Honda Air Blade 110 Fi - Service Manual-299

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SERVICE MANUAL
Honda Air Blade 110 Fi (AB Thái)

(ANC110)
How to use this manual
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper set-up and pre-delivery are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper set-up or pre-delivery service can create

an unsafe condition that can cause your customer
to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual and other service materials carefully.
For Your Safety

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

tions can cause you to be seriously hurt or killed.
ual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
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How To Use This Manual
This manual describes the service procedures for the ANC110.
Sections 1 and 4 apply to the whole scooter. Section 3 illustrates procedures for removal/installation of components that may be
required to perform service described in the following sections.
Section 5 through 20 describe parts of the scooter, grouped according to location.
If you are not familiar with this scooter, read Technical Feature in Section 2.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent
pages give detailed procedure.
If you don't know the source of the trouble, go to Troubleshooting section.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messag-
es and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards as-
sociated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Mo-
tor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING
ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER-
MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE
ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: September, 2008
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0-2
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Honda Moly 60 (U.S.A. only)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.

CONTENTS
GENERAL INFORMATION 1
TECHNICAL FEATURES 2
FRAME/BODY PANELS/EXHAUST SYSTEM 3
MAINTENANCE 4
LUBRICATION SYSTEM 5
FUEL SYSTEM (Programmed Fuel Injection) 6
ENGINE AND DRIVE TRAIN
COOLING SYSTEM 7
ENGINE REMOVAL/INSTALLATION 8
CYLINDER HEAD/VALVES 9
CYLINDER/PISTON 10
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH 11
FINAL REDUCTION 12
CRANKCASE/CRANKSHAFT 13
FRONT WHEEL/SUSPENSION/STEERING 14
CHASSIS
REAR WHEEL/SUSPENSION 15
BRAKE SYSTEM 16
BATTERY/CHARGING SYSTEM/ALTERNATOR 17
ELECTRICAL
IGNITION SYSTEM 18
ELECTRIC STARTER SYSTEM 19
LIGHTS/METERS/SWITCHES 20
WIRING DIAGRAM 21
TROUBLESHOOTING 22
ANC110AVC-A ADDENDUM 23
INDEX

MEMO

GENERAL INFORMATION
REAR BRAKE CABLE THROTTLE CABLE
FUEL LID OPENER CABLE
SPEEDOMETER SUB HARNESS
FRONT BRAKE HOSE
CONNECTORS:
· SPEEDOMETER SUB HARNESS 9P
CONNECTOR
CONNECTOR
· IGNITION SWITCH 2P CONNECTOR
OVERFLOW HOSE
FUEL FEED HOSE
FUEL TRAY
DRAIN HOSE
REAR BRAKE CABLE
THROTTLE CABLE
SIDESTAND SWITCH WIRE
REAR BRAKE CABLE

1-21
GENERAL INFORMATION
ENGINE SUB HARNESS

Install the ground cable
ECM 33P (BLACK) CONNECTOR terminals as shown.
FUEL PUMP 5P CONNECTOR
SEAT LOCK CABLE GROUND

CABLE
MAIN WIRE HARNESS
STARTER ALTERNATOR/CKP
RADIATOR
MOTOR SENSOR WIRE
SIPHON HOSE
WIRE SIDESTAND
RADIATOR SIPHON HOSE SWITCH WIRE
Cut off the extra part:
MAIN WIRE HARNESS
ENGINE SUB HARNESS
5 mm MAX. STARTER MOTOR WIRE

SEAT LOCK
MAIN WIRE HARNESS CABLE
ALTERNATOR/CKP SENSOR WIRE ENGINE SUB HARNESS ALTERNATOR/
STARTER MOTOR WIRE CKP SENSOR

GENERAL INFORMATION
STARTER MOTOR WIRE

IACV 4P (BLACK) CONNECTOR
UPPER
90°
SENSOR UNIT 5P (BLACK)
CONNECTOR
THROTTLE CABLE
GROUND
TERMINALS
STARTER MOTOR WIRE
FUEL FEED
HOSE
CRANKCASE
BREATHER
GROUND HOSE
CABLE
INJECTOR 2P
(BLACK)
RADIATOR
CONNECTOR
STARTER MOTOR SIPHON HOSE
WIRE MAIN WIRE HARNESS
UPPER STARTER
MOTOR WIRE
ENGINE SUB
HARNESS
ENGINE SUB
HARNESS
ECT SENSOR 2P
CONNECTOR
O2 SENSOR 1P (BLACK)
CONNECTOR

1-23
GENERAL INFORMATION
MAIN WIRE HARNESS

SEAT LOCK CABLE
ECT SENSOR 2P (BLACK) CONNECTOR
ENGINE SUB HARNESS

RADIATOR SIPHON HOSE
STARTER
MOTOR WIRE
SPARK
PLUG
WIRE
O2 SENSOR 1P (BLACK) CONNECTOR
STARTER MOTOR WIRE ALTERNATOR/CKP SENSOR WIRE
ALTERNATOR/CKP
SENSOR WIRE
O2 SENSOR WIRE
ENGINE SUB HARNESS

SPARK PLUG WIRE

GENERAL INFORMATION
THROTTLE CABLE
FUEL TRAY
DRAIN HOSE
RADIATOR
OVERFLOW
HOSE
UPPER UPPER
FUEL FEED
HOSE REAR BRAKE
30° – 40°
SIDESTAND CABLE
SWITCH WIRE
Band screw direction:
RESISTORS
IGNITION COIL
CRANKCASE BREATHER HOSE
SPARK PLUG WIRE
SEAT LOCK CABLE

O2 SENSOR WIRE

1-25
GENERAL INFORMATION
REAR COMBINATION LIGHT 6P

CONNECTOR
RESISTOR WIRE
MAIN WIRE HARNESS
MAIN WIRE HARNESS
RESISTOR WIRE
REAR BRAKE CABLE

Sidestand spring
direction: Centerstand spring
direction:

GENERAL INFORMATION
STARTER MOTOR CABLE To be butted
UPPER
THROTTLE CABLE
90°
STARTER MOTOR
GROUND CABLE INJECTOR WIRE
CRANKCASE
BREATHER HOSE

FUEL FEED HOSE
WATER HOSE
SPARK PLUG WIRE
INJECTOR WIRE CRANKCASE

BREATHER HOSE
FUEL FEED HOSE
WATER HOSE
ENGINE SUB HARNESS

STARTER MOTOR CABLE
ALTERNATOR/CKP SENSOR WIRE
Align the filter of O2

O2 SENSOR WIRE sensor and concave
of engine harness
clamp stay.

1-27
GENERAL INFORMATION
Insert the grommet into

ALTERNATOR/CKP SENSOR WIRE
the groove completly
HEADLIGHT WIRE
RIGHT FRONT TURN

LEFT FRONT TURN
SIGNAL WIRE
SIGNAL WIRE
HEADLIGHT 6P CONNECTOR

GENERAL INFORMATION
BRAKE LIGHT WIRE

LEFT REAR TURN
RIGHT REAR TURN SIGNAL WIRE
SIGNAL WIRE
TAIL LIGHT WIRE

1-29
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of carbon
monoxide, oxides of nitrogen and hydrocarbons is very important because, under certain conditions, they react to form
photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes various systems (page 1-31), to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by
gas is returned to the combustion chamber through the air cleaner and throttle body.

AIR CLEANER HOUSING
THROTTLE BODY
FRESH AIR
BLOW-BY GAS

GENERAL INFORMATION
THREE-WAY CATALYTIC CONVERTER
This scooter is equipped with a three-way catalytic converter.
The three-way catalytic converter is in the exhaust system. Through chemical reactions, they convert HC, CO and NOx in the
engine’s exhaust to carbon dioxide (CO2), nitrogen (N2) and water vapor.
No adjustment to these systems should be made although periodic inspection of the components is recommended.
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law may prohibit the following acts or the causing
thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of
any device or element of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate customer or while it is in use; (2) the use of the vehicle after such device or element of design has been removed or
rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.

1-31
MEMO

1. GENERAL INFORMATION
SERVICE RULES ··········································1-2 FRONT WHEEL/SUSPENSION/

STEERING SPECIFICATIONS ·····················1-7
MODEL IDENTIFICATION ····························1-2
REAR WHEEL/SUSPENSION
GENERAL SPECIFICATIONS ······················1-4 SPECIFICATIONS·········································1-7
LUBRICATION SYSTEM BRAKE SYSTEM SPECIFICATIONS ···········1-8

SPECIFICATIONS ·········································1-5
BATTERY/CHARGING SYSTEM/
FUEL SYSTEM (PGM-FI) ALTERNATOR SPECIFICATIONS ···············1-8
SPECIFICATIONS ·········································1-5
IGNITION SYSTEM SPECIFICATIONS ········1-8
COOLING SYSTEM SPECIFICATIONS ·······1-5
ELECTRIC STARTER SYSTEM
CYLINDER HEAD/VALVES SPECIFICATION ···········································1-8
SPECIFICATIONS ·········································1-6
LIGHTS/METERS/SWITCHES
CYLINDER/PISTON SPECIFICATIONS ·······1-6 SPECIFICATION ···········································1-8
KICKSTARTER/DRIVE PULLEY/DRIVEN STANDARD TORQUE VALUES···················1-9

PULLEY/CLUTCH SPECIFICATION ············1-6
ENGINE & FRAME TORQUE VALUES········1-9
FINAL REDUCTION SPECIFICATIONS ·······1-7
LUBRICATION & SEAL POINTS················1-12
CRANKCASE/CRANKSHAFT
SPECIFICATIONS ·········································1-7 CABLE & HARNESS ROUTING·················1-14
EMISSION CONTROL SYSTEMS ··············1-30

1-1
GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design
specifications may cause damage to the scooter.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the scooter. Metric bolts, nuts and screws are not interchangeable with English fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-14).
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
CKP sensor Crankshaft Position sensor
DLC Data Link Connector
ECM Engine Control Module
ECT sensor Engine Coolant Temperature sensor
IAT sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
MIL Malfunction Indicator Lamp
PGM-FI Programmed Fuel Injection
SCS connector Service Check Short connector
TP sensor Throttle Position sensor
IACV Idle Air Control Valve
DESTINATION CODE
Throughout this manual, the following codes are used to identify individual types for each region.
DESTINATION CODE REGION
TH Thailand
MODEL IDENTIFICATION
This manual covers 2 types of ANC110 models.
• Standard type: Spoke wheel and front disc brake
• CBS type: Cast wheel and combined brake system

GENERAL INFORMATION
The frame serial number is stamped on the seat stay as shown.
FRAME SERIAL NUMBER
The engine serial number is stamped on the lower left side of the
crankcase.
ENGINE SERIAL NUMBER
The throttle body identification number is stamped on the lower side of the
throttle body.
THROTTLE BODY IDENTIFICATION NUMBER

1-3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1,894 mm (74.6 in)
Overall width 680 mm (26.8 in)
Overall height 1,119 mm (44.1 in)
Wheelbase 1,273 mm (50.1 in)
Seat height 767 mm (30.2 in)
Footpeg height 258 mm (10.2 in)
Ground clearance 134.6 mm (5.3 in)
Curb weight (Spoke wheel type) 107.2 kg (236.3 lbs)
(Cast wheel-CBS type) 107.1 kg (236.1 lbs)
FRAME Frame type Under bone type
Front suspension Telescopic fork
Front axle travel 81.0 mm (3.19 in)
Rear suspension Unit swing
Rear axle travel 80.0 mm (3.3 in)
Front tire size 80/90 - 14M/C40P
Rear tire size 90/90 - 14M/C46P
Tire brand Front/Rear NR73TZ/NR73T (IRC)
V338F/V338R (VEE RUBBER)
Front brake Hydraulic disc brake
Rear brake Mechanical leading trailing
Caster angle 26°40’
Trail length 80.0 mm (3.15 in)
Fuel tank capacity 4.5 liter (1.19 US gal, 0.99 lmp gal)
ENGINE Bore and stroke 50.0 x 55.0 mm (1.97 x 2.17 in)
Displacement 108.0 cm3 (6.59 cu-in)
Compression ratio 11.0 : 1
Valve train 2 valve, single chain driven SOHC
Intake valve opens at 1 mm (0.04 in) lift 5° BTDC
closes at 1 mm (0.04 in) lift 30° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 30° BBDC
closes at 1 mm (0.04 in) lift 0° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Paper filter
Engine dry weight 27.3 kg (60.2 lbs)
FUEL DELIV- Type PGM-FI (Programmed Fuel Injection)
ERY SYSTEM Throttle bore 22 mm (0.9 in) or equivalent
DRIVE TRAIN Clutch system Dry, automatic centrifugal clutch
Drive belt ratio 2.53 : 1 - 0.85 : 1
Final reduction 10.624 (51/18 x 45/12)
ELECTRICAL Ignition system Full transistorized
Starting system Kickstarter with electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR opened/single phase, half wave rectifi-
cation
Lighting system Alternator

GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt) –
After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt) –
Recommended engine oil API classification: SE, SF or SG
(except oils labeled as energy conserving
on the circular API service label) –
Viscosity: SAE 10W-30
JASO T 903 standard: MB
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
FUEL SYSTEM (PGM-FI) SPECIFICATIONS

ITEM SPECIFICATIONS
Throttle body identification number GQR8A
Engine idle speed 1,700 ± 100 min-1 (rpm)
Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)
ECT sensor resistance (40°C/104°F) 1.0 – 1.3 kǡ
(100°C/212°F) 0.1 – 0.2 kǡ
Fuel injector resistance (20°C/68°F) 9 – 12 ǡ
Fuel pressure at idle 294 kPa (3.0 kgf/cm2, 43 psi)
Fuel pump flow (at 12 V) 120 cm3 (4.1 US oz, 4.2 Imp oz) minimum/10 seconds
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 0.49 liter (0.52 US qt, 0.43 lmp qt)
Reserve tank 0.24 liter (0.25 US qt, 0.21 lmp qt)
Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm2, 16 – 20 psi)
Thermostat Begin to open 74 – 78 °C (165 – 172 °F)
Fully open 100 °C (212 °F)
Valve lift 8 mm (0.3 in) minimum
Recommended coolant Honda PRE-MIX COOLANT

1-5
GENERAL INFORMATION
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
Cylinder compression 941 kPa (9.6 kgf/cm2, 137 psi) at 550
–
min-1 (rpm)
Cylinder head warpage – 0.05 (0.002)
Rocker Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.04 (0.395)
arm Rocker arm shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm to shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.08 (0.003)
Camshaft Cam lobe height IN 32.525 – 32.765 (1.2805 – 1.2900) 32.50 (1.280)
EX 32.227 – 32.467 (1.2688 – 1.2782) 32.20 (1.268)
Valve, Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) –
valve EX 0.20 ± 0.02 (0.008 ± 0.001) –
guide Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.90 (0.193)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Valve guide projection above IN/EX 9.1 – 9.3 (0.36 – 0.37) –
cylinder head
Valve seat width IN/EX 1.0 (0.04) 1.5 (0.06)
Valve spring free length Inner IN/EX 31.53 (1.241) 30.66 (1.207)
Outer IN/EX 38.33 (1.509) 37.04 (1.458)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
Cylinder I.D. 50.000 – 50.010 (1.9685 – 1.9689) 50.10 (1.972)
Out-of-round – 0.05 (0.002)
Taper – 0.05 (0.002)
Warpage – 0.05 (0.002)
Piston, piston Piston O.D. 49.975 – 49.995 (1.9675 – 1.9683) 49.95 (1.967)
rings, piston Piston O.D. measurement point 6.0 (0.24) from bottom of skirt –
pin Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring-to-ring Top 0.015 – 0.045 (0.0006 – 0.0018) 0.08 (0.003)
groove clearance Second 0.015 – 0.045 (0.0006 – 0.0018) 0.08 (0.003)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Second 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –
Cylinder-to-piston clearance 0.005 – 0.035 (0.0002 – 0.0014) 0.09 (0.004)
Connecting rod small end I.D. 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)
Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.05 (0.002)
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

SPECIFICATION
Unit: mm (in)
Drive belt width 19.0 (0.75) 18.0 (0.71)
Movable drive face Bushing I.D. 22.035 – 22.085 (0.8675 – 0.8695) 22.11 (0.871)
Boss O.D. 22.010 – 22.025 (0.8665 – 0.8671) 21.98 (0.865)
Weight roller O.D. 17.92 – 18.08 (0.706 – 0.712) 17.5 (0.69)
Clutch Lining thickness – 2.0 (0.08)
Clutch outer I.D. 125.0 – 125.2 (4.92 – 4.93) 125.5 (4.94)
Driven pulley Face spring free length 111.4 (4.39) 108.0 (4.25)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)
Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)

GENERAL INFORMATION
FINAL REDUCTION SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
Final reduction oil capacity After draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
After disassembly 0.12 liter (0.13 US qt, 0.11 lmp qt)
Recommended final reduction oil API classification: SE, SF or SG
(except oils labeled as energy conserving on the circular API
service label)
CRANKCASE/CRANKSHAFT SPECIFICATIONS
Unit: mm (in)
Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod radial clearance 0.004 – 0.016 (00002 – 0.0006) 0.05 (0.002)
Runout – 0.10 (0.004)
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)
Minimum tire tread depth – To the indicator
Cold tire pressure Driver only 200 kPa (2.00 kgf/cm2, 29 psi) –
Driver and passenger 200 kPa (2.00 kgf/cm2, 29 psi) –
Axle runout – 0.2 (0.01)
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (Spoke wheel type) 0 ± 1.0 (0 ± 0.04) –
Fork Spring free length 307.0 (12.09) 301.0 (11.85)
Pipe runout – 0.2 (0.01)
Recommended fluid Fork fluid –
Fluid level 86.5 (3.41) –
Fluid capacity 62.5 ± 1.5 cm3
–
(2.11 ± 0.05 US oz, 2.20 ± 0.05 Imp oz)
REAR WHEEL/SUSPENSION SPECIFICATIONS

Unit: mm (in)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (Spoke wheel type) 6.5 ± 1.0 (0.26 ± 0.04) –

1-7
GENERAL INFORMATION
BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in)
Brake lever freeplay 10 – 20 (0.4 – 0.8) –
Brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Specified brake fluid DOT 3 or 4 –
Brake disc Thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
Warpage – 0.10 (0.004)
Master cylinder Cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)
Piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Caliper Cylinder I.D. 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)
Piston O.D. 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)
BATTERY/CHARGING SYSTEM/ALTERNATOR SPECIFICATIONS

ITEM SPECIFICATIONS
Battery Capacity 12 V – 3 Ah
Current leakage 0.1 mA max.
Voltage Fully charged 13.0 – 13.2 V
Needs charging Below 12.4 V
Charging cur- Normal 0.3 A/5 – 10 h
rent Quick 3.0 A/0.5 h
Alternator Capacity 0.160 kW/5,000 min-1 (rpm)
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Spark plug CPR7EA – 9 (NGK), U22EPR9 (ND)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing 10° BTDC at idle speed
ELECTRIC STARTER SYSTEM SPECIFICATION

Unit: mm (in)
Starter motor brush length 7.0 (0.28) 3.5 (0.14)
LIGHTS/METERS/SWITCHES SPECIFICATION
ITEM SPECIFICATIONS
Bulbs Headlight 12 V – 25/25 W x 2
Tail light 12 V – 5 W
Brake light LED
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Instrument light 12 V – 1.7 W x 2
PGM-FI malfunction indicator lamp 12 V – 1.7 W
(MIL)
High beam indicator 12 V – 1.7 W
Turn signal indicator 12 V – 3 W x 2
Coolant temperature warning indi- LED
cator
Fuse Main fuse 15 A x 1
Sub fuse 10 A x 1
Resistor resistance (20°C/68°F) 9.5 – 10.5 ǡ

GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm hex bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
(Include SH flange bolt) 6 mm flange bolt 12 (1.2, 9)
8 mm hex bolt and nut 22 (2.2, 16) (Include NSHF) and nut
10 mm hex bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
FRAME/BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Pillion step bracket socket bolt 2 8 26.5 (2.7, 20)
Muffler mounting bolt 2 8 26.5 (2.7, 20)
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
Spark plug 1 10 16 (1.6, 12)
Valve adjusting screw lock nut 2 5 10 (1.0, 7) Apply oil to the threads and
seating surface
Engine oil drain bolt 1 12 24 (2.4, 18)
Engine oil strainer screen cap 1 30 20 (2.0, 15)
Final reduction oil check bolt 1 8 13 (1.3, 10)
Final reduction oil drain bolt 1 8 13 (1.3, 10)
Air cleaner housing cover screw 4 5 1.1 (0.1, 0.8)
Equalizer connecting cable lock nut 1 8 6.4 (0.7, 4.7)
(CBS type only)
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Oil pump plate screw 1 4 3 (0.3, 2.2)
Oil pump mounting bolt 2 6 10 (1.0, 7)
FUEL SYSTEM (PGM-FI)

THREAD TORQUE
ITEM Q'TY REMARKS
ECT sensor 1 12 17.7 (1.8, 13)
Sensor unit torx screw 3 5 3.4 (0.3, 2.5)
Throttle cable stay mounting screw 1 5 3.4 (0.3, 2.5)
IACV torx screw 2 4 2.1 (0.2, 1.5)
O2 sensor 1 12 25 (2.5, 18)
COOLING SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Cooling fan mounting bolt 3 6 8 (0.8, 5.9)
Radiator drain bolt 1 10 1 (0.1, 0.7)
Thermostat mounting bolt 2 6 9 (0.9, 6.6)
Water pump impeller 1 6 10 (1.0, 7)

1-9
GENERAL INFORMATION
ENGINE REMOVAL/INSTALLATION
THREAD TORQUE
ITEM Q'TY REMARKS
Engine hanger link pivot nut 1 10 69 (7.0, 51)
(Frame side)
CYLINDER HEAD/VALVES
THREAD TORQUE
ITEM Q'TY REMARKS
Cylinder head cover special bolt 2 6 12 (1.2, 9)
Cylinder head nut 4 7 18 (1.8, 13) Apply oil to the threads and
seating surface.
Cylinder head bolt 2 6 12 (1.2, 9) Apply oil to the threads and
seating surface.
Cam sprocket bolt 2 5 8 (0.8, 5.9) Apply oil to the threads and
seating surface.
Cam chain tensioner lifter screw 1 6 4 (0.4, 3.0)
THREAD TORQUE
ITEM Q'TY REMARKS
Left crankcase cover plate screw 5 4 3 (0.3, 2.2)
Drive pulley face nut 1 14 108 (11.0, 80) Apply oil to the threads and
seating surface.
Clutch/driven pulley nut 1 28 54 (5.5, 40)
Clutch outer nut 1 12 49 (5.0, 36)
FRONT WHEEL/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
Front axle nut 1 12 59 (6.0, 44) U-nut
Front brake disc socket bolt 4 8 42 (4.3, 31) ALOC bolt:
replace with new ones
Front spoke (Spoke wheel type) 36 BC 3.2 3.7 (0.4, 2.7)
Handlebar post nut 1 10 59 (6.0, 44)
Rear brake lever pivot bolt (Standard 1 5 1 (0.1, 0.7)
type)
Rear brake lever pivot nut (Standard type) 1 5 4.5 (0.5, 3.3) U-nut
Bottom bridge pinch bolt 4 10 64 (6.5, 47)
Fork pipe seat socket bolt 2 10 23 (2.3, 17) Apply locking agent to the
threads
Fork cap bolt 2 8 20 (2.0, 15)
Steering stem top thread 1 26 – For tightening sequence;
See page 14-23
Steering stem lock nut 1 26 – For tightening sequence;
See page 14-23
THREAD TORQUE
ITEM Q'TY REMARKS
Rear axle nut 1 16 118 (12.0, 87) U-nut, Apply oil to the
threads and seating sur-
face.
Rear spoke (Spoke wheel type) 36 BC 3.2 3.7 (0.4, 2.7)
Engine hanger link nut (Engine side) 1 10 49 (5.0, 36)

GENERAL INFORMATION
BRAKE SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Rear brake arm bolt 1 6 10 (1.0, 7) ALOC bolt: replace with a
new one
Brake caliper bleed valve 1 8 5.4 (0.6, 4.4)
Brake master cylinder reservoir cap screw 2 4 1.5 (0.2, 1.1)
Brake pad pin 1 10 18 (1.8, 13)
Front brake lever pivot bolt 1 6 1 (0.1, 0.7)
(Standard type only)
Front brake lever pivot screw 1 6 1 (0.1, 0.7)
(CBS type only)
Front brake lever pivot nut 1 6 6 (0.6, 4.4)
Front brake light switch screw 1 4 1 (0.1, 0.7)
Brake hose oil bolt 2 10 34 (3.5, 25)
Rear brake lever pivot screw (CBS type 1 5 4.2 (0.4, 3.1)
only)
Rear brake lever pivot nut (CBS type only) 1 5 5.2 (0.5, 3.8) U-nut
Equalizer rod pivot screw (CBS type only) 1 5 4.2 (0.4, 3.1)
Equalizer rod pivot nut 1 5 5.2 (0.5, 3.8) U-nut
(CBS type only)
Rear brake lever bracket cover screws 2 5 4.2 (0.4, 3.1)
(CBS type only)
Rear brake lever bracket cover special 1 5 4.2 (0.4, 3.1)
screw (CBS type only)
Brake caliper mounting bolt 2 8 30.4 (3.1, 22) ALOC bolt: replace with
new ones
Brake caliper torque pin 1 8 22(2.2, 16)
Brake caliper pin 1 8 18 (1.8, 13)
BATTERY/CHARGING SYSTEM/ALTERNATOR
THREAD TORQUE
ITEM Q'TY REMARKS
Stator mounting socket bolt 3 6 10 (1.0, 7)
Flywheel nut 1 12 59 (6.0, 44)
THREAD TORQUE
ITEM Q'TY REMARKS
Starter motor cable screw 1 4 2 (0.2, 1.5)
Starter motor case screw 3 4 2 (0.2, 1.5)
OTHERS
THREAD TORQUE
ITEM Q'TY REMARKS
Muffler protector mounting bolt 2 6 10 (1.0, 7)
Brake shoe anchor pin nut 1 8
(When using the stake nut) 20 (2.0, 15)
(When using the normal nut) 18 (1.8, 13)
Sidestand pivot nut 1 10 29 (3.0, 21)
Sidestand pivot bolt 1 10 10 (1.0, 0.7)

1-11
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Liquid sealant (recommend- Right crankcase mating surface See page 13-10
ed: Three Bond 1207B or
Three Bond 1215 or equiva-
lent)
Liquid sealant (recommend- Cylinder head mating surface (semicircular area) See page 9-8
ed: Three Bond 5211C or
SHINETSU-SILICONE
KE45T or Three Bond 1215
or equivalent)
Locking agent (recommend- Driveshaft bearing set plate bolt threads See page 12-13
ed: Three Bond 2415 or
1322N or LOCKTITE 200 or
equivalent)
Molybdenum disulfide oil (a Camshaft cam lobes
mixture of 1/2 engine oil and
1/2 molybdenum disulfide
grease)
Molybdenum disulfide paste Kickstarter spindle sliding surface 0.1 – 0.3 g
Kickstarter driven gear shaft 0.2 – 0.3 g
Kickstarter driven gear friction spring sliding area
Grease (Shell ALVANIA R3 Driven face inner surface 7.0 – 8.0 g
or IDEMITSU AUTOREX B Movable driven face cam groove 1.5 – 2.0 g
or equivalent) Starter pinion gear shaft (both end) 0.1 – 0.3 g
Driven face ball bearing and needle bearing
Bearing area of final shaft
Engine oil (Without molybde- Oil pump drive gear teeth
num additives) Oil pump rotor whole surface
Oil pump shaft and pump cover sliding area
Oil pump driven gear teeth
Rocker arm shaft sliding surface
Rocker arm roller sliding area
Camshaft decompressor rotating surface 0.5 – 1.0 cc
Camshaft bearing
Cam sprocket teeth
Cam chain whole surface
Timing sprocket teeth
Piston and cylinder sliding surfaces
Piston ring whole surface and ring grooves
Piston pin outer surface
Connecting rod small end inner surface
Crankshaft bearings Fill up 2 cc minimum
Connecting rod big end bearing Fill up 3 cc minimum
Valve stem (valve guide sliding area)
Valve stem seal inner surface
Bearing area of drive and counter shaft
Drive, counter and final gear teeth
Water pump shaft sliding area
Water pump chain whole surface
Water pump driven gear teeth
Ball/needle bearing sliding area
Each O-ring whole surface
Oil seal lips and outer surfaces
Degrease Right crankshaft tapered area
Drive/driven pulley face and drive belt
Left crankcase cover bearing bushing inner surface

GENERAL INFORMATION
FRAME
Multi-purpose grease with Steering bearing race Spread each 3 g minimum
extreme pressure (recom- Steering stem dust seal lip Spread each 3 g minimum
mended: EXCELIGHT EP2
manufactured by KYODO
YUSHI, japan. or Shell AL-
VANIA EP2 or equivalent)
Grease (Shell BEARING Speedometer gear box inside
GREASE HD or equivalent)
Multi-purpose grease Front/rear wheel dust seal lip
Front wheel axle sliding surface
Front wheel distance collar whole surface
Speedometer gear box seal lip
Throttle cable-to-throttle drum sliding area Apply 0.1 - 0.2 g
Rear brake cam and shaft Spread each 0.2 - 0.3 g
Rear brake anchor pin shaft Spread 0.2 - 0.3 g
Rear brake dust seal lip
Rear brake lever pivot screw sliding surface
Equalizer rod pivot screw sliding surface (CBS type only)
Seat catch contact area Apply 2.2 g minimum
Fuel lid lock pin contact area Apply 2.2 g minimum
Centerstand pivot area
Sidestand pivot area
Silicone grease Rear brake cable cap boot inside
Front brake lever-to-master piston contacting area Spread each 0.1 g
Front brake lever pivot sliding area
Brake caliper pin sliding area Spread 0.4 g minimum
Brake caliper pad pin O-ring whole surface.
Brake caliper dust seal whole surface
Brake equalizer cable cap boot inside (CBS type only)
Speedometer cable
Throttle cable boot inside Fill up 0.1 g
Throttle cable inside Fill up 0.2 g minimum
Brake fluid Master cylinder inside and sliding area
(DOT 3 or DOT 4) Brake caliper piston seal whole surface
Brake caliper piston whole surface
Master cylinder piston cup
Fork fluid Fork dust seal and oil seal lips
Fork spring seat O-ring whole surface
Adhesive (Honda bond A or Handlebar grip rubber inside
equivalent) Air cleaner connecting hose-to-housing mating area

1-13
GENERAL INFORMATION
CABLE & HARNESS ROUTING
STANDARD TYPE
DIMMER SWITCH 3P CONNECTOR
TURN SIGNAL SWITCH 3P

(Red) CONNECTOR
TURN SIGNAL RELAY
RIGHT HANDLEBAR REAR BRAKE LIGHT

SWITCH WIRE SWITCH WIRE
STARTER SWITCH 3P HORN SWITCH 3P

(Black) CONNECTOR (Black) CONNECTOR
FRONT BRAKE LIGHT

REAR BRAKE CABLE
SWITCH WIRE
SPEEDOMETER CABLE
FRONT BRAKE HOSE
SPEEDOMETER
SUB HARNESS
THROTTLE CABLE THROTTLE
REAR BRAKE
DLC (DATA LINK CONNECTOR) CABLE
FRONT BRAKE HOSE

SPEEDOMETER CABLE
STARTER RELAY
SEAT LOCK CABLE
BATTERY POSITIVE
BATTERY NEGATIVE (+) CABLE
(–) CABLE
LIGHTING
CUT RELAY

GENERAL INFORMATION
CBS TYPE
DIMMER SWITCH 3P CONNECTOR

(Red) CONNECTOR
TURN SIGNAL RELAY
COMBINED BRAKE REAR BRAKE LIGHT

CABLE SWITCH WIRE

FRONT BRAKE LIGHT

SWITCH WIRE
REAR BRAKE CABLE
FRONT BRAKE HOSE SPEEDOMETER CABLE
SPEEDOMETER
THROTTLE CABLE SUB HARNESS
THROTTLE
CABLE
DLC (DATA LINK CONNECTOR) REAR BRAKE
FRONT BRAKE HOSE
SPEEDOMETER CABLE
SEAT LOCK CABLE
STARTER RELAY
BATTERY NEGATIVE (–) CABLE BATTERY POSITIVE (+) CABLE
LIGHTING CUT RELAY

1-15
GENERAL INFORMATION
STANDARD TYPE
TURN SIGNAL RELAY
REAR BRAKE CABLE
FRONT BRAKE HOSE
THROTTLE CABLE MAIN FUSE 15A

SUB FUSE 10A
BATTERY POSITIVE
(+) CABLE
SEAT LOCK CABLE
CONNECTORS:
· SPEEDOMETER SUB HARNESS
9P CONNECTOR
4P CONNECTOR
· IGNITION SWITCH 2P
IGNITION SWITCH WIRE
SEAT LOCK
FUEL PUMP WIRE CABLE
MAIN WIRE HARNESS

CONNECTORS:
· STARTER MOTOR 2P
CONNECTOR
· SIDESTAND SWITCH 3P
(GREEN) CONNECTOR
SPEEDOMETER
CABLE
SPEEDOMETER CABLE

GENERAL INFORMATION
CBS TYPE
TURN SIGNAL RELAY REAR BRAKE CABLE
COMBINED BRAKE CABLE

FRONT BRAKE HOSE
THROTTLE CABLE
MAIN FUSE 15A
SUB FUSE 10A
BATTERY POSITIVE
(+) CABLE
SEAT LOCK CABLE
CONNECTORS:
9P CONNECTOR
4P CONNECTOR
SEAT LOCK
MAIN WIRE HARNESS
CONNECTORS:
· STARTER MOTOR 2P
CONNECTOR
· SIDESTAND SWITCH 3P (GREEN)
CONNECTOR
SPEEDOMETER
CABLE
SPEEDOMETER CABLE

1-17
GENERAL INFORMATION
STANDARD TYPE
TURN SIGNAL RELAY REAR BRAKE LIGHT SWITCH WIRE
BATTERY NEGATIVE
(–) CABLE
REGULATOR/
SPEEDOMETER SPEEDOMETER
RECTIFIER
CABLE SUB HARNESS
SPEEDOMETER
STARTER RELAY CABLE
REAR
BRAKE REGULATOR/
CABLE RECTIFIER
FRONT BRAKE
HOSE THROTTLE
THROTTLE STARTER CABLE
CABLE RELAY
WIRE REAR BRAKE
CABLE
FRONT BRAKE
HOSE
HORN WIRE
FRONT BRAKE HOSE
FUEL FEED HOSE
THROTTLE CABLE
REAR BRAKE CABLE
OVERFLOW HOSE
FUEL TRAY DRAIN HOSE
FUEL FEED HOSE
THROTTLE CABLE OVERFLOW HOSE
REAR BRAKE CABLE FUEL TRAY DRAIN HOSE

GENERAL INFORMATION
CBS TYPE
TURN SIGNAL RELAY COMBINED BRAKE CABLE
REAR BRAKE LIGHT SWITCH WIRE
BATTERY NEGATIVE
(–) CABLE
REGULATOR/
SPEEDOMETER SPEEDOMETER RECTIFIER
CABLE SUB HARNESS
SPEEDOMETER
STARTER RELAY CABLE
REAR BRAKE
CABLE REGULATOR/
RECTIFIER
FRONT BRAKE
HOSE
STARTER THROTTLE
THROTTLE CABLE RELAY CABLE
WIRE REAR BRAKE
CABLE
FRONT BRAKE
HOSE
HORN WIRE
FRONT BRAKE HOSE
FUEL FEED HOSE
THROTTLE CABLE
REAR BRAKE CABLE
OVERFLOW HOSE
FUEL FEED HOSE
THROTTLE CABLE OVERFLOW HOSE
REAR BRAKE CABLE FUEL TRAY DRAIN HOSE

1-19
GENERAL INFORMATION
CONNECTORS: BATTERY NEGATIVE (–) CABLE

· SPEEDOMETER SUB HARNESS 9P CONNECTOR
· SPEEDOMETER SUB HARNESS 4P CONNECTOR
· IGNITION SWITCH 2P CONNECTOR
FUEL LID
OPENER CABLE
HEADLIGHT 6P IGNITION SWITCH WIRE

CONNECTOR
LIGHTING CUT RELAY

REGULATOR/
RECTIFIER
ENGINE SUB HARNESS

14P (GRAY) CONNECTOR
HORN WIRE
SEAT
LOCK
CABLE
SPEEDOMETER
CABLE
ECM 33P (BLACK)

CONNECTOR
RADIATOR SIPHON
HOSE CONNECTORS:
· STARTER MOTOR 2P CONNECTOR
· SIDESTAND SWITCH 3P (GREEN) CONNECTOR
FUEL PUMP WIRE · ALTERNATOR 3P CONNECTOR

2. TECHNICAL FEATURES
PGM-FI (Programmed Fuel Injection) POWER SUPPLY CIRCUIT ························2-17

SYSTEM ························································2-2

2-1
TECHNICAL FEATURES
PGM-FI (Programmed Fuel Injection) SYSTEM
TECHNICAL FEATURES
SYSTEM COMPONENTS
This model utilizes PGM-FI (Programmed Fuel Injection) system, instead of conventional carburetor system. This system consists
of the following: Injector, throttle body, ECM, fuel pump, sensor unit (MAP/TP/IAT sensors), CKP sensor, ECT sensor, O2 sensor
and IACV.
IACV SENSOR UNIT (INSTALLED ON THROTTLE BODY)

(INSTALLED ON THROTTLE BODY) ·MAP sensor (measures intake manifold vacuum pressure)
Controlled by ECM, it automatically regulates the ·TP sensor (measures throttle position)
volume of air that passes through throttle valve in ·IAT sensor (measures intake air temperature)
order to maintain the specified idle speed.
INJECTOR
Electromagnetic valve
to discharge fuel
THROTTLE BODY
It controls the volume of
intake air by opening/
closing the throttle valve.
ECM
ECM regulates amount of fuel discharged by
CKP SENSOR O2 SENSOR
injector. It also controls PGM-FI electrical
It measures the crankshaft It measures the amount of system such as IACV and ignition system,
rotation speed. oxygen in exhaust gas. according to collected signals from each
sensor.
ECT SENSOR FUEL PUMP
It measures the engine It delivers fuel from fuel tank
coolant temperature. to injector by applying
constant pressure.
PGM-FI Programmed Fuel Injection IAT SENSOR Intake Air Temperature Sensor
MAP SENSOR Manifold Absolute Pressure Sensor CKP SENSOR Crankshaft Position Sensor
TP SENSOR Throttle Position Sensor IACV Idle Air Control Valve
ECT SENSOR Engine Coolant Temperature Sensor ECM Engine Control Module

TECHNICAL FEATURES
PGM-FI SYSTEM DIAGRAM
MAIN FUSE LIGHTING SUB FUSE

15A CUT RELAY 10A
R R/W R/W R/Y Bl/Br
R/W Bl
IGNITION
SWITCH
BATTERY
W REGULATOR/ R/Bl Bl
RECTIFIER
G
Bu/Y 12 PCP Bl
W/Y 23 PCM
CKP
SENSOR PRC 7 W/Bl
ALTERNATOR
IGP 1 Bl
SENSOR UNIT
Y/O 6 VCC FUEL PUMP

(1) Y/R 27 PB FLR 8 Br/Bl Bl
MAP
SENSOR
(8) W/R 5 THL INJ 16 P/Bu
TP
SENSOR Bl (12)
INJECTOR
W/Bu 14 TA
IGPLS 11 G/R Bl
(9)
IAT
SENSOR
IGNITION
P/W 24 TW COIL
(7)
ECT
SENSOR G/O G/O 4 SG ECM SPARK Bl
PLUG
(21) Bl Bl
O2 Bl/O 3 O2
SENSOR MIL
FRONT REAR
FI WARN 22 Bu/Y Bl BRAKE BRAKE
LIGHT LIGHT
SWITCH SWITCH
From starter relay Y/G 33 S/RELAY TW WARNING
INIDICATOR G/Y G/Y
To sidestand switch G/W 25 SSTAND
TW WARN 18 Lg/R Bl
DLC
SCS Bl Bl
CONNECTOR G/Y
O/W 30 K-LINE IACV1A 21 Lg/R
Br 15 SCS IACV1B 32 Gr/R

(29)
G/Bl G/Bl 2 LG IACV2A 20 Br/R IACV STARTER
SWITCH
G/Bl 10 PG2 IACV2B 31 Bl/R
G 9 PG1
STSW 29 Y/G
1 11
Bl : Black Br : Brown
12 22 Y : Yellow O : Orange
( ) : Number of MIL blinks Bu : Blue Lg : Light green
23 33
G : Green P : Pink
: The engine does not start if there is mulfunction ECM 33P CONNECTOR R : Red Gr Gray
ECM side of the male terminals W : White

2-3
TECHNICAL FEATURES
OUTLINE
The Programmed Fuel Injection (PGM-FI) system injects the required amount of fuel calculated by computer, using sensor to
collect information, such as revolution of the engine, suction pressure in the intake manifold, throttle opening and temperature.
While the engine takes fuel from the nozzle using suction force when carburetor is used, the PGM-FI system injects pressurized
fuel into the intake port by force from an injector (solenoid nozzle).
The construction of the PGM-FI can be divided in 2 major systems, the “fuel supply system” and the “electronic control system”.
The electronic control system consists of the detector section to send information from sensors to the Engine Control Module
(ECM) and the control section that processes information in the ECM before sending fuel injection commands to the fuel supply
system.
The fuel supply system consists of the fuel pump for forced delivery of fuel, the pressure regulator (integrated in the fuel pump) that
maintains the fuel pressure constant and the injector that injects fuel according to the signal sent from the ECM.
ELECTRONIC CONTROL SYSTEM

SYSTEM OUTLINE
The electronic control system consists of the ECM with sensors and functional parts. The ECM receives electric signals from
sensors and controls functional parts, such as the injector and fuel pump.
DETECTOR SECTION CONTROL SECTION OPERATION SECTION
SENSOR UNIT
FUEL INJECTION CONTROL

TP SENSOR
MAP SENSOR FUEL PUMP CONTROL
INJECTOR
IAT SENSOR
MIL CONTROL
FUEL PUMP
DLC
CKP SENSOR
MIL
ECT SENSOR
ECM
O2 SENSOR
BATTERY VOLTAGE

TECHNICAL FEATURES
SENSORS
There are two kinds of sensor output: One translates changes of the electrical resistance into changes of voltage, the other
produces its own voltage or current.
OUTPUT VOLTAGE SENT TO ECM
• As shown on the diagram below, two resistors divide the source voltage when connected to the source in series.
5V
2.5 V A= 1 kΩ
2.5 V
B= 1kΩ
When resistor A and B have same resistance value, source voltage would be divided equally. When one of them has larger
resistance value than the other, it would receive larger share of the load.
ECT sensor and IAT sensor utilize this principle.
ECM receives changes of physical information (changes of temperature, pressure etc.) as variable voltage by reading it at both
ends of resistor B (Resistor A: fixed resistor/Resistor B: variable resistor that reacts to physical changes).
For example, when source voltage is 5 V, resistance value of resistor A is 1.5 kΩ, resistance value of resistor B is 2.5 kΩ, the
voltage measured at point C would be 3.125 V as shown below. If the value of resistor B is 0.1 k Ω, the voltage measured at
point C would be 0.3125 V.
e.g.: ECT (engine coolant temperature) SENSOR
WHEN ENGINE COOLANT TEMPERATURE IS 20°C: WHEN ENGINE COOLANT TEMPERATURE IS 113 – 116°C:
ECM ECM
5V 5V
ECT SENSOR ECT SENSOR
A= 1.5 kΩ A= 1.5 kΩ
CPU CPU
B= 2.5 kΩ C= 3.125 V B= 0.1 kΩ C= 0.3125V

2-5
TECHNICAL FEATURES
TP SENSOR
• TP sensor detects the opening degree of throttle valve.
• TP sensor consists of a variable resistor (volume) located on the same axis with throttle valve and a contact point (brush) that
moves above the variable resistor in accordance with the throttle valve.
• TP sensor detects the changes of brush angle synchronized with throttle valve movement by converting them into variable
resistance values. The input voltage from ECM becomes regulated by this varying resistance value and comes back into ECM.
• Output voltage sent back to ECM is low when throttle opening is small. The voltage becomes higher as throttle opening
becomes larger.
• Depending on output voltage, ECM controls the following:
– determines basic discharge duration and cuts off fuel supply on deceleration (with CKP sensor)
– increases the amount of fuel injected on acceleration
ECM
SENSOR UNIT
5V
TP SENSOR
OUTPUT
VOLTAGE
TP SENSOR
VARIABLE RESISTOR (VOLUME)

OUTPUT VOLTAGE
4.13 – 4.76 V
0.29 – 0.71 V
CONTACT POINT (BRUSH)
FULL FULL
CLOSE OPEN
(IDLE)
THROTTLE VALVE OPENING DEGREE

TECHNICAL FEATURES
MAP SENSOR
• MAP sensor detects the changes of vacuum pressure inside the intake manifold.
• MAP sensor consists of the following: a pressure sensing device (silicone diaphragm) that varies its resistance value when
pressure is applied, and an amplifier that boosts tiny changes of voltage.
• MAP sensor outputs the changes of vacuum pressure by converting them into changes of resistance value and amplifies them.
ECM receives the output signal from the sensor as variable voltages.
• Output voltage into ECM is low when intake manifold vacuum pressure is low. The voltage becomes higher as vacuum pressure
becomes greater.
• Depending on output voltage, ECM determines basic discharge duration with CKP sensor.
SENSOR UNIT
ECM
5V
MAP SENSOR 5V
OUTPUT
VOLTAGE
MAP SENSOR
PRESSURE SENSING DEVICE

OUTPUT VOLTAGE (SILICONE DIAPHRAGM)
3.41 V
0.5 V
13 kPa 120 kPa AMPLIFIER
LOW HIGH PRESSURE VACUUM INLET

2-7
TECHNICAL FEATURES
IAT SENSOR
• IAT sensor detects temperature of incoming air into engine.
• IAT sensor consists of a thermistor that varies its resistance value according to changes of temperature.
• IAT sensor detects changes of intake air temperature by converting them into the changes of thermistor's resistance values.
ECM receives the output signal from the sensor as variable voltages.
• Output voltage into ECM is high when intake air temperature is low. The voltage becomes lower as temperature increases.
• Depending on output voltage, ECM corrects discharge duration corresponding with intake air temperature.
SENSOR UNIT
ECM
5V
IAT SENSOR
OUTPUT
VOLTAGE
IAT SENSOR
OUTPUT
VOLTAGE
THERMISTOR
4.63 V
0.47 V
INTAKE AIR
-20°C 100°C TEMPERATURE

