIGHT WIRE
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Ch
· FRONT TURN SIGNAL LIGHT GROUND WIRE

id
ib
oh
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1-17
GENERAL INFORMATION
THROTTLE
n
CABLE A
ió
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2 – 4 mm
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THROTTLE
CABLE B
er st
om Di
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dy n y
F ció
R
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|
p r
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Ch Re
C
|
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SPEEDOMETER
CABLE
a
id
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WHITE IDENT MARK

AREA (15 mm)
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WHITE IDENT MARK

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1-18
GENERAL INFORMATION
INSIDE BOOT
CONNECTORS: BATTERY
· REAR BRAKE LIGHT SWITCH 2P NEGATIVE (–)
NEUTRAL
n
· ALTERNATOR 3P CABLE
SWITCH
ió
· ALTERNATOR 2P WIRE
· NEUTRAL SWITCH WIRE
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To be butted.
rib
O2 SENSOR
2P CONNECTOR
er st
ALTERNATOR
WIRE
om Di
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EOT SENSOR
dy n y
2P CONNECTOR DLC
ECM 33P
CONNECTOR
F ció
R
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re
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|
p r
hi
Ch Re
C
|
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STARTER
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MOTOR
CABLE
a
id
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BATTERY
NEGATIVE (–)
oh
CABLE
45° ± 5°
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ALTERNATOR
WIRE
BATTERY
NEGATIVE (–)
CABLE
NEUTRAL
SWITCH WIRE
1-19
GENERAL INFORMATION
NEUTRAL
NEUTRAL
SWITCH WIRE
SWITCH WIRE
n
ió
uc
DRIVE
SPROCKET
COVER
rib
NEUTRAL
SWITCH WIRE
er st
om Di
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DRIVE
dy n y
SPROCKET
COVER
F ció
R
DRIVE
SPROCKET
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COVER
re
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|
p r
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CKP SENSOR
Ch Re
C
WIRE
|
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a
id
ib
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ALTERNATOR
WIRE
Pr
1-20
Pr
oh
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a
la
Ch Re
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|
p r
C od
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|
F ció
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dy n y
R
om Di
er st
o rib
3P CONNECTOR
uc
BANK ANGLE SENSOR
ió
n
WIRE
GENERAL INFORMATION
IGNITION COIL
1-21
GENERAL INFORMATION
MAIN WIRE
HARNESS
n
ió
INJECTOR 2P
uc
CONNECTOR
er st
rib
om Di
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dy n y
MAIN WIRE
F ció
HARNESS
R
IACV 4P
CONNECTOR
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re
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|
p r
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Ch Re
C
|
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MAIN WIRE
HARNESS
a
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TURN SIGNAL
oh
LIGHT WIRE
Pr

· LICENSE LIGHT 2P
· BRAKE/TALE LIGHT 3P
· LEFT REAR TURN SIGNAL LIGHT WIRE
· RIGHT REAR TURN SIGNAL LIGHT WIRE
· REAR TURN SIGNAL LIGHT GROUND WIRE
1-22
Pr
oh
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id
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Ch Re
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p r
C od
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|
F ció
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dy n y
R
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uc
ió
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FUEL FEED HOSE
GENERAL INFORMATION
1-23
GENERAL INFORMATION
TECHNICAL FEATURES
FUEL PUMP SYSTEM WITH A FUEL FILTER BLOCKAGE REMINDER
FUNCTION
n
ió
FUEL TANK
BREATHER FILTER
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FUEL PUMP
rib
FUEL LEVEL
st
Di
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BREATHER
PASSAGE
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PUMP CHAMBER
ió
To FUEL INJECTOR
R
cc
dy
FUEL FILTER
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du
F
: Air suction passage under fuel filter blockage

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: Air discharge passage under normal fuel filter condition

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: Fuel flow under normal fuel filter condition

C
R
The fuel pump system of this model consists of the following components:
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– Fuel pump chamber

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ile
– Fuel filter
– Breather passage
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Ch
– Breather filter
Under normal condition, the fuel pump chamber sucks fuel through the fuel filter and then supplies it to the injector.
id
When the fuel filter is clogged, the fuel is sucked into the pump chamber through the breather passage in order to
keep the vehicle running. The breather filter is located in the upper inner side of fuel tank. When the fuel is consumed
ib
to the point where the breather filter is exposed above the fuel level, a certain amount of air will be drawn into the
pump chamber via the breather filter and breather passage. This incoming air produces "a lack of fuel", which impairs
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engine performance in order to notify the rider of the fuel filter blockage. This symptom works as a reminder for the
filter replacement.
This system eliminates the need of fuel filter replacement according to a fixed interval, as the rider will experience the
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symptom and notice the filter blockage during vehicle usage.

The driveability remains normal as long as the fuel level in tank is maintained above the breather filter because no air
will be drawn into the pump chamber, even when the fuel filter is clogged.
If the fuel in tank is sufficient but such symptom as poor engine performance, lack of fuel, or engine start failure exist,
perform the fuel supply test.
1-24
GENERAL INFORMATION
MAINTENANCE SCHEDULE
• Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
• I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
• The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may
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require more technical information and tools. Consult a dealer.
ió
• Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this
manual.
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FREQUENCY (NOTE 1) REFER
ANNUAL REGULAR
ITEMS NOTE X1,000 km 1 6 12 18 24 30 36 CHECK REPLACE TO
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X1,000 mi 0.6 4 8 12 16 20 24 PAGE
* FUEL LINE I I I I I I I
* THROTTLE OPERATION I I I I I I I
st
* AIR CLEANER NOTE2 R R 2-7
CRANKCASE BREATHER NOTE3 C C C C C C
Di
SPARK PLUG I R I R I R 4-22
* VALVE CLEARANCE I I I I I I 2-14
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ENGINE OIL R R R R R R R R 2-13
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** ENGINE OIL STRAINER
C C C 2-13
SCREEN n
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** ENGINE OIL CENTRIFUGAL
C C C 2-21
FILTER
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* ENGINE IDLE SPEED I
R I I I I I I I
DRIVE CHAIN NOTE4 Every 1000 Km (600 mi) I, L
cc
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DRIVE CHAIN SLIDER I I I I I I
BRAKE FLUID NOTE5 I I I I I I I 2 years
re
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BRAKE SHOES/PADS WEAR I I I I I I I

BRAKE SYSTEM I I I I I I I I
F
BRAKE LIGHT SWITCH I I I I I I I

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HEADLIGHT AIM I I I I I I I 4-33

CLUTCH SYSTEM I I I I I I I I
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SIDESTAND I I I I I I I
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* SUSPENSION I I I I I I I
* NUTS, BOLTS, FASTENERS NOTE4 I I I I I
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** WHEELS/TIRES NOTE4 I I I I I I I
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** STEERING HEAD BEARINGS I I I I

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• * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
• ** In the interest of safety, we recommend these items be serviced only by a dealer.
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• Honda recommends that a dealer should road test the vehicle after each periodic maintenance is carried out.
NOTES:
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1. At higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in unusually wet or dusty areas.
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3. Service more frequently when riding in rain or at full throttle.

4. Service more frequently when riding OFF-ROAD.
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5. Replacement requires mechanical skill.

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1-25
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F ió
MEMO
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R y
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2. FUEL & ENGINE
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FUEL LINE················································ 2-2 CYLINDER/PISTON ······························· 2-20
ió
FUEL PUMP UNIT ···································· 2-4 CLUTCH/GEARSHIFT LINKAGE ·········· 2-21
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FUEL TANK·············································· 2-6 ALTERNATOR/STARTER CLUTCH······ 2-24
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AIR CLEANER·········································· 2-7 CRANKCASE/CRANKSHAFT/
BALANCER ············································ 2-26
st
THROTTLE BODY···································· 2-8
TRANSMISSION ···································· 2-28
Di
LUBRICATION SYSTEM························ 2-12
ENGINE UNIT ········································· 2-31
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CYLINDER HEAD··································· 2-14
er
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F
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C
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2-1
FUEL & ENGINE
FUEL LINE
FUEL & ENGINE
• This vehicle uses resin for the part of materials in the fuel
feed hose. Do not bend or twist the fuel feed hose.
• Seat 3-4
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• Fuel tank shroud 3-8
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• Fuel pump 5P connector
• Let the engine idle until it stops.
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• Battery negative (–) cable 4-28
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• Do not use tools in removal. If the connector does not
move, alternately pull and push the connector until it
comes off easily.
• Check the fuel quick connect fitting for dirt, and clean if
F ció
R necessary.
• Place a shop towel over the quick connect fitting.
• Push the retainer tab forward.
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• Press down the retainer and disconnect the connector

from the fuel pump joint/injector joint.
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• Check the retainer condition and replace the fuel feed

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hose if necessary.
• To prevent damage and keep foreign matter out, cover the
|
disconnected connector and pipe end with the plastic

r
bags.
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• Press the connector onto the fuel joint until the retainer
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locks with a “CLICK”. If it is hard to connect, put a small

Ch Re
amount of engine oil on the pipe end.

C
• Make sure the connection is secure; check visually and by

pulling the connector.
|
• After installing the removed parts, turn the ignition switch

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ON. (Do not start the engine.)

The fuel pump will run for about 2 seconds, and fuel
a
pressure will rise. Repeat 2 or 3 times, and check that

there is no leakage in the fuel supply system.
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2-2
FUEL & ENGINE
FUEL SUPPLY TEST
• If the fuel in tank is sufficient but such symptom as poor en-
gine performance, lack of fuel, or engine start failure exist,
perform the following.
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– Perform the fuel pressure test. 2-3
– Fuel flow inspection if the fuel pressure is within specifi-
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cation. 2-3
– Fuel flow inspection in the specified fuel quantity. 2-3
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FUEL PRESSURE TEST
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• Quick connect fitting (fuel pump side)
[A]
st
• Attach the fuel pressure gauge and attachment.
[A] Fuel pressure gauge: 07406-0040004
Di
[B] Fuel pressure gauge attachment: 070MJ-K260100
• Temporarily connect the negative cable to the battery and
[B]
o
fuel pump 5P connector.
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Start the engine and let it idle, and read the fuel pressure.
er
Standard: 294 kPa
n
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• If the fuel pressure is higher than specified, replace the fuel
pump assembly. 2-4
ió
to INJECTOR • If the fuel pressure is lower than specified, inspect the
R
(fuel feed hose) following.
– Fuel line leaking
cc
dy
– Any erratic swing or vibration of the gauge needle in the
pressure gauge reading.
re
du
• If the needle is swing or vibration, replace the fuel fil-

ter. 2-5
F
• If the needle is not swing or vibration, replace the fuel

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pump unit. 2-4

|
from FUEL PUMP

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FUEL FLOW INSPECTION

C
R
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• Quick connect fitting (injector side) 2-2

from FUEL PUMP • Place the end of the hose into an approved gasoline con-
la
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tainer. Wipe off spilled out gasoline.

• Turn the ignition switch ON (Do not start the engine.) and
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Ch
the fuel pump operates for 2 seconds. Repeat 5 times to

meet the total measuring time.
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Standard: 58.6 cm3 minimum/10 seconds

• If fuel flow is less than specified, inspect the following:
– Clogged fuel hose
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– Fuel pump unit

• Place the vehicle on the level ground with its sidestand.
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Adjust the fuel in the tank so that the fuel gauge is posi-
[A] tioned the specified range [A], and inspect the fuel flow.
– If the fuel flow is above specification, check for other mal-
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functioning parts.
– If the fuel flow is under specification, replace the fuel fil-
ter. 2-5
2-3
FUEL & ENGINE
FUEL PUMP UNIT
12 N·m
n
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st
Di
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R
cc
dy
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F
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C
R
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• Quick connect fitting (fuel pump side) 2-2

• Fuel tank 2-6
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• Loosen the nuts in a crisscross pattern in several steps.

• Carefully remove the fuel pump unit from the fuel tank to prevent damaging the fuel level sensor.
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• Install a new outer packing onto the fuel pump unit groove by aligning the tab with the boss.
• Set the setting plate onto the fuel pump by aligning the hole and boss.
• Install the fuel pump into the fuel tank by aligning the setting plate triangle mark with the fuel tank triangle
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mark.
• Tighten the fuel pump setting plate nuts in the specified sequence as shown.
• Make sure that the outer packing tab can be seen in the setting plate hole.
• Fuel pump malfunction and inspection
2-4
FUEL & ENGINE
FUEL FILTER
G Y G
n
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Y
st
Di
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R
cc
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G
C
R
|
Y
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Ch
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R Bl Y G
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• To prevent dirt and debris from entering the fuel pump unit, always clean it before disassembly.
• Clean the fuel pump unit and fuel pump filter with clean gasoline. Never use commercially available
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carburetor cleaners.
• Release the hooks from the stoppers by slightly spreading the hooks using the special tool.
Fuel pump case remover: 070MF-KVS0300
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• Release the hooks from the stoppers by slightly spreading the hooks, and then turn the filter.
• Fuel filter for clogs or excessive damage
• If the fuel filter is clogged, replace it with a new one.
• Before installing the fuel pump filter, check the fuel pump unit for dirt. If necessary, clean the fuel pump unit
with compressed air. Do not blow into the fuel pump unit.
• If the R or Bl wire connector is disconnected, replace the fuel level sensor with a new one.
• Connect the fuel pump motor wires to the specified terminals.
• Make sure the "CLICK" when the fuel pump unit is assembled.
• Route the fuel pump motor wires and fuel level sensor wires to the guide and terminals properly.
2-5
2-6
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FUEL TANK
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FUEL & ENGINE
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Ch Re
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C

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F ció
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R
om Di
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FUEL & ENGINE
AIR CLEANER
1.0 N·m
1.0 N·m
n
ió
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st
Di
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R
cc
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F
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1.0 N·m
hi
C
R
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• Discard the air cleaner element in accordance with the maintenance schedule. 1-25
• Replace the element any time if it is excessively dirty or damaged.
• Seat 3-4
• Side cover 3-7
• Rear center cowl 3-5
• Battery box 3-11
2-7
FUEL & ENGINE
THROTTLE BODY
12 N·m
n
ió
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st
Di
2.5 N·m
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n 4.5 N·m
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R
cc
dy
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• Injector 2-11
F
• If the throttle body is replaced, perform the TP sensor reset procedure. 2-10
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|
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• Throttle body cleaning and inspection

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C
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2-8
FUEL & ENGINE
3.4 N·m
[A]
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Di
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2.1 N·m
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R
cc
dy
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F
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3.4 N·m
le
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
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• Do not loosen or tighten the white painted fastener. Loosening or tightening it can cause throttle body malfunction.
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Sensor unit
C
R
• Throttle body 2-8

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• Install the sensor unit to the throttle body by aligning the clip of the sensor unit with the boss of the throttle
valve.
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• Perform the TP sensor reset procedure. 2-10

IACV
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• Throttle cable cover 2-8

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• Turn the slide valve [A] clockwise until lightly seated on IACV.
• Align the slot in the set plate with the lug of the IACV.
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• Align the slide valve groove with the pin.

• Check the IACV for wear or damage.
• The IACV operation can be checked visually as follows:
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1. Connect the IACV 4P connector.

2. Turn ignition switch ON, check the slide valve operation.
2-9
FUEL & ENGINE
TP SENSOR RESET PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, TP sensor reset mode won’t start by follow-
ing the procedure below.
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• Left side cover 3-7
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• Connector cover from the DLC [A].
• Connect the special tool to the DLC.
SCS short connector: 070PZ-ZY30100
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[A]
st
• EOT sensor 2P connector [B].
• Short the EOT sensor 2P connector terminals with jumper
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wire.
Connection: Y/Bu – G/W
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Y/Bu G/W n
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R
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[B]
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• Turn the ignition switch ON, and then disconnect the

jumper wire from the EOT sensor 2P connector within 10
F
seconds while the MIL is blinking (reset receiving pattern).

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[B] • Check for the MIL blinks.

After disconnecting the jumper wire, the MIL should start
le
short blinking. (reset completed pattern)

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If the jumper wire is connected for more than 10 seconds,

the MIL will stay ON (unsuccessful pattern). Try again from
C
within 10 sec. the first.

R
• Check the engine idle speed.

|
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Reset procedure and MIL blinking pattern

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within 10 sec.
0.3 sec.
0.3 sec.
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0.1 sec.
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1.3 sec.
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Reset receiving Reset completed
2-10
FUEL & ENGINE
INJECTOR
5.1 N·m
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ió
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om Di
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dy n y
F ció
R
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|
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Ch Re
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2-11
FUEL & ENGINE
LUBRICATION SYSTEM
SYSTEM DIAGRAM
n
OIL STRAINER
OIL PUMP
ió
SCREEN
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CENTRIFUGAL
OIL FILTER
rib
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Di
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R
cc
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F
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C
R
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ENGINE OIL LEVEL CHECK

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Ch
• Place the vehicle on the level ground.

• Let the engine idle for 3 – 5 minutes.
id
• Wait for 2 – 3 minutes.

UPPER
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• Hold the vehicle in an upright position.

• Clean and insert the oil filler cap/dipstick without screwing
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it in, remove it and check the oil level.

• If the oil level is below or near the lower level line on the
LOWER dipstick, add the recommended oil to the upper level.
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• Check that the O-ring on the oil filler cap is in good

condition, and replace it if necessary.
• RECOMMENDED ENGINE OIL:
Honda “4-stroke motorcycle oil” or an equivalent mo-
tor oil.
API service classification: SG or higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
2-12
FUEL & ENGINE
ENGINE OIL CHANGE
• Drain oil completely.
30 N·m
• Fill the crankcase with the recommended engine oil.
n
ió
• ENGINE OIL CAPACITY:
1.0 liter after draining
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1.2 liter after disassembly
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st
Di
ENGINE OIL STRAINER SCREEN/OIL PUMP
o
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R
cc
dy
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F
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C
R
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Ch
id
3.0 N·m
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• Right crankcase cover 2-21

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• Align the cutouts of the oil pump drive shaft and inner rotor.
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• Oil pump inspection
2-13
FUEL & ENGINE
CYLINDER HEAD
• The following services can be serviced with the engine installed in the frame.
VALVE CLEARANCE
n
• Inspect while the engine is cold (below 35°C).
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10 N·m • Cylinder head cover 2-15
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• Rotate the crankshaft counterclockwise and align the "T"
mark on the flywheel with the index notch on the left crank-
case cover.
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st
Di
15 N·m
• The index lines on the cam sprocket are aligned with the
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y
[B]
cylinder head tabs [A].
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• Make sure that the mark [B] on the cam sprocket is in the
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position shown (TDC).
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If the cam sprocket mark is not in position shown, rotate
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the crankshaft one full turn.
R
cc
dy
[A]
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F
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• Valve clearance (Insert a feeler gauge between the valve

adjusting screw and valve stem).
le
ep
IN: 0.08 ± 0.02 mm, EX: 0.24 ± 0.02 mm

hi
Locknut wrench, 10 x 12 mm: 07708-0030200

Tappet adjusting wrench, 3 x 4 mm: 07908-KE90000
C
R
• Loosen the lock nut and turn the adjusting screw until there
is a slight drag on the feeler gauge.
|
• Hold the adjusting screw and tighten the lock nut.

la
ile
• Recheck the valve clearance after tightening.

a
Ch
18 N·m
id
ib
oh
Pr
2-14
Pr
oh
ib
id
a
la
Ch R
ep

ile
| ro
CYLINDER HEAD COVER
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
FUEL & ENGINE
2-15
FUEL & ENGINE
CAMSHAFT/ROCKER ARM
• Set the piston to the TDC on the compression stroke.
2-14
• Install the special tool into the tensioner body and turn the
n
tool clockwise until it stops. Hold the tensioner lifter by
pushing the tool while aligning the tabs of the tool with the
ió
grooves of the tensioner lifter.
Tensioner stopper: 070MG-0010100
uc
rib
4.0 N·m
st
Di
Intake:
o
y
er
n
om
Cam chain side [B]
ió
R
cc
dy
re
[A]
du
F
9.0 N·m
ro
|
le
ep
hi
C
R
5.0 N·m
|
12 N·m
la
ile
a
Ch
id
ib
Exhaust:
oh
Cam chain side

Pr
• Install the camshaft with its flange tab facing up.