TECHNICAL FEATURES
ECT SENSOR
• ECT sensor detects engine coolant temperature.
• ECT sensor consists of a thermistor that varies its resistance value according to changes of temperature.
• ECT sensor detects the changes of engine coolant temperature by converting them into the changes of thermistor's resistance
values. ECM receives the output signal from the sensor as variable voltages.
• Output voltage into ECM is high when engine coolant temperature is low. The voltage becomes lower as temperature increases.
• Depending on output voltage, ECM corrects discharge duration corresponding with engine coolant temperature.
ECM
5V
ECT SENSOR
OUTPUT
VOLTAGE
ECT SENSOR
OUTPUT
VOLTAGE
4.54V THERMISTOR
0.43V
ENGINE
-
-20°C 100°C COOLANT
TEMPERATURE

2-9
TECHNICAL FEATURES
O2 SENSOR
• O2 sensor detects the amount of oxygen in exhaust gas.
• O2 sensor consists of a cylindrical-shaped, white gold-coated zirconia device. The inside of the device is exposed to
atmosphere, whereas its outside is exposed to exhaust gas.
Zirconia device: produces electromotive force by difference of oxygen concentration between atmosphere and exhaust gas
when temperature is higher than certain value.
• O2 sensor detects changes of oxygen concentration in exhaust gas by measuring the electromotive force. ECM receives the
values as voltages.
• The output voltage of O2 sensor is about 0 V when the difference of oxygen concentration between the atmosphere and the
exhaust gas is very small (when air/fuel ratio is lean), whereas about 1 V when the difference is very big (when air/fuel ratio is
rich).
• Depending on output voltage, ECM corrects discharge duration corresponding with oxygen concentration in exhaust gas.
ECM
O2 SENSOR
OUTPUT
VOLTAGE
O2 SENSOR
ATMOSPHERE
WHITE GOLD-COATED
GENERAL IDEA OF O2 SENSOR OUTPUT CHARACTERISTICS: POLE
ELECTROMOTIVE FORCE ZIRCONIA DEVICE

(VOLTAGE) RICH AIR/FUEL RATIO
WHITE GOLD-COATED
HIGH POLE
LEAN AIR/FUEL RATIO

LOW
INTAKE IGNITION INTAKE IGNITION INTAKE
PROCESS
COMPRESSION EXHAUST COMPRESSION EXHAUST

TECHNICAL FEATURES
CKP SENSOR
GENERAL DESCRIPTION
• CKP sensor detects engine revs and crankshaft angle.
• CKP sensor consists of the reluctors on the flywheel (9 projections) and the pickup in CKP sensor with built-in permanent
magnet and coil.
• When reluctors on the flywheel cross CKP sensor as the crankshaft rotates, changes of magnetic flux in the pickup coil occur.
CKP sensor detects the changes by converting them into pulse voltages and sends the pulse into ECM (9 pulses per 1
crankshaft rotation).
• Depending on output voltage, ECM controls the following:
– determines timing of fuel discharge
– determines basic discharge duration (with TP sensor and MAP sensor)
– cuts off fuel supply on deceleration (with TP sensor)
– determines ignition timing
RELUCTOR
PICKUP
ECM (WITH BUILT-IN PERMANENT
FLYWHEEL MAGNET AND COIL)
OUTPUT
VOLTAGE
OUTPUT
CKP SENSOR VOLTAGE
RELUCTOR
CKP SENSOR
CKP SENSOR
OUTPUT
VOLTAGE

2-11
TECHNICAL FEATURES
SELF DIAGNOSIS FUNCTION
MIL
(Malfunction Indicator Lamp)
MIL (Malfunction Indicator Lamp)

• When ignition switch is turned ON, PGM-FI malfunction indicator lamp (MIL) will stay on for a few seconds, then go off.
• When ECM detects an abnormal response from the electrical system, MIL blinks according to the self-diagnosis function of the
system in order to notify the user of a problem.
• MIL blinks only when the ignition switch is ON with engine stopped, or the engine rev is below 2200 min-1(rpm).
• The malfunction detected by self-diagnosis function is either open circuit or short circuit.
• ECM stores a failure code when problem is detected. Once recorded, the code remains in erasable memory until the clearing
procedure is performed.
• PGM-FI system is provided with a fail-safe function that maintains a minimum running capability by using a programmed value in
the simulated map even when there is problem in the system.
When any abnormality is detected in injector and/or crankshaft position (CKP) sensor, the fail-safe function stops the engine to
protect it from serious damage.
• The time of blinks represents each failure code (0 – 29). The MIL uses two kinds of blink duration, long blink lasts 1.3 second,
whereas the short blink lasts 0.3 second.
ON
IGNITION
SWITCH OFF
ON
NO
PROBLEM
DETECTED OFF
0.5 sec.
0.3 sec. 0.4 sec. 1.3 sec. 0.3 sec.
3.0 sec.
ON
PROBLEM
DETECTED
OFF
CODE "7" CODE "12"

TECHNICAL FEATURES
FUEL SUPPLY SYSTEM
GENERAL DESCRIPTION
• Fuel pump is located inside the fuel tank.
• Fuel pump draws in the fuel via fuel filter and delivers it to the injector.
The pressure regulator (integrated in the fuel pump) maintains fuel pressure in constant at 294 kPa (3.0 kgf/cm2, 43 psi).
• This system uses resin for the part of materials in the fuel feed hose. Do not bend or twist the fuel feed hose.
FUEL TANK
FUEL PUMP
INJECTOR
FUEL FILTER
FUEL FEED HOSE

2-13
TECHNICAL FEATURES
FUEL PUMP CONSTRUCTION
Fuel pump assembly consists of armature coil, pump section, residual pressure check valve, suction port and discharge port.
The pump section consists of armature coil-driven impeller and pump chamber composed of pump casing and pump cover.
FUEL PUMP OPERATION
• When the motor turns, fin grooves located on impeller circumference produce pressure difference due to hydro-friction force,
fuel is drawn into the pump, then delivered out of the pump.
• The drawn fuel via the filter circulates inside the motor and passes the residual pressure check valve, then becomes delivered
through the discharge port.
• When engine is turned OFF and fuel pump is not operating, the check valve maintains residual fuel pressure to ease engine
restarting.
• Fuel pressure regulator maintains fuel pressure in constant by the regulator valve that opens when fuel pressure in discharge
circuit (between the pump and injector) becomes higher than certain.
DISCHARGE PORT
To INJECTOR
FIN GROOVES
delivery suction
RESIDUAL PRESSURE
CHECK VALVE
REGULATOR
VALVE
PUMP COVER
FIN GROOVES
IMPELLER CASING
ARMATURE COIL
CASING
IMPELLER
FILTER

TECHNICAL FEATURES
INJECTOR
GENERAL DESCRIPTION
• Fuel injector is a solenoid valve that consists of needle valve/plunger,
solenoid coil, solenoid spring and filter.
• Constantly pressurized fuel (294 kPa (3.0 kgf/cm2, 43 psi)) is supplied to
the injector. It sprays the proper amount of fuel through idle to maximum PLUNGER
engine revs. (NEEDLE VALVE) FILTER
• The injector is either fully closed or fully open with fixed stroke. The
amount of fuel injected is dependent on how long the injector is kept
open.
• The ignition switch supplies constant power for the injector. When ECM
starts up the drive transistor, current flows through the solenoid coil and
injector opens.
SOLENOID SPRING SOLENOID COIL
OPERATION
1. The fuel pressurized by the fuel pump is blocked at the injector nozzle that consists of plunger/needle valve and valve seat.
2. When ECM turns the drive transistor ON, current flows through the solenoid coil in the injector. The electromagnetized coil pulls
up the plunger/needle valve while compressing the solenoid spring.
3. Nozzle opens as the plunger/needle valve lifts up. The fuel blocked at the injector nozzle passes the filter and then sprays into
the intake manifold.
BATTERY
FILTER VOLTAGE
FUEL PUMP
SOLENOID DRIVE TRANSISTOR

SPRING
CPU
SOLENOID
COIL
ECM
PLUNGER/
NEEDLE VALVE
VALVE
INJECTOR NOZZLE SEAT
4. When ECM turns the drive transistor OFF, current no longer flows through the solenoid coil in the injector.
The solenoid spring closes the nozzle and injecting stops in result.
BATTERY
VOLTAGE
FUEL PUMP
SOLENOID DRIVE TRANSISTOR

SPRING
CPU
SOLENOID
COIL
ECM
PLUNGER/
NEEDLE VALVE
VALVE
INJECTOR NOZZLE SEAT

2-15
TECHNICAL FEATURES
IDLE AIR CONTROL VALVE (IACV)
IACV consists of ECM, step motor, slide valve and bypass circuit.
IACV regulates the amount of air flow through the throttle valve by operating the slide valve in accordance with the input signal from
ECM in order to maintain specified engine idle speed at 1,700 ± 100 min-1 (rpm).
THROTTLE VALVE
BYPASS CIRCUIT IACV
SLIDE
VALVE
SLIDE VALVE MAXIMUM SLIDE VALVE MINIMUM

AIR FLOW POSITION AIR FLOW POSITION
STEP
MOTOR
WHEN IGNITION SWITCH IS TURNED ON:
SLIDE SLIDE
VALVE VALVE
STEP
MOTOR
When ignition switch is turned ON, ECM turns the step motor and it pulls the slide valve toward itself. While detecting engine
coolant temperature, ECM drives the motor in order to slide the valve back to proper position where necessary amount of incoming
air for starting the engine can be obtained.
DURING WARM UP:
When the engine is still cold, ECM controls the slide valve position in order to increase the amount of incoming air. As a result,
engine idle speed is maintained at 1,900 ± 100 min-1 (rpm)
As the engine gets warmed up, slide valve returns toward its original position. ECM decreases the amount of incoming air by
controlling the position of the slide valve in order to obtain specified engine idle speed at 1,700 ± 100 min-1 (rpm).
SLIDE
SLIDE
VALVE
VALVE
STEP
MOTOR

TECHNICAL FEATURES
POWER SUPPLY CIRCUIT
GENERAL DESCRIPTION
This scooter adopts a power supply circuit that utilizes the output from the alternator as power supply required when starting the
engine, even when the battery is discharged.
When starting the engine with normal battery, it can supply enough voltage required for lighting system such as turn signal or each
indicator, as well as the electric starter system, ignition system and fuel system.
When the ECM detects low battery voltage, the output voltage generated from alternator is supplied exclusively for ignition system
and fuel system operation when starting the engine, whereas the power supply for the charging/lighting system are shut off.
- TURN SIGNAL LIGHT RELAY

- BRAKE LIGHT SWITCH/BRAKE/TAIL LIGHT
- FUEL METER
- HEADLIGHT
LIGHTING CUT RELAY - BRAKE/TAIL LIGHT
SUB FUSE 10 A
MAIN FUSE 15 A
IGNITION SWITCH
ECM BATTERY
REGULATOR/
RECTIFIER
INJECTOR
ALTERNATOR
FUEL PUMP
IGNITION COIL/
SPARK PLUG
STARTER RELAY
STARTER MOTOR

2-17
TECHNICAL FEATURES
OPERATION
When the battery is adequately charged:
• When the ignition switch is turned ON, the ECM detects the battery voltage.
If the battery voltage is normal, ECM turns ON the lighting cut relay (page 2-20) and the battery voltage is supplied to electric
parts.
The battery voltage is supplied for ignition system and fuel system via regulator/rectifier internal circuit (B – A) and ignition
switch.
The headlight does not turn ON as it relies on the alternator output voltage.
LIGHTING CUT RELAY

To ECM To ELECTRIC PARTS - TURN SIGNAL LIGHT RELAY
- FUEL METER
- PGM-FI SYSTEM
- ELECTRIC STARTER
IGNITION SWITCH
A B C
REGULATOR/ BATTERY
RECTIFIER
ALTERNATOR To ELECTRIC PARTS - HEADLIGHT

- BRAKE/TAIL LIGHT
• When the engine is started, the output voltage from alternator is supplied for electric devices as well as the ignition system and
fuel system via the regulator/rectifier.
The voltage generated by the alternator is also utilized for charging the battery.
LIGHTING CUT RELAY

- FUEL METER
- PGM-FI SYSTEM
- ELECTRIC STARTER
IGNITION SWITCH
A B C
REGULATOR/ BATTERY
RECTIFIER

- BRAKE/TAIL LIGHT

TECHNICAL FEATURES
When the battery is discharged:
• When the ECM detects the low battery voltage, ECM leaves the lighting cut relay OFF (page 2-20), in result, the power supply
for electrical devices, such as turn signal relay, remains OFF. The voltage generated by the alternator is exclusively supplied for
ignition and fuel system via regulator/rectifier and ignition switch when the kickstarter is operated.
LIGHTING CUT RELAY

- FUEL METER
- PGM-FI SYSTEM
- ELECTRIC STARTER
IGNITION SWITCH
A B C
REGULATOR/ BATTERY
RECTIFIER

- BRAKE/TAIL LIGHT
• When the engine is started, the ECM turns ON the lighting cut relay. In result, the voltage generated by alternator is also
supplied for charging and operating other electrical devices.
LIGHTING CUT RELAY

- FUEL METER
- PGM-FI SYSTEM
- ELECTRIC STARTER
IGNITION SWITCH
A B C
REGULATOR/ BATTERY
RECTIFIER

- BRAKE/TAIL LIGHT

2-19
TECHNICAL FEATURES
LIGHTING CUT RELAY
Lighting cut relay turns ON/OFF the power supply for lighting devices, such
as turn signal relay. LIGHTING CUT RELAY
When the ignition switch is turned ON, the ECM detects the battery voltage.
The coil inside the lighting cut relay becomes electromagnetized when the
ECM grounds the power, in result, the lighting cut relay turns ON.
From IGNITION SWITCH From IGNITION SWITCH

LIGHTING CUT RELAY LIGHTING CUT RELAY
CPU CPU
ECM ECM
ELECTRIC PARTS ELECTRIC PARTS

3. FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS ·························3-2 LUGGAGE BOX ··········································3-11
BODY PANEL REMOVAL CHART ···············3-2 REAR CENTER COVER ·····························3-11
SERVICE INFORMATION ·····························3-3 PILLION STEP BRACKET··························3-11
TROUBLESHOOTING···································3-3 RADIATOR COVER ····································3-12
FRONT FENDER ···········································3-4 GRAB RAIL ·················································3-12
FRONT TOP COVER·····································3-4 FUEL LID/SEAT OPENER ··························3-13
MAIN PIPE UPPER COVER··························3-5 BODY COVER·············································3-14
SIDE GARNISH ·············································3-5 REAR FENDER/REAR INNER FENDER····3-15
FRONT INNER COVER·································3-6 FRONT SIDE COVER ·································3-15
FRONT COVER ·············································3-6 MAIN PIPE SIDE COVER ···························3-16
FRONT HANDLEBAR COVER ·····················3-8 FRONT LOWER COVER ····························3-17
REAR HANDLEBAR COVER ·······················3-8 UNDER COVER ··········································3-17
MAINTENANCE LID······································3-9 FUEL LID/CENTER COVER ·······················3-18
SEAT····························································3-10 EXHAUST PIPE/MUFFLER ························3-19
BODY GARNISH ·········································3-10

3-1
BODY PANEL LOCATIONS
(7)
(23) (6)
(22) (8) (10)
(12)
(2) (13)
(1)
(5)
(3)
(11)
(4)
(24) (15)
(9) (18)
(21) (20)
(19) (14) (16) (17)
(1) Front fender (page 3-4) (9) Maintenance lid (page 3-9) (17) Rear fender/rear inner fender
(page 3-15)
(2) Front top cover (page 3-4) (10) Seat (page 3-10) (18) Front side cover (page 3-15)
(3) Main pipe upper cover (page 3-5) (11) Body garnish (page 3-10) (19) Main pipe side cover (page 3-16)
(4) Side garnish (page 3-5) (12) Luggage box (page 3-11) (20) Front lower cover (page 3-17)
(5) Front inner cover (page 3-6) (13) Rear center cover (page 3-11) (21) Under cover (page 3-17)
(6) Front cover (page 3-6) (14) Pillion step bracket (page 3-11) (22) Rearview mirror (page 3-8)
(7) Front handlebar cover (page 3-8) (15) Fuel lid/center cover (page 3-18) (23) Grab rail (page 3-12)
(8) Rear handlebar cover (page 3-8) (16) Body cover (page 3-14) (24) Radiator cover (page 3-12)
BODY PANEL REMOVAL CHART

• This chart shows removal order of body panels by means of arrow.
(23) Grab rail (2) Front top cover
(3) Main pipe upper cover
(12) Luggage box (5) Front inner cover
(15) Fuel lid/center cover (4) Side garnish (22) Rearview mirror
(13) Rear center cover (14) Pillion step bracket (7) Front handlebar cover
(16) Body cover (18) Front side cover (8) Rear handlebar cover
(24) Radiator cover (6) Front cover
(17) Rear fender/rear inner fender

(1) Front fender
(20) Front lower cover
(9) Maintenance lid
(10) Seat
(19) Main pipe side cover (21) Under cover (11) Body garnish

SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels and exhaust system.
• Always replace the exhaust pipe gasket after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust joint first, then
tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Pillion step bracket socket bolt 2.65 N·m (2.7 kgf·m, 20 lbf·ft)
Muffler mounting bolt 2.65 N·m (2.7 kgf·m, 20 lbf·ft)
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler

3-3
FRONT FENDER
REMOVAL/INSTALLATION
Release the speedometer cable guide from the hole on
the front fender.
Remove the four bolts and front fender. FRONT FENDER
Installation is in the reverse order of removal.
SPEEDOMETER
CABLE GUIDE
BOLTS
FRONT TOP COVER

Remove the screws/washers.
Be careful not to Slightly slide the front top cover upward and release the
damage the hooks hooks and tabs from the slots, then remove the front top
and tabs. cover by sliding it backward.
FRONT TOP COVER SCREWS/WASHERS
HOOKS
TABS

MAIN PIPE UPPER COVER
Unlock the fuel lid with fuel lid opener.
Open the fuel lid.
Remove the four tapping screws and a screw.
Be careful not to Slightly slide the main pipe upper cover backward and
damage the hooks release the hooks and tabs from the slots, then remove
and tabs. it.
MAIN PIPE UPPER COVER SCREW
TABS
HOOKS
TAPPING SCREWS
SIDE GARNISH
Remove the screw/washer.
Release the hook on the upper side, slide the side HOOK
garnish backward and remove it.
SCREW/
WASHER
SIDE GARNISH

3-5
FRONT INNER COVER
Remove the main pipe upper cover (page 3-5).
FRONT INNER COVER
Be careful not to Slightly slide the front inner cover upward and unhook
damage the hooks the hooks from the slots, then remove the front inner
and slots. cover.
SCREWS/
HOOKS
WASHERS
FRONT COVER
Remove the following:
– Front top cover (page 3-4)
– Side garnish (page 3-5)
– Front inner cover (page 3-6)
Disconnect the headlight 6P connector.
Remove the two bolts and four screws.
Be careful not to Release the hooks on the front side cover from the slots
damage the hooks, on the front cover.
slots and the boss. Release the boss from the grommet, then remove the
front cover.
GROMMET
HOOKS
SCREWS
6P CONNECTOR
BOLTS
FRONT COVER
BOSS

DISASSEMBLY/ASSEMBLY
– Four screws/washers
– Two screws SCREWS/
– Headlight unit FRONT COVER WASHERS
SCREWS
HEADLIGHT UNIT
– Screw
– Front grill
LEFT FRONT COVER
Be careful not to Separate the right and left front covers by releasing the
damage the tabs. tabs. RIGHT FRONT COVER
Assembly is in the reverse order of disassembly.
SCREW
FRONT GRILL
TABS

3-7
FRONT HANDLEBAR COVER
Loosen the lock nuts and remove the rearview mirrors
by turning them counterclockwise. REARVIEW MIRRORS
LOCK NUTS
Remove the following: SCREWS FRONT

– Front top cover (page 3-4) HANDLEBAR
– Six screws COVER
Be careful not to Release the stoppers around the front handlebar cover.
damage the Release the right and left bosses of the front handlebar
BOSSES
stoppers and cover from the rear handlebar cover holes by carefully
bosses. lifting the front handlebar cover upward.
Remove the front handlebar cover. HOLES
REAR HANDLEBAR COVER

Remove the following: WIRE GUIDES
– Front handlebar cover (page 3-8)
Disconnect the following connectors:
– Headlight unit 6P connector
– Speedometer 9P connector
– Speedometer 4P connector
Release the speedometer sub harness from the wire
guides.
CONNECTORS

Disconnect the following:
CBS type shown:
– Rear brake light switch wire connectors REAR HANDLEBAR
– Front brake light switch wire connectors COVER
– Speedometer cable BRAKE LIGHT
SWITCH WIRE
Remove the three screws and rear handlebar cover. CONNECTORS
Route the wire Installation is in the reverse order of removal.
harness properly
(page 1-14).
SPEEDOMETER CABLE
SCREWS
MAINTENANCE LID
Remove the screw and special screw.
Be careful not to Slightly slide the maintenance lid backward and release HOOK SPECIAL SCREW
damage the hook the hook and the tabs.
and tabs. Remove the maintenance lid.
Installation is in the reverse order of removal. TABS
SCREW
MAINTENANCE LID

3-9
SEAT
Unlock the seat with seat opener.
Open the seat. SEAT
Remove the nuts and seat.

NUTS
BODY GARNISH
Remove the screw/washer.
SCREW/
Be careful not to Release the hooks on the body garnish by pulling it WASHER
damage the hooks. backward and remove it.
BODY GARNISH
HOOKS

LUGGAGE BOX
Remove the grab rail (page 3-12).
BOLTS/WASHERS
Remove the four bolts/washers and luggage box.
LUGGAGE
BOX
REAR CENTER COVER

Remove the grab rail (page 3-12).
REAR
Be careful not to Release the front tabs by slightly pulling the rear center CENTER
damage the tabs cover backward. COVER
and hook. Slightly slide the rear center cover forward and release
the hook, then remove the rear center cover.
TABS
HOOK
PILLION STEP BRACKET

Remove the two socket bolts and pillion step bracket.
PILLION STEP
Install the pillion step bracket and tighten the socket BRACKET
bolts to the specified torque.
TORQUE: 26.5 N·m (2.7 kgf·m, 20 lbf·ft)
BOLTS

3-11
RADIATOR COVER
Remove the pillion step bracket (page 3-11).
Release the wire boss from the radiator cover.
Be careful not to Remove the three bolts and radiator cover. WIRE BOSS
damage the radiator
surface.
harness properly
(page 1-14).
BOLTS
RADIATOR COVER
GRAB RAIL
Unlock the seat with the ignition key.
Open the seat. BOLTS GRAB RAIL

– Four bolts
– Grab rail

FUEL LID/SEAT OPENER
Remove the front cover (page 3-6).
HOOK
Remove the tapping screw and fuel lid/seat opener
lower cover by releasing its hook.
TAPPING SCREW LOWER COVER
Disconnect the fuel lid/seat opener cables from the

cable levers.
Remove the following from the switch housing:

– Special screws/switch cover
– Cable levers
– Washer
– Lever pivot shaft
– Switch knob pivot shaft
– Switch knob
– Ball
– Spring OPENER CABLES
Be careful not to Installation is in the reverse order of removal.

lose the ball and
spring.
Position the ball in the cut-out SWITCH KNOB PIVOT SHAFT

of the switch knob.
BALL
SWITCH COVER
Position the spring in the SPRING
groove of the switch cover.
SPECIAL
SCREWS
WASHER
SWITCH KNOB
LEVERS
SWITCH HOUSING
LEVER PIVOT SHAFT

3-13
BODY COVER
– Pillion step brackets (page 3-11).
– Fuel lid/center cover (page 3-18).
– Rear center cover (page 3-11).
– Two tapping screws from the lower side
– Two screws/washers from the upper side
Be careful not to Disconnect the rear combination light 6P connector.
damage the boss, Release the hooks and tabs from the slots and boss
tabs and hooks. from the grommet, then remove the body cover
backward.
TABS SCREWS/WASHERS
BODY COVER
6P CONNECTOR
HOOKS
BOSS
TAPPING SCREWS
REAR UNDER
SCREWS
– Body garnish (page 3-10) COVER
– Two screws
– Rear under cover REAR
– Right/left body covers COMBINATION
– Rear combination light unit LIGHT UNIT
BODY COVERS

REAR FENDER/REAR INNER FENDER
– Body cover (page 3-14)
– Three bolts/washers
– Rear fender
– Rear inner fender
BOLTS/WASHERS
REAR INNER FENDER REAR FENDER
FRONT SIDE COVER

– Four screws
Be careful not to Release the following tabs/hook and remove the front
damage the tabs side cover.
SCREWS
and hooks.
– Lower tabs from the grooves on the front inner cover
– Front hook from the slot on the front cover
– Tabs from the slots on the main pipe side cover
HOOK
TABS
FRONT SIDE COVER

3-15
MAIN PIPE SIDE COVER
– Fuel lid/center cover (page 3-18)
– Front lower cover (page 3-17)
– Pillion step bracket (page 3-11)
– Maintenance lid (right side only) (page 3-9)
Remove the screw, two bolts and two special bolts.
Be careful not to Slightly spread the body cover and release its holes
damage the hooks from the frame bosses.
and slots. Slightly slide the main pipe side cover backward and
release the lower hooks from the slots.
Release the slot from the front hook on the body cover
and remove the main pipe side cover.
Left side shown: HOOK

SLOTS
SLOT
BOLTS
SPECIAL BOLTS
SCREW
HOOKS
Remove the following: Left side shown:
– Five screws (Left side:)
FLOOR STEP
– Four screws (Right side:)
– Floor step SCREWS
– Glove box GLOVE
BOX

FRONT LOWER COVER
Remove the front side covers (page 3-15).
Be careful not to Remove the six screws.
damage the slots Release the lower tabs from the slots of under cover
and tabs. Remove the front lower cover.
TABS
SCREWS
FRONT LOWER COVER
UNDER COVER
Support the scooter with its centerstand.
– Front lower cover (page 3-17)
– Four special bolts
– Four bolts
Disconnect the radiator overflow hose and fuel tray
drain hose from the under cover.
Be careful not to Slightly spread the main pipe side covers.
damage the main Release the slots from the hooks on the main pipe side
pipe side covers covers by pulling the under cover forward and remove
and under cover. it.
SPECIAL BOLTS
HOOKS
OVERFLOW
HOSE
SLOTS
BOLTS
FUEL TRAY
DRAIN HOSE
UNDER COVER

3-17
FUEL LID/CENTER COVER
– Main pipe upper cover (page 3-5).
– Luggage box (page 3-11).
Release the fuel lid cable from the cable holder and
disconnect the cable from the opener.
Remove the four screws.
Be careful not to Release the hooks and tabs by pulling the fuel lid/center
damage the hooks cover upward and remove it.
and tabs.
FUEL LID/CENTER COVER
SCREWS TABS
CABLE HOLDER
FUEL LID CABLE
HOOKS
FUEL LID OPENER
FUEL LID FUEL LID TRAY
– Five screws
– Fuel lid
– Fuel lid tray
– Center cover
SCREWS
CENTER COVER

EXHAUST PIPE/MUFFLER
REMOVAL
Remove the exhaust pipe joint nuts.
Remove the muffler mounting bolts, collar, exhaust
pipe/muffler and the gasket.
INSTALLATION
Replace the exhaust gasket with a new one.
Align the exhaust pipe flange with the stud bolts and
install the joint nuts, but do not tighten yet.
Install the muffler mounting bolts and collar, but do not
tighten yet.
Tighten the exhaust pipe joint nuts.
Tighten the muffler mounting bolts to the specified
torque.
After installation, make sure the exhaust system does
not leak.
GASKET
JOINT NUTS
COLLAR
MOUNTING BOLTS
EXHAUST PIPE/MUFFLER 26.5 N·m (2.7 kgf·m, 20 lbf·ft)

3-19
MEMO

4. MAINTENANCE
SERVICE INFORMATION ·····························4-2 FINAL DRIVE OIL ·······································4-14
MAINTENANCE SCHEDULE························4-4 BRAKE FLUID·············································4-15
FUEL LINE·····················································4-5 BRAKE SHOES/PADS WEAR····················4-15
THROTTLE OPERATION······························4-5 BRAKE SYSTEM ········································4-16
AIR CLEANER···············································4-6 BRAKE LIGHT SWITCH ·····························4-19
CRANKCASE BREATHER ···························4-7 BRAKE LOCK OPERATION·······················4-20
SPARK PLUG················································4-7 HEADLIGHT AIM ········································4-20
VALVE CLEARANCE····································4-9 CLUTCH SHOES WEAR·····························4-21
ENGINE OIL ················································4-10 SIDESTAND ················································4-21
ENGINE OIL STRAINER SCREEN ·············4-12 SUSPENSION ·············································4-21
ENGINE IDLE SPEED ·································4-12 NUTS, BOLTS, FASTENERS ·····················4-22
RADIATOR COOLANT ·······························4-13 WHEELS/TIRES ··········································4-22
COOLING SYSTEM·····································4-13 STEERING HEAD BEARINGS ···················4-24
DRIVE BELT················································4-14

4-1
MAINTENANCE
SERVICE INFORMATION
MAINTENANCE
GENERAL
• Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing
flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion.
• If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the
engine in an open area or with an exhaust evacuation system in enclosed area.
• Place the scooter on a level ground before starting any work.
SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug Standard CPR7EA-9 (NGK) U22EPR9 (ND)
Valve clearance IN 0.14 ± 0.02 mm (0.006 ± 0.001 in)
EX 0.20 ± 0.02 mm (0.008 ± 0.001 in)
service label)
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 Imp qt)
After disassembly 0.8 liter (0.8 US qt, 0.7 Imp qt)
Drive belt width Service limit: 18.0 mm (0.71 in)
service label)
Final reduction oil After draining 0.10 liter (0.11 US qt, 0.09 Imp qt)
capacity After disassembly 0.12 liter (0.13 US qt, 0.11 Imp qt)
Rear brake lever freeplay 10 – 20 mm (0.4 – 0.8 in)
Clutch lining thickness Service limit: 2.0 mm (0.08 in)
Cold tire pressure Driver only Front 200 kPa (2.00 kgf/cm2, 29 psi)
Rear 225 kPa (2.25 kgf/cm2, 33 psi)
Driver and passenger Front 200 kPa (2.00 kgf/cm2, 29 psi)
Rear 225 kPa (2.25 kgf/cm2, 33 psi)
Tire size Front 80/90 – 14M/C40P
Rear 80/90 – 14M/C46P
Tire brand IRC Front NR73TZ
Rear NR73T
VEE RUBBER Front V338F
Rear V338R
Minimum tire tread depth Front To the indicator
Rear To the indicator

MAINTENANCE
TORQUE VALUES
Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft)
Valve adjusting screw lock nut 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply engine oil to the threads and seating
surface.
Engine oil drain bolt 24 N·m (2.4 kgf·m, 18 lbf·ft)
Engine oil strainer screen cap 20 N·m (2.0 kgf·m, 15 lbf·ft)
Final reduction oil check bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)
Final reduction oil drain bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)
Air cleaner housing cover screw 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)
Equalizer connecting cable lock nut 6.4 N·m (0.7 kgf·m, 4.7 lbf·ft)
(CBS type only)
Headlight aim adjusting bolts 0.6 N·m (0.1 kgf·m, 0.4 lbf·ft)
Spoke 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
TOOLS
Valve adjusting wrench Spoke wrench, 5.8 x 6.1 mm
07708-0030400 07701-0020300

4-3
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult an authorized Honda dealer.
FREQUENCY WHICHEVER ODOMETER READING (NOTE 1)
COMES FIRST
REFER TO
X1,000 km 1 4 8 12
PAGE
X1,000 mi 0.6 2.5 5 7.5
ITEMS Months 6 12 18
* FUEL LINE I I I 4-5
* THROTTLE OPERATION I I I 4-5
AIR CLEANER NOTE2 EVERY 16,000 km (10,000 mi) R 4-6
CRANKCASE BREATHER NOTE4 C C C 4-7
SPARK PLUG I R I 4-7
* VALVE CLEARANCE I I I I 4-9
ENGINE OIL R R 4-10
* ENGINE OIL STRAINER SCREEN C 4-12
* ENGINE IDLE SPEED I I I I 4-12
RADIATOR COOLANT NOTE3 I 4-13
* COOLING SYSTEM I 4-13
* DRIVE BELT EVERY 8,000 km (5,000 mi) I,
4-14
EVERY 24,000 km (15,000 mi) R
* FINAL DRIVE OIL NOTE3 4-14
BRAKE FLUID NOTE3 I I I 4-15
BRAKE SHOES/PADS WEAR I I I 4-15
BRAKE SYSTEM I I I I 4-16
* BRAKE LIGHT SWITCH I I I 4-19
* BRAKE LOCK OPERATION I I I I 4-20
* HEADLIGHT AIM I I I 4-20
** CLUTCH SHOES WEAR I 4-21
SIDESTAND I I I 4-21
* SUSPENSION I I I 4-21
* NUTS, BOLTS, FASTENERS I I 4-22
** WHEELS/TIRES I I I I 4-22
** STEERING HEAD BEARINGS I I 4-24
* SHOULD BE SERVICED BY AN AUTHORIZED Honda DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SER-
VICE DATA AND IS MECHANICALLY QUALIFIED.
** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED Honda
DEALER.
Honda recommends that an authorized Honda dealer should road test your scooter after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service at every 16,000 km (10,000 mi) or more frequently when riding in unusually wet or dusty areas (cleaning is prohibited).
3. Replace every 2 years. Replacement requires mechanical skill.
4. Service more frequently when riding in rain or at full throttle.

MAINTENANCE
FUEL LINE
Remove the left main pipe side cover (page 3-16).
Check the fuel hose for deterioration, damage or
leakage.
Also, check the fuel hose fittings for leakage.
Replace the fuel hose if necessary.
Install the left main pipe side cover (page 3-16).
THROTTLE OPERATION
• Reusing a damaged or abnormally bent or kinked
throttle cable can prevent proper throttle slide
operation and may lead to a loss of throttle control
while riding.
Check for any deterioration or damage to the throttle
cable. Check the throttle grip for smooth operation.
Check that the throttle opens and automatically closes
in all steering positions.
If the throttle grip does not return properly, lubricate the
throttle cable.
For cable lubrication, disconnect the throttle cable at
their pivot points and apply commercially available
cable lubricant or light weight oil.
If the throttle grip still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure that the idle speed does not
change. If idle speed increases, check the throttle grip
freeplay and throttle cable routing.

4-5
MAINTENANCE
Measure the throttle grip freeplay at the throttle grip
flange.
FREEPLAY:2 – 6 mm (0.1 – 0.2 in)
2 – 6 mm (0.1 – 0.2 in)
Throttle grip freeplay can be adjusted by turning the

ADJUSTER
adjuster.
Loosen the lock nut and turn the adjusting nut as
required.
Tighten the lock nut.
Recheck the throttle operation.
LOCK NUT
AIR CLEANER
• The viscous paper element cannot be cleaned
because the element contains a dust adhesive.
• If the scooter is used in unusually wet or dusty SCREWS
areas, more frequent inspections are required.
Remove the screws and air cleaner housing cover from
the left side.
Remove and discard the air cleaner element in
accordance with the maintenance schedule (page 4-4).
Replace the element any time if it is excessively dirty or
damaged.
Install the removed parts in the reverse order of
removal.
TORQUE: COVER ELEMENT
Air cleaner housing cover screw:
1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)

MAINTENANCE
CRANKCASE BREATHER
• Service more frequently when ridden in rain, at full
throttle, or after the scooter is washed or overturned.
Service if the deposit level can be seen in the
transparent section of the drain plug.
Remove the crankcase breather drain plug from the air
cleaner and drain deposits into a suitable container.
Install the crankcase breather drain plug.
DRAIN PLUG
Remove the body cover (page 3-14).

Check the crankcase breather hose for deterioration,
damage or leakage.
Replace the crankcase breather hose if necessary.
Also check the crankcase breather hose fittings for
leakage.
Install the body cover (page 3-14).
BREATHER HOSE
SPARK PLUG
• Clean around the spark plug base with compressed
air before removing the plug, and make sure that no
debris is allowed to enter the combustion chamber.
Remove the maintenance lid (page 3-9).
Disconnect the spark plug cap and clean around the
spark plug base.
SPARK PLUG CAP

4-7
MAINTENANCE
Remove the spark plug.
SPARK PLUG
Inspect or replace as described in the maintenance

schedule (page 4-4). CENTER ELECTRODE
Check the following and replace if necessary.

• Insulator for damage
• Electrodes for wear
• Burning condition, coloration;
– Dark to light brown indicates good condition.
– Excessive lightness indicates malfunctioning ignition
system or lean mixture.
– Wet or black sooty deposit indicates over-rich
mixture.
If the electrode is contaminated with carbon deposits,
clean the electrode using a spark plug cleaner. INSULATOR SIDE ELECTRODE
Always use the specified spark plug on this scooter.

SPECIFIED SPARK PLUG:
Standard: CPR7EA-9 (NGK), U22EPR9 (ND)
Measure the spark plug gap between the center and
side electrodes with a feeler gauge of a wire type.
If necessary, adjust the gap by bending the side
electrode carefully.
SPARK PLUG GAP: 0.8 – 0.9 mm (0.03 – 0.04 in) 0.8 – 0.9 mm
(0.03 – 0.04 in)
Do not overtighten Install and hand tighten the spark plug to the cylinder
the spark plug. head, then tighten the spark plug to the specified SPARK PLUG
torque.
TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft)

MAINTENANCE
Connect the spark plug cap.
Install the maintenance lid (page 3-9).
SPARK PLUG CAP
VALVE CLEARANCE
INSPECTION
• Inspect and adjust the valve clearance while the

engine is cold (below 35°C/95°F).
Remove the cylinder head cover (page 9-7).
KICKSTARTER
Rotate the crankshaft by operating the kickstarter
slowly and align the "T mark" on the flywheel with the
index notch on the right crankcase.
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
This position can be confirmed by checking that there is
slack in the rocker arm.
If there is no slack, it is because the piston is moving
through the exhaust stroke to TDC.
Rotate the crankshaft one full turn by operating the
kickstarter slowly and match up the "T" mark again.
"T" MARK
NOTCH
Check the valve clearance by inserting a feeler gauge

between the valve adjusting screw and valve stem. FEELER GAUGE
VALVE CLEARANCE:
IN: 0.14 ± 0.02 mm (0.006 ± 0.001 in)
EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in)

4-9
MAINTENANCE
If the valve clearance is incorrect, loosen the valve
VALVE ADJUSTING WRENCH
adjusting screw lock nut and adjust the valve clearance
by turning the adjusting screw until there is a slight drag
on the feeler gauge.
Apply engine oil to the valve adjusting screw lock nut
threads and seating surface.
Hold the adjusting screw and tighten the lock nut.
TOOL:
Valve adjusting wrench 07708-0030400

Recheck the valve clearance.
Install the cylinder head cover (page 9-8). LOCK NUT ADJUSTING SCREW
ENGINE OIL
OIL LEVEL CHECK
Support the scooter with its centerstand on a level
surface. FILLER CAP/DIPSTICK
Start the engine and let it idle for 3 - 5 minutes.
Stop the engine and wait for 2 - 3 minutes.
Remove the oil filler cap/dipstick and wipe off the oil
from the dipstick with a clean cloth.
UPPER
Insert the oil filler cap/dipstick without screwing it in,
remove it and check the oil level.
The level should be between the "UPPER" and LOWER
"LOWER" level lines of the oil filler cap/dipstick.
Other viscosities If the oil level is below or near the lower level line on the
shown in the chart dipstick, add the recommended oil to the upper level.
may be used when
the average RECOMMENDED ENGINE OIL:
temperature in your API classification: SE, SF or SG
riding area is within (except oils labeled as energy conserving on the
the indicated range. circular API service label)
Make sure the O-ring is in good condition and replace it

if necessary. O-RING
Coat the O-ring with engine oil and install the oil filler
cap/dipstick.
For engine oil change, See page 4-11.
FILLER CAP/DIPSTICK

MAINTENANCE
OIL CHANGE
• Change the engine oil with the engine warm and the
scooter on level ground to assure complete draining.
Start the engine, warm it up and stop it.
Remove the oil filler cap/dipstick.
FILLER CAP/DIPSTICK
Place an oil drain pan under the engine to collect the oil,
then remove the oil drain bolt and sealing washer.
Slowly apply kickstarter and drain the engine oil.
After draining the oil completely, install the new sealing
washer and oil drain bolt.
Tighten the drain bolt to the specified torque.
Fill the crankcase with the recommended engine oil.
ENGINE OIL CAPACITY:
0.7 liter (0.7 US qt, 0.6 lmp qt) after draining
0.8 liter (0.8 US qt, 0.7 lmp qt) after disassembly
WASHER/DRAIN BOLT
RECOMMENDED ENGINE OIL:
API classification: SE, SF or SG
(except oils labeled as energy conserving on the
circular API service label)
Check the oil level (page 4-10).
Make sure that there are no oil leaks.

4-11
MAINTENANCE
ENGINE OIL STRAINER SCREEN
Drain the engine oil (page 4-11).
OIL STRAINER SCREEN OIL STRAINER
Remove the oil strainer screen cap, O-ring, spring and SCREEN CAP
oil strainer screen.
Wash the strainer screen thoroughly in non-flammable
or high flash point cleaning solvent until all accumulated
dirt has been removed.
Blow dry it with compressed air to clean completely.
Before installing the strainer screen, it should be
examined closely for damage and make sure the O-RING
sealing rubber is in good condition.
Make sure the O-ring is in good condition and replace it
if necessary.
SPRING
Install the oil strainer screen and spring with the strainer
sealing rubber toward the crankcase.
Coat the O-ring with engine oil and install the oil strainer
screen cap.
Tighten the oil strainer screen cap to the specified
torque.
Fill the crankcase with recommended engine oil and
check the engine oil level (page 4-10).
Make sure that there are no oil leaks.
ENGINE IDLE SPEED

• Inspect the idle speed after all other engine
maintenance items have been performed and are
within specifications.
• Before checking the idle speed, inspect following
items.
– No MIL blinking
– Spark plug condition (page 4-7)
– Air cleaner condition (page 4-6)
• The engine must be warm for accurate idle speed
inspection.
• This system eliminates the need for manual idle
speed adjustment.
• Use a tachometer with graduations of 50 min-1 (rpm)
or smaller that will accurately indicate a 50 min-1
(rpm) change.
Warm up the engine about ten minutes.
Connect the tachometer and check the idle speed.
ENGINE IDLE SPEED: 1,700 ± 100 min-1 (rpm)
If the idle speed is out of the specification, check the
following:
• Throttle operation and throttle grip freeplay (page 4-
5).
• Intake air leak or engine top-end problem (page 9-
6).
• IACV operation (page 6-38).

MAINTENANCE
RADIATOR COOLANT
Support the scooter with its centerstand. RESERVE TANK CAP
UPPER
Check the coolant level of the reserve tank with the LEVEL
engine running at normal operating temperature.
The level should be between the "UPPER" and
"LOWER" level lines with the scooter upright on a level
surface.
Use only genuine "Honda PRE-MIX COOLANT"

containing corrosion inhibitors, specifically
recommended for aluminium engines when adding or
replacing the coolant.
LOWER
If the level is low, fill as follows: LEVEL
Unlock the fuel lid with ignition key and open the lid.
Remove the reserve tank cap and fill the tank to the
"UPPER" level line with recommended coolant.
RECOMMENDED COOLANT:
"Honda PRE-MIX COOLANT"
Check if there are any coolant leaks when the coolant
level decreases very rapidly.
If the reserve tank becomes completely empty, there is
a possibility of air getting into the cooling system.
Be sure to remove all air from the cooling system as
described on page 7-8.
COOLING SYSTEM
– Body cover (page 3-14) WATER HOSES
– Luggage box (page 3-11)
– Radiator cover (page 3-12)
Check the radiator for leakage.
Check for coolant leakage from the water pump, water RADIATOR
pipe, water hoses and hose joints.
Check the water hoses for cracks or deterioration and
replace if necessary.
Check that all hose clamps are tight.
WATER
PIPE
WATER HOSE WATER PUMP
Check the radiator air passage for clogs or damage.

Straighten bent fins with a small, flat blade screwdriver
and remove insects, mud or other obstructions with
compressed air or low pressure water.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
removal.

4-13
MAINTENANCE
DRIVE BELT
Remove the left crankcase cover (page 11-13).
Check the drive belt for cracks, separation or abnormal
or excessive wear and replace it if necessary (page 11-
13).
DRIVE BELT
Using the suitable two flat plates, measure the drive belt
width as shown. DRIVE BELT
SERVICE LIMIT: 18.0 mm (0.71 in)

Replace the drive belt if it is less than the service limit
(page 11-13).
DRIVE BELT
FINAL DRIVE OIL

OIL LEVEL CHECK
Make sure that the final reduction case has no oil leaks.
Support the scooter with its centerstand. SEALING WASHER
Remove the oil check bolt.
Check whether the oil flows out from the check bolt
hole.
If the level is low (oil does not flow out), add the
recommended oil as described below.
RECOMMENDED FINAL REDUCTION OIL:
API classification: SE, SF or SG
(except oils labeled as energy conserving on the
circular API service label)
Viscosity: SAE 10W-30 CHECK BOLT LOWER LEVEL
Install the oil check bolt with a new sealing washer and
tighten it to the specified torque.