• Insert the rocker arm shafts into the cylinder head as shown using a flat-tip screwdriver and align the bolt
holes in the shafts and the cylinder head.
• The index lines on the cam sprocket are align with the cylinder head tabs [A]. Make sure that the mark [B]
on the cam sprocket is in the position shown.
• Camshaft inspection
2-16
FUEL & ENGINE
30 N·m
7.4 – 12 mm
n
ió
uc
rib
9.0 N·m
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
• Camshaft/rocker arm 2-16

• Exhaust pipe/muffler 3-13
oh
• Insulator 2-8
• Upper engine hanger bracket 2-31
• Spark plug 4-22
Pr
• EOT sensor 4-19

• O2 sensor 4-20
• Remove the cylinder head bolts.
• Loosen the cylinder head nuts in a crisscross pattern in several steps.
• Remove the stud bolts.
• Install the cam chain guide while aligning its pins with the grooves on the cylinder and its end with the
groove on the left crankcase.
• After tightening the cylinder head nuts, check that the length from the cylinder stud bolt head to the cylinder
head nut upper surface is within specification.
2-17
FUEL & ENGINE
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
• Remove the valve cotters.

Valve spring compressor: 07757-0010000
ib
• Ream the valve guide to remove any carbon build up before measuring the guide. Insert the reamer from
the combustion chamber side of the cylinder head and always rotate the reamer clockwise.
oh
Valve guide reamer, 5.0 mm: 07984-MA60001

• Support the cylinder head and drive the valve guides out of the cylinder head from the combustion
chamber side.
Pr
Valve guide driver, 4.8 mm: 07942-MA60000

• Drive new valve guides into the cylinder head until they are fully seated.
Valve guide driver, 4.8 mm: 07942-MA60000
VALVE GUIDE PROJECTION: (Reference) 16.8 – 17.0 mm
• Valve and valve spring inspection
• Valve guide inspection
• Valve seat inspection
2-18
FUEL & ENGINE
CAM CHAIN TENSIONER
• Install the special tool into the tensioner body and turn the
tool clockwise until it stops. Hold the tensioner lifter by
pushing the tool while aligning the tabs of the tool with the
n
grooves of the tensioner lifter.
Tensioner stopper: 070MG-0010100
ió
uc
rib
4.0 N·m
st
• Check the cam chain tensioner lifter operation:
– The tensioner shaft should not go into the body when it
Di
is pushed.
– When it is turned clockwise with the tensioner stopper,
o
the tensioner shaft should be pulled into the body. The
y
er
shaft should protrude from the body as soon as the
n tensioner stopper is released.
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
2-19
FUEL & ENGINE
CYLINDER/PISTON
• This service can be serviced with the engine installed in the frame.
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
• Cylinder head 2-14

• Cam chain tensioner 2-19
ib
• Spread each piston ring and remove it by lifting up at a point opposite the gap.
• Carefully install the piston rings into the piston ring grooves with the markings facing up.
oh
Top ring: “1R” or “TOP-1” mark

Second ring: “RN” or “TOP-2” mark
• Install the piston with the “IN” mark facing the intake side.
Pr
• Do not align the piston pin clip end gap with the piston cut-out.
• Piston and piston rings inspection
• Cylinder inspection
2-20
Pr
oh
ib
id
a
la
1.0 mm
Ch R
ile ep
| ro
C du
hi
le
| cc
F ió
CLUTCH/GEARSHIFT LINKAGE
re n
dy
R y
om Di
er st
o rib
uc
ió
n
FUEL & ENGINE
0.5 – 1.0 mm
2-21
FUEL & ENGINE
22 N·m
n
ió
uc
rib
st
12 N·m
Di
o
y
er
12 N·m
n
om
83 N·m
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
12 N·m
|
4.0 N·m
la
ile
a
Ch
Each bearing
83 N·m
Each gear tooth
id
Coating width:
6.5 ± 1 mm from the tip
ib
• Shift change pedal 3-9

• Loosen the oil filter rotor lock nut.
oh
Gear holder: 07724-0010200

• Loosen the clutch center lock nut.
Clutch center holder: 07GMB-KT70101
Pr
• Align the punch marks of the balancer driven gear and drive gear.
2-22
FUEL & ENGINE
n
[A]
ió
uc
rib
st
Di
o
y
er
n
om
[B]
ió
R
cc
• Install the two types of clutch discs properly as shown.

dy
[A] 22201-KRE-G01
[B] 22201-KTT-900
re
du
• Assemble clutch discs, clutch plates and pressure plate onto clutch center, while aligning " " marks of
clutch center and pressure plate.
F
• Install the tabs of the clutch disc (outside) into the shallow slots in the clutch outer.
ro
|
• Clutch inspection
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
2-23
FUEL & ENGINE
• This service can be serviced with the engine installed in the frame.
n
Clean.
ió
uc
rib
st
Di
74 N·m
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
• Drive sprocket cover 3-9

• Hold the flywheel with the special tool for the nut removal.
Flywheel holder: 07725-0040001
• Flywheel
Flywheel puller: 07933-KM10001
• Clean any oil and grease from crankshaft and flywheel contact area. Install the flywheel onto the crank-
shaft by aligning the key way with the woodruff key.
2-24
FUEL & ENGINE
n
ió
uc
rib
16 N·m
st
Di
o
y
er
n
om
ió
R Coating width:
cc
dy
re
du
F
12 N·m 12 N·m
ro
|
le
ep
hi
C
R
|
12 N·m
la
ile
a
Ch
id
ib
oh
Pr
Coating width:
• Apply sealant (TB 1141G, 1215, 1207G, or equivalent) to the seating surface.
2-25
FUEL & ENGINE
CRANKCASE/CRANKSHAFT/BALANCER
Coating width:
[A] 64 N·m 6.5 ± 1 mm from the tip
Each bearing
n
Each gear tooth
ió
[B]
uc
rib
1 – 2 cm3
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
[A]
C
R
|
10 N·m
la
ile
[B]
55 N·m
a
Ch
• Engine unit 2-31 • Oil pump 2-13

• Cylinder/piston 2-20 • Neutral switch 4-26
id
• Clutch/gearshift linkage 2-21 • Starter motor 4-25

• Alternator/starter clutch 2-24
ib
• Remove the crankcase bolts in a crisscross pattern in 2 – 3 steps.

• Place the crankcase with the left crankcase facing down and separate.
oh
• Install the gear holder [A]. Temporarily install the balancer drive gear and loosen the right side of the bal-
ancer driven gear lock nut [B].
Gear holder: 07724-0010200
Pr
• Install the gear holder [A] and loosen the left side of the balancer nut [B].
Gear holder: 07724-0010200
• Align with the cut-outs of the crankshaft and balancer shaft.
• Install the push plug by aligning its flat surface with the crankshaft bearing outer race.
• Temporarily install the balancer drive gear and align with the punch marks of the balancer driven gear and
drive gear.
• Apply sealant (TB1215, 1207G, or equivalent) to the left crankcase mating surface.
• Crankshaft inspection
• Connecting rod inspection
2-26
FUEL & ENGINE
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
• Balancer inspection
F
ro
|
le
CRANKSHAFT RUNOUT INSPECTION

ep
hi
• Set the crankshaft on V-blocks and measure the runout us-

C
ing a dial indicator.

R
Limit: 0.03 mm
|
la
ile
a
Ch
id
ib
47.5 mm 45.0 mm
oh
Pr
2-27
FUEL & ENGINE
TRANSMISSION
Coating width:
Each bearing
n
Each gear tooth
ió
uc
rib
st
R/L
Di
o
y
er
n
om
ió
R
cc
dy
C
12 N·m
re
du
F
ro
|
le
0.5 – 1.0 mm
ep
0.5 – 1.0 mm
hi
C
R
|
la
ile
a
Ch
• Separate the crankcase 2-26

id
• Each shift fork has an identification mark.

R/L: right and left
ib
C: center
• Install the oil seal to the left crankcase so that the depth as shown.
• Align the wide tooth with the wide groove of the kickstarter spindle.
oh
Pr
2-28
FUEL & ENGINE
MAINSHAFT
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
Each gear tooth R
cc
• Transmission inspection
dy
re
du
F
COUNTERSHAFT
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
Each gear tooth
• Transmission inspection
2-29
FUEL & ENGINE
n
ió
uc
er st
rib
om Di
o
dy n y
F ció
R
le uc
re
od
|
p r
hi
Ch Re
C
|
la
ile
a
id
ib
• Hook the return spring to the hole of the kickstarter spindle, and then install the collar by aligning its cut-
oh
out with the spring.

• Kickstarter inspection
Pr
2-30
FUEL & ENGINE
ENGINE UNIT
35 N·m
60 N·m
n
ió
35 N·m
uc
rib
st
Di
60 N·m
o
y
er
n
om
ió
R
cc
dy
re
du
35 N·m
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
12 N·m
35 N·m
• Exhaust pipe/muffler 3-13

• Fuel tank 2-6
2-31
Pr
oh
ib
id
a
la
Ch R
ile ep
| ro
C du
hi
le
| cc
F ió
MEMO
re n
dy
R y
om Di
er st
o rib
uc
ió
n
3. FRAME & CHASSIS
n
BODY PANELS ········································ 3-2 STEERING STEM··································· 3-19
ió
SIDESTAND ··········································· 3-12 REAR WHEEL ········································ 3-21
uc
EXHAUST PIPE/MUFFLER···················· 3-13 REAR SUSPENSION ····························· 3-23
rib
FRONT WHEEL······································ 3-14 FRONT BRAKE ······································ 3-24
st
FORK ······················································ 3-16 REAR BRAKE ········································ 3-27
Di
HANDLEBAR ········································· 3-18
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
3-1
FRAME & CHASSIS
BODY PANELS
FRAME & CHASSIS
[1]
[2]
n
[3]
ió
uc
[8]
rib
st
Di
[4]
o
y
er
n
om
[5]
ió
[7]
R
[6]
cc
dy
[9]
[16]
[15]
re
du
F
ro
|
[10]
le
ep
hi
C
[14]
R
|
la
ile
a
Ch
[13]
id
ib
[11]
oh
[12]
Pr
[1] Rearview mirror 3-3 [9] Front cowl 3-3

[2] Battery box 3-11 [10] Front fender 3-4
[3] Seat 3-4 [11] Brake pedal 3-10
[4] Tool box 3-12 [12] Side cover 3-7
[5] Drive chain case 3-7 [13] Rear fender 3-6
[6] Drive sprocket cover 3-9 [14] Rear grip 3-5
[7] Shift change pedal 3-9 [15] Rear center cowl 3-5
[8] Fuel tank shroud 3-8 [16] Throttle cable cover 3-11
3-2
Pr
oh
ib
id
a
FRONT COWL
la
Ch R
REARVIEW MIRROR
ile ep
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
FRAME & CHASSIS
3-3
3-4
SEAT
Pr
oh
ib
id
FRONT FENDER

a
la
FRAME & CHASSIS
Ch R
ile ep
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
FRAME & CHASSIS
REAR CENTER COWL
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
• Seat 3-4
re
du
F
REAR GRIP
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
3-5
FRAME & CHASSIS
REAR FENDER
n
ió
uc
er st
rib
om Di
o
dy n y
F ció
R
le uc
re

od
• Rear turn signal light 3-5

|
p r
hi
Ch Re
C
|
la
ile
a
id
ib
oh
Pr
CL only :
3-6
Pr
oh
ib
id
a
SIDE COVER
la
Ch R
DRIVE CHAIN CASE

ile ep
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
FRAME & CHASSIS
3-7
3-8
Pr
oh
ib
id

a
la
FUEL TANK SHROUD
FRAME & CHASSIS
Ch R
ile ep
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
CL only :
uc
ió
n
Pr
oh
ib
id
a
la
Ch R
ile ep
SHIFT CHANGE PEDAL
| ro
C
DRIVE SPROCKET COVER

hi du
le
| cc
F ió
re n
dy
R y
om Di
er st
o
98 mm
rib
uc
ió
n
FRAME & CHASSIS
3-9
3-10
Pr
oh
ib
BRAKE PEDAL
id
a
la
FRAME & CHASSIS
Ch R
ile ep
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
108 mm
er st
o rib
uc
ió
n
FRAME & CHASSIS
BATTERY BOX
n
ió
uc
er st
rib
om Di
o
dy n y
F ció
R
• Battery 4-28
le uc
• Seat 3-4
re
od
THROTTLE CABLE COVER

|
p r
hi
Ch Re
C
|
la
ile
a
id
ib
oh
Pr
3-11
FRAME & CHASSIS
TOOL BOX
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
SIDESTAND
ro
|
le
39 N·m
ep
hi
C
R
|
10 N·m
la
ile
Sliding surface
a
Ch
id
ib
oh
Pr
• After tightening the pivot bolt to the specified torque, turn it 45 – 90 ° counterclockwise.
• When tightening the pivot nut, hold the pivot bolt securely.
3-12
FRAME & CHASSIS
EXHAUST PIPE/MUFFLER
n
ió
uc
rib
14 N·m
st
Di
o
y
er
n
om
ió
R
cc
dy
10 N·m
re
du
20 N·m
F
ro
|
le
ep
hi
C
R
|
21
la
ile
.5
±1
.0
mm
a
Ch
11 N·m
id
ib
oh
Pr
10 N·m 18 N·m
• Muffler 3-13
3-13
3-14
Pr
oh
ib
id
FRONT WHEEL
• Wheel inspection
a
la
FRAME & CHASSIS
Ch R
ile ep
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
44 N·m
FRAME & CHASSIS
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
15 N·m
le
ep
hi
C
R
|
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
la
ile
and drive out the bearing from the wheel hub.

Bearing remover head, 12 mm: 07746-0050300
a
Ch
Bearing remover shaft: 07746-0050100

• Drive in a new bearing squarely with its marked side facing outside until it is fully seated.
id
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 12 mm: 07746-0040200
ib
• Install the distance collar.

• Drive in a new bearing squarely with its marked side facing outside until it is seated on the distance collar.
oh
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 12 mm: 07746-0040200
Pr
• Wheel disassembly and inspection
3-15
FRAME & CHASSIS
FORK
n
ió
uc
rib
22 N·m
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
32 N·m
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
12 N·m
• Front fender 3-4

Pr
• Front wheel 3-14

• Front brake caliper 3-26
• Align the mating surface with the top surface of the top bridge.
3-16
FRAME & CHASSIS
184 mm
n
ió
uc
rib
22 N·m
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
20 N·m
LEFT RIGHT
id
• Remove the oil seal.

Oil seal remover: 07748-0010001
ib
• Drive in a new oil seal squarely with its marked side facing up until it is fully seated.
oh
Fork seal driver weight: 07747-0010100

Fork seal driver attachment: 07747-0010400
• Pour the specified amount of recommended fork fluid into the fork pipe.
RECOMMENDED FORK FLUID: CN10# or equivalent
Pr
FORK FLUID CAPACITY: 183 ± 2.5 cm3

• Compress the fork leg fully and measure the fluid level from the top of the fork pipe.
FORK FLUID LEVEL: 184 mm
• Pull the fork pipe up and install the fork spring with its tightly wound coil side facing down.
• Fork disassembly and inspection
3-17
FRAME & CHASSIS
HANDLEBAR
3.0 N·m
3.8 N·m
n
ió
26 N·m
uc
3.0 N·m
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
1.0 N·m
id
ib
oh
5.9 N·m
Pr
• Front brake master cylinder 3-25

• Rearview mirror 3-3
• Align the punch mark with the top surface of the top bridge.
• Align the punch mark with the mating surface.
• Align the punch mark with the lower throttle housing index line.
• Align the locating pin with the handlebar hole.
3-18
FRAME & CHASSIS
STEERING STEM
TOP BRIDGE
22 N·m
n
103 N·m
ió
uc
er st
rib
om Di
o
dy n y
F ció
R
le uc
re
od
|
p r
hi
Ch Re
C
|
la
ile
a
id
• Speedometer 4-34
• Handlebar 3-18
ib
oh
Pr
3-19
FRAME & CHASSIS
BOTTOM BRIDGE
n
[A]
ió
uc
rib
3–5g
st
3–5g
Di
o
y
er
n
om
3–5g
ió
R [B] [C] [D]
cc
dy
3–5g
[B] [C] [D]
re
du
F
ro
|
le
ep
hi
C
R
|
Multi-purpose extreme pressure

la
3–5g
ile
grease NLGI #2 (EXCELITE EP2

3–5g
manufactured by KYODO YUSHI
CO., LTD. or equivalent) [E]
a
Ch
• STEERING STEM:
id
[A] Lock nut wrench: 07916-KA50100

• STEERING STEM BEARING:
[B] Ball race remover set: 07953-MJ10000
ib
• STEERING STEM BEARING:

[C] Driver: 07749-0010000
oh
[D] Attachment 42 x 47 mm: 07746-0010300

• STEERING STEM:
[A] Lock nut wrench: 07916-KA50100
Pr
[E] Fork seal driver attachment: 07747-0010300

• Install the adjusting nut. Hold the steering stem and tighten the adjusting nut to the initial torque.
TORQUE: 5.0 N·m
• Turn the steering stem lock-to-lock several times to seat the bearing. Completely loosen the top thread.
• Tighten the steering stem adjusting nut to the specified torque using the special tool.
TORQUE: 5.0 N·m
• Steering disassembly/assembly and inspection
3-20
Pr
oh
ib
id
a
la
REAR WHEEL
R
• Wheel inspection
Ch ep
ile
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
FRAME & CHASSIS
93 N·m
3-21
FRAME & CHASSIS
32 N·m
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive out the bearing from the wheel hub.
C
R
Remover head, 17 mm: 07746-0050500

|
Bearing remover shaft: 07746-0050100

• Drive in a new bearing squarely until it is fully seated.
la
ile
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
a
Ch
Pilot, 17 mm: 07746-0040400

• Install the distance collar.
id
• Drive in a new bearing squarely with its marked side facing outside until it is seated on the distance collar.
Driver: 07749-0010000
Attachment, 42 x 47 mm: 07746-0010300
ib
Pilot, 17 mm: 07746-0040400

• Wheel disassembly and inspection
oh
Pr
3-22
FRAME & CHASSIS
REAR SUSPENSION
44 N·m
n
40 mm
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
44 N·m
re
du
• If you dispose of the shock absorber, drill at the specified point as shown.
F
ro
|
le
88 N·m
ep
hi
C
R
|
la
ile
a
Ch
44 N·m
id
ib
oh
Pr
• Rear wheel 3-21

• Drive chain case 3-7
3-23
FRAME & CHASSIS
n
ió
uc
rib
st
Di
8 – 9 mm
o
y
er
n
om
6.0 N·m
ió
R
cc
dy
• Press the bearings with the marked side facing out.

re
du
F
FRONT BRAKE
ro
|
le
BRAKE FLUID REPLACEMENT

ep
hi
1.5 N·m
C
R
|
la
ile
a
Ch
id
ib
oh
Set line
Pr
• Fill the reservoir with brake fluid from a sealed container to the set line.
RECOMMENDED BRAKE FLUID: DOT 3 or DOT 4
3-24
FRAME & CHASSIS
BRAKE MASTER CYLINDER
12 N·m
n
ió
uc
rib
st
Di
o
y
er
n
om
34 N·m
ió
R
cc
dy
• Install the brake master cylinder and holder with the "UP" mark facing up. Align the edge of the master
cylinder with the punch mark on the handlebar.
re
du
F
ro
|
1.0 N·m
le
ep
Silicone grease
hi
Silicone grease
C
R
|
la
ile
a
Ch
id
ib
oh
1.2 N·m
Pr
5.9 N·m
• Brake fluid 3-24