MAINTENANCE
OIL CHANGE
Place an oil drain pan under the final reduction case to
SEALING WASHER
collect the oil, then remove the oil check bolt, oil drain
bolt and sealing washers.
Slowly turn the rear wheel and drain the oil.
After draining the oil completely, install the oil drain bolt
with a new sealing washer and tighten the drain bolt to
the specified torque.
Fill the final reduction case with recommended oil up to
the correct level (page 4-14).
FINAL REDUCTION OIL CAPACITY:
0.10 liter (0.11 US qt, 0.09 lmp qt) after draining DRAIN BOLT CHECK BOLT
0.12 liter (0.13 US qt, 0.11 lmp qt) after disassem-
bly
Install the oil check bolt with a new sealing washer and
tighten it to the specified torque.
BRAKE FLUID
• Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
• Do not mix different types of fluid, as they are not
compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
• When the fluid level is low, check the brake pads for
wear (page 4-15). A low fluid level may be due to
wear of the brake pads.
If the brake pads are worn, the caliper piston is
pushed out, and this accounts for a low reservoir
level. If the brake pads are not worn and the fluid
level is low, check entire system for leaks (page 4- "LOWER" LEVEL MARK
16).
Turn the handlebar to the left so the reservoir is level
and check the front brake reservoir fluid level through
the sight glass.
If the level is near the lower level mark, check the brake
pads for wear (page 4-15).
BRAKE SHOES/PADS WEAR

FRONT DISC BRAKE PADS
Check the brake pads for wear.
Replace the brake pads if either pad is worn to the wear
limit groove.
To replace the brake pad, See page 16-9.
LIMIT GROOVES

4-15
MAINTENANCE
REAR DRUM BRAKE SHOES
Check the wear indicator position when the brake lever
WEAR
is applied.
INDICATOR
If the indicator aligns with the " " mark, inspect the
brake drum (page 16-7).
Replace the brake shoes if the drum I.D. is within
service limit.
" " MARK
BRAKE SYSTEM
FRONT DISC BRAKE
Firmly apply the brake lever and check that no air has
entered the system.
If the lever feels soft or spongy when operated, bleed
the air from the system.
For air bleeding procedures (page 16-8).
Remove the front handlebar cover (page 3-8).

Inspect the brake hose and fittings for deterioration,
cracks, or signs of leakage.
Tighten any loose fittings.
Replace the hose and fittings as required.
Install the front handlebar cover (page 3-8).
BRAKE
HOSE

MAINTENANCE
REAR DRUM BRAKE
Check the brake cable and brake lever for loose
connections, excessive play or other damage.
Replace or repair if necessary.
10 – 20 mm (0.4 – 0.8 in)
Measure the rear brake lever freeplay at the end of the
lever.
FREEPLAY: 10 – 20 mm (0.4 – 0.8 in)
Make sure the cut- Adjust the rear brake lever freeplay by turning the rear
out of the adjusting brake arm adjusting nut.
nut is seated on the
joint pin.
ADJUSTING NUT
CBS TYPE
• Before inspection, check the following first:
– Rear brake system (page 4-17)
– Front brake system (page 4-16)
Apply the rear brake lever.
Make sure that the rear wheel does not rotate while the
rear brake lever is applied.

4-17
MAINTENANCE
Lift the front wheel off the ground and rotate it by hand.
Make sure that the front wheel rotates smoothly.
Lift the front wheel off the ground and apply the rear
brake lever.
Make sure that the front wheel does not rotate while the
rear brake lever is applied.
If it is abnormal, inspect as follows:

Measure the distance between the edge surface of the
knocker and the edge surface of the master cylinder 0 – 0.1 mm (0 – 0.004 in)
body with the feeler gauge. LOCK NUT
STANDARD: 0 – 0.1 mm (0 – 0.004 in)

If the distance exceeds the standard, adjust the ADJUSTER
connecting cable.
Loosen the lock nut and turn the adjuster until the
distance between the edge surfaces is within standard. KNOCKER
INSPECTION
POINT
Check that there is no gap between the knocker pin and ADJUSTER
the end of the slot of the knocker joint. LOCK NUT
If there is any gap, loosen the lock nut and turn the
adjuster until there is no gap between the knocker pin
and the end of the slot of the knocker joint.
After the adjustment, hold the adjuster and tighten the
lock nut to the specified torque.
TORQUE: 6.4 N·m (0.7 kgf·m, 4.7 lbf·ft)
After tightening the lock nut, check that there is no gap KNOCKER PIN
between the knocker pin and the end of the slot of the
knocker joint.
Apply rear brake lever several times and check that the KNOCKER JOINT
distance between the edges has not been changed
after applying the brake.

MAINTENANCE
Recheck the distance between the edge surface of the
knocker and the edge surface of the master cylinder
body is within standard. 0 – 0.1 mm (0 – 0.004 in)
LOCK NUT
STANDARD: 0 – 0.1 mm (0 – 0.004 in)
Recheck the combined brake system.
If the combined brake system adjustment is normal, but ADJUSTER
the front wheel rotates abnormally, check for other
malfunction parts.
Install the front handlebar cover (page 3-8). KNOCKER
INSPECTION
POINT
BRAKE LIGHT SWITCH

• The brake light switch on the brake lever cannot be
adjusted. If the brake light switch actuation and FRONT BRAKE REAR BRAKE
brake engagement are not synchronized, either LIGHT SWITCH: LIGHT SWITCH:
replace the switch or malfunction parts of the
system.
Check that the brake light comes on just prior to the
brake actually being engaged.
For brake light switch inspection (page 20-17).

4-19
MAINTENANCE
BRAKE LOCK OPERATION
STANDARD TYPE
• Check the brake lock operation after the rear brake

LOCK LEVER
lever freeplay is checked and adjusted (page 4-17).
Squeeze the rear brake lever and set the lock lever.
Check that the rear wheel is locked completely.
BRAKE LEVER
CBS TYPE
• Check the brake lock operation after the rear brake

lever freeplay is checked and adjusted (page 4-17). LOCK LEVER
Squeeze the rear brake lever and set the lock lever by
pulling it up.
Check that the rear wheel is locked completely.
BRAKE LEVER
HEADLIGHT AIM
• Adjust the headlight beam as specified by local laws
and regulations.
ADJUSTING GEAR
Place the scooter on a level ground.
Adjust the headlight beam vertically by turning the
headlight aim adjusting gear using the screwdriver.
A clockwise rotation moves the beam down and
counterclockwise rotation moves the beam up.

MAINTENANCE
CLUTCH SHOES WEAR
Remove the clutch assembly (page 11-19).
Check the clutch shoes for abnormal wear.
Measure the thickness of each shoe.
Replace the clutch shoes if they are less than the
service limit (page 11-20).
Install the clutch assembly (page 11-22).
CLUTCH SHOE
SIDESTAND
Check the sidestand spring for damage or loss of
tension.
Check the sidestand assembly for freedom of
movement and lubricate the sidestand pivot if
necessary.
Check the sidestand ignition cut-off system:
1. Retract the sidestand.
2. Start the engine.
3. Move the sidestand full down.
4. The engine should stop as the sidestand is lowered.
If there is a problem with the system, check the SIDESTAND
sidestand switch (page 18-9).
SUSPENSION
FRONT
Loose, worn or Check the action of the forks by operating the front
damaged brake and compressing the front suspension several
suspension parts times.
impair scooter Check the entire assembly for signs of leaks, damage
stability and control. or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
For fork service (page 14-11).

4-21
MAINTENANCE
REAR
Check the action of the shock absorber by compressing
it several times.
Check the entire shock absorbers assembly for signs of
leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
For rear shock absorber service (page 15-8).
Support the scooter securely and raise the rear wheel

off the ground.
Check for worn engine mounting bushings by grabbing
the engine and attempting to move the wheel side to
side.
For engine bushing service (page 15-9).
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-9).
Check that all cotter pins, safety clips, hose clamps and
cable stays are in place and properly secured.
WHEELS/TIRES
Making sure that the fork is not allowed to move, raise
the front wheel and check for play.
Check for worn front wheel bearings by grabbing the
front wheel and attempting to move the wheel side to
side.
Replace the front wheel bearings if any looseness is
noted.
Turn the wheel and check that it rotates smoothly with
no unusual noises.
If any abnormal conditions are suspected, inspect the
front wheel bearings (page 14-10).

MAINTENANCE
Support the scooter securely and raise the rear wheel.
Check for worn final gear shaft bearings by grabbing
the rear wheel and attempting to move the wheel side
to side.
Replace the final gear shaft bearings if any looseness is
noted.
Turn the wheel and check that it rotates smoothly with
no unusual noises.
If any abnormal conditions are suspected, check the
final reduction (page 12-8).
Check the tire pressure with the air pressure gauge

when the tires are cold.
RECOMMENDED TIRE PRESSURE:
Driver only:
FRONT: 200 kPa (2.00 kgf/cm2, 29 psi)
REAR: 225 kPa (2.25 kgf/cm2, 33 psi)
Driver and passenger:
FRONT: 200 kPa (2.00 kgf/cm2, 29 psi)
REAR: 225 kPa (2.25 kgf/cm2, 33 psi)
PRESSURE GAUGE
Inspect the wheel rims and spokes for damage.

Tighten any loose spokes.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300
SPOKE WRENCH
Check the tires for cuts, embedded nails, or other

INDICATOR
damage.
Check the front wheel and rear wheel for trueness.
RECOMMENDED TIRE SIZE AND TIRE BRAND:
FRONT REAR
Tire size 80/90-14M/C40P 80/90-14M/C46P
Tire IRC NR73TZ NR73T
brand VEE V338F V338R
RUBBER
Measure the tread depth at the center of the tires.

Replace the tires when the tread depth reaches the
following limits.
MINIMUM TIRE TREAD DEPTH:
FRONT/REAR: To the indicator

4-23
MAINTENANCE
STEERING HEAD BEARINGS
• Check that the control cables do not interfere with
handlebar rotation.
Support the scooter with its centerstand and raise the
front wheel off the ground.
Check that the handlebar moves freely from side-to-
side. If the handlebar moves unevenly or binds, inspect
the steering head bearings (page 14-21).
Hold the scooter and check the steering head bearings

for wear by moving the fork forward and backward.
If the steering stem has vertical movement, inspect the
steering head bearing (page 14-21).

5. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM ············5-2 TROUBLESHOOTING ··································5-3
SERVICE INFORMATION ·····························5-3 OIL PUMP······················································5-4

5-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM
INLET ROCKER ARM SHAFT
CAMSHAFT
PISTON
CRANKSHAFT
OIL PUMP
OIL STRAINER SCREEN

LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
• The oil pump can be serviced with the engine installed in the frame.
• The service procedures in this section must be performed with the engine oil drained.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks.
SPECIFICATIONS
Unit: mm (in)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
TORQUE VALUES
Oil pump plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Oil pump mounting bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
TROUBLESHOOTING
Engine oil level too low
• Oil consumption
• External oil leak
• Worn piston rings or incorrect piston ring installation (page 10-10)
• Worn cylinder (page 10-6)
• Worn valve guide or seal (page 9-24)
Oil contamination
• Oil not changed often enough
• Faulty cylinder head gasket
• Worn piston rings (page 10-10)

5-3
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
• When removing the oil pump, do not allow dust or
BOLTS
dirt to enter the engine.
Remove the stator base/water pump (page 7-13).
Remove the oil pump mounting bolts and oil pump.
OIL PUMP
INSTALLATION
Install the oil pump to the crankcase by aligning the
dowel pins and holes. Align
OIL PUMP
Install and tighten the oil pump mounting bolts to the

BOLTS
specified torque.

Install the stator base/water pump (page 7-15).

LUBRICATION SYSTEM
– Dowel pins
– Oil pump plate screw
– Pump plate
– Outer rotor
– Inner rotor
Apply engine oil to Assembly is in the reverse order of disassembly.
the inner rotor and
outer rotor.
TORQUE: Oil pump plate screw
3 N·m (0.3 kgf·m, 2.2 lbf·ft)
PUMP PLATE DOWEL PINS
OUTER ROTOR
PUMP BODY
SCREW
3 N·m (0.3 kgf·m, 2.2 lbf·ft)
INNER ROTOR
INSPECTION
TIP CLEARANCE
• Measure at several points and use the largest
TIP CLEARANCE:
reading to compare the service limit.
Temporarily install the outer rotor and inner rotor to
pump body and oil pump shaft into the oil pump inner
rotor.
Measure the clearance between the outer rotor and the
inner rotor with a feeler gauge.

5-5
LUBRICATION SYSTEM
BODY CLEARANCE
Measure the clearance between the oil pump body and
BODY CLEARANCE:
the outer rotor with a feeler gauge.
SIDE CLEARANCE
Measure the side clearance using a straight edge and a SIDE CLEARANCE:
feeler gauge.

6. FUEL SYSTEM (Programmed Fuel Injection)
COMPONENT LOCATION ····························6-2 FUEL PUMP UNIT·······································6-29
SERVICE INFORMATION ·····························6-3 FUEL TANK·················································6-31
PGM-FI SYMPTOM AIR CLEANER HOUSING···························6-32

TROUBLESHOOTING···································6-5
SENSOR UNIT ············································6-34
PGM-FI SYSTEM LOCATION ·······················6-6
IACV ····························································6-37
PGM-FI SYSTEM DIAGRAM·························6-7
THROTTLE BODY ······································6-39
CONNECTOR LOCATION ····························6-8
ECM ·····························································6-42
PGM-FI TROUBLESHOOTING
INFORMATION············································6-10 INJECTOR···················································6-44
MIL CODE INDEX········································6-14 ECT SENSOR··············································6-45
MIL TROUBLESHOOTING ·························6-15 O2 SENSOR·················································6-47
MIL CIRCUIT INSPECTION ························6-24 INTAKE PIPE ··············································6-48
FUEL LINE INSPECTION····························6-25

6-1
FUEL SYSTEM (Programmed Fuel Injection)
COMPONENT LOCATION

SERVICE INFORMATION
GENERAL
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
• Before disconnecting the fuel feed hose, relieve fuel pressure from the system by disconnecting the quick connect fitting at the
fuel pump (page 6-25).
• Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resu-lting in loss
of vehicle control.
• Use an electric heating element to heat the coolant for the ECT sensor inspection, keep flammable materials away from the
electric heating element. Wear protective clothing, insulated gloves and eye protection.
• Do not apply commercially available carburetor cleaners to the inside of the throttle bore.
• Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incor-rect idle
operation.
• Seal the intake port with tape or a clean cloth to keep dirt and debris from entering the engine after the throt-tle body has been
removed.
• Do not damage the throttle body. It may cause incorrect throttle valve operation.
• Prevent dirt and debris from entering the throttle bore and air passages after the throttle body has been removed. Clean them
using com-pressed air if necessary.
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• Do not loosen or tighten the white painted nut and screw of the throttle body. Loosening or tightening them can cause throttle
valve and idle control failure.
• The parts of the throttle body not shown in this manual should not be disassembled.
• Always replace the packing when the fuel pump is removed.
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
• The PGM-FI system is equipped with the Self-Diagnostic System described (page 6-10). If the MIL blinks, follow the Self-
Diagnostic Procedures to remedy the problem.
• When checking the PGM-FI, always follow the steps in the troubleshooting flow chart.
• The PGM-FI system is provided with fail-safe function to secure a minimum running capability even when there is any trouble in
the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by making use of the
numerical values of a situation preset in the simulated program map.
It must be remembered, however, that when any abnormality is detected in injector, the fail-safe function stops the engine to
protect it from damage.
• For PGM-FI system location (page 6-6).
• When disassembling the fuel system parts, note the location of the O-rings. Replace them with new ones upon reassembly.
• Use a digital tester for PGM-FI system inspection.
• For fuel level sensor inspection (page 20-11).
SPECIFICATIONS
ITEM SPECIFICATIONS
(100°C/212°F) 0.1 – 0.2 kǡ
TORQUE VALUES
ECT sensor 17.7 N·m (1.8 kgf·m, 13 lbf·ft)
IACV torx screw 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
Sensor unit torx screw 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
Throttle cable stay mounting screw 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
O2 sensor 25 N·m (2.5 kgf·m, 18 lbf·ft)

6-3
TOOLS
Fuel pressure gauge Pressure gauge manifold Hose attachment, 9 mm/9 mm
07406-0040004 07ZAJ-S5A0111 07ZAJ-S5A0120
Hose attachment, 6 mm/9 mm Attachment joint, 6 mm/9 mm Test probe

07ZAJ-S5A0130 07ZAJ-S5A0150 07ZAJ-RDJA110
SCS connector
070PZ-ZY30100

PGM-FI SYMPTOM TROUBLESHOOTING
When the scooter has one of these symptoms, check the MIL blinking, refer to the MIL code index (page 6-14) and begin the
appropriate troubleshooting procedure. If there are no MIL blinking stored in the ECM memory, do the diagnostic procedure for the
symptom, in sequence listed below, until you find cause.
Symptom Diagnosis procedure Also check for
Engine cranks but won’t start 1. Crank the engine for more than • No fuel to injector
(No MIL blinking) ten seconds and check the MIL – Clogged fuel filter
(page 6-10) and execute the trou- – Clogged fuel filler cap breather hole
bleshooting according to the MIL. – Pinched or clogged fuel feed hose
2. Inspect the fuel supply system – Faulty fuel pump
(page 6-25). – Faulty fuel pump circuits
• Intake air leak
• Contaminated/deteriorated fuel
• Faulty fuel injector
• IACV stuck
• Faulty ignition system
Engine cranks but won’t start 1. ECM power/ground circuits mal- • Open circuit in the power input and/or ground
(No fuel pump operation function (page 6-43). wire of the ECM
sound when turning the igni- 2. Inspect the fuel supply system • Blown main fuse (15 A)
tion ON) (page 6-25).
Engine stalls, hard to start, 1. Check the idle speed (page 4-12). • Restricted fuel feed hose
rough idling 2. Check the IACV (page 6-38). • Clogged fuel filler cap breather hole
3. Inspect the fuel supply system • Contaminated/deteriorated fuel
(page 6-25). • Intake air leak
4. Inspect the battery charging sys- • Restricted fuel tank cap breather
tem (page 17-12). • Faulty ignition system
Backfiring or misfiring during Check the ignition system (page 18-
acceleration 5).
Poor performance (driveabili- Inspect the fuel supply system (page • Pinched or clogged fuel feed hose
ty) and poor fuel economy 6-25). • Faulty pressure regulator (fuel pump)
• Faulty injector
• Faulty ignition system
Idle speed is below specifica- 1. Check the idle speed (page 4-12). • Faulty fuel supply system
tions (No MIL blinking) 2. Check the IACV (page 6-38). • Faulty ignition system
Idle speed is above specifica- 1. Check the idle speed (page 4-12). • Faulty ignition system
tions (No MIL blinking) 2. Check the throttle operation and • Intake air leak
freeplay (page 4-5). • Engine top-end problem
3. Check the IACV (page 6-38). • Air cleaner condition
MIL stays ON or MIL never Inspect the MIL circuit (page 6-24).
comes ON at all (Engine oper-
ates normally)
MIL stays ON Inspect the DLC circuit.
(Engine operates normally
and No MIL code set)

6-5
PGM-FI SYSTEM LOCATION
SENSOR UNIT (MAP/ INJECTOR IGNITION
IAT/TP SENSORS) SWITCH
DLC
REGULATOR/
RECTIFIER
ECT SENSOR
CKP SENSOR
O2 SENSOR
FUEL PUMP
ECM
MIL

PGM-FI SYSTEM DIAGRAM
MAIN FUSE LIGHTING SUB FUSE
15A CUT RELAY 10A
R R/W R/W R/Y Bl/Br
R/W Bl
IGNITION
SWITCH
BATTERY
W REGULATOR/ R/Bl Bl
RECTIFIER
G
Bu/Y 12 PCP Bl
W/Y 23 PCM
CKP
SENSOR PRC 7 W/Bl
ALTERNATOR
IGP 1 Bl
SENSOR UNIT
Y/O 6 VCC FUEL PUMP

(1) Y/R 27 PB FLR 8 Br/Bl Bl
MAP
SENSOR
(8) W/R 5 THL INJ 16 P/Bu
TP
SENSOR Bl (12)
INJECTOR
W/Bu 14 TA
IGPLS 11 G/R Bl
(9)
IAT
SENSOR
IGNITION
P/W 24 TW COIL
(7)
ECT
SENSOR G/O G/O 4 SG ECM SPARK Bl
PLUG
(21) Bl Bl
O2 Bl/O 3 O2
SENSOR MIL
FRONT REAR
FI WARN 22 Bu/Y Bl BRAKE BRAKE
LIGHT LIGHT
SWITCH SWITCH
From starter relay Y/G 33 S/RELAY TW WARNING
INIDICATOR G/Y G/Y
To sidestand switch G/W 25 SSTAND
TW WARN 18 Lg/R Bl
DLC
SCS Bl Bl
CONNECTOR G/Y
O/W 30 K-LINE IACV1A 21 Lg/R
Br 15 SCS IACV1B 32 Gr/R

(29)
G/Bl G/Bl 2 LG IACV2A 20 Br/R IACV STARTER
SWITCH
G/Bl 10 PG2 IACV2B 31 Bl/R
G 9 PG1
STSW 29 Y/G
1 11
Bl : Black Br : Brown
12 22 Y : Yellow O : Orange
( ) : Number of MIL blinks Bu : Blue Lg : Light green
23 33
G : Green P : Pink
: The engine does not start if there is mulfunction ECM 33P CONNECTOR R : Red Gr Gray
ECM side of the male terminals W : White

6-7
CONNECTOR LOCATION
NOTE 1: Remove the front top cover (page 3-4).
DLC 4P (Red) CONNECTOR (NOTE 1)
NOTE 2: Remove the right main pipe side cover (page 3-16).
ECM 33P (Black) CONNECTOR (NOTE 2)
NOTE 3:
– Maintenance lid (page 3-9)
O2 SENSOR CAP (NOTE 3)

NOTE 4: Remove the luggage box (page 3-11).
IACV 4P (Black) CONNECTOR

(NOTE 4)
SENSOR UNIT 5P (Black)

CONNECTOR (NOTE 4)
INJECTOR 2P (Black)
CONNECTOR (NOTE 4)
ECT SENSOR 2P (Black)

CONNECTOR (NOTE 4)

6-9
PGM-FI TROUBLESHOOTING INFORMATION
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The PGM-FI system is equipped with the self-diagnostic system. When any
abnormality occurs in the system, the ECM turns on the MIL (Malfunction
Indicator Lamp) and stores a failure code in its erasable memory.
CURRENT FAILURE CODE/STORED FAILURE CODE
The failure code is indicated in two ways according to the failure status.
• In case the ECM detects the problem at present, the MIL will start
blinking as its failure code. It is possible to read out the MIL blink pattern
as the current failure code.
• In case the ECM does not detect any problem at present but has a
problem stored in its memory, the MIL will not blink. If it is necessary to
retrieve the past problem, read out the stored failure code by following
the failure code readout procedure (page 6-11). MIL (Malfunction
MIL BLINK PATTERN Indicator Lamp)
• Failure code can be read by the MIL blink pattern.
• In case the ECM does not detect any problem at present, when the ignition switch is turned "ON", the MIL will stay on for a few
seconds, then go off.
• In case the ECM detects the problem at present, when the ignition switch is turned "ON", the MIL will stay on for a few seconds
and go off, then the MIL blinks as its failure code.
• The MIL has two types of blinks, a long blink and short blink. The long blinking lasts for 1.3 seconds, the short blinking lasts for
0.3 seconds. One long blink is the equivalent to ten short blinks. For example, when two long blinks are followed by five short
blinks, the MIL is 25 (two long blinks = 20 blinks, plus five short blinks).
• The MIL will start blinking when the ignition switch is "ON" or engine revs are below 2,200 min-1 (rpm). In any other conditions,
the MIL will illuminate and stay on.
ON
IGNITION
SWITCH
OFF
ON
MIL
(No problem at present)
OFF
0.5 sec.
0.3 sec. 0.4 sec. 3.0 sec. 1.3 sec. 0.3 sec.
MIL
ON
(Detect the problem at
present)
OFF
CODE "7" CODE "12"
MIL CIRCUIT CHECK

If the MIL does not come on or stays on when the ignition switch is turned "ON", inspect the MIL circuit (page 6-24).
FAIL-SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system. When any abnormality is detected by the self-diagnosis function, running capability is main-tained by pre-programed value
in the simulated program map. When any abnormality is detected in the injector and/or crankshaft position (CKP) sensor, the fail-
safe function stops the engine to protect it from damage.

FAILURE CODE READOUT
CURRENT FAILURE CODE
Support the scooter with its centerstand and check the MIL.
• When the ignition switch is turned "ON", the MIL will stay on for a few
seconds, then go off.
If the MIL stays on or blinks, note how many times the MIL blinks and
determine the cause of the problem.
If the MIL does not blink, the system is normal at present. If you wish to read
the stored failure code, perform the following:
MIL (Malfunction
Indicator Lamp)
TO READ THE STORED FAILURE CODE

Turn the ignition switch "OFF".
CONNECTOR
Remove the front top cover (page 3-4). COVER
Remove the DLC (Date Link Connector) from the connector cover and short
the DLC terminals using the special tool.
TOOL:
SCS connector 070PZ-ZY30100
CONNECTION: Brown – Green/Black
DLC (Data Link

Connector) SCS CONNECTOR
If the ECM has no stored failure code, the MIL will illuminate, when you turn the ignition switch "ON".
If the ECM has stored failure code, the MIL will illuminate 0.3 seconds and go off, then start blinking as its failure code when you
turn the ignition switch "ON".
Note how many times the MIL blinks, and determine the cause of the problem.
ON
IGNITION
and SWITCH OFF
ON
MIL
(No stored failure code)
OFF
ON
MIL
(Stored failure code)
OFF
0.3 sec. STORED FAILURE CODE

6-11
ERASING STORED FAILURE CODE
• The stored failure code can not be erased by simply disconnecting the battery negative cable.
1. Turn the ignition switch "OFF".
CONNECTOR
2. Remove the front top cover (page 3-4). COVER
3. Remove the DLC from the connector cover and short the DLC terminals
using the special tool.
TOOL:
SCS connector 070PZ-ZY30100
CONNECTION: Blue – Green
4. Turn the ignition switch "ON".
DLC (Data Link

Connector) SCS CONNECTOR
5. Disconnect the special tool from the DLC.

Connect the DLC short connector to the DLC again while the MIL stays
ON about 5 seconds (reset receiving pattern).
6. The stored failure code is erased if the MIL goes off and starts blinking
(successful pattern).
• The DLC must be jumped while the MIL lights. If not, the MIL will go off
and stay on (unsuccessful pattern). In that case, turn the ignition switch
to "OFF" and try again from step 3.
• Note that the self-diagnostic memory cannot be erased if the ignition
switch is turned “OFF” before the MIL starts blinking.
SCS CONNECTOR
2 – 3 sec.
0.3 sec.
within 5 sec.
MIL
STORED
ON FAILURE CODE
IS ERASED.
OFF
IGNITION
FAILURE PATTERN RESET RECEIVING SUCCESSFUL
SWITCH
PATTERN PATTERN
ON
OFF
MIL more than 5 sec.

NOT ERASED.
ON TRY AGAIN
FROM STEP 3.
OFF
IGNITION
SWITCH FAILURE PATTERN RESET RECEIVING UNSUCCESSFUL
PATTERN PATTERN
ON
OFF

GENERAL TROUBLESHOOTING
INTERMITTENT FAILURE
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check
for poor contact or loose pins at all connectors related to the circuit. If the MIL was on, but then went out, the original problem may
be intermittent.
OPENS AND SHORTS
"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With
ECMs this can sometimes mean something works, but not the way it’s supposed to.
If the Engine has problem, and MIL comes on
Refer to FAILURE CODE READOUT (page 6-11).
If the Engine has problem, but MIL does not stay on or blink
Do the SYMPTOM TROUBLESHOOTING (page 6-5).
CIRCUIT INSPECTION
INSPECTION AT ECM AND SENSOR UNIT CONNECTOR
• Always clean around and keep any foreign material away from the
connector before disconnecting it.
• A faulty PGM-FI system is often related to poorly connected or corroded
connections. Check those connections before proceeding.
• When testing at connector (wire harness side) terminal, always use the
test prove. Insert the test prove into the connector terminal, then connect
the digital multimeter probe to the test probe.
TOOL:
Test probe 07ZAJ-RDJA110
TEST PROBE

6-13
MIL CODE INDEX
Refer
MIL Function Failure Symptom/Fail-safe function
to
MAP sensor malfunction • Engine operates normally
1 • Loose or poor contact of the MAP sensor connector • Pre-program value: 481 mmHg/641 hPa 6-15
• MAP sensor or its circuit malfunction
ECT sensor malfunction • Hard start at a low temperature
7 • Loose or poor contact of the ECT sensor connector • Pre-program value: 83°C/181°F 6-16
• ECT sensor or its circuit malfunction
TP sensor malfunction • Poor engine acceleration
8 • Loose or poor contact of the TP sensor connector • Pre-program value: 0° 6-17
• TP sensor or its circuit malfunction
IAT sensor malfunction • Engine operates normally
9 • Loose or poor contact of the IAT sensor connector • Pre-program value: 35°C/95°F 6-19
• IAT sensor or its circuit malfunction
Injector malfunction • Engine does not start
12 • Loose or poor contact of the injector connector • Injector, fuel pump and ignition coil shut 6-20
• Injector or its circuit malfunction down
O2 sensor malfunction • Engine operates normally
21 • Loose or poor contact of the O2 sensor connector 6-21
• O2 sensor or its circuit malfunction
IACV malfunction • Engine stalls, hard to start, rough idling
29 • Loose or poor contact of the IACV connector 6-22
• IACV or its circuit malfunction

MIL TROUBLESHOOTING
MIL 1 BLINK (MAP SENSOR)
• Before starting the inspection, check for loose or
poor contact on the sensor unit 5P (Black) connector
and ECM 33P (Black) connector and recheck the
MIL blinking.
1. Sensor Unit Power Input Voltage Inspection
SENSOR UNIT 5P (Black) CONNECTOR
Disconnect the sensor unit 5P (Black) connector.
(Wire side/female terminals)
Turn the ignition switch "ON".
Measure the voltage at the wire side.
CONNECTION:
Yellow/orange (+) – Green/orange (–)
STANDARD: 4.75 – 5.25 V
Yellow/orange Green/orange
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 3.
NO – GO TO STEP 2.
2. Sensor Unit Circuit Inspection

Disconnect the ECM 33P (Black) connector. SENSOR UNIT 5P (Black) CONNECTOR
Check for continuity between the sensor unit 5P
connector and the ECM 33P connector of the wire
harness side.
TOOL: Yellow/orange Green/
Test probe 07ZAJ-RDJA110 orange
CONNECTION STANDARD
Yellow/orange – Yellow/orange
Continuity
Green/orange – Green/orange
Are the above inspections normal?
ECM 33P (Black) CONNECTOR
YES – Replace the ECM with a known good one, (Wire side/female terminals)
and recheck.
NO – • Open circuit in Yellow/orange wire
• Open circuit in Green/orange wire
3. MAP Sensor Input Voltage Inspection
Measure the voltage at the sensor unit 5P (Black) SENSOR UNIT 5P (Black) CONNECTOR
connector of the wire side. (Wire side/female terminals)
CONNECTION:
Yellow/red (+) – Ground (–)
STANDARD: 4.75 – 5.25 V
YES – Replace the sensor unit with a new one
and recheck (faulty MAP sensor) Yellow/red

6-15
4. MAP Sensor Output Line Circuit Inspection
Disconnect the ECM 33P (Black) connector. SENSOR UNIT 5P (Black) CONNECTOR
(Wire side/female terminal)
Check the continuity between the ECM 33P
connector and sensor unit 5P (Black) connector of
the wire side.
Check for continuity between sensor unit 5P
Yellow/red
connector and ground.
TOOL:
CONNECTION STANDARD
Yellow/red – Yellow/red Continuity
Yellow/red – Ground No Continuity
Are the above inspections normal? (Wire side/female terminals)
YES – Replace the ECM with a known good one,
and recheck
NO – • Open circuit in Yellow/red wire
• Short circuit in Yellow/red wire
MIL 7 BLINKS (ECT SENSOR)

poor contact on the ECT sensor 2P (Black)
connector and ECM 33P (Black) connector and
recheck the MIL blinking.
1. ECT Sensor Input Voltage Inspection
ECT SENSOR 2P (Black) CONNECTOR
Disconnect the ECT sensor 2P (Black) connector.
Measure the voltage at the ECT sensor 2P
connector of the wire side and ground.
CONNECTION: Pink/white (+) –Green/orange (–)
STANDARD: 4.75 – 5.25 V
Green/orange Pink/white
YES – Inspect the ECT sensor (page 6-46), and if
the sensor is normal, replace the ECM with
a known good one, and recheck.

2. ECT Sensor Circuit Inspection
Turn the ignition switch "OFF". ECT SENSOR 2P (Black) CONNECTOR
Disconnect the ECM 33P (Black) connector.
Check the continuities between the ECM 33P
connector and ECT sensor 2P (Black) connector of
the wire side.
Pink/white
Check for continuity between ECT sensor 2P
connector and ground.
TOOL:
CONNECTION STANDARD
Pink/white – Pink/white Green/
Continuity
Green/orange – Green/orange orange ECM 33P (Black) CONNECTOR
Pink/white – Ground No Continuity (Wire side/female terminals)
and recheck.
NO – • Open circuit in Pink/white wire
• Short circuit in Pink/white wire
MIL 8 BLINKS (TP SENSOR)

MIL blinking.
1. Sensor Unit Power Input Voltage Inspection
CONNECTION:
Yellow/orange (+) – Green/orange (–)
STANDARD: 4.75 – 5.25 V
Yellow/orange Green/orange
If the voltage within 4.75 – 5.25 V?
2. Sensor Unit Circuit Inspection

(Black) connector and the ECM 33P connector of
the wire harness side.
TOOL: Green/
Yellow/orange
Test probe 07ZAJ-RDJA110 orange
CONNECTION STANDARD
Yellow/orange – Yellow/orange
Continuity
Green/orange – Green/orange
YES – Replace the ECM with a known good one, (Wire side/female terminals)
and recheck.
NO – • Open circuit in Yellow/orange wire

6-17
3. TP Sensor Inspection
Continuity Resistance inspection (with
Check for continuity between the following terminals inspection: throttle operation):
of the sensor side.
CONNECTION: C–D C D B C
STANDARD: Continuity
Check that the resistance between the following
terminals changes in accordance with the throttle
operation.
CONNECTION: B–C
YES – GO TO STEP 4. SENSOR UNIT 5P CONNECTOR (Sensor
side/male terminal)
NO – Replace the sensor unit with a new one,
and recheck. (Faulty TP sensor)
4. TP Sensor Signal Line Circuit Inspection
(Black) connector of the wire side and ECM 33P
connector of the wire harness side.
(Black) connector and ground.
TOOL:
White/red
CONNECTION STANDARD
White/red – White/red Continuity
White/red – Ground No Continuity
and recheck.
NO – • Open circuit in White/red wire
• Short circuit in White/red wire

MIL 9 BLINKS (IAT SENSOR)
MIL blinking.
1. IAT Sensor Input Voltage Inspection
CONNECTION: White/blue (+) – Green/orange (–)
STANDARD: 4.75 – 5.25 V
White/blue Green/orange
If the voltage within 4.75 – 5.25 V?
2. IAT Sensor Circuit Inspection

Disconnect the ECM 33P (Black) connector. (Wire side/female terminals)
(Black) connector and the ECM 33P connector of
the wire harness side.
Check for continuity between sensor unit 5P White/ Green/
connector and ground. blue orange
TOOL:
CONNECTION STANDARD
White/blue – White/blue
Continuity
Green/orange – Green/orange ECM 33P (Black) CONNECTOR
White/blue – Ground No Continuity (Wire side/female terminals)

and recheck.
NO – • Open circuit in White/blue wire
• Short circuit in White/blue wire
3. IAT Sensor Resistance Inspection
A B C D E
Measure the resistance between the sensor unit 5P
connector terminals.
CONNECTION: C – E
STANDARD: 1 – 4 kǡ (20°C/68°F)
Is the resistance within 1 – 4 kǡ (20°C/68°F)?

NO – Replace the sensor unit with a new one,
and recheck. (Faulty IAT sensor)
and recheck.
SENSOR UNIT 5P CONNECTOR
(Sensor side/male terminals)

6-19
MIL 12 BLINKS (INJECTOR)
poor contact on the injector 2P (Black) connector
MIL blinking.
1. Injector Input Voltage Inspection
Disconnect the injector 2P (Black) connector. INJECTOR 2P (Black) CONNECTOR
Measure the voltage between the injector 2P
CONNECTION: Black (+) – Ground (–) Black
STANDARD: Above (Battery voltage – 1.1) V
Does the standard voltage exist?
NO – Open or short circuit in Black wire
2. Injector Resistance Inspection

INJECTOR 2P CONNECTOR
Measure the resistance of the injector 2P connector (Injector side/male terminals)
terminals.
STANDARD: 9 – 12 ǡ (20°C/68°F)
Is the resistance within 9 – 12 ǡ (20°C/68°F)?

NO – Faulty injector
3. Injector Signal Line Circuit Inspection

Disconnect the ECM 33P (Black) connector. INJECTOR 2P (Black) CONNECTOR
Check the continuity between the ECM 33P (Wire side/female terminal)
connector and injector 2P (Black) connector of the
wire side.
Pink/
Check the continuity between the injector 2P
blue
TOOL:
CONNECTION STANDARD
Pink/blue – Pink/blue Continuity
Pink/blue – Ground No Continuity ECM 33P (Black) CONNECTOR
Are the above inspections normal? (Wire side/female terminals)

and recheck.
NO – • Open circuit in Pink/blue wire
• Short circuit in Pink/blue wire

MIL 21 BLINKS (O2 SENSOR)
poor contact on the O2 sensor 1P (Black) connector
MIL blinking.
1. O2 Sensor Short Circuit Inspection
O2 SENSOR CAP
Disconnect the ECM 33P (Black) connector and O2
sensor cap.
Check the continuity between the O2 sensor cap
terminal and ground.
CONNECTION: O2 sensor cap terminal – Ground
TERMINAL
Is there continuity?
YES – • Short circuit in Black/orange wire.
• Short circuit in O2 sensor Black/orange
wire
2. O2 Sensor Circuit Continuity Inspection

Check for continuity between the O2 sensor cap
terminal and the ECM 33P (Black) connector of the O2 SENSOR CAP
wire harness side. TERMINAL
TOOL:
CONNECTION: ECM 33P (Black) CONNECTOR

O2 sensor cap terminal – Black/orange (Wire side/female terminals)
NO – • Open circuit in Black/orange wire.
• Open circuit in O2 sensor Black/orange
Black/orange
wire
3. O2 Sensor Inspection
Replace the O2 sensor with a known good one
(page 6-47).
Erase the self diagnosis memory data from the ECM
(page 6-12).
Start the engine and warm it up.
Test-ride the scooter and recheck the MIL blinking.
Does the MIL blink 21 times?
and recheck.
NO – Faulty original O2 sensor

6-21
MIL 29 BLINKS (IACV)
poor contact on the IACV 4P (Black) connector and
ECM 33P (Black) connector and recheck the MIL
blinking.
1. IACV Short Circuit Inspection
Disconnect the IACV 4P (Black) connector. (Wire side/female terminals)
Check the connector for loose contacts or corroded
terminals. Light green/red Gray/red
Check for continuities between the IACV 4P
connector of the wire harness side and ground.
Brown/ Black/
Connection: Light green/red – Ground
red red
Brown/red – Ground
Gray/red – Ground
Black/red – Ground
STANDARD: No continuity
Are there continuities?
YES – • Short circuit in Light green/red or
Brown/red wire
• Short circuit in Gray/red or Black/red
wire
2. IACV Circuit Continuity Inspection
Check the continuity between the IACV 4P (Black)
connector terminals and ECM 33P connector (Wire side/female terminals)
terminals of the wire harness side.
Light green/red
Connection: Light green/red – Light green/red
Brown/red – Brown/red
Gray/red – Gray/red
Black/red – Black/red
STANDARD: Continuity
Brown/red
TOOL:
Are there continuity?
NO – • Open circuit in Light green/red or
Brown/red wire
Black/red
• Open circuit in Gray/red or Black/red
wire
Gray/red

(Wire side of female terminals)

3. IACV Resistance Inspection
Measure the resistance at the IACV 4P connector
terminals. IACV 4P CONNECTOR
Connection: A – D (IACV side of male terminals)
B–C
STANDARD: 110 – 150 ǡ (20 °C/68 °F)
Is the resistance within 110 – 150 ǡ (20°C/68°F)? B C

A D
NO – Faulty IACV. Replace the IACV with a new
one, and recheck.
4. IACV Short Circuit Inspection

Check for continuity at the IACV 4P connector
IACV 4P CONNECTOR
terminals of the IACV side.
(IACV side of male terminals)
Connection: A – B
C–D
C
YES – Faulty IACV. Replace the IACV with a new
one, and recheck. A D
B
NO – Replace the ECM with known good one,
and recheck.

6-23
MIL CIRCUIT INSPECTION
WHEN THE IGNITION SWITCH IS
TURNED ON, THE MIL DOES NOT
COME ON
ECM 33P (Black)
Remove the right main pipe side cover (page 3-16). CONNECTOR
Ground the ECM 33P connector terminal of the wire
harness side connector with a jumper wire.
CONNECTION: No.22 (Blue/yellow) – Ground
No.22 (Blue/yellow)
TOOL:
Turn the ignition switch "ON", the MIL should come on.
• If the MIL comes on, replace the ECM with a known
good one, and recheck.
• If the MIL does not come on, check for open circuit
in the Blue/yellow wire between the speedometer
and ECM.
WHEN THE IGNITION SWITCH IS

TURNED ON, THE MIL DOES NOT GO
OFF WITHIN A FEW SECONDS
(ENGINE STARTS)
ECM
Remove the right main pipe side cover (page 3-16).
Turn the ignition switch "ON", the MIL should turn off.
• If the MIL comes on, check for short circuit in the
Blue/yellow wire between the speedometer and
ECM.
• If the MIL turns off, check the following.
33P (Black) CONNECTOR
Check for continuity between the ECM 33P connector

and ground. ECM 33P (Black) 33P (Black)
CONNECTOR CONNECTOR (Wire
CONNECTION: No.15 (Brown) – Ground side/female terminals)
TOOL:
No.15
• If there is continuity, check for short circuit in the (Brown)
Brown wire between the DLC and ECM.
• If there is no continuity, replace the ECM with a
known good one, and recheck.

FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING/QUICK
CONNECT FITTING REMOVAL
• Before disconnecting fuel feed hose, relieve
pressure from the system by following the
procedures below.
• This scooter uses resin for the part of materials in
the fuel feed hose. Do not bend or twist the fuel feed
hose.
1. Turn the ignition switch "OFF".
2. Remove the left main pipe side cover (page 3-16). 5P CONNECTOR
Disconnect the fuel pump 5P connector.
3. Turn the ignition switch "ON".
4. Start the engine and let it idle until the engine stalls.
5. Disconnect the battery negative (–) cable (page 17-
11).
6. Check the fuel quick connect fitting for dirt, and

QUICK CONNECT FITTING
clean if necessary.
Place a shop towel over the quick connect fitting.
SHOP TOWEL
7. Release the fuel hose from the clamp.

FUEL HOSE
CLAMP

6-25
7. COOLING SYSTEM
SYSTEM FLOW PATTERN···························7-2 RADIATOR ··················································7-10 7
COMPONENT LOCATION ····························7-3 COOLING FAN············································7-10
SERVICE INFORMATION ·····························7-4 RADIATOR RESERVE TANK·····················7-11
TROUBLESHOOTING···································7-6 THERMOSTAT ············································7-11
COOLANT SYSTEM TESTING ·····················7-7 WATER PUMP ············································7-13
COOLANT REPLACEMENT ·························7-8

7-1
COOLING SYSTEM
SYSTEM FLOW PATTERN
COOLING SYSTEM
WHEN THE ENGINE IS COLD

RESERVETANK
WATER HOSE
SIPHON HOSE
OVERFLOW HOSE
RADIATOR
THERMOSTAT WATER PUMP
WHEN THE ENGINE IS HOT

RESERVETANK
WATER HOSE
SIPHON HOSE
OVERFLOW HOSE
RADIATOR
THERMOSTAT WATER PUMP

COOLING SYSTEM
COMPONENT LOCATION
9 N·m (0.9 kgf·m, 6.6 lbf·ft)
10 N·m
(1.0 kgf·m, 7 lbf·ft)
59 N·m (6.0 kgf·m, 44 lbf·ft)
8 N·m (0.8 kgf·m, 5.9 lbf·ft)
1 N·m (0.1 kgf·m, 0.7 lbf·ft)

7-3
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap.
• Use only Honda PRE-MIX COOLANT containing corrosion inhibitors, specifically recommended for aluminum engines when
adding or replacing the coolant.
Genuine Honda PRE-MIX COOLANT is excellent at preventing corrosion and overheating. The effects last for up to 2 years.
• The coolant should be inspected and replaced properly by following the maintenance schedule (page 4-4).
• Use any genuine Honda PRE-MIX COOLANT without diluting with water.
• DO NOT use non-ethylene glycol coolant, tap water, nor mineral water when adding or replacing the coolant.
Use of improper coolant may cause damage, such as corrosion in the engine, blockage of the cooling passage or the radiator
and premature wear of the water pump seal.
• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
• All cooling system can be serviced with the engine in the frame.
• Avoid spilling coolant on painted surfaces.
• After servicing the system, check for leaks with a cooling system tester.
SPECIFICATIONS
ITEM SPECIFICATIONS
TORQUE VALUES
Radiator drain bolt 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
Cooling fan mounting bolt 8 N·m (0.8 kgf·m, 5.9 lbf·ft)
Water pump impeller 10 N·m (1.0 kgf·m, 7 lbf·ft)
Thermostat mounting bolt 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
Flywheel nut 59 N·m (6.0 kgf·m, 44 lbf·ft)
Stator mounting socket bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)

COOLING SYSTEM
TOOLS
Driver Attachment, 24 x 26 mm Attachment, 28 x 30 mm
07749-0010000 07746-0010700 07946-1870100
Universal holder Bearing driver Mechanical seal driver attachment

07725-0030000 07945-GC80000 07945-4150400
Inner driver, 22 mm Bearing remover head, 12 mm Bearing remover shaft, 12 mm

07746-0020100 07936-1660110 07936-1660120
Remover weight
07741-0010201

7-5
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
• Thermostat stuck closed
• Faulty radiator cap
• Insufficient coolant
• Passage blocked in radiator, hoses or water jacket
• Air in system
• Faulty water pump
Engine temperature too low
• Thermostat stuck open
Coolant leak
• Deteriorated O-rings
• Faulty radiator cap
• Damaged or deteriorated cylinder head gasket
• Loose hose connection or clamp
• Damaged or deteriorated hoses

COOLING SYSTEM
COOLANT SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cover (page 3-12).
RADIATOR CAP CLAMP
Pinch the siphon hose using a hose clamp.
Remove the radiator cap.
SIPHON HOSE
Wet the sealing surfaces of the cap, then install the cap
onto the tester. RADIATOR CAP TESTER
Pressurize the radiator cap using the tester.

Replace the radiator cap if it does not hold pressure, or
if relief pressure is too high or too low.
The cap must hold the specified pressure for at least 6
seconds.
RADIATOR CAP RELIEF PRESSURE:
108 – 137 kPa (1.1 – 1.4 kgf/cm2, 16 – 20 psi)
RADIATOR CAP
Pressurize the radiator, engine and hoses using the

tester, and check for leaks. RADIATOR CAP TESTER
Repair or replace components if the system will not hold

the specified pressure for at least 6 seconds.
Excessive pressure can damage the cooling system

components. Do not exceed 137 kPa (1.4 kgf/cm2, 20
psi).
Remove the tester and install the radiator cap.
Remove the hose clamp from the siphon hose
Install the radiator cover (page 3-12).
RADIATOR

7-7
COOLING SYSTEM
COOLANT REPLACEMENT
REPLACEMENT/AIR BLEEDING
RADIATOR CAP CLAMP
Remove the radiator cap.
SIPHON HOSE
Remove the radiator drain bolt, seal ring and drain the
SEAL RING
coolant from the radiator.
Remove the hose clamp from the siphon hose and
drain the coolant from the reserve tank.
DRAIN BOLT
Remove the drain bolt with sealing washer from the

water pump cover and drain the coolant from the SEALING WASHER
engine.
DRAIN BOLT
Reinstall the drain bolt with a new sealing washer onto

the water pump cover. DRAIN BOLT SEAL RING
Reinstall the radiator drain bolt with a new seal ring

onto the radiator and tighten it to the specified torque.
TORQUE: 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
SEALING WASHER DRAIN BOLT

COOLING SYSTEM
Use only genuine Honda PRE-MIX COOLANT

containing corrosion inhibitors, specifically FILLER NECK
recommended for aluminum engines when adding or
When filling the Fill the system with the recommended coolant through
system or reserve the filler opening to the filler neck.
tank with coolant, or
checking the
coolant level, Honda PRE-MIX COOLANT
support the scooter Bleed air from the system as follows:
with its centerstand
on a flat, level 1. Start the engine and let it idle for 2 – 3 minutes.
surface. 2. Snap the throttle three or four times to bleed air from
the system.
3. Stop the engine and add coolant up to the filler neck.
4. Reinstall the radiator cap.
Unlock the fuel lid with ignition key and open the lid. RESERVE TANK CAP
UPPER
Remove the reserve tank cap.
LEVEL
Use only genuine Honda PRE-MIX COOLANT

containing corrosion inhibitors, specifically
recommended for aluminum engines when adding or
When filling the Fill the reserve tank with the recommended coolant to
system or reserve the upper level line.
tank with coolant, or
checking the
coolant level, Honda PRE-MIX COOLANT
support the scooter Install the reserve tank cap.
with its centerstand
on a flat, level Install the following:
surface. – Radiator cover (page 3-12)

7-9
COOLING SYSTEM
RADIATOR
Drain the coolant (page 7-8).
SIPHON HOSE
Disconnect the siphon hose and water hose from the
radiator.
WATER HOSE
Disconnect the water hose from the radiator.

WATER HOSE
Remove the four radiator mounting bolts/washers, RADIATOR TOP COVER BOLTS/
radiator top cover and radiator. WASHERS
Make sure that the Fill and bleed the cooling system (page 7-9).
hose clips are After installation, make sure the coolant does not leak.
installed in the
correct direction
(page 1-14).
RADIATOR
COOLING FAN
Remove the radiator (page 7-10).
BOLTS
Remove the three bolts and cooling fan.
TORQUE: COOLING FAN MOUNTING BOLT
8 N·m (0.8 kgf·m, 5.9 lbf·ft)
COOLING FAN

COOLING SYSTEM
RADIATOR RESERVE TANK
HOSE CLAMP
Disconnect the siphon hose from the radiator.
Remove the hose clamp and drain the coolant into the
approved pan.
SIPHON HOSE
Remove the special bolt and reserve tank.

RESERVE TANK OVERFLOW HOSE
Disconnect the siphon hose and overflow hose from the
reserve tank.
Route the hoses Installation is in the reverse order of removal.
properly
Fill the reserve tank with the coolant (page 7-8).
(page 1-14).
BOLT SIPHON HOSE
THERMOSTAT
REMOVAL
BOLTS
Disconnect the water hoses from the thermostat.
Remove the two bolts and thermostat.
Remove the O-ring. O-RING WATER
HOSES
THERMOSTAT

7-11
COOLING SYSTEM
INSTALLATION
Install a new O-ring into the groove of the thermostat.
THERMOSTAT
Install the thermostat to the water pump cover.
O-RING
Install and tighten the two bolts to the specified torque.

BOLTS
Make sure that the Connect the water hoses to the thermostat.
hoses and clips are WATER
Fill and bleed the cooling system (page 7-9).
installed in the HOSES
correct direction After installation, make sure the coolant does not leak.
(page 1-14).
THERMOSTAT
INSPECTION
Visually inspect the thermostat for damage.
Replace the thermostat if it stays open at room THERMOMETER
temperature.
Wear insulated Heat a container of water with an electric heating
gloves and element for 5 minutes.
adequate eye Suspend the thermostat in heated water to check its
protection. Keep operation.
flammable
materials away from
VALVE BEGINS TO LIFT (OPEN):
the electric heating 74 – 78 °C (165 – 172 °F)
element.
Do not let the VALVE LIFT:
thermostat or 8 mm (0.3 in) minimum at 100 °C (212 °F)
thermometer touch
Replace the thermostat if the valve opens at
the pan, or you will
temperature other than specified.
get a false reading.
8 mm (0.3 in)
THERMOSTAT

COOLING SYSTEM
WATER PUMP
REMOVAL
• Water pump can be serviced with the engine
installed on the frame.
WIRE GUIDE
Drain the engine oil (page 4-11).
– Thermostat (page 7-11)
– Flywheel/alternator stator (page 17-7)
– Woodruff key (page 17-9)
Remove the bolts, wire guide and water pump cover.
BOLTS WATER PUMP COVER

Remove the O-ring from the water pump cover.
DOWEL PINS WATER PUMP COVER
Remove the dowel pins.
O-RING
Be careful not to Unhook the clip from the water pipe and slide the water CLIP
damage the water pipe to the stator base side.
pipe.
WATER PIPE

7-13
COOLING SYSTEM
– Four bolts
– Water pump/stator base
– Oil pump driven gear
– Water pump drive gear/oil pump shaft
– Drive chain
– Water pump driven gear
– Two dowel pins
DOWEL PINS
DRIVE CHAIN
WATER PUMP
DRIVEN GEAR
WATER PUMP/
STATOR BASE
BOLTS
OIL PUMP
DRIVEN GEAR
WATER PUMP DRIVE

GEAR/OIL PUMP SHAFT
Remove the water pipe and O-rings. WATER PIPE

O-RINGS

COOLING SYSTEM
Remove the O-ring from the water pump/stator base.
O-RING
INSTALLATION
Apply engine oil to the water pump shaft.
Install a new O-ring into the water pump/stator base
groove.
O-RING
Install the new O-rings into the grooves of the water

pipe. O-RING WATER PIPE
Install the water pipe into the water pump/stator base.
Install the dowel pins.

Apply engine oil to the oil pump drive gear.
DOWEL PINS

7-15
COOLING SYSTEM
Apply engine oil to the oil pump driven gear and oil
OIL PUMP DRIVEN GEAR Align (CUT-OUT)
pump shaft.
Set the oil pump driven gear to the drive gear of the
crankshaft as shown.
Install the water pump drive gear/oil pump shaft by
aligning the oil pump shaft cut-out with the oil pump cut- OIL PUMP
out, and the pin groove of the oil pump driven gear with SHAFT
the pin of the oil pump shaft.
Align (PIN/GROOVE)
Apply engine oil to the water pump drive chain and

WATER PUMP DRIVEN GEAR
water pump driven gear.
Set the drive chain over the water pump drive gear and
driven gear.
Set the water pump driven gear as shown.
DRIVE CHAIN
Apply engine oil to the oil pump shaft journal on the

stator base. WATER PUMP/
STATOR BASE
Install the water pump/stator base to the right
crankcase by aligning the water pump drive gear shaft
with the journal on the stator base.
Align
Align the pin groove of the water pump driven gear with
the pin of the water pump shaft by rotating the water
pump impeller.
IMPELLER

COOLING SYSTEM
Install the woodruff key (page 17-9).
FLYWHEEL
Temporarily install the flywheel by aligning the key way
in the flywheel with the key on the crankshaft.
Make sure that the water pump impeller rotates by
rotating crankshaft.
After inspection, remove the flywheel.
IMPELLER
Install and tighten the four bolts.

BOLTS
Slide the water pipe into the cylinder. WATER PIPE CLIP
Hook the clip to the water pipe groove.
Install the dowel pins.

DOWEL PINS WATER PUMP COVER
Install a new O-ring into the water pump cover groove.
O-RING

7-17
COOLING SYSTEM
Install the water pump cover and the wire guide.
Install the drain bolt with a new sealing washer. WATER PUMP WIRE GUIDE
Install and tighten the bolts. COVER
Install the following:

– Thermostat (page 7-12)
Fill the engine with recommended oil (page 4-11).
Fill and bleed the cooling system (page 7-8).
BOLT/SEALING
BOLTS WASHER
INSPECTION
OIL PUMP DRIVEN GEAR
Check the oil pump driven gear teeth for wear or
damage. OIL PUMP DRIVEN GEAR
WATER PUMP DRIVE GEAR

Check the water pump drive gear teeth for wear or
WATER PUMP
damage.
Check the water pump drive gear shaft and shaft hole DRIVE GEAR
of the stator base for wear or damage.
GEAR SHAFT GEAR SHAFT HOLE
WATER PUMP DRIVEN GEAR

Check the water pump driven gear teeth for wear or
damage. WATER PUMP DRIVEN GEAR

COOLING SYSTEM
WATER PUMP SHAFT
Check the water pump shaft and shaft hole of the right
WATER PUMP SHAFT
crankcase for wear or damage.
SHAFT HOLE
PUMP SHAFT BEARING

Turn the water pump shaft with your finger. The bearing
should turn smoothly and quietly. Also check that the
bearing inner race fits tightly on the pump shaft and the
bearing outer race fits tightly on the water pump/stator
base.
Replace the water pump bearing if the bearing does not
turn smoothly, quietly, or if they fit loosely on the pump
shaft or stator base/water pump (page 7-20).
WATER PUMP
SHAFT BEARING
MECHANICAL SEAL INSPECTION

Check the bleed hole of the water pump for signs of
coolant leakage.
If water leaks through the bleed hole, replace the
mechanical seal (page 7-20).
If oil leaks through the bleed hole, replace the oil seal
(page 7-20).
Make sure that there are no continuous coolant leakage
from the bleed hole while operating the engine.
A small amount of" coolant weeping from the bleed hole

is normal.
BLEED HOLE

7-19
COOLING SYSTEM
MECHANICAL SEAL REPLACEMENT
FLYWHEEL IMPELLER
– Cooling fan (page 7-10)
– Water pump cover (page 7-13)
Hold the flywheel with the special tool and loosen the
water pump impeller.
TOOL:
Universal holder 07725-0030000
Remove the water pump/stator base (page 7-13).
UNIVERSAL
HOLDER
Remove the water pump impeller.
IMPELLER
Be sure to use the Remove the water pump shaft from the water pump/
hydraulic press. stator base using a hydraulic press.
Do not use the
hammer.
When pressing the
water pump shaft/
bearing, be careful
not to damage the
water pump/stator
base mating
surface.
WATER PUMP SHAFT

COOLING SYSTEM
Remove the shaft from the bearing using a hydraulic
press. BEARING
– If the bearing remains in the water pump/stator
base, remove the bearing using the special tools.
TOOLS:
Bearing remover head, 12mm 07936-1660110
Bearing remover shaft, 12mm 07936-1660120
Remover weight 07741-0010201
WATER PUMP SHAFT
REMOVER HEAD If the bearing remains in the

water pump/stator base:
REMOVER
WEIGHT
REMOVER SHAFT
Remove the oil seal from the water pump/stator base.

OIL SEAL
Be careful not to Remove the mechanical seal using a hydraulic press.

damage the water
pump/stator base TOOL:
mating surface. Bearing driver 07945-GC80000 BEARING
DRIVER
MECHANICAL SEAL

7-21
COOLING SYSTEM
WATER PUMP SHAFT
BEARING (6001)
MECHANICAL SEAL
IMPELLER
OIL SEAL
Apply engine oil to a new water pump oil seal lips.

DRIVER
The marked side of Drive a new water pump oil seal until it is flush with the
the oil seal is facing water pump groove.
the water pump
impeller.
TOOLS:
Driver 07749-0010000 ATTACHMENT
Attachment, 24 x 26 mm 07746-0010700
OIL SEAL
Drive a new mechanical seal until it is fully seated on

the water pump groove using the special tools and DRIVER
hydraulic press.
TOOLS:
Driver 07749-0010000
Mechanical seal driver 07945-4150400 ATTACHMENT
attachment
MECHANICAL SEAL

COOLING SYSTEM
Support the inner race of new bearing properly.
Drive the water pump shaft into the new bearing until BEARING
the distance between the bearing surface and the
extended line from the flange of the shaft is
25.9 – 26.1 mm (1.02 – 1.03 in) as shown, using a
hydraulic press.
WATER PUMP
SHAFT
BEARING
25.9 – 26.1 mm
(1.02 – 1.03 in)
WATER PUMP
SHAFT
Drive the water pump shaft/bearing squarely until it is

fully seated on the water pump/stator base using a INNER
hydraulic press. DRIVER
TOOL:
Inner driver, 22 mm 07746-0020100
WATER
PUMP
SHAFT/
BEARING
Install the water pump impeller, but do not tighten it yet.

IMPELLER

7-23
COOLING SYSTEM
FLYWHEEL IMPELLER
– Water pump/stator base (page 7-15)
– Woodruff key (page 17-9)
Hold the flywheel with the special tool and tighten the
water pump impeller to the specified torque.
TOOL:

UNIVERSAL
– Water pump cover (page 7-17) HOLDER
CRANKSHAFT OIL SEAL

REPLACEMENT
Remove the water pump/stator base (page 7-13).
OIL SEAL
Remove the crankshaft oil seal from the stator base.
Apply engine oil to a new crankshaft oil seal lips.

DRIVER
The marked side of Drive a new crankshaft oil seal until it is flush with the
the oil seal is facing stator base.
the flywheel.
TOOLS:
Attachment, 28 x 30 mm 07946-1870100
Install the water pump/stator base (page 7-15).
OIL SEAL

8. ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION ····························8-2 ENGINE REMOVAL ······································8-4

8
SERVICE INFORMATION ·····························8-3 ENGINE INSTALLATION······························8-7

8-1
COMPONENT LOCATION
69 N·m (7.0 kgf·m, 51 lbf·ft)

SERVICE INFORMATION
GENERAL
• Support the frame using a hoist to ease engine mounting bolt removal.
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• The following components require engine removal for service.
– Crankcase/crankshaft
• The following components can be serviced with the engine installed in the frame.
– Drive pulley/driven pulley/clutch
– Final reduction
– Alternator/starter clutch
– Cylinder head/valves
– Cylinder/piston
– Water pump
– Throttle body
– Oil pump
SPECIFICATIONS
ITEM SPECIFICATIONS
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt)
TORQUE VALUE
Engine hanger link pivot nut (frame side) 69 N·m (7.0 kgf·m, 51 lbf·ft)

8-3
ENGINE REMOVAL
Place the scooter on its centerstand.
BRAKE CABLE JOINT PIN
– Main pipe side covers (page 3-16)
– Under cover (page 3-17)
– Injector (page 6-44)
Remove the rear brake adjusting nut and joint pin from
the rear brake cable.
Pull out the brake cable from the cable holder.
CABLE HOLDER ADJUSTING NUT
Remove the cable clamp bolt and cable clamp.

CABLE CLAMP BOLT
CABLE CLAMP
Loosen the band screw and disconnect the air duct
from the left crankcase cover. BAND SCREW
AIR DUCT
Remove the fuel hose clamp bolt and fuel hose clamp
FUEL HOSE CLAMP BOLT
from the cylinder head cover.
hose.
FUEL HOSE CLAMP

Loosen the throttle cable lock nut and adjusting nut and
ADJUSTING CABLE GUIDE CLAMP
disconnect it from the throttle drum.
Release the throttle cable from the cable guide and NUT
clamp.
LOCK NUT THROTTLE DRUM
Release the engine sub harness 14P (Gray) connector

ENGINE SUB HARNESS
from the stay and disconnect it. BOLT
Remove the bolt and ground cable.
GROUND CABLE
STARTER MOTOR ALTERNATOR 3P
– Alternator/CKP sensor 3P connector 2P CONNECTOR CONNECTOR
– Starter motor 2P connector
Release the following wires from the wire guide:
– Engine sub harness wire
– Alternator/CKP sensor wire
– Starter motor wire
WIRE GUIDE
Release the following wires from the wire band:

Release the following wire bosses from the frame:
– Engine sub harness wire boss
– Alternator/CKP sensor wire boss
– Starter motor wire boss
WIRE BOSSES WIRE BAND

8-5
Disconnect the spark plug cap from the spark plug.
Release the spark plug wire boss from the radiator SPARK PLUG CAP
cover.
WIRE BOSS
Pinch the siphon hose using a hose clamp and HOSE CLAMP HOSE GUIDE
disconnect the siphon hose from the radiator.
Plug the joint of the radiator.
Release the siphon hose from the hose guide.
SIPHON HOSE
To avoid damage to Support the frame in upright position.
the rear shock
Remove the rear shock absorber upper mounting bolts.
absorber mounting
bolt threads, the
engine height must
be adjusted
UPPER MOUNTING BOLTS
Support the frame in upright position.

Hold the front wheel.
Remove the nut and engine hanger linkage bolt.
Slightly pull the engine straight back to release it from
the frame and remove the engine, being careful not to
damage the rear fender.
NUT/BOLT

ENGINE INSTALLATION
Hold the front wheel. STOPPER RUBBER
Insert the stopper rubber into the hole of the frame.
HOLE
Install the engine hanger linkage bolt from the left side
of the scooter.
Temporarily tighten the engine hanger linkage nut.
NUT/BOLT
To ease installation Install and tighten the rear shock absorber upper
of the rear shock mounting bolts. NUT
absorber mounting
bolts, slightly lift the
rear wheel and
align the bolt holes.
Retract the Tighten the engine hanger linkage nut to the specified
centerstand before torque.
tightening the
engine hanger
linkage nut.
Remove the plug and connect the siphon hose to the HOSE CLAMP
radiator. HOSE GUIDE
Remove the clamp from the siphon hose.
Secure the siphon hose to the hose guide.
SIPHON HOSE

8-7
Route the wire Connect the spark plug cap to the spark plug.
harness properly Secure the wire boss to the radiator cover. SPARK PLUG CAP
(page 1-14)
WIRE BOSS
Route the wire Secure the following wire bosses to the frame:
harness properly
(page 1-14)
Secure the following wires to the wire band:
Secure the following wires to the wire guide:

– Engine sub harness wire 2P CONNECTOR CONNECTOR
Connect the following:
– Alternator/CKP sensor 3P connector
WIRE GUIDE
Connect the engine sub harness 14P (Gray) connector

ENGINE SUB HARNESS
and secure it to the stay. BOLT
Set the ground cable in position, then install and tighten
the bolt.
GROUND CABLE

Connect the throttle cable to the throttle drum.
CABLE GUIDE CLAMP
Secure the throttle cable to the cable guide and clamp.
THROTTLE CABLE THROTTLE DRUM
Be sure that the Set the fuel hose clamp in position, then install and FUEL HOSE CLAMP
stopper of the tighten the bolt. BOLT
clamp is in the
correct position.
hose.
STOPPER
Connect the air duct to the left crankcase cover.

BAND SCREW
Set the connecting hose band in the specified angle as
shown.
Tighten the band screw so that the clearance between
the band ends is 11 – 13 mm (0.4 – 0.5 in).
AIR DUCT
Clearance:
11 – 13 mm (0.4 – 0.5 in)
30 – 40°
OUT
side

8-9
Set the cable clamp in position, then install and tighten
CABLE CLAMP BOLT
the cable clamp bolt.
CABLE CLAMP
Secure the rear brake cable with the cable holder.
Install the joint pin and adjusting nut. BRAKE CABLE JOINT PIN
Adjust the following:
– Throttle grip free play (page 4-5)
– Rear brake lever free play (page 4-17)

8. ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION ····························8-2 ENGINE REMOVAL ······································8-4

8
SERVICE INFORMATION ·····························8-3 ENGINE INSTALLATION······························8-7

8-1
COMPONENT LOCATION
69 N·m (7.0 kgf·m, 51 lbf·ft)

SERVICE INFORMATION
GENERAL
• Support the frame using a hoist to ease engine mounting bolt removal.
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• The following components require engine removal for service.
– Crankcase/crankshaft
• The following components can be serviced with the engine installed in the frame.
– Drive pulley/driven pulley/clutch
– Final reduction
– Alternator/starter clutch
– Cylinder head/valves
– Cylinder/piston
– Water pump
– Throttle body
– Oil pump
SPECIFICATIONS
ITEM SPECIFICATIONS
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt)
TORQUE VALUE
Engine hanger link pivot nut (frame side) 69 N·m (7.0 kgf·m, 51 lbf·ft)

8-3
ENGINE REMOVAL
Place the scooter on its centerstand.
BRAKE CABLE JOINT PIN
Remove the rear brake adjusting nut and joint pin from
the rear brake cable.
Pull out the brake cable from the cable holder.
Remove the cable clamp bolt and cable clamp.

CABLE CLAMP BOLT
CABLE CLAMP
from the left crankcase cover. BAND SCREW
AIR DUCT
Remove the fuel hose clamp bolt and fuel hose clamp
FUEL HOSE CLAMP BOLT
from the cylinder head cover.
hose.
FUEL HOSE CLAMP

Loosen the throttle cable lock nut and adjusting nut and
ADJUSTING CABLE GUIDE CLAMP
disconnect it from the throttle drum.
Release the throttle cable from the cable guide and NUT
clamp.
LOCK NUT THROTTLE DRUM
Release the engine sub harness 14P (Gray) connector

ENGINE SUB HARNESS
from the stay and disconnect it. BOLT
Remove the bolt and ground cable.
GROUND CABLE
– Alternator/CKP sensor 3P connector 2P CONNECTOR CONNECTOR
Release the following wires from the wire guide:
WIRE GUIDE
Release the following wires from the wire band:

Release the following wire bosses from the frame:

8-5
Release the spark plug wire boss from the radiator SPARK PLUG CAP
cover.
WIRE BOSS
Pinch the siphon hose using a hose clamp and HOSE CLAMP HOSE GUIDE
disconnect the siphon hose from the radiator.
Plug the joint of the radiator.
Release the siphon hose from the hose guide.
SIPHON HOSE
To avoid damage to Support the frame in upright position.
the rear shock
Remove the rear shock absorber upper mounting bolts.
absorber mounting
bolt threads, the
engine height must
be adjusted

Hold the front wheel.
Remove the nut and engine hanger linkage bolt.
Slightly pull the engine straight back to release it from
the frame and remove the engine, being careful not to
damage the rear fender.
NUT/BOLT

ENGINE INSTALLATION
Hold the front wheel. STOPPER RUBBER
Insert the stopper rubber into the hole of the frame.
HOLE
Install the engine hanger linkage bolt from the left side
of the scooter.
Temporarily tighten the engine hanger linkage nut.
NUT/BOLT
To ease installation Install and tighten the rear shock absorber upper
of the rear shock mounting bolts. NUT
absorber mounting
bolts, slightly lift the
rear wheel and
align the bolt holes.
Retract the Tighten the engine hanger linkage nut to the specified
centerstand before torque.
tightening the
engine hanger
linkage nut.
Remove the plug and connect the siphon hose to the HOSE CLAMP
radiator. HOSE GUIDE
Remove the clamp from the siphon hose.
Secure the siphon hose to the hose guide.
SIPHON HOSE

8-7
Route the wire Connect the spark plug cap to the spark plug.
harness properly Secure the wire boss to the radiator cover. SPARK PLUG CAP
(page 1-14)
WIRE BOSS
Route the wire Secure the following wire bosses to the frame:
harness properly
(page 1-14)
Secure the following wires to the wire band:
Secure the following wires to the wire guide:

– Engine sub harness wire 2P CONNECTOR CONNECTOR
Connect the following:
– Alternator/CKP sensor 3P connector
WIRE GUIDE
Connect the engine sub harness 14P (Gray) connector

ENGINE SUB HARNESS
and secure it to the stay. BOLT
Set the ground cable in position, then install and tighten
the bolt.
GROUND CABLE

Connect the throttle cable to the throttle drum.
CABLE GUIDE CLAMP
Secure the throttle cable to the cable guide and clamp.
THROTTLE CABLE THROTTLE DRUM
Be sure that the Set the fuel hose clamp in position, then install and FUEL HOSE CLAMP
stopper of the tighten the bolt. BOLT
clamp is in the
correct position.
hose.
STOPPER

BAND SCREW
shown.
AIR DUCT
Clearance:
11 – 13 mm (0.4 – 0.5 in)
30 – 40°
OUT
side

8-9
Set the cable clamp in position, then install and tighten
CABLE CLAMP BOLT
the cable clamp bolt.
CABLE CLAMP
Secure the rear brake cable with the cable holder.
Install the joint pin and adjusting nut. BRAKE CABLE JOINT PIN
Adjust the following:
– Throttle grip free play (page 4-5)
– Rear brake lever free play (page 4-17)

10. CYLINDER/PISTON
COMPONENT LOCATION ··························10-2 CYLINDER···················································10-4
SERVICE INFORMATION ···························10-3 PISTON························································10-7
TROUBLESHOOTING·································10-3
10

10-1
CYLINDER/PISTON
COMPONENT LOCATION
CYLINDER/PISTON

CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• This section covers maintenance of the cylinder and piston.
• The engine must be removed from the frame to service the cylinder and piston.
• Be careful not to damage mating surfaces when removing the cylinder. Do not tap the cylinder too hard during removal.
• Take care not to damage the cylinder wall and piston.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
• When removing the piston, clean carbon and sludge from the top of the cylinder.
SPECIFICATIONS
Unit: mm (in)
Cylinder I.D. 50.000 – 50.010 (1.9685 – 1.9689) 50.10 (1.972)
Out-of-round – 0.05 (0.002)
Taper – 0.05 (0.002)
Warpage – 0.05 (0.002)
Piston, piston Piston O.D. 49.975 – 49.995 (1.9675 – 1.9683) 49.95 (1.967)
rings, piston Piston O.D. measurement point 6.0 (0.24) from bottom of skirt –
pin Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Second 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
• Bent connecting rod
• Cylinder head/valve problem (page 9-23)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston head or on combustion chamber
Excessive smoke
• Worn cylinder, piston or piston ring
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
• Cylinder head/valve problem (page 9-23)
Abnormal noise
• Worn piston pin or piston pin hole
• Worn connecting rod small end
• Worn cylinder, piston or piston rings
Piston ring sticking/scuffing, bearing damage
• Clogged oil gallery or oil strainer screen
• Internal oil leak
• Not using recommended engine oil

10-3
CYLINDER/PISTON
CYLINDER
REMOVAL
Remove the cylinder head (page 9-14).
CLIP
Unhook the clips and slide the water pipe into the water
pump/stator base.
WATER PIPE WATER PIPE
Attach a piece of Remove the cylinder.

wire to the cam
chain to prevent it
from falling into the
crankcase. Be
careful not to
damage the mating
surface.
CYLINDER CAM CHAIN

Remove the gasket and dowel pins.
GASKET
Clean off any gasket material from the cylinder mating
surface of the crankcase.
DOWEL PINS
Slide the water pipe out of the water pump/stator base.
WATER PIPE
Remove the O-rings from the water pipe.
O-RINGS

CYLINDER/PISTON
INSTALLATION
Install the dowel pins and a new gasket.
GASKET
DOWEL PINS
Install the new O-rings into the grooves of the water
pipe. WATER PIPE
Insert the water pipe into the water pump/stator base.
O-RINGS
Apply engine oil to the cylinder and piston sliding

surface.
Apply engine oil to the piston rings. PISTON RINGS
Attach a piece of Route the cam chain through the cylinder.

wire to the cam
Install the cylinder over the piston while compressing
chain to prevent it
the piston ring with your finger.
from falling into the
crankcase.
CYLINDER CAM CHAIN

Slide the water pipe into the cylinder.
Set the clip to the water pipe as shown. CLIP
Install the cylinder head (page 9-16).
WATER PIPE

10-5
CYLINDER/PISTON
INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D. in the X and Y axis at three
levels. Y
Take the maximum reading to determine the cylinder
wear. TOP X
Calculate the taper and out-of-round at three levels in MIDDLE
the X and Y axis. Take the maximum reading to
determine both measurements.
BOTTOM
SERVICE LIMIT:
Taper: 0.05 mm (0.002 in)
Out of round: 0.05 mm (0.002 in)
The cylinder must be rebored and an oversize piston/
piston rings fitted if the service limits are exceeded.
The following oversize pistons/piston rings are
available:
0.25 mm (0.010 in)
0.50 mm (0.020 in)
0.75 mm (0.030 in)
1.00 mm (0.039 in)
The piston to cylinder clearance for the oversize piston
must be: 0.005 – 0.035 mm (0.0002 – 0.0014 in).
Check the cylinder for warpage with a straight edge and

feeler gauge in the directions shown.

CYLINDER/PISTON
STUD BOLT REPLACEMENT
Thread two nuts onto the stud and tighten them
together, and use wrench on them to turn the stud bolt
out.
Install new stud bolts A, B into the crankcase and STUD BOLT A
tighten them.
178.0 – 179.0 mm (7.01 – 7.05 in)
After crankcase stud bolt installation, check that the
length from the bolt head to the crankcase surface is
within specification.
SPECIFIED STUD BOLT A: 178.0 – 179.0 mm
LENGTH: (7.01 – 7.05 in)
STUD BOLT B: 183.0 – 184.0 mm
(7.20 – 7.24 in)
STUD BOLT B
183.0 – 184.0 mm (7.20 – 7.24 in)
PISTON
REMOVAL
Be careful not to let Remove the cylinder (page 10-4).
the piston pin clips CLIP/PISTON PIN
Remove the piston pin clips with pliers.
fall into the opening
Push the piston pin out of the piston and connecting
of the crankcase.
rod, then remove the piston.
PISTON
Spread each piston ring and remove it by lifting up at a

point opposite the gap. PISTON RING

10-7
CYLINDER/PISTON
Clean carbon deposits from the ring grooves with a ring
that will be discarded. PISTON RING
INSTALLATION
Apply engine oil to the rings and ring grooves.
Carefully install the piston rings into the piston ring
grooves with the markings facing up.
• Do not confuse the top and second rings.
• To install the oil ring, install the spacer first, then
install the side rails.
Stagger the piston ring end gaps 120 degrees apart
from each other.
Stagger the side rail end gaps as shown.
MARK
TOP RING
SECOND RING
120°
MARK 120°
120° TOP RING
SECOND RING
OIL RING
SPACER
SIDE RAILS
20 mm or
more
20 mm or
more

CYLINDER/PISTON
Apply engine oil to the connecting rod small end hole.
CONNECTING ROD
Apply engine oil to the piston pin.
"IN" MARK PISTON
Install the piston with the "IN" mark facing the intake PIN
side.
Install the piston pin.
Be careful not to let Install the new pin clips.

the piston pin clips
• Make sure the piston pin clips are seated securely. CLIP
fall into the opening
• Do not align the piston pin clip end gap with the
of the crankcase.
piston cut-out.
Install the cylinder (page 10-5).
PISTON CUT-OUT
CLIP

10-9
CYLINDER/PISTON
INSPECTION
Inspect the piston rings for movement by rotating the
rings. The rings should be able to move in their grooves
without catching.
Push the ring until the outer surface of the piston ring is
nearly flush with the piston and measure the ring-to-
groove clearance.
SERVICE LIMIT:
Top/Second: 0.08 mm (0.003 in)
PISTON RING
Insert each piston ring into the bottom of the cylinder

PISTON RING
squarely using the piston.
Measure the ring end gap.
SERVICE LIMIT:
Top/Second: 0.45 mm (0.018 in)
Check the piston outer surface for scratches or

damage.
Measure the piston pin hole. Take the maximum
reading to determine I.D.
Measure the piston pin O.D. at piston and connecting
rod sliding areas.
Calculate the piston-to-piston pin clearance.
Measure the piston O.D. at the point 6.0 mm (0.24 in)

from the bottom and 90° to the piston pin hole.

Calculate the cylinder-to-piston clearance (cylinder I.D.:
page 10-6). 90°
6.0 mm (0.24 in)

CYLINDER/PISTON
Measure the connecting rod small end I.D.
Calculate the connecting rod-to-piston pin clearance.

10-11
MEMO

11. KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
COMPONENT LOCATION ··························11-2 DRIVE BELT··············································11-13
SERVICE INFORMATION ···························11-3 DRIVE PULLEY·········································11-13
TROUBLESHOOTING·································11-5 CLUTCH/DRIVEN PULLEY ······················11-17
LEFT CRANKCASE COVER ······················11-6 11

11-1
COMPONENT LOCATION
108 N·m (11.0 kgf·m, 80 lbf·ft)
49 N·m (5.0 kgf·m, 36 lbf·ft)

SERVICE INFORMATION
GENERAL
• This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch.
• These services can be done with the engine installed in the frame.
• Avoid getting grease and oil on the drive belt and drive/driven pulley faces in order to prevent belt slippage.
• Do not apply grease to the weight rollers.
SPECIFICATIONS
Unit: mm (in)
Drive belt width 19.0 (0.75) 18.0 (0.71)
Boss O.D. 22.010 – 22.025 (0.8665 – 0.8671) 21.98 (0.865)
Weight roller O.D. 17.92 – 18.08 (0.706 – 0.712) 17.5 (0.69)
Clutch outer I.D. 125.0 – 125.2 (4.92 – 4.93) 125.5 (4.94)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)
TORQUE VALUE
Left crankcase cover plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Drive pulley face nut 108 N·m (11.0 kgf·m, 80 lbf·ft) Apply engine oil to the threads and seating
surface
Clutch/driven pulley nut 54 N·m (5.5 kgf·m, 40 lbf·ft)
Clutch outer nut 49 N·m (5.0 kgf·m, 36 lbf·ft)

11-3
TOOLS
Clutch center holder Socket wrench, 39 x 41 mm Clutch spring compressor
07724-0050002 07GMA-KS40100 07LME-GZ40201
Driver Pilot, 28 mm Pilot, 20 mm

07749-0010000 07746-0041100 07746-0040500
Flywheel holder Bearing remover, 20 mm Fork seal driver attachment, 35.2 mm

07725-0040001 07931-MA70000 07947-KA20200
Attachment, 28 x 30 mm
07946-1870100

TROUBLESHOOTING
Engine starts but scooter won’t move
• Worn drive belt
• Damaged ramp plate
• Worn or damaged clutch shoe
• Broken driven face spring
Engine stalls or scooter creeps
• Broken clutch shoe spring
Poor performance at high speed or lack of power
• Worn drive belt
• Weak driven face spring
• Worn weight rollers
• Contaminated pulley faces

11-5
LEFT CRANKCASE COVER
REMOVAL
from the left crankcase cover. AIR DUCT
BAND SCREW

BOLTS
– Cover bolts
– Rear brake cable clamp
– Vent hole cover
Remove the left crankcase cover.
REAR BRAKE
CABLE CLAMP VENT HOLE COVER
Remove the two dowel pins and cover gasket from the
left crankcase. GASKET
Clean the gasket mating surface.
DOWEL PINS
INSTALLATION
Clean any oil and grease from the bearing bushing on BUSHING
GASKET
the left crankcase cover.
Install the two dowel pins.
Install a new cover gasket.
DOWEL PINS

Install the left crankcase cover onto the left crankcase
BOLTS
by aligning the dowel pins with the holes.
Install the rear brake cable clamp, vent hole cover and
tighten the left crankcase cover bolts in a crisscross
pattern in two or three steps.
REAR BRAKE
CABLE CLAMP VENT HOLE COVER

AIR DUCT
shown.
BAND SCREW
Clearance:
11 – 13 mm (0.4 – 0.5 in)
30 – 40°
OUT
side
DISASSEMBLY
Raise the lock tabs of the left crankcase cover plate and COVER PLATE
remove the screws and plate.
LOCK TABS/SCREWS

11-7
Remove the kickstarter driven gear while turning the
KICKSTARTER DRIVEN GEAR
kickstarter spindle.
Remove the thrust washer.
THRUST WASHER
Before removing the kickstarter pedal, mark the pedal MARK

and spindle for proper installation position. KICKSTARTER PEDAL
Remove the bolt and the kickstarter pedal.
BOLT
Remove the dust seal from the left crankcase cover.

DUST SEAL
Remove the snap ring and washer from the kickstarter

SNAP RING
spindle.
WASHER

Unhook the return spring from the pin on the crankcase
KICKSTARTER SPINDLE RETURN SPRING
cover.
Remove the kickstarter spindle and return spring.
PIN
Remove the spindle bushing and collar.

BUSHING
COLLAR
ASSEMBLY
KICKSTARTER SPINDLE
COLLAR
BUSHING *1
3 N·m (0.3 kgf·m, 2.2 lbf·ft)
RETURN SPRING
DRIVEN GEAR
*2
COVER PLATE
FRICTION SPRING
THRUST WASHER
SNAP RING
WASHER
DUST SEAL KICKSTARTER PEDAL
BOLT *1: Apply 0.1 – 0.3 g

*2: Apply 0.2 – 0.3 g

11-9
Install the bushing and collar into the left crankcase
BUSHING
cover.
COLLAR
Apply 0.1 – 0.3 g of molybdenum disulfide paste to the

kickstarter spindle.
Hook the short end of the spring to the spindle groove.

RETURN SPRING Hook
Install the spindle and return spring into the crankcase
cover while setting the return spring along the guide on
the crankcase cover.
Hold the kickstarter spindle in position.
SHORT END
KICKSTARTER SPINDLE
Keep holding the Install the washer onto the kickstarter spindle and set
SNAP RING
kickstarter spindle the snap ring to the kickstarter spindle groove.
until the snap ring is
installed in order to
prevent the spring
from coming off
from the guide.
WASHER

Hook the long end of the return spring to the pin on the LONG END PIN
crankcase cover.
Apply grease to a new dust seal lip.

Install the dust seal until it is flush with the left
crankcase cover.
DUST SEAL
When installing the Install the kickstarter pedal in its original position as MARK
kickstarter pedal to marked during removal and tighten the bolt. KICKSTARTER PEDAL
the standard
position, see page
11-8.
BOLT
Install the thrust washer onto the crankcase cover.
THRUST WASHER

11-11
Apply 0.2 – 0.3 g of molybdenum disulfide paste to the
driven gear shaft. DRIVEN GEAR FRICTION SPRING
Apply molybdenum disulfide paste to the friction spring
sliding area.
Depress the kickstarter pedal and hold it.
Install the driven gear while aligning the friction spring
hook with the groove in the crankcase cover, and return
the kickstarter spindle to engage the driven gear teeth
and spindle gear teeth before the wide tooth point.
WIDE TOOTH
Install the left crankcase cover plate and tighten the COVER PLATE
screws to the specified torque.

Bend the lock tabs of the cover plate against the screw
heads.
LOCK TABS/SCREWS
INSPECTION
Inspect the following:
– Spindle for wear or damage RETURN SPRING
– Gear teeth for wear or damage
– Return spring for weakness or damage
COLLAR
– Collar for wear or damage
– Bushing for wear or damage
SPINDLE
BUSHING
– Driven gear for wear or damage

FRICTION SPRING STARTER
– Friction spring for weakness or damage
RATCHET TEETH
– Starter ratchet teeth for wear or damage
DRIVEN GEAR

– Journals of the crankcase cover for wear or damage
JOURNALS
DRIVE BELT
REPLACEMENT
• The drive belt can be serviced with the engine

installed in the frame.
Remove the drive pulley face (page 11-13).
Remove the drive belt and replace it with a new one.
Install the drive pulley face (page 11-14).
BELT
DRIVE PULLEY
REMOVAL
• The drive pulley can be serviced with the engine NUT/WASHER/ DRIVE PULLEY FACE
installed in the frame.
RATCHET PLATE
Hold the drive pulley face with special tool and loosen
the drive pulley face nut.
TOOL:
Clutch center holder 07724-0050002
– Nut
– Washer
– Starter ratchet plate DRIVE FACE FIN
– Drive face fin CLUTCH CENTER HOLDER
– Drive pulley face

11-13
Slide off the drive belt from the drive pulley boss by
squeezing the drive belt. BOSS
BELT
Remove the movable drive face assembly while holding

MOVABLE DRIVE FACE ASSEMBLY
the back of the face (ramp plate) and drive face boss.
BOSS
INSTALLATION
Clean any oil and grease from the drive face and the
MOVABLE DRIVE FACE ASSEMBLY
drive belt.
Be careful not to get Install the movable drive face assembly onto the
the movable drive crankshaft while holding the ramp plate.
face assembly
disassembled and
be sure to install the
assembly until fully
seated.
Compress the driven face spring by squeezing the drive DRIVE BELT
belt until there is enough slack to install the drive belt to
the drive pulley boss.

Be careful not to Set the drive belt onto the drive pulley boss by
DRIVE PULLEY FACE
damage the spline. squeezing it to obtain the clearance between the belt
and shaft.
Install the drive pulley face while aligning its splines with
crankshaft splines.
Align
Make sure that the drive pulley face is fully seated on

the drive pulley boss.
Fully seated (Drive pulley face and boss)
Install the drive face fin and ratchet plate. WASHER DRIVE FACE FIN
Apply engine oil to the drive pulley face nut threads and
seating surface then install it with the washer.
RATCHET PLATE NUT
Hold the drive pulley face with the special tool and
tighten the nut to the specified torque. NUT
TOOL:
Clutch center holder 07724-0050002

Install the left crankcase cover (page 11-6).
CLUTCH CENTER HOLDER

11-15
– Drive face boss
– Ramp plate
– Slide pieces
– Weight rollers
Clean any oil and Assembly is in the reverse order of disassembly.
grease from the
weight rollers and
movable drive face.
MOVABLE DRIVE FACE DRIVE FACE BOSS
Left crankcase
cover side
RAMP PLATE
WEIGHT ROLLERS
SLIDE PIECES
INSPECTION
DRIVE PULLEY FACE
Check the drive pulley face for scratches, scoring or
damage. DRIVE PULLEY FACE
WEIGHT ROLLER
Check each roller for abnormal wear.
Measure the weight roller O.D.

MOVABLE DRIVE FACE BOSS
Check the drive face boss for wear or damage.
Measure the drive face boss O.D.
MOVABLE DRIVE FACE

Check the movable drive face for scratches, scoring or
damage. MOVABLE DRIVE FACE
Measure the drive face bushing I.D.
CLUTCH/DRIVEN PULLEY
REMOVAL
• The clutch/driven pulley can be serviced with the NUT/WASHER

CLUTCH OUTER
engine installed in the frame.
Use the special tool Hold the clutch outer with the special tool and remove
when loosening the the nut.
lock nut. Holding the
rear wheel or rear
TOOL:
brake will damage Flywheel holder 07725-0040001
the final reduction Remove the washer and clutch outer.
system.
FLYWHEEL HOLDER

11-17
Do not get grease Hold the clutch/driven pulley assembly and compress
on the drive shaft the drive face spring by turning movable driven face
splines from the clockwise until it stops.
driven face inside.
CLUTCH/DRIVEN PULLEY ASSEMBLY

To avoid injury to Remove the clutch/driven pulley assembly from the
your finger, do not drive belt by holding the movable driven face. BELT
release the driven
Remove the drive belt from the clutch/driven pulley
pulley while
assembly while removing the clutch/driven pulley
removing the drive
assembly from the drive shaft.
belt. If released
drive face spring
will extend
suddenly and
movable driven
face will turn,
resulting in injury to
your finger.
MOVABLE DRIVEN FACE
INSTALLATION
Clean any oil and grease from the driven face and drive
belt. CLUTCH/DRIVEN
Hold the clutch/driven pulley assembly and compress PULLEY ASSEMBLY
the drive face spring by turning movable driven face
clockwise until it stops.
MOVABLE DRIVEN FACE

To avoid injury to Set the drive belt onto the pulley groove while holding
your finger, do not the movable driven face. BELT
release the driven
pulley while
installing the drive
belt. If released
drive face spring
will extend
suddenly and
movable driven
face will turn,
resulting in injury to
your finger.
MOVABLE DRIVEN FACE

Do not get grease Install the clutch/driven pulley assembly onto the
on the drive shaft driveshaft.
splines from the
driven face inside.
CLUTCH/DRIVEN PULLEY ASSEMBLY
Clean any oil and grease from the clutch outer. Align
Install the clutch outer while aligning its splines with
driveshaft splines.
CLUTCH OUTER
Install the washer and clutch outer nut.

NUT/WASHER
Hold the clutch outer with the special tool and tighten
the clutch outer nut to the specified torque.
TOOL:
Flywheel holder 07725-0040001

FLYWHEEL HOLDER
DISASSEMBLY
Set the clutch spring compressor onto the clutch/driven
pulley by aligning the bosses of the compressor with the CLUTCH SPRING COMPRESSOR
holes of the clutch. CLUTCH/DRIVEN
TOOL: PULLEY
Clutch spring compressor 07LME-GZ40201

11-19
To prevent loss of Hold the clutch/driven pulley by turning the clutch spring
tension, do not compressor clockwise.
compress the
driven face spring
more than
necessary to
remove the clutch/
driven pulley nut.
CLUTCH/DRIVEN
PULLEY
Hold the clutch spring compressor in a vise.

SOCKET WRENCH CLUTCH/DRIVEN
Remove the clutch/driven pulley nut using the special PULLEY NUT
tool.
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100
Loosen the clutch spring compressor gradually and

remove the following: CLUTCH ASSEMBLY
– Clutch assembly
– Spring seat
– Driven face spring SPRING SEAT
– Driven pulley assembly
DRIVEN FACE
DRIVEN PULLEY ASSEMBLY SPRING
CLUTCH
Remove the three E-clips and plate.
PLATE
E-CLIPS

Remove the clutch shoes from the drive plate.
Remove the clutch shoe springs. CLUTCH SHOES SPRINGS
Remove the damper rubbers from the drive plate.
DAMPER RUBBERS DRIVE PLATE
DRIVEN PULLEY
Remove the seal collar.
SEAL COLLAR
Remove the guide pins and guide rollers from the
driven face.
O-RINGS
Remove the movable driven face from the driven face.
Remove the O-rings and oil seals from the movable
driven face.
OIL SEALS
MOVABLE
DRIVEN FACE
GUIDE PINS
DRIVEN FACE
GUIDE
ROLLERS

11-21
ASSEMBLY
GUIDE PINS
GUIDE ROLLERS
OIL SEALS
O-RINGS
SEAL COLLAR
DRIVEN FACE SPRING DRIVEN FACE
MOVABLE DRIVEN FACE

SPRING SEAT
PLATE
E-CLIPS
CLUTCH SHOES
CLUTCH/DRIVEN PULLEY NUT SPRINGS

54 N·m (5.5 kgf·m, 40 lbf·ft) DRIVE PLATE DAMPER RUBBERS
DRIVEN PULLEY
Apply engine oil to new oil seal lips and install them into
the movable driven face. O-RINGS
Coat new O-rings with engine oil and install them into
the movable driven face grooves.
OIL SEALS
Clean any oil and grease from the pulley face.