• Remove the snap ring.
Snap ring pliers: 07914-SA50001
• Master cylinder inspection
3-25
FRAME & CHASSIS
BRAKE CALIPER
BRAKE PAD REPLACEMENT
n
ió
uc
17 N·m
rib
2.5 N·m
er st
om Di
o
dy n y
F ció
R
le uc
re
od
• Install brake pads so that they are set on the brake caliper bracket.
|
p r
hi
Ch Re
C
34 N·m
|
la
ile
a
id
ib
oh
Pr
30 N·m
3-26
FRAME & CHASSIS
Silicone
5.4 N·m grease
n
ió
uc
Silicone
grease
rib
st
Di
22 N·m
o
y
er
Silicone
grease
n
om
ió
• Brake caliper inspection
R
cc
dy
REAR BRAKE
re
du
0.2 – 0.3 g
F
0.2 – 0.3 g
0.2 – 0.3 g
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
0.2 – 0.3 g
oh
Pr
10 N·m
• Rear wheel 3-21
• Align the punch marks of the brake arm and brake cam.
3-27
Pr
oh
ib
id
a
la
Ch R
ile ep
| ro
C du
hi
le
| cc
F ió
MEMO
re n
dy
R y
om Di
er st
o rib
uc
ió
n
4. ELECTRICAL SYSTEM
n
PGM-FI SYSTEM······································ 4-2 LIGHTING SYSTEM ······························· 4-28
ió
IGNITION SYSTEM ································ 4-21 SPEEDOMETER ···································· 4-34
uc
ELECTRICAL STARTER ······················· 4-23 ELECTRICAL COMPONENT ················· 4-37
rib
BATTERY/CHARGING SYSTEM··········· 4-27
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
4-1
ELECTRICAL SYSTEM
PGM-FI SYSTEM
ELECTRICAL SYSTEM
• Refer to "Basic Shop manual" for the following information.

– PGM-FI technical feature and each sensor function.
– Symptom troubleshooting for the PGM-FI system.
n
– MCS (Motorcycle Communication System) information.
ió
DTC CODE INDEX
uc
DTC Function Failure Symptom/Fail-safe function Page
MAP sensor malfunction • Engine operates normally
1-1 4-5
• MAP sensor low voltage
rib
MAP sensor malfunction • Engine operates normally
1-2 4-6
• MAP sensor high voltage
EOT sensor malfunction • Hard start at a low temperature
st
7-1 4-7
• EOT sensor low voltage
EOT sensor malfunction • Hard start at a low temperature
7-2 4-8
Di
• EOT sensor high voltage
TP sensor malfunction • Poor engine acceleration
8-1 4-9
o
• TP sensor low voltage
y
er
TP sensor malfunction • Poor engine acceleration
8-2 4-10
• TP sensor high voltage n
om
IAT sensor malfunction • Engine operates normally
9-1 4-11
• IAT sensor low voltage
ió
IAT sensor malfunction • Engine operates normally
R
9-2 4-12
• IAT sensor high voltage
cc
Injector malfunction • Engine does not start

dy
12-1 4-13
• Injector, fuel pump and ignition coil shut down
21-1 O2 sensor malfunction • Engine operates normally 4-14
re
du
29-1 IACV malfunction • Engine stalls, hard to start, rough idling 4-15
F
ECM EEPROM malfunction • Engine stalls, hard to start, rough idling

• Does not hold the self diagnosis data
ro
|
33-2 4-16
• Does not erase the self diagnosis data with
le
SCS connector
ep
Bank angle sensor malfunction • Engine operates normally

hi
54-1 4-17
• Bank angle sensor low voltage • Engine stop function does not operate
Bank angle sensor malfunction • Engine operates normally
C
54-2 4-18
R
• Bank angle sensor high voltage • Engine stop function does not operate
|
la
ile
a
Ch
id
ib
oh
Pr
4-2
ELECTRICAL SYSTEM
PGM-FI SYSTEM LOCATION
n
ió
uc
FUEL PUMP
rib
IGNITION SWITCH
INJECTOR
st
IACV
Di
o
y
er
DLC
n
om
ió
BANK ANGLE R
SENSOR
cc
dy
re
du
F
ro
|
le
O2 SENSOR
ep
hi
C
R
|
EOT SENSOR
la
ile
CKP SENSOR
a
Ch
id
SENSOR UNIT:
· MAP SENSOR
ib
· IAT SENSOR ECM

· TP SENSOR
oh
Pr
4-3
ELECTRICAL SYSTEM
PGM-FI SYSTEM DIAGRAM
15A 10A
n
R R R/W R/Bu Bl/R
ió
IGNITION
SWITCH
uc
REGULATOR/
RECTIFIER
LOAD CUT
RELAY
rib
BATTERY R Bl/R
st
Bl/G Bl/R
Di
o
(33-2)
y
Bl/R
er
Bl/R ECM PCR
1 IGP 7
(54-1,54-2) R/Bu n
om
26 BA
BANK ANGLE Bl/O FUEL PUMP
SENSOR FFP 8
10A
ió
Y/R
6 VCC INJ
R 16
P/Bl (12-1)
INJECTOR
cc
SENSOR UNIT
dy
(1-1,1-2) Lg/Y
Bl/R
SCS SHORT
27 PB Bu
MAP SENSOR SCS 15 CONNECTOR
re
du
Y
(8-1,8-2) Y
5 THL
K-LINE 30
F
TP SENSOR DLC
G/Bl
Gr/Bu LG 2
ro
|
14 TA
(9-1,9-2)
IAT SENSOR
le
Y/Bu
24 TO
ep
(7-1,7-2) G/W W/Bu Bl

hi
4 SG FI-IND 18
EOT SENSOR
MIL
C
R
Br/W
|
IACV2A 20
Bu/Y Bu/W
12 IACV1A 21
PCP
la
(29-1)
ile
CKP SENSOR W/Y Br/Bl IACV

23 PCM IACV2B 31
Bu/Bl
IACV1B 32
a
Ch
id
G
(21-1) Bl/W PG1 9
3 O2 G
ib
PG2 10
O2 SENSOR
oh
Pr
( ) : DTC
1 2 3 4 5 6 7 8 9 10 11
: Engine does not start
12 13 14 15 16 17 18 19 20 21 22
when detecting DTC
23 24 25 26 27 28 29 30 31 32 33
:Short terminals for
reading DTC
ECM 33P CONNECTOR
(ECM side of the male terminals)
4-4
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW VOLTAGE)
n
ió
MAP Sensor Diagram
uc
Sensor unit 5P connector ECM 33P connector
Y/R Y/R G/W
er st
rib
G/W Lg/Y
Lg/Y
om Di
5V
o
VCC
dy n y
Y/R 5V
Sensor unit PB ECM
Lg/Y
(MAP sensor)
SG
G/W
F ció
R
le uc
1. MAP Sensor System Inspection

re
• Check the MAP sensor voltage with MCS. No • Intermittent failure

od
• Is the voltage about 0 V indicated? ► • Loose or poor contact at the connector

|
Yes ▼
r
2. Sensor unit Power Input Voltage Inspection

p
hi
Ch Re
C
|
• Open or short circuit in Y/R wires

la
ile
• Connection: Y/R (+) – G/W (–) No

• If there is no open or short circuit, replace the ECM
• Is the voltage within 4.75 – 5.25 V? ►
with a new one 4-19, and recheck.
a
Yes ▼
id
3. MAP Sensor Output Voltage Inspection

ib
oh
• Connection: Lg/Y (+) – G/W (–) Yes • Replace the sensor unit (MAP sensor) with a new
• Is the voltage within 3.80 – 5.25 V? ► one 2-8, and recheck.
Pr
No ▼
4. MAP Sensor Output Line Inspection
• Check a short circuit in Lg/Y wire.

• If there is no short circuit, replace the ECM with a
new one 4-19, and recheck.
4-5
ELECTRICAL SYSTEM
DTC 1-2 (MAP SENSOR HIGH VOLTAGE)
n
MAP Sensor Diagram
ió
uc
Y/R Y/R G/W
rib
G/W Lg/Y
Lg/Y
er st
om Di
5V
Y/R VCC
5V
o
Sensor unit PB ECM
dy n y
Lg/Y
(MAP sensor)
SG
G/W
F ció
R
1. MAP Sensor System Inspection
le uc
• Check the MAP sensor voltage with MCS. No • Intermittent failure

re

od
Yes ▼
|
2. MAP Sensor System Inspection 2

p r
hi
Ch Re
C
• Install a jumper wire between the terminals.

|
Connection: Lg/Y – G/W Yes • Replace the sensor unit (MAP sensor) with a new
la
• Check the MAP sensor voltage with MCS. ► one 2-8, and recheck.
ile
• Is the voltage about 0 V indicated?

a
No ▼
id
3. MAP Sensor Output Line Inspection
• Check an open circuit in Lg/Y and G/W wire.

ib
• If there is no open circuit, replace the ECM with a

oh
Pr
4-6
ELECTRICAL SYSTEM
DTC 7-1 (EOT SENSOR LOW VOLTAGE)
n
EOT Sensor Diagram
ió
EOT sensor 2P connector ECM 33P connector
uc
G/W
rib
Y/Bu G/W
Y/Bu
er st
5V
om Di
TO
Y/Bu
o
EOT sensor ECM
dy n y
SG
G/W
F ció
R
1. EOT Sensor System Inspection
• Check the EOT sensor voltage with MCS. No • Intermittent failure

le uc

re
Yes ▼
od
2. EOT Sensor Inspection

|
p r
hi
Ch Re
C
• Check the EOT sensor voltage with MCS. No • Replace the EOT sensor with a new one 4-19,
• Is the voltage about 0 V indicated? ► and recheck.
|
Yes ▼
la
ile
3. EOT Sensor Output Line Inspection

a
• Check an short circuit in Y/Bu wire.

id

ib
oh
Pr
4-7
ELECTRICAL SYSTEM
DTC 7-2 (EOT SENSOR HIGH VOLTAGE)
n
EOT Sensor Diagram
ió
EOT sensor 2P connector ECM 33P connector
uc
G/W
rib
Y/Bu G/W
Y/Bu
er st
5V
om Di
TO
Y/Bu
o
EOT sensor ECM
dy n y
SG
G/W
F ció
R
1. EOT Sensor System Inspection
• Check the EOT sensor voltage with MCS. No • Intermittent failure

le uc

re
Yes ▼
od
2. EOT Sensor Inspection

|
p r
hi
Ch Re
C

Connection: Y/Bu – G/W Yes • Replace the EOT sensor with a new one 4-19,
|
• Check the EOT sensor voltage with MCS. ► and recheck.

la
ile
No ▼
a
3. EOT Sensor Output Line Inspection

id
• Check an open circuit in Y/Bu and G/W wire.

ib

oh
Pr
4-8
ELECTRICAL SYSTEM
DTC 8-1 (TP SENSOR LOW VOLTAGE)
n
TP Sensor Diagram
ió
uc
Y/R Y G/W
rib
G/W Y
Y/R
er st
5V
om Di
VCC
Y/R
Sensor unit
o
Y THL ECM
(TP sensor)
dy n y
SG
G/W
F ció
1. TP Sensor System Inspection
R
• Check the TP sensor voltage with MCS. No • Intermittent failure
le uc
Yes ▼
re
2. Sensor unit Power Input Voltage Inspection

od
|
p r
hi
• Open or short circuit in Y/R wire

Ch Re

C
• Is the voltage within 4.75 – 5.25 V? ►

|
Yes ▼
la
ile
3. TP Sensor Output Line Inspection

a
• Check a open or short circuit in Y wire. Yes

• Faulty Y wire
• Is there open or short circuit? ►
id
No ▼
ib
4. TP Sensor Inspection
oh
• Replace the sensor unit (TP sensor) with a new

one 2-8
• Erase the DTC’s.
Pr
• Check the TP sensor with MCS.