PINS/ROLLERS
Install the movable driven face onto the driven face.
Install the guide rollers and guide pins.
Apply 1.5 – 2.0 g of grease (Shell ALVANIA R3 or
IDEMITSU AUTOREX B or equivalent) to each guide
groove.
MOVABLE DRIVEN FACE

Install the seal collar to the driven pulley.
SEAL COLLAR
CLUTCH
Install the damper rubbers onto the drive plate.
DRIVE PLATE
DAMPER RUBBERS
Install the shoe springs into the clutch shoes as shown.

CLUTCH SHOES SPRINGS
Install the clutch shoes into the drive plate by aligning
the shoe grooves and damper rubbers.
DAMPER RUBBERS DRIVE PLATE
Install the plate and new E-clips.

PLATE
E-CLIPS

11-23
Assemble the following:
CLUTCH ASSEMBLY
– Driven pulley assembly
– Driven face spring
– Spring seat SPRING SEAT
– Clutch assembly
DRIVEN FACE
DRIVEN PULLEY ASSEMBLY SPRING
Set the clutch spring compressor over the clutch/driven

CLUTCH SPRING
pulley assembly aligning the bosses of the compressor
COMPRESSOR
with the holes of the clutch.
TOOL:
Clutch spring compressor 07LME-GZ40201
To prevent loss of
tension, do not
compress the
driven face spring
more than
necessary to
assemble the Align (CUTOUT/ Align (BOSSES/
clutch/driven pulley PLATE HOLES HOLES
nut.
Do not damage the Hold the spring compressor in a vice.
SOCKET WRENCH NUT
pulley nut threads. Tighten the clutch/driven pulley nut using the socket
wrench to the specified torque.
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100

Remove the spring compressor from the clutch/driven
pulley assembly.
CLUTCH SPRING
COMPRESSOR
INSPECTION
CLUTCH OUTER
Check the clutch outer for wear or damage.
Measure the clutch outer I.D.

DRIVEN FACE SPRING
Measure the driven face spring free length.
DRIVEN FACE
Check the driven face for scratches, scoring or
damage.
Measure the driven face boss O.D.
MOVABLE DRIVEN FACE

Check the movable driven face for scratches, scoring or
damage.
Check the guide grooves for stepped wear or damage.
Measure the movable driven face I.D.
DRIVEN FACE BEARING INSPECTION

Check that the bearing outer race fits tightly in the
driven face.
Install the driven face to the driveshaft.
Turn the driven face with your hand. The bearing should
turn smoothly and quietly.
Replace the bearings if they do not turn smoothly,
quietly, or if they fit loosely on the driven face (page 11-
26).
DRIVEN FACE

11-25
DRIVEN FACE BEARING
REPLACEMENT
Remove the driven face needle bearing using the
special tools. BEARING REMOVER
TOOLS:
Bearing remover, 20 mm 07931-MA70000
ATTACHMENT
Fork seal driver attachment, 35.207947-KA20200
mm
NEEDLE BEARING
Remove the snap ring and drive the ball bearing out of
BEARING
the driven face.
SNAP RING
Pack new ball bearing with grease (Shell ALVANIA R3

or IDEMITSU AUTOREX B or equivalent). DRIVER
The sealed side of Install the ball bearing into the driven face squarely until
ball bearing is it is fully seated, using the special tools.
facing the
drivenface.
TOOLS:
Driver 07749-0010000
Pilot, 28 mm 07746-0041100 PILOT
BALL BEARING
Install the snap ring to the groove on the driven face

securely.
IDEMITSU AUTOREX B or equivalent) to the driven
face inner surface.
SNAP RING

Apply grease (Shell ALVANIA R3 or IDEMITSU
AUTOREX B or equivalent) to a new needle bearing. ATTACHMENT DRIVER
The sealed side of Press the needle bearing into the driven face squarely
as shown. 1.0 mm
needle bearing is
facing the special (0.04 in)
tools.
TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 20 mm 07746-0040500
PILOT
NEEDLE BEARING

11-27
MEMO

12. FINAL REDUCTION
COMPONENT LOCATION ··························12-2 FINAL REDUCTION CASE ASSEMBLY ····12-7
SERVICE INFORMATION ···························12-3 FINAL REDUCTION INSPECTION ·············12-8
TROUBLESHOOTING·································12-5 FINAL REDUCTION BEARING

REPLACEMENT········································12-10
FINAL REDUCTION CASE
SEPARATION··············································12-6
12

12-1
FINAL REDUCTION
COMPONENT LOCATION
FINAL REDUCTION

FINAL REDUCTION
SERVICE INFORMATION
GENERAL
• The final reduction can be serviced with the engine installed in the frame.
• When installing the driveshaft, be sure to use the special tools; position the special tools on the bearing inner race and pull the
driveshaft into the bearing until it is fully seated.
SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
service label)
TOOLS
Case puller Remover weight Bearing remover shaft, 10 mm
07SMC-0010001 07741-0010201 07936-GE00100
Bearing remover head, 10 mm Bearing remover shaft, 12 mm Bearing remover head, 12 mm

07936-GE00200 07936-1660120 07936-1660110
Bearing remover shaft, 15 mm Bearing remover head, 15 mm Driver

07936-KC10100 07936-KC10200 07749-0010000

12-3
FINAL REDUCTION
Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 40 x 42 mm
07746-0010100 07746-0010200 07746-0010900
Attachment, 42 x 47 mm Pilot, 10 mm Pilot, 12 mm

07746-0010300 07746-0040100 07746-0040200
Pilot, 15 mm Pilot, 20 mm Pilot, 22 mm

07746-0040300 07746-0040500 07746-0041000
Assembly collar Assembly shaft Assembly collar attachment

07965-GM00100 07965-1660200 07965-GM00200

FINAL REDUCTION
TROUBLESHOOTING
Engine does start but scooter won’t move
• Damaged final reduction
• Seized final reduction
• Faulty drive pulley (page 11-16)
• Faulty driven pulley/clutch (page 11-24)
Abnormal noise
• Worn, seized or chipped gears
• Worn or damaged final reduction bearing
Oil leak
• Oil level too high
• Worn or damaged oil seal
• Cracked crankcase and/or final reduction case

12-5
FINAL REDUCTION
SEPARATION
REMOVAL
• The final reduction can be serviced with the engine
installed in the frame. BREATHER HOSE
Drain the final reduction oil (page 4-15).

– Clutch/driven pulley (page 11-17)
– Rear wheel (page 15-5)
– Rear brake shoes (page 16-6)
Disconnect the final reduction case breather hose from
the final reduction case hose joint.
Remove the bolts and final reduction case.

FINAL REDUCTION
CASE
BOLTS
Remove the dowel pins and gasket.

DOWEL PINS
GASKET

FINAL REDUCTION
– Counter gear COUNTER GEAR
– Final gear shaft
– Countershaft
COUNTERSHAFT
FINAL GEAR SHAFT
FINAL REDUCTION CASE ASSEMBLY

Apply engine oil to each gear tooth and each bearing
sliding area of shaft.
COUNTERSHAFT
Install the final gear shaft.
Install the countershaft into the counter gear while
aligning the countershaft splines with the counter gear
splines and install them to the final reduction case.
SPLINES
FINAL GEAR COUNTER

SHAFT GEAR

12-7
FINAL REDUCTION
Install the dowel pins and a new gasket.
DOWEL PINS
GASKET
Install the final reduction case and tighten the bolts.

FINAL REDUCTION
CASE
BOLTS
Connect the breather hose to the final reduction case

hose joint. BREATHER HOSE

– Rear brake shoes (page 16-6)
– Rear wheel (page 15-5)
Fill the final reduction case with the recommended oil
(page 4-15).
FINAL REDUCTION INSPECTION

BEARING
LEFT CRANKCASE
Check each bearing for wear or damage.
FINAL GEAR DRIVESHAFT
Turn the inner race of the countershaft and final gear SHAFT BEARING BEARING
shaft bearings with your finger. The bearing should turn
smoothly and quietly. Also check that the bearing outer
race fits tightly in the crankcase.
Replace the bearings if they do not turn smoothly,
quietly, or if they fit loosely on the crankcase.
Turn the driveshaft with your hand. The bearing should
turn smoothly and quietly. Also check that the bearing
outer race fits tightly in the crankcase and the bearing
inner race fits tightly on the driveshaft.
Replace the bearing if it does not turn smoothly, quietly,
or if it fits loosely on the crankcase and driveshaft.
COUNTERSHAFT BEARING

FINAL REDUCTION
Check the final reduction case bearings and final gear
shaft oil seal for wear or damage. COUNTERSHAFT BEARING FINAL GEAR
SHAFT
Turn each bearing inner race with your finger. BEARING
The bearing should turn smoothly without friction.
Check that there is no clearance between the outer
race and the final reduction case.
FINAL GEAR
SHAFT OIL SEAL

DRIVESHAFT BEARING
Turn the inner race of the driveshaft bearing with your
finger. The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
crankcase cover.
or if it fits loosely on the crankcase cover.
GEAR/SHAFT
DRIVESHAFT
Check the driveshaft for bend, wear or damage.
DRIVESHAFT

12-9
FINAL REDUCTION
COUNTER GEAR/COUNTERSHAFT/FINAL GEAR
SHAFT
Check the countershaft, counter gear and final gear
shaft for wear or damage. FINAL GEAR SHAFT
COUNTER GEAR COUNTERSHAFT
FINAL REDUCTION BEARING

REPLACEMENT
DRIVESHAFT DRIVESHAFT LEFT

BEARING DRIVESHAFT BEARING (6204) CRANKCASE
(6002 UU)
COUNTERSHAFT
BEARING (6201)
FINAL GEAR SHAFT

BEARING (6022 UU)
LEFT CRANKCASE
COVER
BUSHING
10 x 15 x 9 OIL SEAL
20 x 32 x 6
COUNTERSHAFT
BEARING (6301)
FINAL GEAR SHAFT

BEARING (6302) FINAL REDUCTION
OIL SEAL
CASE
29 x 44 x 7

FINAL REDUCTION
SNAP RING
Remove the snap ring from the left crankcase cover
groove.
Remove the driveshaft bearing/bushing using the

special tools.
TOOLS:
Bearing remover head, 10 mm 07936-GE00200
Bearing remover shaft, 10 mm 07936-GE00100
– If the bearing remains in the left crankcase cover,
remove it using the following tools:
TOOLS:
Bearing remover head, 15 mm 07936-KC10200
Bearing remover shaft, 15 mm 07936-KC10100 DRIVESHAFT
Remover weight 07741-0010201 BEARING/BUSHING
If the bearing remains in

the left crankcase cover:
DRIVESHAFT BEARING
Apply engine oil to the bearing cavity.

DRIVER
Drive a new driveshaft bearing into the left crankcase
cover squarely until it is fully seated, using the special
tools.
TOOLS:
Attachment, 32 x 35 mm 07746-0010100
Pilot, 10 mm 07746-0040100
Clean any oil and grease from the left crankcase cover
bearing bushing inner surface.
DRIVESHAFT
BEARING PILOT

12-11
FINAL REDUCTION
Install the snap ring Install the snap ring to the left crankcase cover groove.
SNAP RING
with the chamfered
edge facing the
bearing.
LEFT CRANKCASE
Separate the final reduction case (page 12-6).
SET PLATE
Remove the two bolts and set plate.
BOLTS
Be careful not to Remove the countershaft and final gear shaft bearings
damage the final using the special tools.
reduction case
mating surface. TOOLS:
Countershaft bearing:
Bearing remover head, 12 mm 07936-1660110
Bearing remover shaft, 12 mm 07936-1660120
Final gear shaft bearing:
Bearing remover head, 15 mm 07936-KC10200
Bearing remover shaft, 15 mm 07936-KC10100
FINAL GEAR COUNTERSHAFT
SHAFT BEARING BEARING

FINAL REDUCTION
Apply engine oil to each bearing cavity.
The marked side of Drive each new bearing into the left crankcase squarely
each bearing is until it is fully seated, using the special tools. COUNTERSHAFT
facing the special BEARING
tools.
TOOLS:
Countershaft bearing:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
Final gear shaft bearing:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 15 mm 07746-0040300 FINAL GEAR
SHAFT BEARING
DRIVER
ATTACHMENT
BEARING PILOT
Clean and apply locking agent to the set plate bolt

threads from its tip to 6.5 ± 1.0 mm (0.26 ± 0.04 in) SET PLATE
down. "OUT" MARK
Install the set plate with its "OUT" mark facing out.
Install and tighten the set plate bolts.
Assemble the final reduction case (page 12-7).
6.5 ± 0.1 mm
(0.26 ± 0.04 in)
BOLTS
DRIVESHAFT
SET PLATE
Remove the two bolts and set plate.
BOLTS

12-13
FINAL REDUCTION
Remove the driveshaft using the special tool. DRIVESHAFT
TOOL:
Case puller 07SMC-0010001
CASE PULLER
CASE PULLER
DRIVESHAFT
Remove the snap ring from the driveshaft groove.

SNAP RING
Remove the driveshaft bearing using a hydraulic press.

BEARING
DRIVESHAFT

FINAL REDUCTION
Remove the driveshaft oil seal.
DRIVESHAFT OIL SEAL

DRIVESHAFT BEARING DRIVER
The marked side of Drive a new driveshaft bearing into the left crankcase
each bearing is squarely until it is fully seated, using the special tools.
facing the special
TOOLS: ATTACHMENT
tools.
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
DRIVESHAFT BEARING PILOT
Install the driveshaft into the bearing.

DRIVESHAFT ASSEMBLY
Position the assembly collar on the driveshaft bearing
BEARING COLLAR
inner race and pull the driveshaft into the bearing until it
is fully seated.
TOOLS:
Assembly shaft 07965-1660200
Assembly collar 07965-GM00100
Assembly collar attachment 07965-GM00200
ASSEMBLY COLLAR ASSEMBLY

ATTACHMENT SHAFT
ASSEMBLY
COLLAR
DRIVESHAFT
ATTACHMENT
BEARING
ASSEMBLY
ASSEMBLY COLLAR SHAFT

12-15
FINAL REDUCTION
Install the snap ring Install the snap ring to the driveshaft groove.
SNAP RING
with the chamfered
edge facing the
bearing.
Apply engine oil to a new driveshaft oil seal lip.

DRIVESHAFT ASSEMBLY COLLAR
Do not insert the oil Install the driveshaft oil seal until it is flush with the left OIL SEAL
seal too far. crankcase.
TOOLS:
Assembly shaft 07965-1660200
Assembly collar 07965-GM00100 ASSEMBLY
Assembly collar attachment 07965-GM00200 SHAFT
ASSEMBLY
COLLAR
ATTACHMENT
ASSEMBLY COLLAR ASSEMBLY
ATTACHMENT COLLAR
DRIVESHAFT ASSEMBLY
OIL SEAL SHAFT
Clean and apply locking agent to the set plate bolt

SET PLATE "OUT" MARK
threads from its tip to 6.5 ± 1.0 mm (0.26 ± 0.04 in)
down.
Install the set plate with its "OUT" mark facing out.
Install and tighten the set plate bolts.
6.5 ± 0.1 mm
(0.26 ± 0.04 in)
BOLTS

FINAL REDUCTION
COUNTERSHAFT FINAL GEAR SHAFT
Be careful not to Remove the final gear shaft oil seal. BEARING BEARING
damage the final
Remove the final gear shaft bearing.
reduction case
mating surface. Remove the countershaft bearing using the special
tools.
TOOLS:
Bearing remover shaft, 12 mm 07936-1660120
OIL SEAL
Apply engine oil to the countershaft bearing cavity.

DRIVER
The marked side of Drive a new countershaft bearing into the final reduction
bearing is facing the case squarely until it is fully seated, using the special
special tools. tools.
TOOLS:
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
COUNTERSHAFT BEARING PILOT
Apply engine oil to the final gear shaft bearing cavity.

DRIVER
The marked side of Drive a new final gear shaft bearing into the final
bearing is facing the reduction case squarely until it is fully seated, using the
special tools. special tools.
TOOLS:
Driver 07749-0010000
ATTACHMENT
Attachment, 40 x 42 mm 07746-0010900
Pilot, 22 mm 07746-0041000
FINAL GEAR
SHAFT BEARING PILOT
Apply engine oil to a new final gear shaft oil seal lip.
DRIVER
Install the oil seal with the flat side facing the rear wheel
side so that the depth from the final reduction case
surface is 1.5 ± 0.5 mm (0.06 ± 0.02 in) using the ATTACHMENT
special tools.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
1.5 ± 0.5 mm
(0.06 ± 0.02 in)
FINAL GEAR SHAFT OIL SEAL

12-17
MEMO

13. CRANKCASE/CRANKSHAFT
COMPONENT LOCATION ··························13-2 CRANKCASE SEPARATION ·····················13-5
SERVICE INFORMATION ···························13-3 CRANKCASE ASSEMBLY ·························13-8
TROUBLESHOOTING·································13-4 CRANKSHAFT INSPECTION ···················13-12
13

13-1
COMPONENT LOCATION

SERVICE INFORMATION
GENERAL
• This section covers the crankcase separation to service the crankshaft.
• The following parts must be removed before separating the crankcase.
– Engine (page 8-4)
– Cylinder head (page 9-14)
– Cylinder (page 10-4)
– Piston (page 10-7)
– Starter pinion (page 19-10)
– Drive pulley (page 11-13)
– Starter motor (page 19-6)
– Flywheel/stator (page 17-7)
• In addition to the parts listed above, remove the following parts when the left crankcase must be replaced.
– Final reduction (page 12-6)
• In addition to the parts listed above, remove the following parts when the right crankcase must be replaced.
– Oil pump (page 5-4)
• Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
• When installing the crankshaft, be sure to use the special tools; position the special tools on the bearing inner race and pull the
crankshaft into the bearing until it is fully seated.
SPECIFICATIONS
Unit: mm (in)
Runout – 0.10 (0.004)

13-3
TOOLS
Case puller Assembly shaft Assembly collar A
07SMC-0010001 07965-VM00200 07965-VM00100
Assembly shaft adaptor Assembly collar B Attachment, 72 x 75 mm

07WMF-KFF0200 07931-KF00100 07746-0010600
Pilot, 35 mm Driver Oil seal driver

07746-0040800 07749-0010000 07965-KE80200
Fork seal driver attachment 41.2 mm Universal bearing puller

07947-KF00100 07631-0010000
TROUBLESHOOTING
Abnormal noise
• Worn crankshaft bearing
• Worn connecting rod big end bearing
• Worn connecting rod small end (page 10-10)

CRANKCASE SEPARATION
Refer to service information (page 13-3) for the parts
which must be removed before separating the
crankcase.
Unhook the centerstand return spring.
RETURN SPRING
Remove the cotter pin and washer. COTTER PIN
WASHER
Remove the bolt and collar from the pivot shaft.

BOLT COLLAR
Pull out the pivot shaft and remove the centerstand.
PIVOT SHAFT CENTERSTAND
Remove the bolt, set plate, spring and plunger from the
SET PLATE PLUNGER
right crankcase.
BOLT SPRING

13-5
Remove the crankcase bolts from the right crankcase.
BOLTS
Be careful not to Place the crankcase with the left crankcase facing
damage the down and separate the left and right crankcase. RIGHT CRANKCASE
crankcase mating
surface.
Remove the dowel pins from the left crankcase.
DOWEL PINS

Lift the cam chain off the timing sprocket on the
crankshaft as shown, using a screwdriver. SCREWDRIVER
Hold the cam chain off the timing sprocket and remove
the crankshaft from the left crankcase using the case
puller.
Remove the cam chain.
TOOL:
Case puller 07SMC-0010001
CAM CHAIN
CRANKSHAFT
LEFT CRANKCASE CASE PULLER

CASE PULLER
CRANKSHAFT

13-7
Remove the left crankshaft bearing using the special
tool. CRANKSHAFT
TOOL:
Universal bearing puller 07631-0010000
– If the left crankshaft bearing remains in the
crankcase, remove it to the right side.
BEARING
BEARING PULLER
- If the left crankshaft bearing

remains in the crankcase:
LEFT CRANKSHAFT BEARING
Remove the snap ring and oil seal from the left SNAP RING
crankcase.
OIL SEAL
CRANKCASE ASSEMBLY
Be careful not to Clean the insides and mating surface of the
damage the crankcases. MATING SURFACE
crankcase mating Check for cracks or other damage.
surface. Remove any roughness or irregularities with an oil
stone.

ATTACHMENT
Press the left crankcase bearing into the left crankcase
DRIVER
squarely until it is fully seated, using the special tool.
TOOLS:
Driver 07749-0010000
Attachment, 72 x 75 mm 07746-0010600
Pilot, 35 mm 07746-0040800
Apply 2 cc minimum of engine oil to a new left
crankcase bearing.
LEFT CRANKSHAFT
PILOT BEARING BEARING
Inject more than 3 cc of engine oil to the connecting rod
ASSEMBLY COLLAR A ASSEMBLY SHAFT
big end bearing.
ADAPTOR
Install the crankshaft into the left crankcase bearing as
follows:
Install the assembly shaft adaptor to the left crankshaft.
Position the assembly collar A on the left crankcase
bearing inner race and set the assembly collar B to the
assembly collar A.
Install the assembly shaft to the assembly collar B and CONNECTING
screw it onto the crankshaft while aligning the center of ROD
the assembly collar B with the assembly shaft.
• When pulling the crankshaft into the bearing, be
careful not to damage the connecting rod. ASSEMBLY COLLAR B ASSEMBLY SHAFT
Pull the crankshaft into the bearing until it is fully seated ASSEMBLY SHAFT
while positioning the connecting rod in the cylinder
sleeve opening on the left crankcase. ASSEMBLY COLLAR A
TOOLS:
Assembly shaft adaptor 07WMF-KFF0200
Assembly shaft 07965-VM00200
Assembly collar A 07965-VM00100
Assembly collar B 07931-KF00100
ASSEMBLY SHAFT
ADAPTOR
ASSEMBLY COLLAR B
Apply engine oil to the timing sprocket and cam chain.

Install the cam chain to the timing sprocket.
CAM CHAIN
TIMING SPROCKET

13-9
Apply sealant (Three bond 1207B or Three bond 1215
or equivalent) to the right crankcase mating surface.
Apply 2 cc minimum of engine oil to right crankshaft

bearing.
Install the dowel pins to the left crankcase.
DOWEL PINS
Assemble the left and right crankcase.

RIGHT CRANKCASE
Install the crankcase bolts and tighten them in a

crisscross pattern in 2 - 3 steps.
BOLTS

Apply engine oil to a new oil seal lip. FORK SEAL OIL SEAL DRIVER
Install the oil seal to the left crankcase squarely until it is DRIVER
fully seated, using the special tool. ATTACHMENT
TOOLS:
Oil seal driver 07965-KE80200
Fork seal driver attachment, 07947-KF00100
41.2 mm
OIL SEAL
install the snap ring.
SNAP RING
Install the plunger and spring.

PLUNGER SET PLATE
Install the set plate with its OUT mark facing out and
tighten the bolt.
OUT
SPRING BOLT Mark
Apply thin coat of grease to the centerstand pivot shaft BOLT

COLLAR
surface.
Install the centerstand and insert the pivot shaft from PIVOT SHAFT
the left crankcase side.
Install the collar to the pivot shaft.
Install the pivot shaft mounting bolt and tighten it.
CENTERSTAND

13-11
Install the washer and new cotter pin.
COTTER PIN
WASHER
Hook the centerstand return spring.

Refer to service information (page 13-3) for installation
of parts removed to perform crankcase service.
RETURN SPRING
CRANKSHAFT INSPECTION
Remove the crankshaft (page 13-5).
RIGHT CRANKCASE BEARING
Turn the outer race of the right crankshaft bearing with
your finger. The bearing should turn smoothly and
quietly. Also check that the bearing inner race fits tightly
on the right crankshaft.
or if it fits loosely on the right crankshaft.
If the timing Check the oil pump drive gear and timing sprocket teeth
sprocket teeth are for wear or damage. OIL PUMP DRIVE GEAR
worn or damaged,
check the cam
chain, tensioner
and cam sprocket.
TIMING SPROCKET

Measure the connecting rod big end side clearance with
FEELER GAUGE
a feeler gauge.
Set the crankshaft on V-blocks and measure the

connecting rod big end radial clearance.
Set the crankshaft on V-blocks and measure the runout

using a dial indicator.
Actual runout is 1/2 of total indicator reading.
65 mm 35 mm
(2.6 in) (1.4 in)

13-13
MEMO

14. FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION ··························14-2 FORK·························································14-11
SERVICE INFORMATION ···························14-3 HANDLEBAR ············································14-18
TROUBLESHOOTING·································14-6 STEERING STEM······································14-21
FRONT WHEEL···········································14-7
14

14-1
COMPONENT LOCATION
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
Standard type:
4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)
59 N·m (6.0 kgf·m, 44 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft)
64 N·m (6.5 kgf·m, 47 lbf·ft)
30.4 N·m (3.1 kgf·m,

22 lbf·ft)
59 N·m (6.0 kgf·m, 44 lbf·ft)

SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• This section covers the front wheel, fork, handlebar and steering stem.
• When servicing the front wheel, fork or steering stem, support the scooter using a jack or other support.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• After the front wheel installation, check the brake operation by applying the brake lever.
• For brake system service, refer to page 16-3.
SPECIFICATIONS
Unit: mm (in)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (Spoke wheel type) 0 ± 1.0 (0 ± 0.04) –
Fluid level 86.5 (3.41) –
Fluid capacity 62.5 ± 1.5 cm3
–
(2.11 ± 0.05 US oz, 2.20 ± 0.05 Imp oz)
TORQUE VALUES
Front axle nut 59 N·m (6.0 kgf·m, 44 lbf·ft) U-nut
Front brake disc socket bolt 42 N·m (4.3 kgf·m, 31 lbf·ft) ALOC bolt; replace with new ones
Front spoke (Spoke wheel type) 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Handlebar post nut 59 N·m (6.0 kgf·m, 44 lbf·ft)
Rear brake lever pivot screw (Standard 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
type)
Rear brake lever pivot nut (Standard type) 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft) U-nut
Brake caliper mounting bolt 30.4 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt; replace with new ones.
Bottom bridge pinch bolt 64 N·m (6.5 kgf·m, 47 lbf·ft)
Fork pipe seat socket bolt 23 N·m (2.3 kgf·m, 17 lbf·ft) Apply locking agent to the threads
Fork cap bolt 20 N·m (2.0 kgf·m, 15 lbf·ft)
Steering stem top thread – For tightening sequence; See page 14-23
Steering stem lock nut – For tightening sequence; See page 14-23

14-3
TOOLS
Bearing remover shaft Bearing remover head, 12 mm Driver
07746-0050100 07746-0050300 07749-0010000
Spoke wrench, 5.8 x 6.1 mm Attachment, 32 x 35 mm Pilot, 12 mm

07701-0020300 07746-0010100 07746-0040200
Fork seal driver body Fork seal driver attachment, 27.2 mm Pin spanner
07747-0010100 07747-0010300 07702-0020001

Socket wrench Steering stem socket Ball race remover shaft
07916-KM10000 07916-3710101 07GMD-KS40100
Ball race remover, 34.5 mm Bearing driver attachment Attachment, 52 x 55 mm

07948-4630100 07946-3710701 07746-0010400
Fork seal driver attachment, 35.2 mm Oil seal remover

07947-KA20200 07748-0010001

14-5
TROUBLESHOOTING
Hard steering
• Insufficient tire pressure
• Faulty tire
• Steering stem lock nut too tight
• Faulty steering head bearing
• Faulty steering head bearing race
• Bent steering stem
Steers to one side or does not track straight
• Bent front axle
• Wheel installed incorrectly
• Worn or damaged front wheel bearings
• Bent fork
• Worn or damaged engine mounting bushings
• Bent frame
• Faulty steering head bearing
Front wheel wobbles
• Loose front axle fasteners
• Bent rim
• Worn or damaged front wheel bearings
• Loose or distorted spokes (Spoke wheel type)
Front wheel turns hard
• Front brake drag
• Bent front axle
• Faulty front wheel bearings
Soft suspension
• Low tire pressure
• Deteriorated fork fluid
• Incorrect fork fluid weight
• Insufficient fluid in fork
• Weak fork spring
Hard suspension
• High tire pressure
• Too much fluid in fork
• Incorrect fork fluid weight
• Bent fork pipes
• Clogged fork fluid passage
Suspension noisy
• Bent fork slider
• Insufficient fluid in fork
• Loose fork fasteners

FRONT WHEEL
Raise and support the scooter using safety stand.
Remove/install the following:
– Speedometer cable
– O-ring
– Axle nut
– Front axle
– Front wheel
– Side collar
– Speedometer gearbox
TORQUE: AXLE NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
• Replace the speedometer cable O-ring with a new

one.
• Apply grease to the front axle, speedometer gear,
speedometer gearbox seal lip and speedometer
cable O-ring.
• Check the brake operation after installation.
Release the tab while pushing it and

disconnect the speedometer cable. O-RING
FRONT AXLE
Align the speedometer
gearbox groove with the
boss on the fork leg.
*
SPEEDOMETER GEARBOX
AXLE NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
SIDE COLLAR
Align the speedometer tabs with
the wheel hub grooves. FRONT WHEEL
GEARBOX SEAL
*: Shell BEARING GREASE HD or equivalent.

14-7
– Dust seals
– Socket bolts
– Brake disc
– Wheel bearings
– Distance collar
TORQUE: BRAKE DISC SOCKET BOLT
42 N·m (4.3 kgf·m, 31 lbf·ft)
• Replace the brake disk socket bolts, bearings and

dust seals with new ones.
• Apply grease to the dust seal lips, bearing cavities
and distance collar.
Refer to page 14-9 for wheel bearing replacement.
RIGHT WHEEL BEARING (6201U)

DUST SEAL
DUST SEAL
SOCKET BOLTS
42 N·m (4.3 kgf·m, 31 lbf·ft)
Tighten the bolts in a criss-
cross pattern in 2 or 3 steps.
DISTANCE
COLLAR
LEFT WHEEL BEARING (6201U)
BRAKE DISC
Install the brake disc with its
marked side facing up.

BEARING REPLACEMENT
Install the bearing remover head into the bearing.
From the opposite side, install the bearing remover REMOVER HEAD REMOVER SHAFT
shaft and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover shaft 07746-0050100
REMOVER
BEARING HEAD
BEARINGS
REMOVER SHAFT REMOVER HEAD
Pack all bearing cavities with grease.

ATTACHMENT DRIVER
Never install the old Drive in a new left bearing squarely with its sealed side
bearings. Once the facing up until it is fully seated.
bearings have been
removed, the
TOOLS:
bearings must be Driver 07749-0010000
replaced with new Attachment, 32 x 35 mm 07746-0010100
ones. Pilot, 12 mm 07746-0040200
BEARING PILOT
Apply thin coat of grease to the distance collar and

install it. DISTANCE BEARING
COLLAR
Drive in a new right bearing squarely with its sealed
side facing up.
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200

14-9
INSPECTION
AXLE
Place the axle on V-blocks and measure the runout with
a dial indicator.

Actual runout is 1/2 of the total indicator reading.
WHEEL BEARING
Turn the inner race of each bearing with your finger, the
bearing should turn smoothly and quietly.
hub.
Replace the Remove and discard the bearings if the races do not
bearings in pairs. turn smoothly, quietly, or if they fit loosely in the hub.
WHEEL RIM
Check the wheel rim runout by placing the wheel on a
turning stand.
Spin the wheel by hand and read the runout using a dial
indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT:
Axial: 2.0 mm (0.08 in)
Radial: 2.0 mm (0.08 in)

WHEEL CENTER ADJUSTMENT
(SPOKE WHEEL TYPE)
Remove the front wheel (page 14-7).
Place the rim on the work bench.
Adjust the hub position so that the distance from the
right end surface of the hub center to the side of the rim
is 0 ± 1.0 mm (0 ± 0.04 in) as shown.
Tighten the spokes in 2 or 3 progressive steps.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300

Check the rim runout (page 14-10). 0 ± 1.0 mm (0 ± 0.04 in)
BASE POINT
FORK
REMOVAL
– Front fender (page 3-4)
– Front wheel (page 14-7) LOWER
– Front brake caliper (page 16-19) PINCH BOLT
Support the front Remove the bolt and brake hose clamp from the left
brake caliper with a fork leg.
piece of wire so that
Remove the bottom bridge upper pinch bolts.
it does not hang
Loosen the bottom bridge lower pinch bolts and remove
from the front brake
the fork legs.
hose.
Do not twist the
brake hose. INSTALLATION
Install the fork pipe into the steering stem.
Install the bottom bridge upper pinch bolts.
Tighten the bottom bridge pinch bolts to the specified
torque.
Install the brake hose clamp and tighten the bolt. UPPER PINCH
BOLT
– Front wheel (page 14-7) BOLT
– Front fender (page 3-4)
– Front brake caliper (page 16-19) FORK
BRAKE HOSE
CLAMP
DISASSEMBLY
Hold the fork slider in a vice with soft jaws or a shop
towel. FORK SLIDER SOCKET BOLT
Loosen the fork socket bolt but do not remove yet.

14-11
Remove the fork cap bolt and O-ring.
FORK CAP BOLT
Remove the fork spring from the fork pipe.
FORK PIPE
O-RING
SPRING
Pour out the fork fluid by pumping the fork pipe several
times.
Remove the oil seal stopper ring.

STOPPER RING

Remove the socket bolt and sealing washer.
SEALING WASHER
SOCKET BOLT
Remove the fork piston and rebound spring from

the fork pipe. FORK PISTON
REBOUND SPRING
Pull the fork pipe out from the fork slider.

FORK SLIDER
FORK PIPE
Remove the oil seal using the special tool.

OIL SEAL REMOVER
TOOL:
Oil seal remover 07748-0010001 or equivalent
OIL SEAL

14-13
ASSEMBLY
FORK PISTON RING FORK CAP BOLT

FORK PIPE FORK PISTON
20 N·m (2.0 kgf·m, 15 lbf·ft)
DUST SEAL
STOPPER RING
OIL SEAL
FORK SLIDER
O-RING
FORK SPRING
SOCKET BOLT
SEALING WASHER REBOUND SPRING
23 N·m (2.3 kgf·m, 17 lbf·ft)
Before assembly, wash all parts with high flash point or

non-flammable solvent and wipe them dry. FORK SLIDER
Install the fork pipe into the fork slider.
FORK PIPE
Install the fork If removing the fork piston ring from the fork piston,
piston ring with its install a new fork piston ring to the fork piston groove. FORK PISTON
cut-out side facing
down.
Make sure that the Install the rebound spring and fork piston into the fork
fork piston ring is pipe.
seated in the
groove.
REBOUND SPRING

Clean the socket bolt threads and apply locking agent
to the bolt threads.
SEALING WASHER
Install and tighten the socket bolt with a new sealing
washer to the fork piston.
SOCKET BOLT
Apply fork fluid to the lip of a new oil seal.

FORK SEAL
Install the oil seal Drive the oil seal into the fork slider using the special DRIVER
with its marked side tools until it is fully seated.
facing up.
TOOLS:
Fork seal driver body 07747-0010100
Fork seal driver attachment, 07747-0010300
27.2 mm
ATTACHMENT OIL SEAL
Install the oil seal stopper ring into the stopper ring
groove on the fork slider. STOPPER RING DUST SEAL
Apply fork fluid to a new dust seal lip.

Do not tap the dust Install the dust seal until it is fully seated.
seal lip too hard.
Pour the specified amount of recommended fork fluid

into the fork pipe.
FORK FLUID CAPACITY:
62.5 ± 1.5 cm3 (2.11 ± 0.05 US oz, 2.20 ± 0.05 Imp oz)
Pump the fork pipe several times to remove trapped air
from the lower portion of the fork pipe.

14-15
Be sure the oil level Compress the fork leg fully and measure the fluid level
is same in the both from the top of the fork pipe.
forks.
FORK FLUID LEVEL: 86.5 mm (3.41 in)
86.5 mm (3.41 in)
Pull the fork pipe up and install the fork spring with its
FORK CAP BOLT
tightly wound side facing up.
Coat a new O-ring with fork fluid and install it into the O-RING
groove in the fork cap bolt.
Install the fork cap bolt and tighten it to the specified
torque. FORK PIPE

Tightly
wound
side
SPRING
Hold the fork slider in a vise with soft jaws or a shop

towel. FORK SLIDER
Tighten the fork socket bolt to the specified torque.
SOCKET BOLT

INSPECTION
FORK SPRING
Measure the fork spring free length.
SERVICE LIMIT: 301.0 mm (11.85 in) SPRING
FORK PIPE/SLIDER/PISTON
Check the fork pipe, fork slider and fork piston for score
mark, and excessive or abnormal wear. FORK SLIDER
Check the fork piston ring for wear or damage.

Check the rebound spring for fatigue or damage.
Replace the components if necessary.
FORK PIPE
REBOUND FORK
SPRING PISTON
FORK PISTON
RING
Place the fork pipe on V-block and measure the runout.

Actual runout is 1/2 the total indicator reading.

14-17
HANDLEBAR
STANDARD TYPE
Loosen the rear brake cable by turning the adjusting
nut.
– Rear handlebar cover (page 3-8)
– Rear brake lever pivot screw/nut
– Rear brake cable/lever
– Master cylinder/holder/bolts
– Screw/upper throttle housing/lower throttle housing
– Throttle cable/throttle pipe
– Left handlebar grip
– Nut/collars/bolt/handlebar post
TORQUE: HANDLEBAR POST NUT
59 N·m (6.0 kgf·m, 44 lbf·ft) ADJUSTING NUT
REAR BRAKE LEVER PIVOT SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
REAR BRAKE LEVER PIVOT NUT
4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)
• Refer to page 14-20 for handlebar post/handlebar

grip/throttle housing installation.
• Route the wires/cables properly (page 1-14).
• Adjust the rear brake lever freeplay (page 4-17).
• Apply grease to the rear brake lever pivot screw,
rear brake cable and throttle cable sliding surface.
Align the end of master Tighten the upper bolt first,

THROTTLE PIPE cylinder with the punch then the lower bolt.
SCREW mark on handlebar.
UPPER HOUSING BOLTS
HOLDER
PIVOT SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft) Set the holder with its
"UP" mark facing up.
PIVOT NUT
MASTER CYLINDER 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)
LOWER HOUSING
REAR BRAKE LEVER
THROTTLE CABLE
REAR BRAKE CABLE
NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
BOLT COLLAR COLLAR

CBS TYPE
Loosen the rear brake cable by turning the adjusting
nut.
– Rear handlebar cover (page 3-8)
– Rear brake lever bracket/holder/bolt
– Master cylinder/holder/bolts
– Screw/upper throttle housing/lower throttle housing
– Throttle cable/throttle pipe
– Left handlebar grip
– Nut/collars/bolt/handlebar post
TORQUE: HANDLEBAR POST MOUNTING NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
ADJUSTING NUT
• Refer to page 14-20 for handlebar post/handlebar

grip/throttle housing installation.
• Route the wires/cables properly (page 1-14).
• Apply grease to the throttle cable sliding surface.
Align the end of master

cylinder with the punch Tighten the upper bolt first,
mark on handlebar. then the lower bolt.
THROTTLE PIPE
SCREW
UPPER HOUSING
HOLDER
Set the holder with its
"UP" mark facing up.
BOLTS
HOLDER BOLT
HOLDER
MASTER CYLINDER
LOWER HOUSING
REAR BRAKE LEVER BRACKET

THROTTLE CABLE
NUT
BOLT COLLAR COLLAR 59 N·m (6.0 kgf·m, 44 lbf·ft)

14-19
HANDLEBAR POST INSTALLATION
Install the handlebar post onto the steering stem while
aligning the bolt holes.
BOLT REAR COLLAR
Rear collar is taller Install the front/rear collars, bolt and nut.
than the front collar.
Tighten the nut to the specified torque.
FRONT COLLAR NUT
HANDLEBAR GRIP INSTALLATION

If the handlebar grips were removed, apply Honda
HANDLEBAR GRIP LEFT HANDLEBAR
Bond A or equivalent to the inside of the grip and to the
clean surfaces of the left handlebar.
Wait 3 – 5 minutes and install the grip.
Allow the adhesive Rotate the grip for even application of the adhesive and
to dry for 1 hour align the line of the grip with punch mark on the
before using. handlebar. LINE
PUNCH MARK
THROTTLE HOUSING INSTALLATION

Install the throttle pipe.
Apply grease to the throttle cable sliding area and
connect it to the throttle pipe.
Install the lower throttle housing by aligning the hole on
the handlebar with the locating pin of the lower throttle
housing.
Align
THROTTLE CABLE
Install the upper housing by aligning the groove of the

upper housing and tab of the lower housing. SCREW UPPER HOUSING
Install the screw and tighten it.
LOWER HOUSING

STEERING STEM
REMOVAL
Remove the following: BOLT SPEEDOMETER CABLE
– Fork (page 14-11)
– Handlebar (page 14-18)
Remove the bolt and brake hose clamp.
Release the speedometer cable from the cable guide.
HOSE CLAMP CABLE GUIDE
Hold the top thread using the pin spanner and loosen
the steering stem lock nut using the socket wrench. STEM LOCK NUT SOCKET
WRENCH
TOOLS:
Socket wrench 07916-KM10000
Pin spanner 07702-0020001
Remove the steering stem lock nut.
PIN SPANNER
Be careful not to Hold the steering stem and loosen the top thread using
drop the steering the stem socket. STEM
stem. SOCKET
TOOL:
Steering stem socket 07916-3710101
Remove the top thread while holding the steering stem.
TOP THREAD
Be careful not to • Always replace the steel balls and races as a set.
UPPER INNER STEEL
drop the steering
Remove the upper bearing inner race and the upper RACE BALLS (23)
stem and the upper
steel balls (23 balls) while holding the steering stem.
steel balls.
STEERING STEM

14-21
Be careful not to Remove the steering stem and lower steel balls (29
STEERING STEM
drop the steering balls).
stem and the lower
steel balls.
STEEL
BALLS (29)
• Always replace the steel balls and races as a set.

UPPER
Remove the upper bearing outer race using the OUTER RACE
following tool.
TOOL:
Ball race remover shaft 07GMD-KS40100
BALL RACE
REMOVER SHAFT
Remove the lower bearing outer race using the

BALL RACE
following tools.
REMOVER SHAFT
TOOLS:
Ball race remover, 34.5 mm 07948-4630100
Ball race remover shaft 07GMD-KS40100
BALL RACE LOWER

REMOVER OUTER RACE
Remove the dust seal from the steering stem lower

DUST SEAL LOWER
bearing inner race.
INNER RACE
Remove the lower bearing inner race with a chisel or
equivalent tool being careful not to damage the stem.
Remove the washer from the steering stem.
STEERING STEM WASHER

INSTALLATION
• Always replace the steel balls and races as a set.
TOP THREAD LOCK NUT
LOWER OUTER RACE
UPPER BEARING (23)

UPPER INNER RACE
LOWER BEARING (29)
UPPER OUTER RACE
LOWER INNER RACE
DUST SEAL
WASHER
STEERING STEM
BOLT
FRONT BRAKE grease with extreme pressure agent

HOSE CLAMP (recommended: EXCELIGHT EP2
manufactured by KYODO YUSHI, japan or
Shell ALVANIA EP2 or equivalent)
Install the washer to the steering stem.

Install a new lower bearing inner race using the LOWER INNER RACE
WASHER
following tool and hydraulic press.
TOOL:
Fork seal driver attachment, 07947-KA20200
35.2 mm
FORK SEAL DRIVER

ATTACHMENT

14-23
Apply 3 g of grease with extreme pressure agent
(recommended: EXCELIGHT EP2 manufactured by
KYODO YUSHI, japan or Shell ALVANIA EP2 or
equivalent) to a new dust seal lip then install it to the
lower bearing inner race.
DUST SEAL
Drive a new upper bearing outer race into the head pipe
using the following tools. DRIVER/ATTACHMENT
TOOLS:
Driver 07749-0010000
Bearing driver attachment 07946-3710701
UPPER OUTER RACE
Drive a new lower bearing outer race into the head pipe
using the following tools. LOWER OUTER RACE
TOOLS:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
DRIVER/ATTACHMENT

(recommended: EXCELIGHT EP2 manufactured by STEEL BALLS (29 balls)
equivalent) to the lower bearing races.
Attach new steel balls (29 balls) to the lower bearing
outer race.
Be careful not to Insert the steering stem into the steering head pipe,
drop the steering being careful not to drop the steel balls.
stem and the lower
steel balls.
STEERING STEM

(recommended: EXCELIGHT EP2 manufactured by UPPER INNER RACE
equivalent) to the upper bearing races.
Install new steel balls (23 balls) onto the upper bearing
outer race.
Install a new upper bearing inner race onto the stem. STEEL BALLS
Be careful not to
drop the steering (23 balls)
stem and the upper
steel balls.
Install the top thread.

Hold the steering stem and tighten the stem top thread STEM SOCKET
to the initial torque using the special tool.
TOOL:
Steering stem socket 07916-3710101
TOP THREAD
Turn the steering stem lock-to-lock several times to

seat the bearing.
Completely loosen the top thread.
Tighten the top thread fully by hand while holding the

steering stem, then turn the top thread
counterclockwise about 45 degrees.
TOP THREAD

14-25
Hold the top thread using the pin spanner and tighten
the steering stem lock nut to the specified torque. STEM LOCK NUT
TOOLS:
Socket wrench 07916-KM10000
Pin spanner 07702-0020001

Make sure the steering stem moves smoothly without
play or binding. SOCKET
WRENCH
PIN SPANNER
Install the brake hose clamp and tighten the bolt. BOLT SPEEDOMETER CABLE
Route the speedometer cable through the cable guide.
– Handlebar (page 14-18)
– Fork (page 14-11)
HOSE CLAMP CABLE GUIDE

15. REAR WHEEL/SUSPENSION
COMPONENT LOCATION ··························15-2 REAR WHEEL/SWINGARM ·······················15-5
SERVICE INFORMATION ···························15-3 REAR SHOCK ABSORBER ·······················15-8
TROUBLESHOOTING·································15-4 HANGER LINKAGE ····································15-9
15

15-1
COMPONENT LOCATION
118 N·m (12.0 kgf·m, 87 lbf·ft)
49 N·m (5.0 kgf·m, 36 lbf·ft)

SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
• Use genuine Honda replacement bolts and nut for all suspension pivots and mounting points.
• For brake system service, refer to section 16.
SPECIFICATIONS
Unit: mm (in)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance (Spoke wheel type) 6.5 ± 1.0 (0.26 ± 0.04) –
TORQUE VALUES
Rear axle nut 118 N·m (12.0 kgf·m, 87 lbf·ft) U-nut, Apply engine oil to the threads and
seating surface
Rear spoke (Spoke wheel type) 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
Engine hanger link nut (Engine side) 49 N·m (5.0 kgf·m, 36 lbf·ft)
TOOL
Spoke wrench, 5.8 x 6.1 mm
07701-0020300

15-3
TROUBLESHOOTING
Rear wheel wobbles
• Bent rim
• Faulty tire
• Loose or distorted spokes
• Axle nut and/or engine mounting bolt/nut not tightened properly
• Loose or worn final gear shaft bearing
Soft suspension
• Weak rear shock absorber spring
• Oil leakage from damper unit
• Low tire pressure
Stiff suspension
• Bent damper rod
• High tire pressure
Rear suspension noisy
• Loose mounting fasteners
• Faulty shock absorber
• Weak rear suspension bushings

REAR WHEEL/SWINGARM
REMOVAL
Remove the exhaust pipe/muffler (page 3-19).
LOWER MOUNTING BOLT
Support the scooter on its centerstand and remove the
following:
– Axle nut
– Right rear shock absorber lower mounting bolt
AXLE NUT
Remove the swingarm mounting bolts and swingarm.
MOUNTING BOLTS
SWINGARM
Remove the rear wheel.
REAR WHEEL
INSTALLATION
Be careful not to Install the rear wheel onto the final shaft, aligning the
damage the splines.
splines.
Apply grease to grease groove and bearing fitting area
of the final shaft.
(GROOVE)

15-5
Install the swingarm onto the final shaft.
MOUNTING BOLTS
Install and tighten the swingarm mounting bolts.
SWINGARM
Install and tighten the right rear shock absorber lower

mounting bolt. LOWER MOUNTING BOLT
Apply engine oil to the threads and seating surface of

the rear axle nut.
Install the rear axle nut and tighten it to the specified
torque.
Install the exhaust pipe/muffler (page 3-19).
AXLE NUT
WHEEL INSPECTION
Check the wheel rim runout using dial indicators.
Actual runout is 1/2 the total indicator readings.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
WHEEL CENTER ADJUSTMENT

(SPOKE WHEEL TYPE)
Remove the rear wheel (page 15-5).
Put the rim on the work bench.
Adjust the hub position so that the distance from the left
end surface of the hub center to the side of the rim is
6.5 ± 1.0 mm (0.26 ± 0.04 in) as shown.
Tighten the spokes in 2 or 3 progressive steps.
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300

6.5 ± 1.0 mm
Install the rear wheel (page 15-5). (0.26 ± 0.04 in) BASE POINT
Check the rim runout (page 15-6).

SWINGARM BEARING INSPECTION/
REPLACEMENT
Remove the swingarm (page 15-5).
DUST SEALS
Remove the side collars and dust seals from the
swingarm.
SWINGARM
SIDE COLLARS
Turn the inner race of the bearing with your finger.

The bearing should turn smoothly and quietly.
swingarm.
Replace the bearing if the inner race does not turn
smoothly and quietly, or if the outer race fits loosely.
SWINGARM BEARING
Remove the snap ring.

Drive the bearing out of the swingarm. SNAP RING
BEARING
Drive in new bearing squarely with the marked side

facing up until it is fully seated. DRIVER
TOOL:
Driver 07908-KE90000
Attachment, 42 x 47 mm 07746-0010300 BEARING ATTACHMENT
Pilot, 17 mm 07746-0040400
PILOT

15-7
Install the snap ring into the swingarm groove securely
with the chamfered side facing the bearing. SNAP RING
Apply grease to the new dust seal lips. DUST SEALS

Install each dust seals until they are flush with the
swingarm surfaces.
Install the swingarm (page 15-5).
REAR SHOCK ABSORBER

REMOVAL
SHOCK ABSORBER
– Exhaust pipe/muffler (page 3-19)
To avoid damage to Remove the bolts and rear shock absorber.
the rear shock
absorber mounting
bolt threads, slightly
lift the rear wheel.
BOLTS
INSTALLATION
To avoid damage to Install the rear shock absorber and tighten the bolts.
the rear shock SHOCK ABSORBER
absorber mounting
bolt threads, slightly – Body cover (page 3-14)
lift the rear wheel. – Exhaust pipe/muffler (page 3-19)
BOLTS
INSPECTION
Check the damper unit for leakage or other damage.
BUSHING
Check the shock absorber bushing for wear or damage.
Replace the shock absorber assembly if necessary.
SHOCK ABSORBER

Check the rear shock absorber mount bushings for
wear or damage. REAR SHOCK ABSORBER MOUNT BUSHINGS
HANGER LINKAGE
REMOVAL
Remove the nut and engine hanger link bolt.
Remove the engine hanger link from the engine.
BOLT/NUT ENGINE HANGER LINK
INSTALLATION
Install the engine hanger link onto the engine.
Install the engine hanger link bolt from the left side of
the engine.
Install the engine hanger link nut and tighten it to the
specified torque.
BOLT/NUT ENGINE HANGER LINK
INSPECTION
Check the hanger link bushings and stopper rubber for
wear or damage. HANGER LINK BUSHINGS
STOPPER RUBBER

15-9
Check the engine mount bushings for wear or damage.
ENGINE MOUNT BUSHINGS

16. BRAKE SYSTEM
COMPONENT LOCATION ··························16-2 BRAKE PAD/DISC ······································16-9
SERVICE INFORMATION ···························16-3 BRAKE MASTER CYLINDER···················16-12
TROUBLESHOOTING·································16-5 COMBINED BRAKE EQUALIZER

(CBS TYPE)···············································16-16
REAR DRUM BRAKE ·································16-6
BRAKE CALIPER ·····································16-19
BRAKE FLUID REPLACEMENT/
AIR BLEEDING ···········································16-7
16

16-1
BRAKE SYSTEM
COMPONENT LOCATION
BRAKE SYSTEM
FRONT DISC BRAKE

STANDARD TYPE
34 N·m (3.5 kgf·m, 25 lbf·ft)
30.4 N·m (3.1 kgf·m, 22 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
COMBINED BRAKE SYSTEM (CBS) TYPE
34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft)
30.4 N·m (3.1 kgf·m, 22 lbf·ft)
REAR DRUM BRAKE
118 N·m (12.0 kgf·m, 87 lbf·ft)

BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad and shoe dust, regardless of material composition, could be hazardous to your heal
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts.
Be careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• Check the brake system by applying the brake lever after the air bleeding.
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
fluid, they may not be compatible.
• Always check brake operation before riding the scooter.
SPECIFICATIONS
Unit: mm (in)
Brake lever freeplay 10 – 20 (0.4 – 0.8) –
Brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Warpage – 0.10 (0.004)
Piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Piston O.D. 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)

16-3
BRAKE SYSTEM
TORQUE VALUES
Rear axle nut 118 N·m (12.0 kgf·m, 87 lbf·ft) U-nut, Apply engine oil to the threads
and seating surface
Rear brake arm bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) ALOC bolt; replace with new one.
Brake caliper bleed valve 5.4 N·m (0.6 kgf·m, 4.4 lbf·ft)
Brake master cylinder reservoir cap screw 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
Brake pad pin 18 N·m (1.8 kgf·m, 13 lbf·ft)
Front brake lever pivot bolt 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
(Standard type only)
Front brake lever pivot screw 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
(CBS type only)
Front brake lever pivot nut 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
Front brake light switch screw 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft)
Brake caliper mounting bolt 30.4 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt; replace with new ones.
Rear brake lever pivot screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
(CBS type only)
Rear brake lever pivot nut 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft) U-nut
(CBS type only)
Equalizer rod pivot screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
(CBS type only)
Equalizer rod pivot nut 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft) U-nut
(CBS type only)
Rear brake lever bracket cover screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
(CBS type only)
Rear brake lever bracket cover special screw 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
(CBS type only)
Brake caliper torque pin 22 N·m (2.2 kgf·m, 16 lbf·ft)
Brake caliper pin 18 N·m (1.8 kgf·m, 13 lbf·ft)
Equalizer connecting cable lock nut 6.4 N·m (0.7 kgf·m, 4.7 lbf·ft)
(CBS type only)
TOOL
Snap ring pliers
07914-SA50001

BRAKE SYSTEM
TROUBLESHOOTING
Poor rear brake performance
• Incorrect adjustment of rear brake lever
• Contaminated brake shoes
• Worn brake shoes
• Worn brake cam
• Worn brake drum
• Improperly installed brake arm
• Improperly engaged brake arm serrations
Brake lever soft or spongy
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pad/disc
• Worn caliper piston seals
• Worn master cylinder piston cups
• Worn brake pad/disc
• Contaminated caliper
• Contaminated master cylinder
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Bent brake lever
Brake lever hard
• Clogged/restricted brake system
• Sticking/worn caliper piston
• Worn caliper piston seal
• Sticking/worn master cylinder piston
• Bent brake lever
Brake drags
• Contaminated brake pad/disc
• Misaligned wheel
• Badly worn brake pad/disc
• Warped/deformed brake disc
• Clogged/restricted fluid passage
• Sticking caliper piston
• Improperly adjusted connecting cable (CBS type only)

16-5
BRAKE SYSTEM
REAR DRUM BRAKE
• Always replace the brake shoes as a set.
• Mark all parts during disassembly so they can be
placed back in the original locations.
Remove the rear wheel (page 15-5).
Remove the adjusting nut and brake cable from the joint
pin.
Remove the joint pin and return spring.
Expand the brake shoes and remove the brake shoes/
shoe springs from the brake panel.
– Brake arm bolt
– Brake arm/brake cam
– Dust seals
removal.
TORQUE: BRAKE ARM BOLT
10 N·m (1.0 kgf·m, 7 lbf·ft)
• Apply grease to the new dust seals, brake cam
sliding surface and brake shoe contacting area.
• Replace the dust seals and brake arm bolt with new
ones.
*: Apply each 0.2 - 0.3 g of grease.

DUST SEALS
Align *
BRAKE CAM BRAKE SHOES
BRAKE ARM
BRAKE ARM BOLT

10 N·m (1.0 kgf·m, 7 lbf·ft)
ADJUSTING NUT
SHOE SPRINGS
JOINT PIN
Set the return spring ends into the hole

on the left crankcase and onto the pin
RETURN SPRING on the brake arm.

BRAKE SYSTEM
INSPECTION
Measure the rear brake drum I.D.
BRAKE FLUID REPLACEMENT/

AIR BLEEDING
BRAKE FLUID DRAINING
• Do not mix different types of fluid, as they are not
compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
Spilled fluid can damage painted, plastic or rubber

parts. Place a rag over these parts whenever the
system is serviced.
Turn the handlebar until the reservoir is parallel to the
ground before removing the reservoir cap. RESERVOIR CAP SCREWS
Remove the screws, reservoir cap, diaphragm plate
and diaphragm.
DIAPHRAGM
PLATE
DIAPHRAGM
Connect a bleed hose to the caliper bleed valve.

BLEED VALVE BLEED HOSE
Loosen the bleed valve and pump the brake lever until
no more fluid flows out of the bleed valve.

16-7
BRAKE SYSTEM
BRAKE FLUID FILLING/AIR BLEEDING
Do not mix different Fill the master cylinder reservoir with DOT 3 or DOT 4
UPPER LEVEL
types of fluid. They brake fluid from the sealed container to the upper level.
are not compatible.
• Check the fluid level often while bleeding the brake
to prevent air from being pumped into the system.
Connect a commercially available brake bleeder to the

bleed valve. BLEED VALVE
Operate the brake bleeder and loosen the bleed valve.

If air enters the
bleeder from
around the bleed
valve threads, seal
the threads with
teflon tape.
Check the fluid level
often while bleeding
the brake to prevent
air from being
pumped into the
system.
If the brake bleeder is not available, perform the
following procedure.
Pump up the system pressure with the brake lever until
the lever resistance is felt.
Check the fluid Connect a bleed hose to the bleed valve and bleed the
BLEED VALVE BLEED HOSE
level often while system as follows:
bleeding the brake
1. Squeeze the brake lever all the way and loosen the
to prevent air from
bleed valve 1/2 of a turn. Wait several seconds and
being pumped into
then close the bleed valve.
the system.
2. Release the brake lever slowly and wait several
Do not release the
seconds after it reaches the end of its travel.
brake lever until the
3. Repeat the steps 1 and 2 until there are no air
bleed valve has
bubbles in the bleed hose.
been closed.
After bleeding the system completely, tighten the bleed
valve to the specified torque.

BRAKE SYSTEM
Do not mix different Fill the reservoir to the upper level with DOT 3 or DOT 4
UPPER LEVEL
types of fluid. They brake fluid from a sealed container.
are not compatible.
Install the diaphragm, diaphragm plate and reservoir

RESERVOIR CAP
cap, then tighten the screws to the specified torque. SCREWS
DIAPHRAGM
PLATE DIAPHRAGM
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Check the brake Push the caliper pistons all the way in to allow
fluid level in the installation of new brake pads.
reservoir as this
operation causes
the level to rise.
BRAKE CALIPER
Remove the pad pin from the brake caliper.

Remove the O-ring from the pad pin.
PAD PIN / O-RING

16-9
BRAKE SYSTEM
Remove the brake pads from the brake caliper.
BRAKE
PADS
Always replace the Install new brake pads so that they are set on the brake
Set the pads BRACKET PIN
brake pads in pairs caliper bracket and bracket pin.
to assure even disc
pressure.
BRAKE
PADS
Apply silicon grease to the new O-ring and install it to

the pad pin.
Install the pad pin by pushing the brake pads against O-RING
the pad spring to align the pad pin holes on the pads
and caliper hole.
PAD PIN
After the brake pad Tighten the pad pin to the specified torque.
replacement, check
the brake operation TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)
by applying the
brake lever.
PAD PIN

BRAKE SYSTEM
BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or cracks.
Measure the brake disc thickness at several points.
Check the brake disc for warpage.

If the warpage exceeds the service limit, check the
wheel bearings for excessive play.
For brake disc replacement, refer to page 14-8.

16-11
BRAKE SYSTEM
BRAKE MASTER CYLINDER
STANDARD TYPE
Drain the brake fluid (page 16-7).
Remove the rear handlebar cover (page 3-8).
Disconnect the front brake light switch wire (Green/
Yellow, Black) connectors.
Remove the oil bolt, brake hose and sealing washers.
removal.
TORQUE: OIL BOLT
34 N·m (3.5 kgf·m, 25 lbf·ft)
• Replace the sealing washers with new ones.
• Fill and air bleed the hydraulic system (page 16-7).
SCREW BOLTS
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Align the end of master
HOLDER cylinder with the punch
mark on handlebar.
RESERVOIR CAP
Tighten the upper
bolt first, then the
lower bolt.
DIAPHRAGM PLATE
Set the holder with

DIAPHRAGM its "UP" mark facing
up.
SEALING WASHERS
MASTER CYLINDER
WIRE (Green/Yellow, Black) OIL BOLT

CONNECTORS 34 N·m (3.5 kgf·m, 25 lbf·ft) Set the brake hose
eyelet against the
BRAKE HOSE
stopper.
CBS TYPE
Drain the brake fluid (page 16-7).
Loosen the rear brake adjusting nut until the play of the
brake cable becomes maximum.
ADJUSTING NUT

BRAKE SYSTEM
Loosen the lock nut and turn the adjuster until the play
LOCK NUT
of the connecting cable becomes maximum.
CONNECTING
Compress the return spring and disconnect the tip of CABLE
the connecting cable from the knocker joint.
Remove the return spring.
Remove the connecting cable.
Remove the master cylinder (page 16-12).
KNOCKER RETURN
JOINT SPRING ADJUSTER
Install the master cylinder (page 16-12).

INSPECTION
Install the connecting cable to the master cylinder. POINT
Turn in the adjuster completely.
Set the return spring on the connecting cable.
Compress the return spring and connect the tip of the
connecting cable to the knocker joint.
Fill and air bleed the hydraulic system (page 16-7).
Turn the adjuster until the edge surface of the knocker
seats on the edge surface of the master cylinder body.
KNOCKER
RETURN CONNECTING
SPRING ADJUSTER CABLE
Check that there is no gap between the knocker pin and

LOCK NUT ADJUSTER
the end of the slot of the knocker joint.
If there is any gap, turn the adjuster until there is no gap
knocker joint.
After adjustment, hold the adjuster and tighten the lock
nut to the specified torque.
After tightening the lock nut, check that there is no gap KNOCKER PIN
knocker joint.
Apply rear brake lever several times and check that the KNOCKER JOINT
distance between the edges has not been changed
after applying the brake.
Recheck the edge surface of the knocker seats on the
INSPECTION
edge surface of the master cylinder body.
POINT
Adjust the rear brake lever freeplay (page 4-17).
Install the rear handlebar cover (page 3-8).
KNOCKER

16-13
BRAKE SYSTEM
STANDARD TYPE
SNAP RING PLIERS
– Brake lever pivot nut, bolt and brake lever
– Screw and brake light switch
– Boot
Remove/install the snap ring using the special tool.
TOOL:
Snap ring pliers 07914-SA50001
Remove/install the washer, master piston and spring.
TORQUE: FRONT BRAKE LEVER PIVOT BOLT
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
FRONT BRAKE LEVER PIVOT NUT
6 N·m (0.6 kgf·m, 4.4 lbf·ft) SNAP RING
FRONT BRAKE LIGHT SWITCH SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
• Keep the piston, cups, spring, snap ring and boot as
a set; do not substitute individual parts.
• When installing the cups, do not allow the lips to turn
inside out.
• Be sure that snap ring is firmly seated in the groove.
• Apply silicone grease to the pivot bolt sliding
surface, boots inside and lever to piston contact
area.
• Apply brake fluid to master piston, piston cups and
spring.
(Lever contact area) PIVOT BOLT

SPRING
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
BOOT
MASTER
WASHER PISTON CUPS CYLINDER BODY
SNAP RING
MASTER PISTON
BRAKE LIGHT
BRAKE LEVER
SWITCH
*: Apply 0.1 g of silicone grease

PIVOT NUT SCREW
6 N·m (0.6 kgf·m, 4.4 lbf·ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft)

BRAKE SYSTEM
CBS TYPE
– Brake lever pivot nut/screw/brake lever/knocker/
return spring/spring
– Screw and brake light switch
– Boot
Remove/install the snap ring using the snap ring pliers
(page 16-14).
Remove/install the washer, master piston and spring.
TORQUE: FRONT BRAKE LEVER PIVOT SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
FRONT BRAKE LEVER PIVOT NUT
6 N·m (0.6 kgf·m, 4.4 lbf·ft)
FRONT BRAKE LIGHT SWITCH SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
• Keep the piston, cups, spring, snap ring and boot as
a set; do not substitute individual parts.
• When installing the cups, do not allow the lips to turn
inside out.
• Be sure that snap ring is firmly seated in the groove.
• Apply silicone grease to the pivot screw sliding
surface, boots inside and lever to piston contact
area.
• Apply brake fluid to master piston, piston cups and
spring.
WASHER PISTON CUPS

SNAP RING
BOOT SPRING PIVOT SCREW

1 N·m (0.1 kgf·m, 0.7 lbf·ft)
*
(Lever contact area)
MASTER
MASTER PISTON CYLINDER BODY
BRAKE LIGHT
SWITCH
SPRING
BRAKE LEVER
RETURN
SPRING
PIVOT NUT SCREW

*: Apply 0.1 g of silicone grease KNOCKER
6 N·m (0.6 kgf·m, 4.4 lbf·ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
INSPECTION
Check the piston cups for wear, deterioration or
damage.
Check the master cylinder inner surface and piston
outer surface for scratches or damage.
Measure the master cylinder I.D.
Measure the master piston O.D.

16-15
BRAKE SYSTEM
COMBINED BRAKE EQUALIZER
(CBS TYPE)
Disconnect the connecting cable (page 16-12).
– Special screw/set rubber
– Screws/bracket cover
Be careful when – Lock lever/return spring
removing the lock – Bolt/holder/lever bracket
lever. The return – Brake lever pivot screw/nut
spring may pop out. – Equalizer rod pivot screw/nut
– Brake lever
– Brake cable/connecting cable
– Brake light switch/grommet
TORQUE: BRACKET COVER SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
BRACKET COVER SPECIAL SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
REAR BRAKE LEVER PIVOT SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
REAR BRAKE LEVER PIVOT NUT
5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
EQUALIZER ROD PIVOT SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
EQUALIZER ROD PIVOT NUT
5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
• Apply grease to the pivot screws and equalizer sliding surface.
BRAKE LEVER PIVOT SCREW BOLT

4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) HOLDER
BRAKE LIGHT SWITCH

EQUALIZER ROD PIVOT SCREW
BRAKE LEVER BRACKET 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
BRAKE CABLE
EQUALIZER
BRAKE LEVER
CONNECTING CABLE
PIVOT NUTS
BOOT GROMMET 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
Install the spring as shown:

SET RUBBER
RETURN
SPRING
BRACKET
SPECIAL SCREW COVER
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) LOCK LEVER
SCREWS
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)

BRAKE SYSTEM
Install the rear brake light switch while aligning its tab
WIRE CONNECTORS
with the groove on rear brake lever bracket.
Connect the brake light switch wire connectors.
Align
Apply grease to the sliding surface of the equalizer. EQUALIZER

BRAKE
Install the boot grommet over the equalizer. CABLE
Connect the rear brake cable to the equalizer with the
"F" mark of the equalizer facing up and set the rear
brake cable to the rear brake lever bracket.
Connect the connecting cable to the equalizer and set
the connecting cable to the rear brake lever bracket.
Install the equalizer boots grommet to the rear brake
lever bracket.
BOOT
CONNECTING CABLE "F" MARK GROMMET
Set the rear brake lever to the rear brake lever bracket EQUALIZER ROD
and the equalizer. PIVOT SCREW
Apply grease to the sliding surface of the rear brake BRAKE LEVER
lever pivot screw. PIVOT SCREW
Install and tighten the pivot screw to the specified
torque.
Apply grease to the sliding surface of the equalizer rod
pivot screw.
Install and tighten the pivot screw to the specified
torque.
NUTS BRAKE LEVER
Install and tighten the brake lever pivot nut to the
specified torque while holding the pivot screw.
Install and tighten the equalizer rod pivot nut to the
specified torque while holding the pivot screw.
Align the boss of the rear brake lever bracket with the Align (Boss and hole) BRACKET HOLDER
hole of the handlebar and install the rear brake lever
bracket.
Install the bracket holder onto the handlebar by aligning
the groove of the holder and tab of the lever bracket.
Align
(Tab and hole)

16-17
BRAKE SYSTEM
Install and tighten the holder bolt.
HOLDER BOLT
Set the return spring to the rear brake lock lever.

Install the rear brake lock lever to the rear brake lever RETURN SPRING
bracket and make sure that the return spring is set in
position as shown.
LOCK LEVER
Set the bracket cover to the rear brake lever bracket

BRACKET COVER LOCK LEVER
while holding the rear brake lock lever.
Tighten the bracket cover screws to the specified
torque.
SCREWS
Install the set rubber to the rear brake lock lever and
SET RUBBER SPECIAL SCREW
tighten the bracket cover special screw to the specified
torque.

Check the brake lock lever operation (page 4-20).
Connect the connecting cable (page 16-12).
Install the front handlebar cover (page 3-8).

BRAKE SYSTEM
BRAKE CALIPER
REMOVAL
Avoid spilling fluid Drain the brake fluid (page 16-7).
on painted, plastic,
or rubber parts.
Place a shop towel – Oil bolt/sealing washers
over these parts – Brake pads (page 16-9)
whenever the – Mounting bolts
system is serviced. – Brake caliper
INSTALLATION
Install the front brake caliper onto the left fork leg.
Install new mounting bolts and tighten them to the
specified torque.
Connect the brake hose to the brake caliper with the oil
bolt and new sealing washers.
Tighten the oil bolt Tighten the oil bolt to the specified torque.
while pushing the
brake hose eyelet
joint against the Install the brake pads (page 16-9).
stopper. Fill the brake fluid and bleed the hydraulic system (page
16-7).
BRAKE HOSE
OIL BOLT
34 N·m (3.5 kgf·m, 25 lbf·ft)
SEALING WASHERS
BRAKE CALIPER
BRAKE CALIPER MOUNTING BOLTS
30.4 N·m (3.1 kgf·m, 22 lbf·ft)

16-19
BRAKE SYSTEM
– Caliper bracket
– Pin boots
– Pad spring
Place a shop towel over the piston.
Do not use high Position the caliper body with the piston facing down
pressure air or bring and apply small squirts of air pressure to the fluid inlet
the nozzle too close to remove the piston.
to the inlet.
Remove the dust seal/piston seal.
removal.
• Apply silicone grease to the dust seal and bracket
pin boots.
• Apply brake fluid to the piston and piston seal.
• Replace the dust seal and piston seal with new ones.
DUST SEAL PAD SPRING

*
BRACKET PIN BOOT

CALIPER BRACKET
BLEED VALVE
5.4 N·m (0.6 kgf·m, 4.4 lbf·ft)
PISTON SEAL
CALIPER BODY
CALIPER PISTON
Install the caliper piston with
its opened end facing the
brake pads. * *: Apply 0.4 g minimum of silicone grease
BRACKET PIN BOOT
INSPECTION
Check the caliper cylinder for scoring, scratches or
damage.
Measure the caliper cylinder I.D.
Check the caliper piston for scoring, scratches or
damage.
Measure the caliper piston O.D.

17. BATTERY/CHARGING SYSTEM/ALTERNATOR
SYSTEM LOCATION···································17-2 FLYWHEEL/ALTERNATOR STATOR········17-7
SYSTEM DIAGRAM ····································17-2 ALTERNATOR INSPECTION ···················17-11
COMPONENT LOCATION ··························17-3 BATTERY ··················································17-11
SERVICE INFORMATION ···························17-4 CHARGING SYSTEM ·······························17-12
TROUBLESHOOTING·································17-6 REGULATOR/RECTIFIER ························17-13
RIGHT SIDE COVER···································17-7
17

17-1
SYSTEM LOCATION
BATTERY
REGULATOR/RECTIFIER
ALTERNATOR
SYSTEM DIAGRAM
G: Green
R: Red
W: White
MAIN FUSE 15 A
ALTERNATOR
BATTERY REGULATOR/
RECTIFIER

COMPONENT LOCATION
10 N·m (1.0 kgf·m, 7 lbf·ft)
59 N·m (6.0 kgf·m, 44 lbf·ft)

17-3
SERVICE INFORMATION
GENERAL
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charg-
ing.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
– If electrolyte gets on your skin, flush with water.
– If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
– If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physician imme-
diately.
• Always turn off the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• This model comes with a maintenance free (MF) battery. Remember the following about MF batteries.
– Use only the electrolyte that comes with the battery.
– Use all of the electrolyte.
– Seal the battery properly.
– Never open the seals after installation.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every two weeks.
• For a battery remaining in a stored scooter, disconnect the negative battery cable from the battery terminal.
• The maintenance free battery must be replaced when it reaches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions
contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2-
3 years.
• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out.
For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the
battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does
not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes
down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the scooter.
• The battery will self-discharge when the scooter is not in use. For this reason, charge the battery every two weeks to prevent
sulfation from occurring.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-6).
• For battery charging, do not exceed the charging current and time specified on the battery. Use of excessive current or charging
time may damage the battery.
• The flywheel, alternator and ignition pulse generator services can be done with the engine installed in the frame.
• Refer to page 18-6 for CKP sensor inspection.
BATTERY CHARGING
• Turn the power ON/OFF at the charger, not at the battery terminal.
• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending
the charging time may damage the battery.
• Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instruction of the Operation Manual for the recommended battery tester for details about battery testing.
The recommended battery tester puts a "load" on the battery so that the actual battery condition of the load can be measured.
Recommended battery tester: BM-210 or BATTERY MATE or equivalent

SPECIFICATIONS
ITEM SPECIFICATIONS
TORQUE VALUES
Flywheel nut 59 N·m (6.0 kgf·m, 44 lbf·ft)
Stator mounting socket bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
TOOLS
Universal Holder Flywheel puller
07725-0030000 07733-0010000

17-5
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. Battery Test
Remove the battery (page 17-11).
Check the battery condition using the recommended battery tester.
RECOMMENDED BATTERY TESTER:BM-210 or BATTERY MATE or equivalent
Is the battery in good condition?
NO – Faulty battery
2. Current Leakage Test
Install the battery (page 17-11).
Check the battery current leakage (page 17-12).
Is the current leakage below 0.1 mA?
3. Current Leakage Test Without Regulator/rectifier
Disconnect the regulator/rectifier connector and recheck the battery current leakage.
Is the current leakage below 0.1 mA?
YES – Faulty regulator/rectifier
NO – • Shorted wire harness
• Faulty ignition switch
4. Alternator Charging Coil Inspection
Check the alternator charging coil (page 17-11).
Is the alternator charging coil resistance within 0.2 – 1.0 ǡ (20°C/68°F)?
NO – Faulty charging coil
5. Charging Voltage Inspection
Measure and record the battery voltage using a digital multimeter (page 17-12).
Start the engine.
Measure the charging voltage (page 17-13).
Compare the measurements to result of the following calculation.
STANDARD:Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage (page 17-12)
• CV = Charging Voltage
Is the measured charging voltage within the standard voltage?
YES – Faulty battery
6. Regulator/rectifier System Inspection
Check the voltage and resistance at the regulator/rectifier connectors (page 17-13).
Are the results of checked voltage and resistance correct?
YES – Faulty regulator/rectifier
NO – • Open circuit in related wire
• Loose or poor contacts of related terminal
• Shorted wire harness

RIGHT SIDE COVER
Remove the cooling fan (page 7-10). RIGHT SIDE COVER BOLTS
Remove the mounting bolts and right side cover.
Remove the two dowel pins.

DOWEL PINS
FLYWHEEL/ALTERNATOR STATOR
REMOVAL
UNIVERSAL HOLDER NUT/WASHER
– Right main pipe side cover (page 3-16)
– Right side cover (page 17-7)
Hold the flywheel with the special tool and loosen the
flywheel nut.
TOOL:
Remove the flywheel nut and washer.
Remove the flywheel using the special tool.

FLYWHEEL
TOOL:
Flywheel puller 07733-0010000
FLYWHEEL PULLER

17-7
Disconnect the alternator/CKP sensor 3P connector.
ALTERNATOR/CKP SENSOR
Release the alternator/CKP sensor wire from the wire 3P CONNECTOR
band and guide.
WIRE GUIDE
WIRE BAND
Remove the wire band bosses.

ALTERNATOR/CKP
SENSOR WIRE
WIRE BAND BOSSES
Remove the bolt, wire holder and release the wire

WIRE HOLDER GROMMET
grommet from the right crankcase.
Remove the two bolts and set plate from the CKP
sensor.
SET PLATE
BOLT
BOLTS CKP SENSOR
Remove the three mounting socket bolts, stator and

STATOR
CKP sensor from the stator base.
SOCKET
BOLTS

Be careful not to Remove the woodruff key.
WOODRUFF KEY
damage the key
and groove.
INSTALLATION
Be careful not to Install the woodruff key into the crankshaft key groove.
WOODRUFF KEY
damage the key
Clean any oil and grease from the crankshaft.
and groove.
Set the stator onto the stator base.

STATOR
Install and tighten the stator mounting socket bolts to
the specified torque.
SOCKET
BOLTS
Install the set plate onto the CKP sensor and tighten the
WIRE HOLDER GROMMET
mounting bolts
Route the wire properly and set the wire grommet into
the right crankcase groove.
Set the wire holder and tighten the holder bolt.
SET PLATE
BOLT
BOLTS CKP SENSOR

17-9
Route the Install the wire band bosses.
alternator/CKP ALTERNATOR/CKP
sensor wire SENSOR WIRE
properly
(page 1-14).
WIRE BAND BOSSES
Secure the alternator/CKP sensor wire with the wire

guide and band.
3P CONNECTOR
Connect the alternator/CKP sensor 3P connector.
WIRE GUIDE
WIRE BAND
Install the flywheel onto the crankshaft by aligning the Align (WOODRUFF KEY/KEY WAY)
key way on the flywheel with the key on the crankshaft.
FLYWHEEL
Install the flywheel onto the crankshaft by aligning the

key way on the flywheel with the key on the crankshaft.
WASHER

Install the flywheel nut.
NUT
Hold the flywheel with the special tool and tighten the
nut to the specified torque.
TOOL:

– Right side cover (page 17-7)
– Radiator (page 7-10)
UNIVERSAL
– Right main pipe side cover (page 3-16)
HOLDER
ALTERNATOR INSPECTION
Remove the front lower cover (page 3-17).
Disconnect the alternator/CKP sensor 3P connector.
Check the resistance between the following terminals.
STANDARD:
Charging coil (White – ground):
0.2 – 1.0 ǡ (at 20°C/68°F)
Replace the alternator stator if measured readings are
far beyond the standard.
3P CONNECTOR
BATTERY
• Always turn the ignition switch "OFF" before

POSITIVE (+) CABLE
removing the battery.
BATTERY
Remove the front top cover (page 3-4). BOLTS
Remove the bolts and holder.
Remove the bolt and disconnect the negative (–) cable.
Remove the bolt and disconnect the positive (+) cable.
Remove the battery.
Connect the Install the battery in the reverse order of removal.
positive terminal
Reinstall the removed parts.
first and then the
negative terminal.
NEGATIVE (–) CABLE HOLDER

17-11
VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (20°C/68°F):
Fully charged: 13.0 – 13.2 V
Under charged: Below 12.4 V
• When measuring the battery voltage after charging,

leave it for least 30 minutes, or the accurate results
cannot be obtained because the battery voltage
fluctuates just after charging.
BATTERY TESTING
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery tester BM-210, BATTERY
MATE or equiva-
lent
CHARGING SYSTEM
CURRENT LEAKAGE TEST
Remove the front top cover (page 3-4).
(–) PROBE (+) PROBE
Turn the ignition switch to OFF and disconnect the
negative (–) cable from the battery.
Connect the ammeter (+) probe to the negative (–)
cable and the ammeter (–) probe to the battery (–)
terminal.
With the ignition switch turned to OFF, check for current
leakage.
• When measuring current using a tester, set it to a

high range, and then bring the range down to an
appropriate level. Current flow higher than the range
selected may blow the fuse in the tester. (–) CABLE
• While measuring current, do not turn the ignition
switch ON, A sudden surge of current may blow the
fuse in the tester.
SPECIFIED CURRENT LEAK-0.1 mA max.

AGE:
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the current.

CHARGING VOLTAGE INSPECTION
• Make sure the battery is in good condition before

performing this test.
• Do not disconnect the battery or any cable in the
charging system without first switching the ignition
switch to OFF. Failure to follow this precaution can
damage the tester or electrical components.
Warm up the engine to normal operating temperature.
Stop the engine.
To prevent a short, Remove the front top cover (page 3-4) and connect the
make absolutely multimeter as shown.
certain which are
Connect a tachometer.
the positive and
negative terminals With the headlight on high beam, restart the engine.
or cables. Measure the voltage on the multimeter when the engine
runs at 5,000 min-1 (rpm).
STANDARD:
Measured BV < Measured CV < 15.5 V
• BV = Battery Voltage (page 17-12)
• CV = Charging Voltage
REGULATOR/RECTIFIER
Remove the fuel lid/center cover (page 3-18).
REGULATOR/
Turn the ignition switch to OFF. RECTIFIER BOLTS
Disconnect the regulator/rectifier 6P (White) connector.
Remove the bolts and the regulator/rectifier.
6P (White) CONNECTOR
SYSTEM INSPECTION
Disconnect the regulator/rectifier 6P (White) connector
and check it for loose contact or corroded terminals.
If the battery charging voltage reading (page 17-13) is
out of the specification, inspect the connector terminals
(wire harness side) as follows:
Item Terminal Specification
Battery charging Red/white (+) and Battery voltage
line ground (–) should register
Charging coil White and 0.2 – 1.0 Ω
line ground (at 20° C/68° F)
REGULATOR/RECTIFIER
Ground line Green and ground Continuity should
exist

17-13
If all components of the charging system are normal
and there are no loose connections, replace the
regulator/rectifier unit.
R R/W W G W
REGULATOR/RECTIFIER
R R/W W G W
REGULATOR/RECTIFIER
R R/W W G W
REGULATOR/RECTIFIER

18. IGNITION SYSTEM
SYSTEM LOCATION···································18-2 IGNITION SYSTEM INSPECTION ··············18-5
SYSTEM DIAGRAM ····································18-2 IGNITION COIL ···········································18-7
SERVICE INFORMATION ···························18-3 IGNITION TIMING ·······································18-8
TROUBLESHOOTING·································18-4 SIDESTAND SWITCH ·································18-8
18

18-1
IGNITION SYSTEM
SYSTEM LOCATION
IGNITION SYSTEM
IGNITION SWITCH
SIDESTAND
SWITCH
IGNITION COIL
CKP SENSOR
SPARK PLUG ENGINE CONTROL
MODULE (ECM)
SYSTEM DIAGRAM
Bl: Black
Y: Yellow
Bu: Blue
G: Green
MAIN FUSE R: Red
15 A IGNITION SWITCH
W: White
Bl
G R
G/R Bl
BATTERY IGNITION
CKP SENSOR COIL
Bl G/W G/Bl G/W
Bu/Y
G R/W R/Bl W G/R G G/Bl G G
W/Y
REGULATOR/ ECM
ALTERNATOR
RECTIFIER SPARK
PLUG
SIDESTAND
SWITCH

IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
• The ECM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may
damage the ECM. Always turn the ignition switch OFF before servicing.
• Use spark plug with the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is turned ON and current is present.
• When servicing the ignition system, always follow the steps in the troubleshooting (page 18-4).
• The ignition timing cannot be adjusted since the ECM is factory preset.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
• Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking
speed as well as no spark at the spark plug.
• Inspect the following:
– Spark plug (page 4-7)
– Ignition switch (page 20-14)
• Refer to CKP sensor service (page 17-7).
SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug CPR 7EA – 9 (NGK), U22EPR9 (ND)
Ignition timing 10° BTDC at idle speed
TOOLS
Imrie diagnostic tester (model 625) Test probe
Peak voltage adaptor 07ZAJ-RDJA110
07HGJ-0020100
with commercially available digital mul-

timeter (impedance 10 MΩ/DCV mini-
mum)

18-3
IGNITION SYSTEM
TROUBLESHOOTING
• Inspect the following before diagnosing the system.
– Faulty spark plug
– Loose spark plug cap or spark plug wire connection
– Water in the spark plug cap (Leaking the ignition coil secondary voltage)
• “Initial voltage” of the ignition primary coil is the battery voltage with the ignition switch turned ON. (The engine is not cranked by
the starter motor.)
No spark at spark plug
UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order)
Ignition coil pri- No initial voltage with the ignition 1. An open circuit or loose connection in black wire.
mary voltage switch turned ON. (Other electrical 2. Loose or poor connection of the ignition coil primary wire ter-
components are normal) minal or an open circuit in primary coil.
3. Faulty ECM (in case when the initial voltage is normal when
ECM 33P (Black) connector is disconnected).
Initial voltage is normal, but it drops 1. Incorrect peak voltage adaptor connections. (System is nor-
by 2 – 4 V while cranking the engine. mal if measured voltage is over the specifications with reverse
connections.)
2. Battery is undercharged. (Voltage drops largely when the en-
gine is started.)
3. Loose or poor connection or an open circuit in Green wire of
the ECM.
4. Loose or poor connection or an open circuit in Green/Red wire
between the ignition coil and ECM.
5. A short circuit in the ignition primary coil.
6. Faulty CKP sensor. (Measure peak voltage.)
7. Faulty ECM (in case when above No. 1 through 6 are normal).
Initial voltage is normal but there is 1. Incorrect peak voltage adaptor connections. (System is nor-
no peak voltage while cranking the mal if measured voltage is over the specifications with reverse
engine. connections.)
2. Open circuit or poor connection in Green/white wire or Green
wire of the sidestand switch.
3. Faulty sidestand switch.
4. Faulty peak voltage adaptor.
5. Faulty ECM (in case when above No. 1 and 4 are normal).
Initial voltage is normal but peak volt- 1. The multimeter impedance is too low; below 10 MΩ/DCV.
age is lower than the standard value. 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling timing of the tester and measured pulse were
not synchronized. (System is normal if measured voltage is
over the standard voltage at least once.)
4. Faulty ECM (in case when above No. 1 through 3 are normal).
Initial and peak voltages are normal 1. Faulty spark plug or leaking ignition coil secondary current.
but no spark jumps. 2. Faulty ignition coil.
CKP sensor Peak voltage is lower than the stan- 1. The multimeter impedance is too low; below 10 MΩ/DCV.
dard value. 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling timing of the tester and measured pulse were
not synchronized. (System is normal if measured voltage is
over the standard voltage at least once.)
4. Faulty CKP sensor (in case when above No. 1 through 3 are
normal).
No peak voltage. 1. Faulty peak voltage adaptor.
2. Faulty CKP sensor.

IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spark present at the plug, check all
connections for loose or poor contact before
measuring the peak voltage.
• Use a commercially available digital multimeter
(impedance 10 MΩ/DCV minimum).
• The display value differs depending upon the
internal impedance of the multimeter.
• If the Imrie diagnostic tester (model 625) is used,
follow the manufacturer's instruction.
Connect the peak voltage adapter to the digital
multimeter, or use the imrie diagnostic tester. DIGITAL MULTIMETER
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter (im-
pedance 10 MΩ/DCV minimum)
PEAK VOLTAGE ADAPTOR
IGNITION COIL PRIMARY

PEAK VOLTAGE
• Check all system connections before inspection. If
the system is disconnected, incorrect peak voltage
might be measured.
• Check cylinder compression and check that the
spark plug is installed correctly.
Support the scooter with its centerstand on a level
surface. KNOWN-GOOD SPARK PLUG
Remove the maintenance lid (page 3-9).
Connect a known-good spark plug to the spark plug cap
and ground it to the cylinder head cover bolt as done in
a spark test.

18-5
IGNITION SYSTEM
With the ignition coil primary wires connected, connect Black
the imrie diagnostic tester or peak voltage adaptor IGNITION COIL
probes to the ignition coil primary terminal and ground.
TOOL:
CONNECTION: Green/Red (+) – Ground (–)

Turn the ignition switch ON.
Check the initial voltage at this time.
The battery voltage should be measured. Green/Red
If the initial voltage cannot be measured, follow the
checks in the troubleshooting table (page 18-4).
IGNITION COIL
Squeeze the brake lever fully.
Retract the sidestand.
Crank the engine with the starter motor and measure
the ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
(+)
Bl G/R
If the peak voltage is lower than the standard value, FROM
follow the checks in the troubleshooting table (page 18- IGNITION
4). PV
SWITCH
ECM SPARK
(–) PLUG
CKP SENSOR PEAK VOLTAGE

• Check all system connections before inspection. If
the system is disconnected, incorrect peak voltage
might be measured.
• Check cylinder compression and check that the
spark plug is installed correctly.
Turn the ignition switch OFF.
Disconnect the ECM 33P (Black) connector (page 6- ECM 33P (Black) CONNECTOR
42). (Wire side/female terminals)
Connect the Imrie diagnostic tester or peak voltage

adaptor probes to the ECM 33P connector terminals.
W/Y
TOOLS:
with commercially available digital multimeter (im- Bu/Y
CONNECTION: No. 12 (Blue/Yellow) (+) – No. 23

(White/Yellow) (–)
Turn the ignition switch ON and squeeze the brake
lever fully.
Crank the engine with the starter switch and measure
the CKP sensor peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at the ECM 33P
connector is abnormal, measure the peak voltage at the
CKP sensor 3P connector.

IGNITION SYSTEM
CKP SENSOR 3P CONNECTOR
Disconnect the CKP sensor 3P connector and connect
the imrie diagnostic tester or peak voltage adaptor
probes to the connector terminals of the CKP sensor
side.
TOOL:
CONNECTION: White/Yellow (+) – Blue/Yellow (–)

Turn the ignition switch ON and squeeze the brake
lever fully. CKP SENSOR 3P CONNECTOR
Crank the engine with the starter motor and measure
the CKP sensor peak voltage.
PV
PEAK VOLTAGE: 0.7 V minimum
(–)
In the same manner as at the ECM 33P (Black) (+)
connector, measure the peak voltage and compare it to
the voltage measured at the ECM 33P connector.
• If the peak voltage measured at the test harness is Bu/Y W/Y
abnormal and the one measured at the CKP sensor
is normal, the wire harness has an open or short
circuit, or loose connection.
• If both peak voltages are abnormal, check each item CKP SENSOR
in the troubleshooting chart (page 18-4).
For CKP sensor replacement (page 17-7).
IGNITION COIL
SPARK PLUG CAP
Disconnect the spark plug cap.
Release the wire band boss from the radiator cover and
wire guide. GUIDE
WIRE BAND BOSS
Disconnect the ignition coil primary wire connectors. WIRE CONNECTORS

Remove the mount bolts and ignition coil. BOLTS

harness properly
(page 1-14).
IGNITION COIL

18-7
IGNITION SYSTEM
IGNITION TIMING
• The ignition timing can not be adjusted since the
ECM is factory preset.
Start the engine, warm it up to normal operating
temperature and stop it. INDEX
MARK
Read the Connect the timing light to the spark plug wire.
instructions for "F" MARK
timing light
Start the engine and let it idle (1,700 ± 100 min-1 (rpm)).
operation. The ignition timing is correct if the index mark on the
right crankcase aligns with the "F" mark on the flywheel.
If the ignition timing is incorrect, inspect the CKP sensor
(page 18-6).
TIMING LIGHT
SIDESTAND SWITCH
Remove the left main pipe side cover (page 3-16).
SIDESTAND SWITCH 3P
Disconnect the sidestand switch 3P (Green) connector. (Green) CONNECTOR
Release the sidestand switch wire from the wire guide.
WIRE GUIDE
Release the sidestand switch wire from the wire guides.