• If DTC 8-1 is indicated, replace the ECM with a
4-9
ELECTRICAL SYSTEM
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
n
TP Sensor Diagram
ió
uc
Y/R Y G/W
rib
G/W Y
Y/R
er st
5V
om Di
VCC
Y/R
Sensor unit
o
Y THL ECM
(TP sensor)
dy n y
SG
G/W
F ció
1. TP Sensor System Inspection
R
• Check the TP sensor voltage with MCS.
• Operate the throttle from fully closed to fully
• Check the TP sensor voltage with MCS when the
le uc
No opened.
throttle fully closed.
re
► • If the voltage is not increase continuously, replace

the sensor unit (TP sensor) with a new one 2-8,
od
and recheck.
|
Yes ▼
r
2. TP Sensor Ground Line Inspection

p
hi
• Check a open circuit in G/W wire. No

Ch Re
• Faulty G/W wire

C
• Is there open circuit? ►

|
Yes ▼
la
ile
3. TP Sensor Inspection
a
• Replace the sensor unit (TP sensor) with a new

one 2-8
id
• Check the TP sensor with MCS.

ib

oh
Pr
4-10
ELECTRICAL SYSTEM
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
n
IAT Sensor Diagram
ió
uc
G/W
rib
Gr/Bu G/W
er st
Gr/Bu
om Di
5V
TA
Gr/Bu
o
Sensor unit
dy n y
(IAT sensor) ECM
G/W SG
F ció
R
1. IAT Sensor System Inspection
le uc
• Check the IAT sensor voltage with MCS. No • Intermittent failure

re

od
Yes ▼
|
2. IAT Sensor Inspection

p r
hi
Ch Re
C
• Check the IAT sensor voltage with MCS. No • Replace the sensor unit (IAT sensor) with a new
|
• Is the voltage about 0 V indicated? ► one 2-8, and recheck.

la
ile
Yes ▼
a
3. IAT Sensor Output Line Inspection

id
• Check an short circuit in Gr/Bu wire.

ib
oh
Pr
4-11
ELECTRICAL SYSTEM
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)
n
IAT Sensor Diagram
ió
uc
G/W
rib
Gr/Bu G/W
er st
Gr/Bu
om Di
5V
TA
Gr/Bu
o
Sensor unit
dy n y
(IAT sensor) ECM
G/W SG
F ció
R
1. IAT Sensor System Inspection
le uc
• Check the IAT sensor voltage with MCS. No • Intermittent failure

re

od
Yes ▼
|
2. IAT sensor Inspection

p r
hi
Ch Re
C

|
Connection: Gr/Bu – G/W Yes • Replace the sensor unit (IAT sensor) with a new
• Check the IAT sensor voltage with MCS. ► one 2-8, and recheck.
la
ile

a
No ▼
3. IAT Sensor Voltage Input Line Inspection

id
• Check an open circuit in Gr/Bu and G/W wire.

ib

oh
Pr
4-12
ELECTRICAL SYSTEM
DTC 12-1 (INJECTOR)
n
Injector Diagram
ió
Injector 2P connector Injector 2P connector ECM 33P connector
(Injector side) (Wire side)
uc
P/Bl
rib
A B Bl/R P/Bl
st
From Battery
Di
Bl/R
o
Injector ECM
y
er
INJ
P/Bl
n
om
ió
1. Fuel Injector System Inspection R
cc
• Check the fuel injector with MCS. No • Intermittent failure

dy
• Is the DTC 12-1 is indicated? ► • Loose or poor contact at the connector

re
du
Yes ▼
F
2. Fuel Injector Input Voltage Inspection

ro
|
le
ep
hi
• Connection: Bl/R (+) – Ground (–) No

• Open circuit in Bl/R wire
C
• Does the battery voltage exist? ►

R
|
Yes ▼
la
ile
3. Fuel Injector Signal Line Inspection

a
Ch
• Check a open or short circuit in P/Bl wire. Yes

• Faulty P/Bl wire
id
No ▼
ib
4. Fuel Injector Resistance inspection

oh
Pr
• Connection: A – B No
• Faulty fuel injector
• Is the resistance within 11 – 13 Ω (24 °C)? ►
Yes ▼
• Replace the ECM with a new one 4-19, and re-

check.
4-13
ELECTRICAL SYSTEM
DTC 21-1 (O2 SENSOR)
n
O2 Sensor Diagram
ió
O2 sensor 2P connector ECM 33P connector
uc
Bl/W
rib
Bl/W
er st
O2
om Di
Bl/W
ECM
O2 sensor
o
dy n y
F ció
1. O2 Sensor System Inspection

R
• Test-ride the vehicle and check the O2 sensor with
No • Intermittent failure
MCS.
le uc
► • Loose or poor contact at the connector

• Is the DTC 21-1 is indicated?
re
Yes ▼
od
|
2. O2 Sensor Circuit Inspection

r
• Check an open or short circuit in Bl/W wire. Yes

• Faulty Bl/W wire
p

hi
Ch Re
No ▼
C
3. O2 Sensor Inspection
|
la
• Replace the O2 sensor with a new one. 4-20

ile

• Test-ride the vehicle and check the O2 sensor with
a
MCS.
id

ib
oh
Pr
4-14
ELECTRICAL SYSTEM
DTC 29-1 (IACV)
n
IACV Diagram
ió
IACV 4P connector IACV 4P connector ECM 33P connector
(IACV side) (Wire side)
uc
Br/W Br/Bl Bu/W Br/W
rib
A B C D
Bu/W Bu/Bl
st
Bu/Bl Br/Bl
Di
o
y
er
Bu/W IACV1A
n Bu/Bl IACV1B ECM
om
IACV
Br/W IACV2A
ió
Br/Bl
R IACV2B
cc
dy
1. IACV System Inspection

re
du
• Check the IACV with MCS. No • Intermittent failure

F
Yes ▼
ro
|
2. IACV Circuit Inspection

le
ep
hi
• Check a open or short circuit in Bu/W, Br/W, Br/Bl

Yes
and Bu/Bl wires. • Faulty Bu/W, Br/W, Br/Bl or Bu/Bl wire
►
C
• Is there open or short circuit?

R
|
No ▼
la
ile
3. IACV Resistance Inspection

a
Ch
id
• Connection: A – D, B – C No
ib
• Faulty IACV
• Is the resistance within 110 – 150 Ω (25 °C)? ►
oh
Yes ▼
4. IACV Short Circuit Inspection

Pr
• Connection: A – B, C – D Yes
• Faulty IACV
• Is there continuity? ►
No ▼
• Replace the ECM with a new one 4-19, and re-

check.
4-15
ELECTRICAL SYSTEM
DTC 33-2 (EEPROM)
1. EEPROM System Inspection
• Check the EEPROM with MCS. No • Intermittent failure
n
ió
Yes ▼
• Replace the ECM with a new one. 4-19, and re-
uc
check.
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
4-16
ELECTRICAL SYSTEM
DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)
n
Bank Angle Sensor Diagram
ió
Bank angle sensor
ECM 33P connector
3P connector
uc
G/W
rib
G/W R/Bu Y/R
er st
Y/R R/Bu
om Di
5V
VCC
Y/R 5V
o
Bank angle BANK ECM
R/Bu
dy n y
sensor SG
G/W
F ció
1. Bank Angle Sensor System Inspection

R
• Check the bank angle sensor voltage with MCS. No • Intermittent failure
le uc
re
Yes ▼
od
2. Bank Angle Sensor Power Input Voltage In-

spection
|
p r
hi
Ch Re
C
• Faulty Y/R wire

|
• Is the voltage about 5 V indicated? ►

la
ile
Yes ▼
a
3. Bank Angle Sensor Output Line Inspection

id
• Check a short circuit in R/Bu wire. Yes

• Faulty R/Bu wire
• Is there short circuit? ►
ib
No ▼
oh
4. Bank Angle Sensor Inspection
• Replace the bank angle sensor with a new one.

4-20
Pr
• Erase the DTCs.

• Check the bank angle sensor with MCS.
4-17
ELECTRICAL SYSTEM
DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)
• Bank angle sensor (Connector is connected.) 4-20
n
Bank Angle Sensor Diagram
ió
Bank angle sensor
ECM 33P connector
3P connector
uc
G/W
rib
G/W R/Bu Y/R
er st
Y/R R/Bu
om Di
5V
VCC
Y/R 5V
o
Bank angle BANK ECM
R/Bu
dy n y
sensor SG
G/W
F ció
1. Bank Angle Sensor System Inspection

R
• Check the bank angle sensor voltage with MCS. No • Intermittent failure
le uc
re
Yes ▼
od
2. Bank Angle Sensor Power Input Voltage In-

spection
|
p r
hi
Ch Re
C

• Faulty G/W wire
• Is the voltage about 5 V indicated? ►
|
la
Yes ▼
ile
3. Bank Angle Sensor Output Line Inspection

a
• Check an open circuit in R/Bu wire. Yes

• Faulty R/Bu wire
id
• Is there open circuit? ►
No ▼
ib
4. Bank Angle Sensor Inspection

oh
• Replace the bank angle sensor with a new one.