WIRE GUIDES

IGNITION SYSTEM
Remove the bolt and sidestand switch.
Install the sidestand switch while aligning its groove BOLT
with the spring pin.
Install and tighten the sidestand switch bolt.
Route the wire Secure the sidestand switch wire with the frame
harness properly clamps.
(page 1-14).
Connect the sidestand switch 3P (Green) connector.
Install the left main pipe side cover (page 3-16).
• Do not reuse the broken sidestand switch.

• Remove the sidestand switch before retightening the Align SIDESTAND SWITCH
sidestand pivot nut.
INSPECTION
33P (Black) CONNECTOR
Check for continuity between the ECM 33P (Black)

Continuity (Sidestand retracted):
TOOL:
CONNECTION: Green/White – Body ground

There should be continuity with the sidestand retracted,
and there should be no continuity with the sidestand
applied.
If there is no continuity with the sidestand retracted, the
wire harness is broken or the sidestand switch is faulty.
No continuity (Sidestand applied):

Green/
White

18-9
MEMO

19. ELECTRIC STARTER SYSTEM
SYSTEM LOCATION···································19-2 STARTER MOTOR······································19-6
SYSTEM DIAGRAM ····································19-2 STARTER PINION·····································19-10
SERVICE INFORMATION ···························19-3 STARTER RELAY·····································19-11
TROUBLESHOOTING·································19-4
19

19-1
SYSTEM LOCATION
FRONT BRAKE REAR BRAKE LIGHT SWITCH

LIGHT SWITCH
STARTER SWITCH
STARTER RELAY
STARTER MOTOR
SUB FUSE 10A
RESISTOR
MAIN FUSE 15A
BATTERY
ENGINE CONTROL
IGNITION SWITCH MODULE (ECM)
SYSTEM DIAGRAM
Bl: Black
Y: Yellow
G: Green
R: Red
MAIN FUSE LIGHTING SUB FUSE W: White
15 A CUT RELAY 10 A Br: Brown
R R/W R/W R/Y Bl/Br P: Pink
R R/W
Bl
REGULATOR/ Bl Bl
R/Bl
RECTIFIER FRONT REAR
G IGNITION BRAKE BRAKE
BATTERY SWITCH LIGHT LIGHT
SWITCH SWITCH
G/Y G/Y
G R Bl
STARTER
G/Y
RELAY
R/W Y/G Y/G Y/G
Bl W/Bl P
G/W ECM RESISTOR

SERVICE INFORMATION
GENERAL
• Always turn the ignition switch "OFF" before servicing the starter motor. The motor could suddenly start, causing serious injury.
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• The starter motor can be serviced with the engine in the frame.
• When checking the starter system, always follow the steps in the troubleshooting (page 19-4).
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be
damaged.
• Refer to the following component information.
– Ignition switch (page 20-13)
SPECIFICATION
Unit: mm (in)
Starter switch resistor resistance (20°C/68°F) 9 – 12 Ω –
TORQUE VALUE
Starter motor cable screw 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
Starter motor case screw 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
TOOL
Test probe
07ZAJ-RDJA110

19-3
TROUBLESHOOTING
Starter motor does not turn
1. Standard inspection
Check the following:
– Battery condition
– Burned fuses
– Brake light operation (page 4-19)
– Lighting cut relay operation (page 20-19)
Are the above items in good condition?
NO – Replace or repair the malfunction part(s).
2. Starter relay operation
Squeeze the brake lever fully and push the starter switch.
You should hear the relay "CLICK" when the starter switch is depressed.
Is the "CLICK" heard?
3. Starter motor inspection
Apply battery voltage to the starter motor directly and check the operation. (A large amount of current flows,
so do not use a thin wire.)
Does the starter motor turn?
NO – Inspect the starter motor (page 19-9).
4. Starter relay continuity Inspection
Check the starter relay for continuity (page 19-11).
YES – • Loose or poorly connected starter motor cable.
• Loose or poorly connected starter relay connector terminal.
• Open circuit in starter motor ground cable.
• Open circuit in Red wire between the battery and starter relay.
• Open circuit in Red/white wire between the starter relay and starter motor.
NO – Faulty starter relay.
5. Engine control module (ECM) system circuit inspection
Turn the ignition switch ON and check the PGM-FI malfunction indicator lamp (MIL).
Does the indicator stay off?
YES – Inspect the ECM power/ground line (page 6-43).
6. Starter relay coil line inspection
Turn the ignition switch ON and measure the battery voltage between the ECM 33P (Black) connector and
ground.
CONNECTION: No.33 (Yellow/Green) (+) – Ground (–)
Does the battery voltage exist?
NO – • Loose or poorly connected connector.
• Open circuit in Black wire between the starter relay and ignition switch.
• Open circuit in Yellow/Green wire between the starter relay and ECM.

7. Brake light switch/starter switch line inspection
Ground the ECM 33P connector White/Black terminal of the wire harness side with a jumper wire.
Squeeze the brake lever fully and push the starter switch then measure the battery voltage between the
ECM 33P connector and ground.
Does the battery voltage exist?
YES – Replace the ECM with a known good one and recheck.
NO – • Loose or poorly connected connector.
• Open circuit in Green/Yellow wire between the brake light switch and starter switch.
• Faulty starter switch (page 20-15).
• Open or short circuit in Yellow/Green wire between the starter switch and ECM.
• Open or short circuit in Black/Brown or Black wire between the brake light switch and sub fuse.
• Open or short circuit in Red/Yellow wire between the sub fuse and lighting cut relay.
• Open circuit in Red/White wire between the lighting cut relay and main fuse.
Starter motor turns engine slowly

• Low battery voltage.
• Poorly connected battery terminal cable.
• Poorly connected starter motor cable.
• Faulty starter motor.
• Poor connected battery ground cable.
Starter motor turns, but engine does not turn

• Starter motor is running backwards.
– Case assembled improperly.
– Terminals connected improperly.
• Faulty starter pinion.
Starter relay "CLICK", but engine does not turn

• Crankshaft does not turn due to engine problems.

19-5
STARTER MOTOR
REMOVAL
Remove the air cleaner housing (page 6-32).
MOUNT BOLT
Remove the mount bolts and ground cable.
MOUNT BOLT/
GROUND CABLES
Pull off the dust cover.

Remove the screw and ground cable from the starter SCREW/STARTER DUST COVER
motor. MOTOR CABLE
Remove the screw and starter motor cable from the

starter motor.
SCREW/GROUND CABLES
Remove the O-ring from the starter motor.

STARTER
MOTOR
O-RING
INSTALLATION
Coat a new O-ring with engine oil and install it into the
starter motor groove. STARTER
MOTOR
O-RING

Install the starter motor cable and screw, then tighten
the screw to the specified torque. SCREW/STARTER DUST COVER
MOTOR CABLE
Put the dust cover back in the appropriate position.
Install the ground cable and screw, then tighten the
screw to the specified torque.
SCREW/GROUND CABLES
Route the starter Install the starter motor to the engine.

motor cable and Set the ground cables and tighten the starter mounting MOUNT BOLT
ground cables bolts.
properly
Install the air cleaner housing (page 6-33).
(page 1-14).
MOUNT BOLT/
GROUND CABLES
DISASSEMBLY
Remove the screws and starter motor case.
– Armature
– Bracket
– Springs
– Gasket
MOTOR CASE
ARMATURE
SPRINGS
2 N·m (0.2 kgf·m, 1.5 lbf·ft)
GASKET
BRACKET

19-7
ASSEMBLY
Install the springs in the brush holders.
BRUSH HOLDERS
SPRINGS
Install the armature into the bracket while holding the

brushes. ARMATURE
BRUSHES
Install a new gasket onto the bracket.

BRACKET MOTOR CASE
The coil may be Install the bracket and armature to the motor case while
damaged if the holding the bracket side armature shaft tightly.
magnet pulls the
armature against
the case.
ARMATURE
GASKET
Install the motor case screws and tighten them to the

specified torque. SCREWS

INSPECTION
BRUSH
Inspect the brushes for damage and measure the brush
length.
ARMATURE
Do not use emery Inspect the commutator bars of the armature for
or sand paper on discoloration. COMMUTATOR BARS
the commutator.
Bars discolored in pairs indicate shorted coils.
Check for continuity between each pair of commutator

CONTINUITY:
bars.
There should be continuity.
Check for continuity between each commutator bar and

the armature shaft. NO CONTINUITY:
There should be no continuity.

19-9
STARTER PINION
REMOVAL
STARTER PINION HOLDER
Remove the starter pinion holder.
Remove the starter pinion.

STARTER PINION
INSTALLATION
STARTER PINION
IDEMITSU AUTOREX B or equivalent) to the ends of
the starter pinion.
Install the starter pinion into the left crankcase.
Install the starter pinion holder into the left crankcase.

STARTER PINION HOLDER

INSPECTION
Check that the starter pinion operates smoothly.
DRIVEN GEAR
Check the pinion gear teeth and shaft for wear or
damage.
Check the starter driven gear teeth of the drive pulley
face for wear or damage.
PINION GEAR
STARTER RELAY
Remove the starter relay from the stay. STARTER RELAY
Disconnect the starter relay 5P connector.

5P CONNECTOR
OPERATION INSPECTION
Squeeze the brake lever fully and push the starter
switch.
The system is normal if the starter relay clicks.
If you don’t hear the relay "CLICK", inspect the
following:
– Starter relay coil circuit (page 19-12)
– Brake light switch/starter switch circuit (page 20-17)
– ECM power/ground circuit (page 6-43)
If you hear the relay "CLICK", but starter does not turn, STARTER RELAY
inspect the starter relay continuity (page 19-14).

19-11
STARTER RELAY COIL CIRCUIT
INSPECTION
Measure the voltage between the ECM connector of the
wire harness side and ground.
TOOL:

If the battery voltage appears only when the ignition
switch is "ON", the circuit is normal.
IGNITION
SWITCH From
REGULATOR
Y/G Bl /RECTIFIER
STARTER
RELAY

BRAKE LIGHT SWITCH/STARTER
SWITCH CIRCUIT INSPECTION
Ground the ECM 33P connector White/Black terminal of
the wire harness side with a jumper wire.
CONNECTION: White/Black – Ground
Squeeze the brake lever fully and push the starter
switch.
Measure the voltage between the ECM connector of the
wire harness side and ground.
TOOL:
ECM 33P (Black)
CONNECTION: No.29 (Yellow/Green) (+) – Ground (–) CONNECTOR
JUMPER
If the battery voltage appears only when the ignition WIRE
switch is "ON", the brake lever is fully squeezed and the
starter switch is pushed, the circuit is normal.
W/Bl
Y/G
From
LIGHTING STARTER
CUT SWITCH
RELAY
G/Y
G/Y G/Y
FRONT BRAKE REAR BRAKE

LIGHT SWITCH LIGHT SWITCH
Bl Bl
From LIGHTING
CUT RELAY

19-13
STARTER RELAY CONTINUITY
INSPECTION
Remove the starter relay (page 19-11).
Connect a fully charged 12 V battery positive wire to the
relay switch terminal A and negative wire to the terminal
B.
Check for continuity at the terminal C and terminal D.
There should be continuity between the C and D
terminals while the battery is connected, and no
continuity when the battery is disconnected.
A C
B
D STARTER RELAY
A B C D

20. LIGHTS/METERS/SWITCHES
ELECTRICAL SYSTEM LOCATION···········20-2 FUEL METER/FUEL LEVEL SENSOR·····20-11
SERVICE INFORMATION ···························20-3 IGNITION SWITCH····································20-13
LIGHTING CIRCUIT INSPECTION ·············20-4 HANDLEBAR SWITCHES ························20-15
HEADLIGHT/FRONT TURN BRAKE LIGHT SWITCH ···························20-17

SIGNAL LIGHT············································20-5
HORN ························································20-17
REAR COMBINATION LIGHT ····················20-6
TURN SIGNAL LIGHT RELAY ·················20-18
SPEEDOMETER··········································20-7
LIGHTING CUT RELAY ····························20-19
COOLANT TEMPERATURE
WARNING INDICATOR·····························20-10 RESISTOR·················································20-21
20

20-1
ELECTRICAL SYSTEM LOCATION
SPEEDOMETER
TURN SIGNAL LIGHT RELAY
DIMMER SWITCH
FRONT BRAKE
LIGHT SWITCH
TURN SIGNAL SWITCH
STARTER SWITCH
REAR BRAKE LIGHT
SWITCH
IGNITION SWITCH
STARTER MOTOR
HORN SWITCH
STARTER RELAY
RESISTOR
SUB FUSE 10A
MAIN FUSE 15A
BATTERY
REGULATOR/
RECTIFIER
IGNITION COIL HORN
ECT SENSOR
SPARK PLUG
SIDESTAND SWITCH
ALTERNATOR
LIGHTING CUT RELAY

FUEL LEVEL SENSOR

SERVICE INFORMATION
GENERAL
• Check the battery condition before performing any inspection that requires proper battery voltage.
• Use an electric heating element to heat the coolant for the ECT sensor inspection. Keep all flammable materials away from the
electric heating element. Wear protective clothing, insulated gloves and eye protection.
• A continuity test can be made with the switches installed on the scooter.
• Route the wires and cables properly after servicing each component (page 1-14).
• Refer to the ECT sensor for PGM-FI systems inspection (page 6-45).
• The following color codes are used throughout this section.
Bu: Blue G: Green Lg: Light Green W: White
Bl: Black Gr: Gray O: Orange Y: Yellow
Br: Brown Lb: Light Blue R: Red
SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight 12 V – 25/25 W x 2
Brake light LED
(MIL)
cator
Sub fuse 10 A x 1
TOOL
Test probe
07ZAJ-RDJA110

20-3
LIGHTING CIRCUIT INSPECTION
HEADLIGHT/METER LIGHTS/TEAIL
LIGHT DO NOT COME ON
Standard Inspection
Check the following:
– Burned out bulb or bulb with unspecified wattage
– Loose connector
– Dimmer switch
If the above items are normal, check as follows:
Lighting Circuit Inspection
HEADLIGHT 6P
Disconnect the following connectors: CONNECTOR
– Headlight 6P connector
– Regulator/rectifier 6P (White) connector
Turn the dimmer switch to Lo position.
Check the continuity between the White terminal of the
headlight 6P connector and Yellow terminal of the
regulator/rectifier 6P connector.
Turn the dimmer switch to Hi position. REGULATOR/
Check the continuity between the Blue terminal of the RECTIFIER 6P
headlight 6P connector and Yellow terminal of the (White)
regulator/rectifier 6P connector. CONNECTOR
If there is continuity, check the following:
HEADLIGHT 6P
CONNECTOR
Bu W
DIMMEW SWITCH
Lo
Hi
Y
REGULATOR/RECTIFIER

Ground Inspection
Check the continuity between the Green terminal of the
headlight 6P connector and ground. HEADLIGHT 6P CONNECTOR
If there is continuity, check the regulator/rectifier (page

17-13).
removal.
HEADLIGHT/FRONT TURN SIGNAL

LIGHT
BULB REPLACEMENT
HEAD LIGHT
Remove the dust cover.
Slightly push the headlight bulb socket and turn it
counterclockwise. BULB SOCKET
Remove the bulb from the headlight unit and replace it
with a new one.
Install a new headlight bulb by aligning the tab on the
headlight bulb with the groove on the headlight unit.
Install the bulb socket by aligning the tabs on the bulb
socket with the slots on the headlight unit.
Push the bulb socket in, turn it clockwise.
Install the dust Install the dust cover tightly on the headlight unit.
cover with its "TOP"
Install the main pipe upper cover (page 3-5).
mark facing up.
HEADLIGHT BULB
"TOP" MARK
DUST COVER

20-5
FRONT TURN SIGNAL LIGHT
BULB SOCKET
Remove the front turn signal light bulb socket from the
light unit.
Remove the bulb from the socket and replace it with a
new one.
Install the turn signal light bulb socket.
FRONT TURN SIGNAL

LIGHT BULB
REAR COMBINATION LIGHT

BRAKE LIGHT INSPECTION
Turn the ignition switch ON, and check the brake light
operation.
Check that all LED in the rear combination light
illuminate with the front brake lever and/or rear brake
lever applied.
If any LED does not turn on, replace the rear
combination light unit.
BRAKE LIGHT
BULB REPLACEMENT
TAILLIGHT
Be careful not to Remove the screws and taillight lens.
damage the lens. TAILLIGHT BULB
Remove the taillight bulb from the socket and replace it
with a new one.
SCREWS
TAILLIGHT LENS

REAR TURN SIGNAL LIGHT
TURN SIGNAL LIGHT BULB
– Body garnish (page 3-10)
– Tail light lens (page 20-6)
Be careful not to Remove the screw.
damage the lens. Remove the rear turn signal light lens backward.
Remove the rear turn signal light bulb from the socket
and replace it with a new one.
TURN SIGNAL
SCREW
LIGHT LENS
SPEEDOMETER
BULB REPLACEMENT
BULB
BULB SOCKET

20-7
Disconnect the following connectors: SCREWS
– Dimmer switch 3P connector CONNECTORS

– Turn signal switch 3P (Red) connector
– Horn switch 3P (Black) connector
– Starter switch 3P (Black) connector
Remove the three screws and the speedometer
assembly from the rear handlebar cover.
SPEEDOMETER

– Turn signal light relay
– Bulb sockets
– Terminal screws and wire terminals
– Wire band screw and speedometer sub harness
– Four screws and meter lens
– Two meter unit screws/washers and speedometer/
fuel meter unit
– Coolant temperature warning indicator unit
– Meter case
• Be careful not to put fingerprints on the meter panel.
• Route the speedometer sub harness as shown.
COOLANT TEMPERATURE WARNING

INDICATOR TERMINAL SCREWS
METER CASE
FUEL METER
COOLANT TEMPERATURE
TERMINAL SCREWS
WARNING INDICATOR UNIT
BULB SOCKETS
SCREWS
METER LENS
WIRE
BAND
SCREW
SCREWS/
WIRE BAND WASHERS
SPEEDOMETER
SUB HARNESS
SPEEDOMETER/
FUEL METER UNIT
SPEEDOMETER WIRE
ROUTING: FUEL METER WIRE (Bu/W)
FUEL METER WIRE (Y/W) FUEL METER WIRE (Bl)
HI BEAM INDICATOR (Bu, G) L. TURN SIGNAL

INDICATOR
(O, G)
R. TURN SIGNAL INDICATOR (Lb, G)
COOLANT TEMPERATURE
WARNING INDICATOR (Bl)
METER LIGHT
COOLANT TEMPERATURE WARNING MIL (Bl, G)
INDICATOR (Lg/R) (Bl, Bu/Y)

20-9
COOLANT TEMPERATURE WARNING
INDICATOR
SYSTEM INSPECTION
• Coolant temperature warning indicator turns on
when the coolant temperature becomes higher than
certain temperature.
• Before performing the system inspection, make sure
that the following item are normal.
– Cooling system flow
– Burned fuse
– Other meter indicators
Turn the ignition switch ON and check the coolant
temperature warning indicator.
When the engine is cold, the indicator should not come
on.
Remove the luggage box (page 3-11).
Disconnect the engine coolant temperature (ECT)
sensor 2P (Black) connector.
Short the ECT sensor connector terminals of the wire
harness side with the jumper wire.
CONNECTION: Pink/White – Green/Orange
Do not leave the INDICATOR

terminal connected Turn the ignition switch ON and check the indicator.
with jumper wire for The indicator should come on.
a long time, as it ECT SENSOR 2P
If the indicator comes on with the engine is cold, check (Black) CONNECTOR
causes damage to
the following:
the coolant
temperature – Light green/Red wire between the meter and ECM
warning indicator. for short circuit
– Pink/White wire between the ECT sensor and ECM
for short circuit
– ECT sensor (page 6-45)
– Indicator unit for short circuit
If the indicator goes off with the ECT sensor connector
shorted, check the following:
– Light green/Red wire between the meter and ECM
for open circuit
– ECT sensor wire for open circuit
– Indicator unit for open circuit COOLANT TEMPERATURE
If above inspections are normal, replace the ECM with a WARNING INDICATOR
new one and recheck.
SUB FUSE
10A
Bl Bl/Br
Lg/R
From
P/W G/O LIGHTING
CUT
ECM RELAY
JUMPER WIRE
ECT SENSOR 2P
(Black) CONNECTOR

FUEL METER/FUEL LEVEL SENSOR
SYSTEM INSPECTION
WHEN FUEL IS ABOUT FULL BUT NEEDLE DOES
NOT MOVE
Before performing the system inspection, check the
following: FUEL PUMP/FUEL LEVEL
SENSOR 5P CONNECTOR
– Burned fuse
– Horn operation
Disconnect the fuel pump/fuel level sensor 5P
connector.
Short the connector terminals of the wire harness side
with the jumper wire.
CONNECTION: Yellow/White – Green/Black
Do not leave the Turn the ignition switch ON, check if the fuel meter
terminals needle moves to "F".
connected with The needle moves if the system circuit is normal.
jumper wire for a In that case, check the fuel level sensor (page 20-11). FUEL METER
long time, as it
If the needle does not move, check the following:
causes damage to
the fuel meter. – Yellow/White wire between the fuel pump/fuel level
sensor and speedometer for open or short circuit
– Black wire between the speedometer 4P connector
and fuel meter for open circuit Bl Bu/W Y/W
– Green/Black and Blue/White wire between the fuel
pump/fuel level sensor and ground for open circuit JUMPER
– Green/Black and Blue/White wire between the WIRE
speedometer and ground for open circuit Bl/Br G/B Y/W
If the wire is normal, replace the speedometer panel G/B
with a new one, and recheck.
From
LIGHTING
CUT
RELAY FUEL PUMP/FUEL LEVEL
SENSOR 5P CONNECTOR
FUEL LEVEL SENSOR INSPECTION

Remove the fuel pump/fuel level sensor (page 6-29).
Measure the resistance between the connector A
terminals at the float upper (full) and lower (empty) FULL
positions.
CONNECTION: A – B B
(20°C/68°F)
FLOAT POSITION FULL EMPTY
6 – 10 ǡ 90 – 100 ǡ
Replace the fuel level sensor if it is out of specification.
EMPTY FUEL LEVEL SENSOR

20-11
FUEL LEVEL SENSOR REMOVAL/
INSTALLATION
Remove the fuel pump unit (page 6-29).
Black Red
Disconnect the fuel level sensor Red and Black wire
connectors.
Release the wires from the guides of the fuel pump unit.
Install the fuel level sensor in the reverse order of
removal.
CONNECTORS
GUODES WIRES
Remove the fuel level sensor from the fuel pump unit by
releasing the three hooks.
FUEL PUMP UNIT
Installation is in the reverse order of the removal.
FUEL LEVEL SENSOR WIRES
FUEL LEVEL SENSOR

IGNITION SWITCH
REMOVAL
Remove the steering stem (page 14-21).
CABLE
Disconnect the ignition switch 2P connector.
Release the fuel lid cable from the cable holder and
disconnect the cable from the opener.
2P CONNECTOR

BOLT
– Bolt
– Screws
– Key shutter and ignition switch
KEY SHUTTER/
SCREWS IGNITION SWITCH
INSTALLATION
Set the ignition switch while aligning its grooves with the
tab on the key shutter.
Turn the ignition switch as shown. IGNITION SWITCH
GROOVES
TABS
Align

20-13
Set the key shutter and ignition switch in position.
BOLT
Install and tighten the bolt and new screws.
• Push the key shutter against the ignition switch
during installation. If the key shutter is not seated on
the ignition switch, it will prevent the ignition key
from being inserted completely.
KEY SHUTTER/
SCREWS IGNITION SWITCH
Connect the fuel lid cable onto the opener and install
the cable onto the cable holder. CABLE
Connect the ignition switch 2P connector.
Install the steering stem (page 14-23).
2P CONNECTOR
INSPECTION
Disconnect the ignition switch 2P connector.
Check for continuity at the terminals of the switch side
connector in each switch position.
Continuity should exist between the color coded wires
as follows:
IGNITION SWITCH 2P
CONNECTOR
IGNITION SWITCH
IGNITION
SWITCH
BAT BAT1
ON
OFF
LOCK
COLOR R/Bl Bl

HANDLEBAR SWITCHES
RIGHT HANDLEBAR SWITCH
INSPECTION
Disconnect the starter switch 3P (Black) connector.
Check for continuity between the terminals of the starter
switch connector in each switch position.
as follows:
STARTER SWITCH 3P
(Black) CONNECTOR
STARTER SWITCH
STARTER SWITCH
ST ECM
FREE
PUSH
COLOR G/Y Y/G

20-15
LEFT HANDLEBAR SWITCH
INSPECTION
DIMMER SWITCH TURN SIGNAL
Disconnect the following: SWITCH 3P (Red)
3P CONNECTOR
– Dimmer switch 3P connector CONNECTOR
– Turn signal light switch 3P (Red) connector
Check for continuity between the wire terminals of the
dimmer switch, turn signal switch and horn switch
connector in each switch position.
as follows:
HORN SWITCH
3P (Black)
CONNECTOR
DIMMER SWITCH
TURN SIGNAL
LIGHT SWITCH
HORN SWITCH
TURN SIGNAL LIGHT SWITCH
WR W WL
ON
OFF
LOCK
COLOR Lb GR O
DIMMER SWITCH
Hi Lo HL
HI
(N)
LO
COLOR Bu W Y
HORN SWITCH
BAT HO
FREE
PUSH
COLOR Bl Lg

BRAKE LIGHT SWITCH
FRONT
Disconnect the front brake light switch wire connectors
and check for continuity of the switch side.
CONNECTION: Green/Yellow – Black
There should be continuity with the front brake lever
squeezed, and there should be no continuity when the
front brake lever is released.
FRONT BRAKE LIGHT SWITCH

WIRE CONNECTORS
REAR
Disconnect the rear brake light switch wire connectors
and check for continuity at the wire connector terminals
of the switch side.
CONNECTION: Green/Yellow – Black
There should be continuity with the rear brake lever
squeezed, and there should be no continuity when the
rear brake lever is released.
REAR BRAKE LIGHT SWITCH

WIRE CONNECTORS
HORN
CONNECTORS
Disconnect the horn connectors from the horn.
Remove the bolt and horn.
BOLT HORN

20-17
INSPECTION
HORN
Disconnect the horn connectors from the horn.
Connect a 12 V battery to the horn terminals.
The horn is normal if it sounds when the 12 V battery is
connected to the horn terminals.

INSPECTION
Before performing the inspection, check the following:
– Burned out bulb or non-specified wattage
– Burned fuse
– Ignition switch and turn signal switch function
– Loose connector
– Horn operation
Disconnect the turn signal light relay 2P connector from
the relay.
Short the turn signal light relay 2P connector terminals TURN SIGNAL LIGHT RELAY
of the wire harness side with a jumper wire. 2P CONNECTOR
CONNECTION: Black – Gray
Turn the ignition switch ON. JUMPER WIRE
Check the turn signal light by turning the switch ON. TURN SIGNAL LIGHT RELAY
If the light comes on, the turn signal light relay is faulty 2P CONNECTOR
or connector has poor connection.
If the light does not come on, the wire harness is
broken.
O
Bl Gr
Lb
G
Bl/Br
SUB FUSE
10A TURN SIGNAL
LIGHT SWITCH
From LIGHTING CUT

RELAY

LIGHTING CUT RELAY
LIGHTING CUT RELAY
Remove the lighting cut relay.
OPERATION INSPECTION
LIGHTING CUT RELAY
The lighting cut relay coil is normal if the lighting cut
relay clicks.
If you hear the lighting cut relay "CLICK", but horn does
not operate when the horn switch is pushed, inspect the
following:
– Lighting cut relay continuity (page 20-19)
– Lighting cut relay switch line (page 20-20)
If you do not hear the relay "CLICK", inspect the
following:
– Lighting cut relay coil line (page 20-20)
– Lighting cut relay continuity (page 20-19)
CONTINUITY INSPECTION
LIGHTING CUT RELAY
Remove the lighting cut relay (page 20-19).
Connect the ohmmeter to the following lighting cut relay
terminals.
Connection: A – B
Connect the 12 V battery to the following lighting cut
relay terminals.
Connection: C – D
There should be continuity between the relay terminals
A B
while the battery is connected, and no continuity when
the battery is disconnected.
C D
D C B A

20-19
SWITCH LINE INSPECTION
LIGHTING CUT JUMPER
Remove the lighting cut relay (page 20-19). RELAY CONNECTOR WIRE
Short the relay connector terminals of the wire harness
side with a jumper wire.
Connection: Red/White – Red/Yellow
MAIN FUSE
Remove the sub fuse 10 A. 15 A
R/W
Measure the voltage between the sub fuse 10 A
connector of the wire harness side and ground. R/Y
R (–)
Connection: Red/Yellow (+) – Ground (–)
If the battery voltage appears, the lighting cut relay G (+)
switch line is normal.
SUB FUSE 10 A
If the battery voltage does not appear, inspect the
CONNECTOR
following:
– Open circuit in Red and/or Red/White wire between
the battery and lighting cut relay
– Open circuit in Red/Yellow wire between the lighting
cut relay and sub fuse 10 A
COIL LINE INSPECTION

COIL POWER LINE
LIGHTING CUT (+) (–)
Remove the lighting cut relay (page 20-19). RELAY CONNECTOR
Measure the voltage between the lighting cut relay
Bl
IGNITION
Connection: Black (+) – Ground (–) SWITCH
MAIN FUSE
If the battery voltage appears, the lighting cut relay coil 15 A
power line is normal.
R R/W R/Bl
If the battery voltage does not appear, inspect the open
circuit in Black wire between the ignition switch and G
REGULATOR/
lighting cut relay. RECTIFIER
COIL GROUND LINE

LIGHTING CUT
Remove the lighting cut relay (page 20-19). RELAY CONNECTOR
Check for continuity between the lighting cut relay
connector and ECM 33P connector of the wire harness
side.
TOOL: W/Bl
Connection: White/black – White/black

If there is continuity, the lighting cut relay coil ground
line is normal. ECM 33P (Black) CONNECTOR
If there is no continuity, inspect the open circuit in
White/black wire between the lighting cut relay and
ECM.

RESISTOR
INSPECTION
Remove the luggage box (page 3-11).
WIRE CONNECTORS
Disconnect the resistor Pink wire connectors.
Measure the resistance between the Pink wire
terminals of the resistor side and ground.
STANDARD: 9.5 – 10.5 ǡ (20°C/68°F)
If the measured value is far beyond the standard,
replace the resistor.
P P
RESISTOR
WIRE CONNECTORS
Disconnect the resistor Pink wire connectors.
Remove the bolt and resistor.

BOLT
Installation is reverse order of removal.
RESISTOR

20-21
MEMO

21. WIRING DIAGRAM
WIRING DIAGRAMS ···································21-2
21

21-1
WIRING DIAGRAM
STARTER LIGHTING
SWITCH REGULATOR/ IGNITION CUT STARTER
TURN RELAY RELAY BATTERY
21-2
RECTIFIER SWITCH ECM
SIGNAL MAIN SUB 12V3AH
RELAY FUSE FUSE
NO
15A 10A
BAT
BAT1
LAMP
BATT OUT
EARTH
CHARGE
V OUT
IGP
LG
O2
SG
THL
VCC (5V)
PRC
FLR
PG1
PG2
IGPLS
PCP
TA
SCS
INJ
TW WARN
IACV2A
IACV1A
FI WARN
PCM
TW
SSTAND
PB
STSW
K-LINE
IACV2B
IACV1B
S/RELAY
ST
ECM
DLC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
HEADLIGHT
12V25W/25W WPC WPC 5P
2P 3P 6P 2P
MINI 4P 33P
Bl W R
6P Bl
Bu Bu
Y
R
R
R
R
G
G
G
Bl
Bl
Bl
Bl
Bl
Bl
W
Br
Br
Gr
W W
Y/R
R/Y
R/Y
G/Y
Y/G
Y/O
Y/G
Y/G
Y/G
G/R
G/O
R/Bl
R/Bl
W/Y
P/W
Bl/R
R/W
G/Bl
G/Bl
Bl/O
W/R
G/Bl
R/W
R/W
R/W
O/W
Br/R
G/W
O/W
W/Bl
Lg/R
Lg/R
Gr/R
W/Bl
Br/Bl
Bu/Y
P/Bu
Bu/Y
Bl/Br
W/Bu
Lb Lb
HEADLIGHT O O
12V25W/25W G G
WIRING DIAGRAM
STANDARD TYPE:
RIGHT FRONT
TURN SIGNAL Lb
LIGHT G RIGHT REAR
12V10W
WIRING DIAGRAMS
TURN SIGNAL LIGHT

12V10W
FRONT BRAKE
LIGHT SWITCH Lb
G/Y
G
Bl
MINI TAIL LIGHT

SPEEDOMETER 4P 12V 5W
G G
Y
Bu/W G/Bl
MINI
FUEL METER Bl Bl/Br 6P
G
Y Y Y Y
RIGHT
TURN SIGNAL 12V Y/G Y/G G G BRAKE LIGHT
INDICATOR 3W Lb Lb Lb Lb
O O O O
G/Y G/Y G/Y G/Y G
LEFT
TURN SIGNAL 12V
INDICATOR 3W Y/W Y/W
G/Y
Bu/Y Bu/Y
INSTRUMENT 12V Lg/R Lg/R
LIGHT 1.7W Lg Lg LEFT REAR
MINI TURN SIGNAL LIGHT
9P 12V10W
INSTRUMENT 12V G
LIGHT 1.7W
P
P
O
HIGH BEAM 12V

INDICATOR 1.7W
12V
Bl
G
MIL
Y/R
Y/O
G/O
P/W
Bl/R
Lg
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
P
P
1.7W
WPC
COOLANT 14P
TEMPERATURE Gr
WARNING
INDICATOR
Bl
Y/R
Y/O
G/O
P/W
Bl/R
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
REAR BRAKE HORN
LIGHT SWITCH

Bl Bl
G
G
W
W/Y
RESISTOR RESISTOR
Bl/O
R/W
G/W
Bu/Y
G/Y G/Y 10 20W 10 20W

MINI WPC 3P 2P
LEFT FRONT 3P 1P
G G Bl
TURN SIGNAL
LIGHT O
12V10W
Y
O
Bl
W
G
G
G
G
Bl
Bl
Bl
Lb
Gr
Lg
W
Bu
Y/R
Y/O
G/R
G/O
G/O
P/W
Bl/R
Y/W
W/Y
W/R
Bl/O
G/Bl
G/Bl
G/Bl
R/W
Br/R
G/W
Lg/R
Gr/R
P/Bu
Br/Bl
Bu/Y
W/Bu
3P 3P 3P WPC WPC WPC WPC WPC

R Bl 5P 2P 4P 2P 5P
Bl Bl Bl Bl
Hi
W
Lo
MAP TP IAT IACV
HL
Ho
WL
WR
BAT
O2 IGNITION
SENSOR COIL E F
G/W
TA
PB
THL
UP FUEL ALTERNATOR
CKP
IACV1A
IACV1B
IACV2A
IACV2B
INJECTOR ENG. LEVEL

DIMMER TURN SIGNAL SIDESTAND ECT FUEL SENSOR SENSOR
SWITCH LIGHT SWITCH HORN SWITCH SWITCH SENSOR PUMP
SENSOR UNIT IACV FRM. ENG. ENG. FRM.
ENG.
Bl BLACK Br BROWN TURN SIGNAL
Y YELLOW O ORANGE IGNITION SWITCH LIGHT SWITCH DIMMER SWITCH HORN SWITCH STARTER SWITCH
Bu BLUE Lb LIGHT BLUE
G GREEN Lg LIGHT GREEN BAT BAT1 WR W WL Hi Lo HL BAT HO ST ECM
R RED P PINK ON R HI FREE FREE
W WHITE Gr GRAY OFF N (N) PUSH PUSH
COLOR COMB : GROUND/MARKING LOCK L LO COLOR Bl Lg COLOR G/Y Y/G
COLOR R/Bl Bl COLOR Lb Gr O COLOR Bu W Y
STARTER LIGHTING
SWITCH REGULATOR/ IGNITION CUT STARTER
TURN RECTIFIER SWITCH ECM RELAY RELAY BATTERY
SIGNAL MAIN SUB 12V3AH
RELAY FUSE FUSE
NO
15A 10A
BAT
BAT1
LAMP
BATT OUT
EARTH
CHARGE
V OUT
IGP
LG
O2
SG
THL
VCC (5V)
PRC
FLR
PG1
PG2
IGPLS
PCP
TA
SCS
INJ
TW WARN
IACV2A
IACV1A
FI WARN
PCM
TW
SSTAND
PB
STSW
K-LINE
IACV2B
IACV1B
S/RELAY
ST
ECM
DLC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
HEADLIGHT
CBS TYPE:
12V25W/25W WPC WPC 5P

2P 3P 6P 2P
MINI 4P 33P
Bl W R
6P Bl
Bu Bu
Y
R
R
R
R
G
G
G
Bl
Bl
Bl
Bl
Bl
Bl
W
Br
Br
Gr
W W
Y/R
R/Y
R/Y
G/Y
Y/G
Y/O
Y/G
Y/G
Y/G
G/R
G/O
R/Bl
R/Bl
W/Y
P/W
Bl/R
R/W
G/Bl
G/Bl
Bl/O
W/R
G/Bl
R/W
R/W
R/W
O/W
Br/R
G/W
O/W
W/Bl
Lg/R
Lg/R
Gr/R
W/Bl
Br/Bl
Bu/Y
P/Bu
Bu/Y
Bl/Br
W/Bu
Lb Lb
HEADLIGHT O O
12V25W/25W G G
RIGHT FRONT
TURN SIGNAL Lb
LIGHT G RIGHT REAR
12V10W TURN SIGNAL LIGHT
12V10W
FRONT BRAKE
LIGHT SWITCH Lb
G/Y G/Y
G
Bl Bl
MINI TAIL LIGHT

SPEEDOMETER 4P 12V 5W
G G
Y
Bu/W G/Bl
MINI
FUEL METER Bl Bl/Br 6P
G
Y Y Y Y
RIGHT
TURN SIGNAL 12V Y/G Y/G G G BRAKE LIGHT
INDICATOR 3W Lb Lb Lb Lb
O O O O
G/Y G/Y G/Y G/Y G
LEFT
TURN SIGNAL 12V
INDICATOR 3W Y/W Y/W
G/Y
Bu/Y Bu/Y
INSTRUMENT 12V Lg/R Lg/R
LIGHT 1.7W Lg Lg LEFT REAR
MINI TURN SIGNAL LIGHT
9P 12V10W
INSTRUMENT 12V G
LIGHT 1.7W
P
P
O
HIGH BEAM 12V

INDICATOR 1.7W
12V
Bl
G
MIL
Y/R
Y/O
G/O
P/W
Bl/R
Lg
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
P
P
1.7W

WPC
COOLANT 14P
TEMPERATURE Gr
WARNING
INDICATOR
Bl
Y/R
Y/O
G/O
P/W
Bl/R
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
REAR BRAKE HORN

LIGHT SWITCH
Bl Bl
G
G
W
W/Y
RESISTOR RESISTOR
Bl/O
R/W
G/W
Bu/Y
G/Y G/Y 10 20W 10 20W

MINI WPC 3P 2P
LEFT FRONT 3P 1P
G G Bl
TURN SIGNAL
LIGHT O
12V10W
Y
O
Bl
W
G
G
G
G
Bl
Bl
Bl
Lb
Gr
Lg
W
Bu
Y/R
Y/O
G/R
G/O
G/O
P/W
Bl/R
Y/W
W/Y
W/R
Bl/O
G/Bl
G/Bl
G/Bl
R/W
Br/R
G/W
Lg/R
Gr/R
P/Bu
Br/Bl
Bu/Y
W/Bu

R Bl 5P 2P 4P 2P 5P
Bl Bl Bl Bl
Hi
W
Lo
MAP TP IAT IACV
HL
Ho
WL
WR
BAT
O2 IGNITION
SENSOR COIL E F
G/W
TA
PB
THL
UP FUEL ALTERNATOR
CKP
IACV1A
IACV1B
IACV2A
IACV2B
INJECTOR ENG. LEVEL

DIMMER TURN SIGNAL SIDESTAND ECT FUEL SENSOR SENSOR
SWITCH LIGHT SWITCH HORN SWITCH SWITCH SENSOR PUMP
ENG.
Bl BLACK Br BROWN TURN SIGNAL
Y YELLOW O ORANGE IGNITION SWITCH LIGHT SWITCH DIMMER SWITCH HORN SWITCH STARTER SWITCH
G GREEN Lg LIGHT GREEN BAT BAT1 WR W WL Hi Lo HL BAT HO ST ECM
R RED P PINK ON R HI FREE FREE
W WHITE Gr GRAY OFF N (N) PUSH PUSH
COLOR COMB : GROUND/MARKING LOCK L LO COLOR Bl Lg COLOR G/Y Y/G
COLOR R/Bl Bl COLOR Lb Gr O COLOR Bu W Y
21-3
WIRING DIAGRAM
MEMO

22. TROUBLESHOOTING
ENGINE DOES NOT START OR POOR PERFORMANCE

IS HARD TO START ···································22-2 AT HIGH SPEED ·········································22-6
ENGINE LACKS POWER ···························22-3 POOR HANDLING ······································22-6
POOR PERFORMANCE AT LOW

AND IDLE SPEED ·······································22-5
22

22-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
TROUBLESHOOTING
1. Spark Plug Inspection

Remove and inspect spark plug (page 4-7).
Is the spark plug in good condition?
NO – • Incorrect spark plug heat range
• Incorrect spark plug gap
• Dirty air cleaner
2. Spark Test
Perform spark test using the same procedure as ignition coil primary peak voltage inspection (page 18-6).
Is there good spark?
NO – • Faulty spark plug
• Broken or shorted spark plug wire
• Loose or disconnected ignition system wires
• Faulty igniting switch
• Faulty ignition coil
• Faulty ECM
• Faulty CKP sensor
3. Fuel Pump Inspection
Check for operation of the fuel pump and inspect the fuel flow (page 6-29).
Is the fuel pump unit normal?
NO – Faulty fuel pump unit
4. PGM-FI System Inspection
Check the PGM-FI system (page 6-5).
Is the PGM-FI system normal?
NO – Faulty PGM-FI system
5. Cylinder Compression
Test cylinder compression (page 9-7).
Is the compression as specified?
NO – • Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing
6. Engine Starting Condition
Start by following normal procedure.
Does the engine start then stops?
YES – • Leaking insulator or intake manifold
• Improper ignition timing (Faulty ECM or CKP sensor)
• Contaminated fuel
• Clogged IACV passage

TROUBLESHOOTING
ENGINE LACKS POWER
1. Drive Train Inspection
Raise wheel off the ground and spin it by hand.
Does the wheel spin freely?
NO – • Brake dragging
• Damaged final reduction system
• Worn or damaged wheel bearings
• Incorrect connecting cable adjustment (CBS type)
2. Tire Pressure Inspection
Check tire pressure (page 4-23).
Are the tire pressures low?
YES – • Faulty tire valve
• Punctured tire
3. Drive Train Inspection
Check the drive train.
Is the drive train normal?
NO – • Fouled or faulty drive belt
• Fouled or faulty drive pulley
• Fouled or faulty driven pulley
• Worn clutch shoes
4. Engine Performance Inspection
Accelerate lightly.
Does the engine speed increase?
NO – • Dirty air cleaner
• Restricted fuel flow
• Clogged exhaust system
Remove and inspect spark plug (page 4-7).
Is the spark plug fouled or discolored?
YES – • Plugs not serviced frequently enough
• Incorrect spark plug heat range
6. Engine Oil Inspection
Check oil level and condition (page 4-10).
Is the engine oil in good condition?
NO – • Oil level too high
• Oil level too low
• Contaminated oil
7. Ignition Timing Inspection
Check ignition timing (page 18-8).
Is the ignition timing as specified?
NO – • Faulty ECM

22-3
TROUBLESHOOTING
8. Cylinder Compression Inspection
Test cylinder compression (page 9-7).
Is the compression as specified?
NO – • Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Improper valve clearance
• Seized valve
• Faulty decompressor
Inspect the fuel flow (page 6-5).
11. Lubrication Inspection
Remove the cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
NO – • Clogged oil passage
• Faulty oil pump
• Oil strainer screen not serviced frequently enough
12. Over Heating Inspection
Check for engine over heating.
Is the engine over heating?
YES – • Excessive carbon build-up in combustion chamber
• Use of poor quality fuel
• Wrong type of fuel
13. Engine Knocking Inspection
Accelerate or run at high speed.
Is there knocking?
YES – • Worn piston and cylinder
• Wrong type of fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advance (Faulty ECM or CKP sensor)

TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
Remove and inspect the spark plug.
Is the spark plug in good condition?
NO – • Plug not serviced frequently enough
• Incorrect spark plug heat range
Check the ignition timing (page 18-8).
5. IACV Inspection
Check the IACV (page 6-38).
Is the IACV normal?
NO – • Faulty IACV
• Clogged IACV passage
6. Intake Pipe Leaking Inspection
Check for leaks at the insulator.
Are there leaks?
YES – • Loose insulator
• Damaged insulator

22-5
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
Check the ignition timing (page 18-8).
In the fuel pump unit operation normal?
4. Valve Timing Inspection
Check the valve timing (page 9-12).
Is the valve timing correct?
NO – Cam sprocket not installed properly.
5. Valve Spring Inspection
Check valve springs (page 9-23).
Is the valve spring free length as specified?
NO – Faulty valve spring
6. Camshaft Inspection
Remove and inspect the camshaft (page 9-13).
Is the cam lobe height as specified?
NO – Faulty camshaft
POOR HANDLING
Steering is heavy
• Steering top thread too tight
• Damaged steering head bearings
Either wheel is wobbling
• Excessive wheel bearing play
• Bent rim
• Improperly installed wheel hub
• Excessively worn engine mounting bushings
• Bent frame
Scooter pulled to one side
• Front and rear wheels not aligned
• Bent fork
• Faulty shock absorber
• Bent axle
• Bent frame

23. ANC110AVC-A ADDENDUM
A Few Words About Safety ·······················23-3 FRONT TOP COVER ································23-23
INTRODUCTION··········································23-4 FRONT COVER·········································23-24
MODEL IDENTIFICATION ··························23-5 REAR INNER LOWER FENDER ··············23-25
SPECIFICATIONS ·······································23-6 HEADLIGHT AIM ······································23-26
STANDARD TORQUE VALUES ···············23-11 FRONT WHEEL·········································23-27
ENGINE & FRAME TORQUE VALUES ····23-11 FORK·························································23-28
LUBRICATION & SEAL POINTS··············23-14 HEADLIGHT/FRONT TURN

SIGNAL LIGHT··········································23-29
CABLE & HARNESS ROUTING ···············23-16
SPEEDOMETER ·······································23-30
BODY PANEL LOCATIONS ·····················23-22
WIRING DIAGRAMS ·································23-31
BODY PANEL REMOVAL CHART ···········23-22
23

23-1
ANC110AVC-A ADDENDUM
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe

condition that can cause your customer to be seri-
ously hurt or killed.
ual and other service materials carefully.
For Your Safety

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

tions can cause you to be seriously hurt or killed.
ual carefully.
Important Safety Precautions

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

INTRODUCTION
This addendum contains information for ANC110.
Refer to ANC110 SHOP MANUAL (No.82KVG00) for service procedures and data not included in this addendum.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messag-
es and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards as-
sociated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Mo-
tor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING
ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER-
MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE
ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: June.: 2009

23-3
MODEL IDENTIFICATION
The frame serial number is stamped on the seat stay as shown.