4-20
• Erase the DTCs.
Pr
• Check the bank angle sensor with MCS.

4-18
ELECTRICAL SYSTEM
ECM
n
ió
uc
er st
rib
om Di
o
dy n y
F ció
R
• ECM power circuit and ground circuit inspection

le uc
re
od
EOT SENSOR
|
p r
hi
Ch Re
C
|
la
ile
a
id
ib
oh
Pr
15 N·m
• EOT sensor inspection
4-19
ELECTRICAL SYSTEM
O2 SENSOR
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
25 N·m
R
cc
dy
• Remove the O2 sensor.
re
du
Flare nut socket: FRXM17 (Snap on) or equivalent
BANK ANGLE SENSOR

F
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
5.8 N·m
ib
oh
Pr
• Bank angle sensor inspection
4-20
ELECTRICAL SYSTEM
IGNITION SYSTEM
IGNITION SYSTEM LOCATION
n
IGNITION SWITCH
ió
uc
MAIN FUSE
15 A
ECM
rib
IGNITION COIL
st
Di
o
y
er
n
om
ió
SPARK PLUG
R
FUSE BOX:
cc
dy
· 10 A
re
du
CKP SENSOR BATTERY

F
ro
IGNITION SYSTEM DIAGRAM

|
le
ep
hi
C
IGNITION
R
15 A SWITCH 10 A
|
R/Bu Bl/R
la
ile
REGULATOR/
RECTIFIER
a
Ch
Bl/R
BATTERY
id
Bu/Y
CKP Bl/R
ib
SENSOR ECM
W/Y P/Bu
oh
G G
G/Bl IGNITION
COIL
Pr
SPARK
PLUG
4-21
ELECTRICAL SYSTEM
SPARK PLUG REPLACEMENT
• Spark plug inspection.
n
ió
uc
rib
st
16 N·m
Di
INSPECTION
o
y
IGNITION COIL PRIMARY PEAK VOLTAGE
er
• Refer to "Basic Shop Manual" for the detail information of
n
om
ignition coil primary peak voltage inspection.
• Support the vehicle on a level surface.
ió
R
• Disconnect the spark plug cap from the spark plug.
cc
dy
• Connect a known-good spark plug to the spark plug cap
and ground it to the cylinder head as done in a spark test.
re
du
• With the ignition coil primary wires connected, connect

the peak voltage adaptor probes to the ignition coil
F
primary terminal and ground.

CONNECTION: P/Bu (+) – Ground (–)
ro
|
le
ep
• Check the initial voltage at this time.

hi
STANDARD VOLTAGE: Battery voltage

C
• Shift the transmission in neutral, and then crank the engine

R
with the starter and measure the ignition coil primary peak
|
voltage.
la
ile
PEAK VOLTAGE: 100 V minimum

a
Ch
IGNITION TIMING
• Warm the engine up to normal operating temperature.

id
• Timing hole cap 2-14

ib
• Connect the timing light to the spark plug wire.

• Start the engine and let it idle
IDLE SPEED: 1,400 ± 100 rpm
oh
• The ignition timing is correct if the "F" mark on the flywheel

aligns with the index notch on the left crankcase cover.
Pr
4-22
ELECTRICAL SYSTEM
ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION
IGNITION SWITCH STARTER SWITCH
n
ió
CLUTCH SWITCH
MAIN FUSE 15 A
uc
rib
st
Di
o
y
STARTER
er
RELAY SWITCH
n
om
ió
R
STARTER MOTOR
cc
dy
re
du
NEUTRAL SWITCH BATTERY FUSE BOX:

F
· 10 A
ro
|
ELECTRICAL STARTER SYSTEM DIAGRAM

le
ep
hi
IGNITION
SWITCH 10 A
C
R/Bu
R
|
STARTER R/W
R MOTOR
la
ile
REGULATOR/
RECTIFIER
a
Ch
R
BATTERY Bl/R
id
STARTER
RELAY MAIN
ib
SWITCH 15 A
oh
G/R
Y/R
STARTER
Pr
Bl SWITCH
Lg/R
CLUTCH
SWITCH NEUTRAL
SWITCH
G
4-23
ELECTRICAL SYSTEM
ELECTRICAL STARTER TROUBLESHOOTING
STARTER MOTOR DOES NOT TURN
n
• Loose or poor contacts of related terminal/connector
ió
• Battery condition
• Burned fuse
uc
Connector Diagram
rib
Starter relay switch 4P connector (View from harness side)
st
Di
G/R Y/R
o
y
er
1. Starter Relay Coil Input Circuit inspection
n
om
ió
R
cc
• Inspect the following.

dy
• Connection: Y/R (+) – Ground (–)
– Ignition switch
(Connector connected) No
– Starter switch
re
du
• Push and hold the starter button. ►

– Regulator/rectifier
• Does the battery voltage exist?
– Starter relay coil input related circuit
F
ro
|
Yes ▼
le
2. Starter Relay Coil Ground Circuit inspection

ep
hi
C
R
|
• Inspect the following.

• Connection: G/R – Ground
la
ile
– Diode
• Squeeze the clutch lever or shift the transmis- No
– Clutch switch
sion in neutral position. ►
a
Ch
– Neutral switch
• Is there continuity?
– Starter relay coil ground related circuit
id
Yes ▼
ib
3. Starter Relay inspection
• Replace the starter relay with a new one, and

oh
Yes
recheck. • Faulty original starter relay
►
• Does the starter motor turn?
Pr
No ▼
• Check a short or open circuit in starter motor

cable.
• If there is no faulty circuit, replace the starter
motor with a new one, and recheck.
4-24
Pr
oh
ib
id
a
la
R
STARTER MOTOR
Ch ep
ile
• Electric starter inspection

| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
ELECTRICAL SYSTEM
4-25
4-26
Pr
oh
ib
id
NEUTRAL SWITCH
a
la
R

Ch
ELECTRICAL SYSTEM
ile ep
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
ELECTRICAL SYSTEM
BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEM LOCATION
n
IGNITION
SWITCH REGULATOR/
ió
RECTIFIER
uc
rib
st
Di
o
y
er
n
om
ió
R
MAIN FUSE 15 A
cc
dy
re
du
F
ALTERNATOR
BATTERY
ro
|
le
ep
BATTERY/CHARGING SYSTEM DIAGRAM

hi
C
R
|
la
ile
15 A
R W
a
Ch
id
R
ib
ALTERNATOR
BATTERY
oh
G
G
Pr
REGULATOR/
RECTIFIER
• Battery/charging system information, troubleshooting and inspection
4-27
ELECTRICAL SYSTEM
BATTERY
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
F
LIGHTING SYSTEM
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
• Front cowl 3-3
• Headlight aim 4-33
4-28
Pr
oh
ib
id
a
la
• Rear fender 3-6

Ch Re
p

ile
|
C
rod
hi
le uc
|
F ció
re
dy n y
R
om Di
19 N·m
er st
o rib
uc
ió
n
ELECTRICAL SYSTEM
4-29
ELECTRICAL SYSTEM
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
• Rear fender 3-6

re
du
F
BULB REPLACEMENT
ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
4-30
Pr
oh
ib
id
a
la
R

Ch ep
ile
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
ELECTRICAL SYSTEM
4-31
4-32
Pr
oh
ib
id
a
la
ELECTRICAL SYSTEM
Ch Re
ile
|
p r
C od
hi
le uc
|
F ció
re
dy n y
R
om Di
er st
o rib
uc
ió
n
Pr
oh
ib
id
a
la
HEADLIGHT AIM
Ch R
ile ep
| ro
C
Beam up
hi du
Beam down
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
ELECTRICAL SYSTEM
4-33
4-34
Pr
oh
ib
id

SPEEDOMETER
a
la 1.2 N·m
Ch R
ELECTRICAL SYSTEM
ile ep
| ro
C du
hi
le
| cc
F ió
re n
dy
R y
om Di
er st
o rib
uc
ió
n
ELECTRICAL SYSTEM
FUEL LEVEL SENSOR
n
ió
uc
rib
st
R
Di
o
y
er
n
om
ió
R R
Bl Y G Bl
cc
dy
• Fuel pump unit 2-4

re
du
F
• Route the fuel level sensor wires properly as shown.

ro
|
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
4-35
ELECTRICAL SYSTEM
FUEL METER TROUBLESHOOTING
FUEL METER NEEDLE DOES NOT MOVE
• Fuel pump unit 2-4
n
• Loose or poor contacts of related terminal/connector
ió
uc
rib
FULL
st
Di
o
y
er
n
om
ió
R
cc
dy
re
du
EMPTY
F
ro
|
le
ep
hi
C
R
|
A B
la
ile
1. Fuel Level Sensor Circuit Inspection

a
Ch
• Check the Y/W and G/Bl wire. Yes

• Faulty Y/W or G/Bl wire
id
No ▼
ib
2. Fuel Level Sensor Inspection

oh
Pr
• Connection: A – B
No • Replace the fuel level sensor with a new one 4-35,
• Standard: FULL 6 – 10 Ω, EMPTY 90 – 100 Ω.
► and recheck.
• Does the standard resistance exist?
Yes ▼
Replace the meter with a new one 4-34, and re-

check.
4-36
ELECTRICAL SYSTEM
ELECTRICAL COMPONENT
IGNITION SWITCH
n
ió
uc
rib
st
Di
o
y
er
n
om
ió
R
cc
dy
• Top bridge 3-19

re
du
F
ro
|
HORN
le
ep
hi
C
R
|
la
ile
a
Ch
id
ib
oh
Pr
4-37
Pr
oh
ib
id
a
la
Ch R
ile ep
| ro
C du
hi
le
| cc
F ió
MEMO
re n
dy
R y
om Di
er st
o rib
uc
ió
n
INDEX
dummytext
INDEX
A Few Words About Safety ·············································1-2 HANDLEBAR································································ 3-18
A H
AIR CLEANER ································································2-7 HORN ··········································································· 4-37

ALTERNATOR/STARTER CLUTCH·····························2-24 How To Use This Manual ··············································· 1-3
BATTERY/CHARGING SYSTEM ·································4-27 IGNITION SYSTEM ······················································ 4-21
B I
BODY PANELS·······························································3-2 INJECTOR···································································· 2-11

BRAKE FLUID REPLACEMENT···································3-24 LIGHTING SYSTEM ····················································· 4-28
n
L
BULB REPLACEMENT·················································4-30 LUBRICATION SYSTEM·············································· 2-12
ió
CABLE & HARNESS ROUTING ···································1-17 MAINTENANCE SCHEDULE ······································· 1-25
C M
CLUTCH/GEARSHIFT LINKAGE ·································2-21 MODEL IDENTIFICATION ············································· 1-5

CRANKCASE/CRANKSHAFT/BALANCER ··················2-26 PGM-FI SYSTEM ··························································· 4-2
P
uc
CYLINDER HEAD ·························································2-14 REAR BRAKE ······························································ 3-27
R
CYLINDER/PISTON······················································2-20 REAR SUSPENSION ··················································· 3-23

ELECTRICAL COMPONENT········································4-37
E
REAR WHEEL ······························································ 3-21 5
rib
ELECTRICAL STARTER ··············································4-23 SIDESTAND ································································· 3-12
S
ENGINE OIL CHANGE ·················································2-13 SPARK PLUG REPLACEMENT··································· 4-22

ENGINE OIL LEVEL CHECK········································2-12 SPECIAL TOOL LIST ··················································· 1-16
ENGINE OIL STRAINER SCREEN ······························2-13 SPECIFICATIONS·························································· 1-6
er st
ENGINE UNIT ·······························································2-31 SPEEDOMETER ·························································· 4-34
EXHAUST PIPE/MUFFLER ··········································3-13 STEERING STEM ························································ 3-19
FORK ············································································3-16 TECHNICAL FEATURES ············································· 1-24
om Di
F T
FRONT BRAKE·····························································3-24 THROTTLE BODY·························································· 2-8

FRONT WHEEL ····························································3-14 TORQUE VALUE·························································· 1-12
o
FUEL LEVEL SENSOR·················································4-35 TP SENSOR RESET PROCEDURE ···························· 2-10
dy n y
FUEL LINE ······································································2-2 TRANSMISSION ·························································· 2-28
FUEL PUMP UNIT ··························································2-4 VALVE CLEARANCE ··················································· 2-14
V
FUEL TANK ····································································2-6

F ció
R
le uc
re
od
|
p r
hi
Ch Re
C
|
la
ile
a
id
ib
oh
Pr
5-1
STARTER
MOTOR
FUSE BOX
SUB1 SUB2
STARTER
R
TURN DC-LOAD ECM
RELAY BANK
SIGNAL SWITCH CUT RELAY ANGLE REAR
IACV1B
IACV2B
IACV1A
IACV2A
BRAKE LIGHT
K-LINE
RELAY IGNITION
IGPLS
NLSW
FI IND
BANK
15A SENSOR
PCM
PCR
VCC
SWITCH
10A
10A
SCS
PCP
SWITCH
PG2
PG1
FFP
THL
IGP
INJ
SG
DLC
TO
PB
O2
LG
TA
-
-
BAT1
IACV
GND
R
OUT
Vcc
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
A-11
A- 9
A- 8
A- 7
A- 6
A- 5
A- 4
A- 3
A- 2
A- 1
4P
VO1
2P R 3P 4P 33P
Bl 4P
BATTERY R
12V 6Ah
Gr/Bu
Bu/W
Bu/W
W/Bu
Bu/Bl
Bu/Bl
R/Bu
R/Bu
R/Bu
Br/W
R/Bu
Br/W
Bu/Y
Br/Bl
Br/Bl
Y/Bu
P/Bu
Bl/W
Lg/Y
G/W
G/W
R/W
Bl/G
Bl/O
Bl/G
G/Bl
G/Bl
W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
P/Bl
G/R
G/R
G/R
G/Y
Y/R
Y/R
Y/R
Bu
Bu
Gr
Bl
Bl
Bl
Bl
G
G
R
R
Y
ó n
ci
2P
Bl 2P
u
FRONT
G/Y
6P
Bl
BRAKE
LIGHT
R/Bu
R/W
SWITCH
ri
G/Y Bl Bl
G/Y G/Y
STARTER ST BAT
Y/R Y/R Y/R
t
SWITCH Bl/R Bl/R Bl/R
Bl
i s G/R
G/R
2P
DIODE
D
Lg/R
FUEL METER Y/W

G/Bl Lg/R
y
HI-BEAM IND Bu 9P Bl
n
12V 1.7W G Bl Bl LICENSE LIGHT
FI IND
12V 3.4W
Bl
W/Bu
Y/W
Bu
W/Bu
Y/W
Bu
W/Bu
r o 12V 5W
e G
ó
Y
N IND Bl
12V 3.4W
i m
Lg/R Lg/R Lg/R
Y Y RIGHT REAR
TURN IND
12V 3.4W
Lb
O Lb Lb
c y R o TURN SIGNAL LIGHT

12V 10W
METER ILLUMI 2
12V 1.7W
Y
G
O
G/Bl
G
4P R
O
G/Bl
G
c
u d
G
Y
2P
G
Y
Lb
G
d
METER ILLUMI 1 Y Lb Lb
12V 2.0W G
e G BRAKE/TAIL LIGHT
Fr
G
G 12V 5W/21W
o O O
pr e |
G/Y G/Y G/Y
RIGHT FRONT G G G
TURN SIGNAL Lb Y Y Y
LIGHT G 3P
12V 10W
e
LEFT REAR
i l TURN SIGNAL LIGHT

12V 10W
R h
HEAD LIGHT
a
4P Bl G
12V 35W/35W
C
Y Y O
Y/R
Y/R
Y/R
Bl Bl Bu
W W W
G G
G
G
G
G
l le
|
a
Lb Lb
POSITION
LIGHT
Y O O
i
d h
Gr/Bu
G
Lg/Y
Bl/W
G/W
Y/R
12V 5W
Bu/Y
Lg/R
W/Y
Y
i
W
G
LEFT FRONT
C 5P
b
2P
TURN SIGNAL O 3P 2P
Bl
i
LIGHT G
12V 10W
Gr/Bu
Bu/Y
W/Y
Lg/Y
G/W
Y/R
W
G
Y
o
9P Bl
L
TURN
r
O O O
W
SIGNAL Gr Gr Gr
SWITCH Lb Lb Lb
P
R
Bl G/R
LO W W W
DIMMER HL Y Y Y
SWITCH Bu Bu Bu
HI
G G
HO
HORN Lg Lg Lg
Bl/O
G/Bl
Bl/R
Y/W
SWITCH BAT
Bl Bl Bl
Gr/Bu
P/Bu
Lg/Y
G/W
G/W
G/W
G/W
G/W
G/W
G/W
G/Bl
G/Bl
R/W
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
P/Bl
Y/R
Y/R
W
Bl
G
G
G
G
Y/Bu
R
Y
Y
G/W
5P
Lg
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FUEL FUEL SENSOR
PUMP LEVEL
SENSOR IGNITION
COIL
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SWITCH SWITCH SWITCH SWITCH SWITCH Bu Blue Lb Light Blue
BAT1 VO1 BAT ST BAT HO W R L HL LO HI G Green Lg Light Green
R Red P Pink
ON FREE FREE R LO
W White Gr Gray
OFF PUSH PUSH N N
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© Honda Motor Co.,Ltd. 2016 Book#: 62K79B0

Published by Honda Motor Co.,Ltd. A. 2016.07
Printed in Japan

SM XR 190L (2017) Eng

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What does the manual cover?

What does the manual cover?

What safety precautions are mentioned?

What safety precautions are mentioned?

Shop Manual

This book is Specific Shop Manual.

A Few Words About Safety

For Your Customer’s Safety

For Your Safety R

Failure to properly follow instructions and

Follow the procedures and precautions in this

Important Safety Precautions

How To Use This Manual

is to help prevent damage to your vehicle, other property, or the environment.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS

PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,

MOTOR SCOOTERS OR ATVS.

© Honda Motor Co., Ltd.

Date of Issue: July, 2016

Refer to “Basic” Service Manual for the instruc-

Use the Honda special tool.

LUBRICATION AND SEAL SYMBOL

Apply molybdenum oil solution (mixture of an

Apply a specified grease. Use a multi-purpose

Apply a liquid sealant.

grease unless otherwise specified.

Apply a locking agent. Use a medium strength

Use DOT 3 or DOT 4 brake fluid.

Use a specified fork oil or suspension fluid.

ENGINE SERIAL NUMBER

Caster angle 26° 12’

Trail length 95.9 mm

Fuel tank reserve capacity 3.9 liter

ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical

Displacement 184.43 cm3

Compression ratio 9.5 : 1

Valve train Chain driven OHC with rocker arm

Intake valve opens 10° BTDC at 1 mm lift

closes 30° ABDC at 1 mm lift

Exhaust valve opens 35° BBDC at 1 mm lift

closes 0° ATDC at 1 mm lift

Lubrication system Forced pressure and wet sump

Cooling system Air cooled

Engine dry weight 29.5 kg

FUEL SYSTEM Type PGM-FI (Programmed Fuel Injection)

Fuel pressure at idle 294 kPa

Fuel pump flow (at 12 V) 58.6 cm3 minimum/10 seconds

ITEM STANDARD LIMIT

Engine oil capacity After draining 1.0 liter –

After disassembly 1.2 liter –

Recommended engine oil Honda “4-stroke motorcycle oil” or an

equivalent motor oil.

API service classification: SG or higher –

JASO T903 standard: MA

Viscosity: SAE 10W-30

Piston Piston O.D. 60.981 – 60.997 at 13 mm from bottom of

Piston pin O.D. 13.994 – 14.000 13.980

Oil (side rail) 0.10 – 0.35 0.55

Piston ring-to-ring Top 0.015 – 0.045 –