FRAME SERIAL NUMBER
The engine serial number is stamped on the lower left side of the
crankcase.
ENGINE SERIAL NUMBER
The throttle body identification number is stamped on the lower side of the
throttle body.
THROTTLE BODY IDENTIFICATION NUMBER

GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1,894 mm (74.6 in)
Overall width 680 mm (26.8 in)
Overall height 1,119 mm (44.1 in)
Wheelbase 1,273 mm (50.1 in)
Seat height 767 mm (30.2 in)
Footpeg height 258 mm (10.2 in)
Ground clearance 135 mm (5.3 in)
Curb weight 107.0 kg (235.9 lbs)
FRAME Frame type Under bone type
Front suspension Telescopic fork
Front axle travel 81.0 mm (3.19 in)
Rear suspension Unit swing
Rear axle travel 80.0 mm (3.3 in)
Front tire size 80/90 - 14M/C 40P
Rear tire size 90/90 - 14M/C 46P
Tire brand Front/Rear NR73TZ/NR73T (IRC)
Front brake Hydraulic disc brake
Rear brake Mechanical leading trailing
Caster angle 26°40’
Trail length 80.0 mm (3.15 in)
Fuel tank capacity 4.5 liter (1.19 US gal, 0.99 lmp gal)
ENGINE Bore and stroke 50.0 x 55.0 mm (1.97 x 2.17 in)
Displacement 108.0 cm3 (6.59 cu-in)
Compression ratio 11.0 : 1
Valve train 2 valve, single chain driven SOHC
Intake valve opens at 1 mm (0.04 in) lift 5° BTDC
closes at 1 mm (0.04 in) lift 30° ABDC
Exhaust valve opens at 1 mm (0.04 in) lift 30° BBDC
closes at 1 mm (0.04 in) lift 0° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Paper filter
FUEL DELIV- Type PGM-FI (Programmed Fuel Injection)
ERY SYSTEM Throttle bore 22 mm (0.9 in) or equivalent
DRIVE TRAIN Clutch system Dry, automatic centrifugal clutch
Drive belt ratio 2.53 : 1 - 0.85 : 1
Final reduction 10.624 (51/18 x 45/12)
ELECTRICAL Ignition system Full transistorized
Starting system Kickstarter with electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR opened/single phase, half wave rectifi-
cation
Lighting system Alternator

23-5
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
FUEL SYSTEM (PGM-FI) SPECIFICATIONS

ITEM SPECIFICATIONS
(100°C/212°F) 0.1 – 0.2 kǡ
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS

CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
Cylinder compression 932 kPa (9.5 kgf/cm2, 135 psi)
–
at 550 min-1 (rpm)
Cylinder head warpage – 0.05 (0.002)
Rocker Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.04 (0.395)
arm Rocker arm shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm to shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.08 (0.003)
Camshaft Cam lobe height IN 32.525 – 32.765 (1.2805 – 1.2900) 32.50 (1.280)
EX 32.227 – 32.467 (1.2688 – 1.2782) 32.20 (1.268)
Valve, Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) –
valve EX 0.20 ± 0.02 (0.008 ± 0.001) –
guide Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.90 (0.193)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Valve guide projection above IN/EX 9.1 – 9.3 (0.36 – 0.37) –
cylinder head
Valve seat width IN/EX 1.0 (0.04) 1.5 (0.06)
Valve spring free length Inner IN/EX 31.53 (1.241) 30.66 (1.207)
Outer IN/EX 38.33 (1.509) 37.04 (1.458)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
Cylinder I.D. 50.000 – 50.010 (1.9685 – 1.9689) 50.10 (1.972)
Out-of-round – 0.05 (0.002)
Taper – 0.05 (0.002)
Warpage – 0.05 (0.002)
Piston, Piston O.D. 49.975 – 49.995 (1.9675 – 1.9683) 49.95 (1.967)
piston rings, Piston O.D. measurement point 6.0 (0.24) from bottom of skirt –
piston pin Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Second 0.10 – 0.25 (0.004 – 0.0020) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –

SPECIFICATION
Unit: mm (in)
Drive belt width 19.0 (0.75) 18.0 (0.71)
Boss O.D. 22.010 – 22.025 (0.8665 – 0.8671) 21.98 (0.865)
Weight roller O.D. 17.92 – 18.08 (0.706 – 0.712) 17.5 (0.69)
Clutch outer I.D. 125.0 – 125.2 (4.92 – 4.93) 125.5 (4.94)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)

23-7
FINAL REDUCTION SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
service label)
CRANKCASE/CRANKSHAFT SPECIFICATIONS
Unit: mm (in)
Runout – 0.10 (0.004)
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)
Axial – 2.0 (0.08)
Fluid level 71 (3.41) –
Fluid capacity 69 ± 1.0 cm3
–
(2.11 ± 0.05 US oz, 2.20 ± 0.05 Imp oz)
REAR WHEEL/SUSPENSION SPECIFICATIONS

Unit: mm (in)
Axial – 2.0 (0.08)

BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in)
Rear brake lever freeplay 10 – 20 (0.4 – 0.8) –
Brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Warpage – 0.10 (0.004)
Piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Piston O.D. 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)
BATTERY/CHARGING SYSTEM/ALTERNATOR SPECIFICATIONS

ITEM SPECIFICATIONS
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Spark plug CPR7EA – 9 (NGK), U22EPR9 (ND)
Ignition timing 10° BTDC at 1,500 min-1 (rpm)
ELECTRIC STARTER SYSTEM SPECIFICATION

Unit: mm (in)
LIGHTS/METERS/SWITCHES SPECIFICATION
ITEM SPECIFICATIONS
Bulbs Headlight 12 V – 35/35 W
Brake light LED
(MIL)
cator
Sub fuse 10 A x 1

23-9
STANDARD TORQUE VALUES
FASTENER TYPE TORQUE FASTENER TYPE TORQUE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm hex bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
(Include SH flange bolt) 6 mm flange bolt 12 (1.2, 9)
8 mm hex bolt and nut 22 (2.2, 16) (Include NSHF) and nut
ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
ITEM Q'TY THREAD TORQUE REMARKS
Pillion step bracket socket bolt 2 8 26.5 (2.7, 20)
Muffler mounting bolt 2 8 26.5 (2.7, 20)
MAINTENANCE
Spark plug 1 10 16 (1.6, 12)
Valve adjusting screw lock nut 2 5 10 (1.0, 7) Apply oil to the threads and
seating surface
Engine oil drain bolt 1 12 24 (2.4, 18)
Engine oil strainer screen cap 1 30 20 (2.0, 15)
Final reduction oil check bolt 1 8 13 (1.3, 10)
Final reduction oil drain bolt 1 8 13 (1.3, 10)
Air cleaner housing cover screw 4 5 1.1 (0.1, 0.8)
Equalizer connecting cable lock nut 1 8 6.4 (0.7, 4.7)
LUBRICATION SYSTEM
Oil pump plate screw 1 4 3 (0.3, 2.2)
Oil pump mounting bolt 2 6 10 (1.0, 7)
FUEL SYSTEM (PGM-FI)

ECT sensor 1 12 17.7 (1.8, 13)
Sensor unit torx screw 3 5 3.4 (0.3, 2.5)
Throttle cable stay mounting screw 1 5 3.4 (0.3, 2.5)
IACV torx screw 2 4 2.1 (0.2, 1.5)
O2 sensor 1 12 25 (2.5, 18)
COOLING SYSTEM
Cooling fan mounting bolt 3 6 8 (0.8, 5.9)
Radiator drain bolt 1 10 1 (0.1, 0.7)
Thermostat mounting bolt 2 6 9 (0.9, 6.6)
Water pump impeller 1 6 10 (1.0, 7)

Engine hanger link pivot nut 1 10 69 (7.0, 51)
(Frame side)
CYLINDER HEAD/VALVES
Cylinder head cover special bolt 2 6 12 (1.2, 9)
Cylinder head nut 4 7 18 (1.8, 13) Apply oil to the threads and
seating surface.
Cylinder head bolt 2 6 12 (1.2, 9) Apply oil to the threads and
seating surface.
Cam sprocket bolt 2 5 8 (0.8, 5.9) Apply oil to the threads and
seating surface.
Cam chain tensioner lifter screw 1 6 4 (0.4, 3.0)
Left crankcase cover plate screw 5 4 3 (0.3, 2.2)
Drive pulley face nut 1 14 108 (11.0, 80) Apply oil to the threads and
seating surface.
Clutch/driven pulley nut 1 28 54 (5.5, 40)
Clutch outer nut 1 12 49 (5.0, 36)
Front axle nut 1 12 59 (6.0, 44) U-nut
Front brake disc socket bolt 4 8 42 (4.3, 31) ALOC bolt:
replace with new ones
Handlebar post nut 1 10 59 (6.0, 44)
Bottom bridge pinch bolt 4 10 64 (6.5, 47)
Fork pipe seat socket bolt 2 8 20 (2.0, 15) Apply locking agent to the
threads.
Steering stem top thread 1 26 – For tightening sequence;
see page 14-25
Steering stem lock nut 1 26 – For tightening sequence;
see page 14-26
Rear axle nut 1 16 118 (12.0, 87) U-nut, Apply oil to the
threads and seating sur-
face.
Engine hanger link nut (Engine side) 1 10 49 (5.0, 36)

23-11
BRAKE SYSTEM
Rear brake arm bolt 1 6 10 (1.0, 7) ALOC bolt: replace with a
new one
Brake caliper bleed valve 1 8 5.4 (0.6, 4.4)
Brake master cylinder reservoir cap screw 2 4 1.5 (0.2, 1.1)
Brake pad pin 1 10 17.2 (1.8, 13)
Front brake lever pivot screw 1 6 1 (0.1, 0.7)
Front brake lever pivot nut 1 6 6 (0.6, 4.4)
Front brake light switch screw 1 4 1 (0.1, 0.7)
Brake hose oil bolt 2 10 34 (3.5, 25)
Rear brake lever pivot screw 1 5 4.2 (0.4, 3.1)
Rear brake lever pivot nut 1 5 5.2 (0.5, 3.8) U-nut
Equalizer rod pivot screw 1 5 4.2 (0.4, 3.1)
Equalizer rod pivot nut 1 5 5.2 (0.5, 3.8) U-nut
Rear brake lever bracket cover screws 2 5 4.2 (0.4, 3.1)
Rear brake lever bracket cover special 1 5 4.2 (0.4, 3.1)
screw
Brake caliper mounting bolt 2 8 30.4 (3.1, 22) ALOC bolt: replace with
new ones
Brake caliper torque pin 1 8 22(2.2, 16)
Brake caliper pin 1 8 17.2 (1.8, 13)
Stator mounting socket bolt 3 6 10 (1.0, 7)
Flywheel nut 1 12 59 (6.0, 44)
Starter motor cable screw 1 4 2 (0.2, 1.5)
Starter motor case screw 3 4 2 (0.2, 1.5)
OTHERS
Muffler protector mounting bolt 2 6 10 (1.0, 7)
Brake shoe anchor pin nut 1 8
(When using the stake nut) 20 (2.0, 15)
(When using the normal nut) 18 (1.8, 13)
Sidestand pivot nut 1 10 29 (3.0, 21)
Sidestand pivot bolt 1 10 10 (1.0, 0.7)

LUBRICATION & SEAL POINTS
ENGINE
Liquid sealant (recommend- Right crankcase mating surface see page 13-10
ed: Three Bond 1207B or
Three Bond 1215 or equiva-
lent)
Liquid sealant (recommend- Cylinder head mating surface (semicircular area) see page 9-8
ed: Three Bond 5211C or
SHINETSU-SILICONE
KE45T or Three Bond 1215
or equivalent)
Locking agent (recommend- Driveshaft bearing set plate bolt threads see page 12-13
ed: Three Bond 2415 or
1322N or LOCKTITE 200 or
equivalent)
Molybdenum disulfide oil (a Camshaft cam lobes
mixture of 1/2 engine oil and
1/2 molybdenum disulfide
grease)
Molybdenum disulfide paste Kickstarter spindle sliding surface 0.1 – 0.3 g
Kickstarter driven gear shaft 0.2 – 0.3 g
Kickstarter driven gear friction spring sliding area
Grease (Shell ALVANIA R3 Driven face inner surface 7.0 – 8.0 g
or IDEMITSU AUTOREX B Movable driven face cam groove 1.5 – 2.0 g
or equivalent) Starter pinion gear shaft (both end) 0.1 – 0.3 g
Driven face ball bearing and needle bearing
Bearing area of final shaft
Engine oil (Without molybde- Oil pump drive gear teeth
num additives) Oil pump rotor whole surface
Oil pump shaft and pump cover sliding area
Oil pump driven gear teeth
Rocker arm shaft sliding surface
Rocker arm roller sliding area
Camshaft decompressor rotating surface 0.5 – 1.0 cc
Camshaft bearing
Cam sprocket teeth
Cam chain whole surface
Timing sprocket teeth
Piston and cylinder sliding surfaces
Piston ring whole surface and ring grooves
Piston pin outer surface
Connecting rod small end inner surface
Crankshaft bearings Fill up 2 cc minimum
Connecting rod big end bearing Fill up 3 cc minimum
Valve stem (valve guide sliding area)
Valve stem seal inner surface
Bearing area of drive and counter shaft
Drive, counter and final gear teeth
Water pump shaft sliding area
Water pump chain whole surface
Water pump driven gear teeth
Ball/needle bearing sliding area
Each O-ring whole surface
Oil seal lips and outer surfaces
Degrease Right crankshaft tapered area
Drive/driven pulley face and drive belt
Left crankcase cover bearing bushing inner surface

23-13
FRAME
Multi-purpose grease with Steering bearing race Spread each 3 g minimum
extreme pressure (recom- Steering stem dust seal lip Spread each 3 g minimum
mended: EXCELIGHT EP2
manufactured by KYODO
YUSHI, japan. or Shell AL-
VANIA EP2 or equivalent)
Grease (Shell BEARING Speedometer gear box inside
GREASE HD or equivalent)
Multi-purpose grease Front/rear wheel dust seal lip
Front wheel axle sliding surface
Front wheel distance collar whole surface
Speedometer gear box seal lip
Throttle cable-to-throttle drum sliding area Apply 0.1 - 0.2 g
Rear brake cam and shaft Spread each 0.2 - 0.3 g
Rear brake anchor pin shaft Spread 0.2 - 0.3 g
Rear brake dust seal lip
Rear brake lever pivot screw sliding surface
Equalizer rod pivot screw sliding surface
Equalizer sliding surface
Seat catch contact area Apply 2.2 g minimum
Fuel lid lock pin contact area Apply 2.2 g minimum
Centerstand pivot area
Sidestand pivot area
Silicone grease Rear brake cable cap boot inside
Front brake lever-to-master piston contacting area Spread each 0.1 g
Front brake lever pivot sliding area
Brake caliper pin sliding area Spread 0.4 g minimum
Brake caliper pad pin O-ring whole surface.
Brake caliper dust seal whole surface
Brake equalizer cable cap boot inside
Speedometer cable
Throttle cable boot inside Fill up 0.1 g
Throttle cable inside Fill up 0.2 g minimum
Brake fluid Master cylinder inside and sliding area
(DOT 3 or DOT 4) Brake caliper piston seal whole surface
Brake caliper piston whole surface
Master cylinder piston cup
Fork fluid Fork dust seal and oil seal lips
Fork spring seat O-ring whole surface
Adhesive (Honda bond A or Handlebar grip rubber inside
equivalent) Air cleaner connecting hose-to-housing mating area

CABLE & HARNESS ROUTING
LIGHTING SWITCH 3P DIMMER SWITCH 3P CONNECTOR
CONNECTOR
LIGHTING SWITCH 3P (Red) (Red) CONNECTOR
CONNECTOR
TURN SIGNAL RELAY
COMBINED BRAKE REAR BRAKE LIGHT

CABLE SWITCH WIRE

FRONT BRAKE LIGHT

SWITCH WIRE
REAR BRAKE CABLE
FRONT BRAKE HOSE SPEEDOMETER CABLE
SPEEDOMETER
THROTTLE CABLE SUB HARNESS
THROTTLE
CABLE
REAR
DLC (DATA LINK CONNECTOR) BRAKE
CABLE
FRONT BRAKE HOSE
SPEEDOMETER CABLE
SEAT LOCK CABLE
STARTER RELAY
BATTERY NEGATIVE (–) CABLE BATTERY POSITIVE (+) CABLE
LIGHTING CUT RELAY

23-15
TURN SIGNAL RELAY REAR BRAKE CABLE
COMBINED BRAKE CABLE

FRONT BRAKE HOSE
THROTTLE CABLE
MAIN FUSE 15A
SUB FUSE 10A
BATTERY POSITIVE
(+) CABLE
SEAT LOCK CABLE
CONNECTORS:

SEAT LOCK
MAIN WIRE HARNESS
CONNECTORS:
· STARTER MOTOR 2P
· ALTERNATOR 3P
SPEEDOMETER
CABLE
SPEEDOMETER CABLE

TURN SIGNAL RELAY COMBINED BRAKE CABLE
REAR BRAKE LIGHT SWITCH WIRE
BATTERY
NEGATIVE
(–) CABLE
REGULATOR/
RECTIFIER
SPEEDOMETER SPEEDOMETER WIRE
CABLE SUB HARNESS
SPEEDOMETER
CABLE
STARTER RELAY
REAR BRAKE
CABLE REGULATOR/
RECTIFIER
FRONT BRAKE
HOSE THROTTLE
CABLE
THROTTLE CABLE STARTER
RELAY REAR BRAKE
WIRE CABLE
FRONT BRAKE
HOSE
HORN WIRE
FRONT BRAKE HOSE
FUEL FEED HOSE
THROTTLE CABLE
SIDESTAND SWITCH
WIRE
REAR BRAKE CABLE
OVERFLOW HOSE
FUEL FEED HOSE
OVERFLOW HOSE

THROTTLE CABLE
REAR BRAKE CABLE

23-17
CONNECTORS: BATTERY NEGATIVE (–) CABLE

FUEL LID
OPENER CABLE
HEADLIGHT 6P IGNITION SWITCH WIRE

CONNECTOR
LIGHTING CUT RELAY

REGULATOR/
RECTIFIER
ENGINE SUB HARNESS

HORN WIRE
SEAT
LOCK
CABLE
SPEEDOMETER
CABLE
ECM 33P (BLACK)

CONNECTOR
RADIATOR SIPHON
HOSE CONNECTORS:
· STARTER MOTOR 2P
FUEL PUMP WIRE · ALTERNATOR 3P

REAR BRAKE CABLE THROTTLE CABLE
SPEEDOMETER SUB HARNESS
FRONT BRAKE HOSE
CONNECTORS:
OVERFLOW HOSE
FUEL FEED HOSE
FUEL TRAY
DRAIN HOSE
REAR BRAKE CABLE
THROTTLE CABLE
REAR BRAKE CABLE

23-19
HEADLIGHT WIRE
RIGHT FRONT TURN

LEFT FRONT TURN
SIGNAL WIRE
SIGNAL WIRE
HEADLIGHT 6P CONNECTOR

BODY PANEL LOCATIONS
(7)
(23) (6)
(22) (8) (10)
(12)
(2) (13)
(1)
(5)
(3)
(11)
(4)
(24) (15)
(9) (18) (25)

(21) (20) (14) (16) (17)
(19)
(1) Front fender (page 3-4) (9) Maintenance lid (page 3-9) (17) Rear fender/rear inner fender
(page 3-15)
(2) Front top cover (page 23-22) (10) Seat (page 3-10) (18) Front side cover (page 3-15)
(3) Main pipe upper cover (page 3-5) (11) Body garnish (page 3-10) (19) Main pipe side cover (page 3-16)
(4) Side garnish (page 3-5) (12) Luggage box (page 3-11) (20) Front lower cover (page 3-17)
(5) Front inner cover (page 3-6) (13) Rear center cover (page 3-11) (21) Under cover (page 3-17)
(6) Front cover (page 23-23) (14) Pillion step bracket (page 3-11) (22) Rearview mirror (page 3-8)
(7) Front handlebar cover (page 3-8) (15) Fuel lid/center cover (page 3-18) (23) Grab rail (page 3-12)
(8) Rear handlebar cover (page 3-8) (16) Body cover (page 3-14) (24) Radiator cover (page 3-12)
(25) Rear inner lower fender
(page 23-24)
BODY PANEL REMOVAL CHART

• This chart shows removal order of body panels by means of arrow.
(23) Grab rail (2) Front top cover
(3) Main pipe upper cover
(12) Luggage box (5) Front inner cover
(15) Fuel lid/center cover (4) Side garnish (22) Rearview mirror
(13) Rear center cover (14) Pillion step bracket (7) Front handlebar cover
(16) Body cover (18) Front side cover (8) Rear handlebar cover
(24) Radiator cover (6) Front cover
(17) Rear fender/rear inner fender

(1) Front fender
(9) Maintenance lid (20) Front lower cover
(10) Seat
(11) Body garnish
(19) Main pipe side cover (21) Under cover (25) Rear inner
lower fender

23-21
FRONT TOP COVER
Be careful not to Slightly slide the front top cover downward and release
damage the hooks the hooks and tab from the slots, then remove the front
and tab. top cover by sliding it forward.
SCREWS/WASHERS
HOOKS
FRONT TOP COVER
TAB

FRONT COVER
– Front top cover (page 23-22)
– Two bolt/washers from the battery side
– Four screws from the front side cover
Be careful not to Release the hooks on the front side cover from the slots
damage the hooks, on the front cover.
slots and the boss. Release the boss from the grommet, then remove the
front cover.
BOLT/WASHERS 6P CONNECTOR
BOSS
FRONT COVER
SCREWS
HOOKS
GROMMET

23-23
– Two screws/washers RIGHT FRONT COVER
– Four screws
– Headlight unit
Be careful not to Separate the right and left front covers by releasing the TABS
damage the tabs. tabs.
Assembly is in the reverse order of disassembly. SCREWS
HEADLIGHT UNIT
SCREWS/
WASHERS
LEFT FRONT COVER
REAR INNER LOWER FENDER

Remove the five screws and rear inner lower fender.
Installation is in the reverse order of removal. SCREWS
SCREWS

HEADLIGHT AIM
• Adjust the headlight beam as specified by local laws
and regulations.
ADJUSTING GEAR
Place the scooter on a level ground.
Adjust the headlight beam vertically by turning the
headlight aim adjusting gear using the screwdriver.
A clockwise rotation moves the beam down and
counterclockwise rotation moves the beam up.

23-25
FRONT WHEEL
Raise and support the scooter using safety stand.
– Axle nut cap
– Speedometer cable
– O-ring
– Axle nut
– Front axle
– Front wheel
– Side collar
– Speedometer gearbox
TORQUE: AXLE NUT

59 N·m (6.0 kgf·m, 44 lbf·ft)
• Replace the speedometer cable O-ring with a new

one.
• Apply grease to the front axle, speedometer gear,
speedometer gearbox seal lip and speedometer
cable O-ring.
• Check the brake operation after installation.
Release the tab while pushing it and

disconnect the speedometer cable.
O-RING FRONT AXLE
Align the speedometer
gearbox groove with the
boss on the fork leg.
SPEEDOMETER GEARBOX
AXLE NUT CUP
AXLE NUT
59 N·m (6.0 kgf·m, 44 lbf·ft)
SIDE COLLAR
FRONT WHEEL
Align the speedometer tabs with
the wheel hub grooves. GEARBOX SEAL
*: Shell BEARING GREASE HD or equivalent.

FORK
Put the suitable tool on the spring seat.

Press the spring seat into the fork pipe using a
suitable tool and hydraulic press, then remove
the stopper ring using a small screwdriver.
SUITABLE TOOL
STOPPER RING
SCREWDRIVER
FORK PIPE FORK PISTON FORK PISTON RING

DUST SEAL
STOPPER RING
OIL SEAL
FORK SLIDER
O-RING
FORK SPRING
SOCKET BOLT
SEALING WASHER REBOUND SPRING
20 N·m (2.0 kgf·m, 15 lbf·ft)

23-27
HEADLIGHT/FRONT TURN SIGNAL
LIGHT
BULB REPLACEMENT
HEAD LIGHT
Remove the main pipe upper cover (page 3-5)
RETAINER
Remove the dust cover.
Release the headlight bulb retainer and remove the
socket.
Install a new headlight bulb by aligning the tab on the
headlight bulb with the groove on the headlight unit.
Install the retainer.
Install the dust Install the dust cover tightly on the headlight unit.
cover with its " "
Connect the headlight 3P connector.
mark facing up.
HEADLIGHT
BULB
" " MARK

HEADLIGHT 3P
DUST COVER CONNECTOR
FRONT TURN SIGNAL LIGHT

Remove the front turn signal light bulb socket from the
light unit by turning it counterclockwise.
Remove the bulb from the socket and replace it with a
new one.
Install the turn signal light bulb socket by turning it
clockwise.
FRONT TURN SIGNAL

BULB SOCKET LIGHT BULB

SPEEDOMETER
Disconnect the following connectors: SCREWS
– Dimmer switch 3P connector CONNECTORS
– Turn signal switch 3P (Red) connector
– Starter switch 3P (Black) connector
– Lighting switch 3P connector
– Lighting switch 3P (Red) connector
Remove the three screws and the speedometer
assembly from the rear handlebar cover.
SPEEDOMETER

23-29
LIGHT SWITCH STATER SWITCH REGULATOR/ IGNITION LIGHTING STARTER
RECUTIFIER SWITCH ECM RELAY RELAY BATTERY
WINKER RESISTOR1 RESISTOR2 MAIN SUB 12V3AH
RELAY 10 20W 10 20W FUSE FUSE
NO
15A 10A
BAT
BAT1
LAMP
BATT OUT
EARTH
CHARGE
V OUT
IGP
LG
O2
SG
THL
VCC (5V)
PRC
FFP
PG1
PG2
IGPLS
PCP
TA
SCS
INJ
TW WARN
IACV2A
IACV1A
FI WARN
PCM
TW
SSTAND
PB
STSW
K-LINE
IACV2B
IACV1B
S/RELAY
HL
C1
C1
TL
ST
ECM
23-30
1
2
3
4
5
6
7
8
9
DLC
11
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
WPC WPC 5P
3P 3P 2P 3P 6P 2P 4P 33P
R Bl W R Bl
Y
Y
P
P
Y
R
R
R
R
G
G
G
Bl
Bl
Bl
Bl
Bl
Bl
Br
Br
Br
Gr
R/Y
R/Y
Y/R
G/Y
Y/G
Y/O
Y/G
Y/G
Y/G
G/R
G/O
W/Y
R/Bl
R/Bl
P/W
Bl/R
R/W
G/Bl
G/Bl
Bl/O
W/R
G/Bl
R/W
R/W
R/W
O/W
Br/R
G/W
O/W
W/Bl
Lg/R
Lg/R
Gr/R
W/Bl
Bu/Y
Bu/Y
Br/Bl
P/Bu
Bl/Br
Bu/W
W/Bu
RIGHT FRONT
TURN SIGNAL G
LIGHT Lb
12V10W
P
P
FRONT BRAKE
LIGHT SWITCH
G/Y G/Y
Bl Bl
POSITION LIGHT Br
12V3.4W G
WIRING DIAGRAMS
HEAD LIGHT
12V35W/35W MINI
6P
G G G
Bu Bu Bu
W W W
RIGHT REAR
Br Br TURN SIGNAL LIGHT
Lb Lb 12V10W
SPEEDOMETER O O
Lb
Bu/W
G
FUEL METER Bl MINI
Y/W 6P
Y Y TAIL LIGHT
RIGHT 12V 5W
TURN SIGNAL 12V Lb
G G
INDICATOR 3W G Y
Bu/W G/Bl
MINI
Bl Bl/Br 6P
COOLANT G
TEMPERATURE Lg/R Br Br Br Y
WARNING
INDICATOR Bl Y/G Y/G G G BRAKE LIGHT
Lb Lb Lb Lb
INSTRUMENT 12V Bl O O O O
LIGHT 1.7W G G/Y G/Y G/Y G/Y G
Y/W Y/W
Bl G/Y
INSTRUMENT 12V Bu/Y Bu/Y
LIGHT 1.7W G
Lg/R Lg/R
Lg Lg LEFT REAR
Bu MINI TURN SIGNAL LIGHT
HIGH BEAM 12V 9P 12V10W
INDICATOR 1.7W G
G
12V Bu/Y
MIL O
1.7W Bl
LEFT O
TURN SIGNAL 12V
INDICATOR 3W G
Bl
Y/R
Y/O
G/O
P/W
Bl/R
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
REAR BRAKE WPC
LIGHT SWITCH 14P
Gr

Bl Bl
G/Y G/Y
Bl
Y/R
Y/O
G/O
P/W
Bl/R
Bl/O
W/R
Br/R
Lg/R
Gr/R
P/Bu
W/Bu
POSITION LIGHT Br
12V3.4W G
G
G
W
W/Y
Bl/O
R/W
G/W
Bu/Y
LEFT FRONT O MINI WPC 3P 2P

TURN SIGNAL 3P 1P
LIGHT G
G Bl
12V10W
O
Bl
W
G
G
G
G
G
Bl
Bl
Bl
Lb
Gr
Lg
W
Bu
Lg
Y/R
Y/O
G/R
G/O
G/O
W/Y
P/W
Bl/R
Y/W
W/R
Bl/O
G/Bl
G/Bl
G/Bl
R/W
Br/R
G/W
Lg/R
Gr/R
Bu/Y
P/Bu
Br/Bl
Bu/W
W/Bu

R Bl 5P 2P 4P 2P 5P
Bl Bl Bl
Hi
W
Lo
MAP TP IAT IACV
HL
Ho
WL
WR
BAT
O2 IGNITION
SENSOR COIL E F
G/W
TA
PB
THL
UP FUEL ALTERNATOR
CKP
IACV1A
IACV2A
IACV1B
IACV2B
INJECTOR ENG UNIT

DIMMER WINKER HORN SIDESTAND TW FUEL SENSOR
LIGHTING SWITCH SWITCH SWITCH HORN SWITCH SWITCH SENSOR PUMP
HL C1 TL
IGNITION SWITCH WINKER SWITCH DIMMER SWITCH HORN SWITCH STARTER SWITCH Bl BLACK Br BROWN ENG
Y YELLOW O ORANGE
(N) BAT BAT1 WR W WL Hi Lo HL BAT HO ST ECM
P ON R HI FREE FREE G GREEN Lg LIGHT GREEN
(N) OFF N (N) PUSH PUSH R RED P PINK
W WHITE Gr GRAY
H LOCK L LO COLOR Bl/Br Lg COLOR G/Y Y/G
COLOR Bu/W Y Br COLOR R/Bl Bl COLOR Lb Gr O COLOR Bu W Bu/W COLOR COMB : GROUND/MARKING
INDEX
INDEX
A Few Words About Safety ·····································0-1,23-2 DRIVE BELT
A
AIR CLEANER ································································4-6 KICKSTARTER/DRIVE PULLEY/

AIR CLEANER HOUSING ············································6-32 DRIVEN PULLEY/CLUTCH ··································· 11-13
ALTERNATOR INSPECTION ·····································17-11 MAINTENANCE ······················································· 4-14 24
BATTERY····································································17-11 DRIVE PULLEY ·························································· 11-13
B
BATTERY/CHARGING SYSTEM/ALTERNATOR ECM·············································································· 6-42

E
SPECIFICATIONS ··················································1-8,23-9 ECT SENSOR ······························································ 6-45

BODY COVER ······························································3-14 ELECTRIC STARTER SYSTEM
BODY GARNISH···························································3-10 SPECIFICATION ···················································· 1-8,23-9
BODY PANEL LOCATIONS ·································3-2,23-21 ELECTRICAL SYSTEM LOCATION ···························· 20-2
BODY PANEL REMOVAL CHART ·······················3-2,23-21 EMISSION CONTROL SYSTEMS ······························· 1-30
BRAKE CALIPER························································16-19 ENGINE & FRAME TORQUE VALUES ··············· 1-9,23-10
BRAKE FLUID·······························································4-15 ENGINE IDLE SPEED·················································· 4-12
BRAKE FLUID REPLACEMENT/AIR BLEEDING ········16-7 ENGINE INSTALLATION ··············································· 8-7
BRAKE LIGHT SWITCH ENGINE OIL ································································· 4-10
LIGHTS/METERS/SWITCHES·······························20-17 ENGINE OIL STRAINER SCREEN ······························ 4-12
MAINTENANCE ·······················································4-19 ENGINE REMOVAL ······················································· 8-4
BRAKE LOCK OPERATION ·········································4-20 EXHAUST PIPE/MUFFLER·········································· 3-19
BRAKE MASTER CYLINDER·····································16-12 FINAL DRIVE OIL························································· 4-14
F
BRAKE PAD/DISC ························································16-9 FINAL REDUCTION BEARING REPLACEMENT ······ 12-10

BRAKE SHOES/PADS WEAR······································4-15 FINAL REDUCTION CASE ASSEMBLY ······················ 12-7
BRAKE SYSTEM ··························································4-16 FINAL REDUCTION CASE SEPARATION ·················· 12-6
BRAKE SYSTEM SPECIFICATIONS ·····················1-8,23-9 FINAL REDUCTION INSPECTION ······························ 12-8
CABLE & HARNESS ROUTING ·························1-14,23-15 FINAL REDUCTION SPECIFICATIONS ················ 1-7,23-8
C
CAM CHAIN GUIDE······················································9-29 FLYWHEEL/ALTERNATOR STATOR·························· 17-7

CAM CHAIN TENSIONER LIFTER·······························9-31 FORK································································ 14-11,23-27
CAM CHAIN TENSIONER SLIDER ······························9-30 FRONT COVER···················································· 3-6,23-23
CAMSHAFT ····································································9-9 FRONT FENDER···························································· 3-4
CHARGING SYSTEM ·················································17-12 FRONT HANDLEBAR COVER······································· 3-8
CLUTCH SHOES WEAR ··············································4-21 FRONT INNER COVER ················································· 3-6
CLUTCH/DRIVEN PULLEY ········································11-17 FRONT LOWER COVER ············································· 3-17
COMBINED BRAKE EQUALIZER (CBS TYPE) ·········16-16 FRONT SIDE COVER ·················································· 3-15
COMPONENT LOCATION FRONT TOP COVER ··········································· 3-4,23-22
BATTERY/CHARGING SYSTEM/ALTERNATOR····17-3 FRONT WHEEL·················································· 14-7,23-26
BRAKE SYSTEM······················································16-2 FRONT WHEEL/SUSPENSION/STEERING
COOLING SYSTEM ···················································7-3 SPECIFICATIONS·················································· 1-7,23-8
CRANKCASE/CRANKSHAFT ··································13-2 FUEL LID/CENTER COVER ········································ 3-18
CYLINDER HEAD/VALVES ·······································9-2 FUEL LID/SEAT OPENER ··········································· 3-13
CYLINDER/PISTON ·················································10-2 FUEL LINE ····································································· 4-5
ENGINE REMOVAL/INSTALLATION·························8-2 FUEL LINE INSPECTION············································· 6-25
FINAL REDUCTION ·················································12-2 FUEL METER/FUEL LEVEL SENSOR ······················ 20-11
FRONT WHEEL/SUSPENSION/STEERING ···········14-2 FUEL PUMP UNIT························································ 6-29
FUEL SYSTEM (Programmed Fuel Injection) ············6-2 FUEL SYSTEM (PGM-FI) SPECIFICATIONS········ 1-5,23-6
KICKSTARTER/DRIVE PULLEY/ FUEL TANK ·································································· 6-31
DRIVEN PULLEY/CLUTCH······································11-2 GENERAL SPECIFICATIONS································ 1-4,23-5
G
REAR WHEEL/SUSPENSION ·································15-2 GRAB RAIL ·································································· 3-12

CONNECTOR LOCATION HANDLEBAR······························································ 14-18
H
FUEL SYSTEM (Programmed Fuel Injection) ············6-8 HANDLEBAR SWITCHES·········································· 20-15

COOLANT REPLACEMENT···········································7-8 HANGER LINKAGE······················································ 15-9
COOLANT SYSTEM TESTING ······································7-7 HEADLIGHT AIM················································ 4-20,23-25
COOLANT TEMPERATURE HEADLIGHT/FRONT TURN SIGNAL LIGHT ····· 20-5,23-28
WARNING INDICATOR ··············································20-10 HORN ········································································· 20-17
COOLING FAN ·····························································7-10 IACV ············································································· 6-37
I
COOLING SYSTEM······················································4-13 IGNITION COIL ···························································· 18-7

COOLING SYSTEM SPECIFICATIONS·················1-5,23-6 IGNITION SWITCH····················································· 20-13
CRANKCASE ASSEMBLY ···········································13-8 IGNITION SYSTEM INSPECTION ······························· 18-5
CRANKCASE BREATHER ·············································4-7 IGNITION SYSTEM SPECIFICATIONS ················· 1-8,23-9
CRANKCASE SEPARATION········································13-5 IGNITION TIMING ························································ 18-8
CRANKCASE/CRANKSHAFT INJECTOR···································································· 6-44
SPECIFICATIONS ··················································1-7,23-8 INTAKE PIPE ······························································· 6-48
CRANKSHAFT INSPECTION·····································13-12 KICKSTARTER/DRIVE PULLEY/
K
CYLINDER ····································································10-4 DRIVEN PULLEY/CLUTCH SPECIFICATIONS····· 1-6,23-7

CYLINDER COMPRESSION TEST································9-7 LEFT CRANKCASE COVER········································ 11-6
L
CYLINDER HEAD ·························································9-14 LIGHTING CIRCUIT INSPECTION ······························ 20-4

CYLINDER HEAD COVER ·············································9-7 LIGHTING CUT RELAY·············································· 20-19
CYLINDER HEAD/VALVES SPECIFICATIONS ·····1-6,23-7 LIGHTS/METERS/SWITCHES
CYLINDER/PISTON SPECIFICATIONS·················1-6,23-7 SPECIFICATIONS·················································· 1-8,23-9
LUBRICATION & SEAL POINTS························ 1-12,23-13
D
LUBRICATION SYSTEM DIAGRAM ······························ 5-2
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INDEX
LUBRICATION SYSTEM SPECIFICATIONS········· 1-5,23-6 LUBRICATION SYSTEM ··········································· 5-3
LUGGAGE BOX ··························································· 3-11 MAINTENANCE ························································· 4-2
MAIN PIPE SIDE COVER ············································ 3-16 REAR WHEEL/SUSPENSION ································· 15-3
M
MAIN PIPE UPPER COVER ·········································· 3-5 SERVICE RULES ··························································· 1-2
MAINTENANCE LID······················································· 3-9 SIDE GARNISH ······························································ 3-5
MAINTENANCE SCHEDULE········································· 4-4 SIDESTAND ································································· 4-21
MIL CIRCUIT INSPECTION ········································· 6-24 SIDESTAND SWITCH ·················································· 18-8
MIL CODE INDEX ························································ 6-14 SPARK PLUG ································································· 4-7
MIL TROUBLESHOOTING ·········································· 6-15 SPEEDOMETER ················································20-7,23-29
MODEL IDENTIFICATION ····································· 1-2,23-4 STANDARD TORQUE VALUES···························1-9,23-10
NUTS, BOLTS, FASTENERS ······································ 4-22 STARTER MOTOR······················································· 19-6
N
O2 SENSOR································································· 6-47 STARTER PINION······················································ 19-10

O
OIL PUMP ······································································ 5-4 STARTER RELAY ······················································ 19-11

PGM-FI (Programmed Fuel Injection) SYSTEM············· 2-2 STEERING HEAD BEARINGS ····································· 4-24
P
PGM-FI SYMPTOM TROUBLESHOOTING··················· 6-5 STEERING STEM······················································· 14-21

PGM-FI SYSTEM DIAGRAM ········································· 6-7 SUSPENSION ······························································ 4-21
PGM-FI SYSTEM LOCATION········································ 6-6 SYSTEM DIAGRAM
PGM-FI TROUBLESHOOTING INFORMATION·········· 6-10 BATTERY/CHARGING SYSTEM/ALTERNATOR···· 17-2
PILLION STEP BRACKET ··········································· 3-11 ELECTRIC STARTER SYSTEM ······························ 19-2
PISTON ········································································ 10-7 IGNITION SYSTEM·················································· 18-2
POWER SUPPLY CIRCUIT ········································· 2-17 SYSTEM FLOW PATTERN ············································ 7-2
RADIATOR ··································································· 7-10 SYSTEM LOCATION
R
RADIATOR COOLANT················································· 4-13 BATTERY/CHARGING SYSTEM/ALTERNATOR···· 17-2

RADIATOR COVER ····················································· 3-12 ELECTRIC STARTER SYSTEM ······························ 19-2
RADIATOR RESERVE TANK ······································ 7-11 IGNITION SYSTEM·················································· 18-2
REAR CENTER COVER ·············································· 3-11 THERMOSTAT ····························································· 7-11
T
REAR COMBINATION LIGHT······································ 20-6 THROTTLE BODY························································ 6-39

REAR DRUM BRAKE··················································· 16-6 THROTTLE OPERATION··············································· 4-5
REAR FENDER/REAR INNER FENDER····················· 3-15 TROUBLESHOOTING
REAR HANDLEBAR COVER········································· 3-8 BATTERY/CHARGING SYSTEM/ALTERNATOR···· 17-6
REAR INNER LOWER FENDER ······························· 23-24 BRAKE SYSTEM ····················································· 16-5
REAR SHOCK ABSORBER········································· 15-8 COOLING SYSTEM ··················································· 7-6
REAR WHEEL/SUSPENSION CRANKCASE/CRANKSHAFT·································· 13-4
SPECIFICATIONS·················································· 1-7,23-8 CYLINDER HEAD/VALVES ······································· 9-6
REAR WHEEL/SWINGARM········································· 15-5 CYLINDER/PISTON ················································· 10-3
REGULATOR/RECTIFIER ········································· 17-13 ELECTRIC STARTER SYSTEM ······························ 19-4
RESISTOR ································································· 20-21 ENGINE DOES NOT START OR
RIGHT SIDE COVER ··················································· 17-7 IS HARD TO START ················································ 22-2
SEAT ············································································ 3-10 ENGINE LACKS POWER ········································ 22-3
S
SENSOR UNIT ····························································· 6-34 FINAL REDUCTION ················································· 12-5

SERVICE INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM··········· 3-3
BATTERY/CHARGING SYSTEM/ALTERNATOR ··· 17-4 FRONT WHEEL/SUSPENSION/STEERING ··········· 14-6
BRAKE SYSTEM ····················································· 16-3 IGNITION SYSTEM·················································· 18-4
COOLING SYSTEM··················································· 7-4 KICKSTARTER/DRIVE PULLEY/
CRANKCASE/CRANKSHAFT ································· 13-3 DRIVEN PULLEY/CLUTCH ····································· 11-5
CYLINDER HEAD/VALVES······································· 9-3 LUBRICATION SYSTEM ··········································· 5-3
CYLINDER/PISTON ················································ 10-3 POOR HANDLING ··················································· 22-6
ELECTRIC STARTER SYSTEM······························ 19-3 POOR PERFORMANCE AT HIGH SPEED ············· 22-6
ENGINE REMOVAL/INSTALLATION ························ 8-3 POOR PERFORMANCE AT LOW
FINAL REDUCTION ················································ 12-3 AND IDLE SPEED···················································· 22-5
FRAME/BODY PANELS/EXHAUST SYSTEM ·········· 3-3 REAR WHEEL/SUSPENSION ································· 15-4
FRONT WHEEL/SUSPENSION/STEERING··········· 14-3 TURN SIGNAL LIGHT RELAY ··································· 20-18
FUEL SYSTEM (Programmed Fuel Injection) ··········· 6-3 UNDER COVER ··························································· 3-17
U
IGNITION SYSTEM ················································· 18-3 VALVE CLEARANCE ····················································· 4-9

V
KICKSTARTER/DRIVE PULLEY/ WATER PUMP······························································ 7-13

W
DRIVEN PULLEY/CLUTCH ····································· 11-3 WHEELS/TIRES ··························································· 4-22

LIGHTS/METERS/SWITCHES ································ 20-3 WIRING DIAGRAMS ··········································21-2,23-30

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TÀI LIỆU

HƯỚNG DẪN SỬA CHỮA

Honda Air Blade 110 Fi (AB Thái)

Improper set-up or pre-delivery service can create

For Your Safety

Failure to properly follow instructions and precau-

Important Safety Precautions

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You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

© Honda Motor Co., Ltd.

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Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use silicone grease.

Use fork or suspension fluid.

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REAR BRAKE CABLE THROTTLE CABLE

FUEL LID OPENER CABLE

SPEEDOMETER SUB HARNESS

FRONT BRAKE HOSE

FUEL FEED HOSE

REAR BRAKE CABLE

SIDESTAND SWITCH WIRE

SIDESTAND SWITCH WIRE

SIDESTAND SWITCH WIRE

REAR BRAKE CABLE

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ENGINE SUB HARNESS

FUEL PUMP 5P CONNECTOR

SEAT LOCK CABLE GROUND

5 mm MAX. STARTER MOTOR WIRE

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STARTER MOTOR WIRE

STARTER MOTOR WIRE

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MAIN WIRE HARNESS

ENGINE SUB HARNESS

O2 SENSOR 1P (BLACK) CONNECTOR

STARTER MOTOR WIRE ALTERNATOR/CKP SENSOR WIRE

ENGINE SUB HARNESS

RADIATOR SIPHON HOSE

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Band screw direction:

SPARK PLUG WIRE

SEAT LOCK CABLE

RADIATOR SIPHON HOSE

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REAR COMBINATION LIGHT 6P

MAIN WIRE HARNESS

CRANKCASE BREATHER HOSE

MAIN WIRE HARNESS

REAR BRAKE CABLE

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STARTER MOTOR CABLE To be butted

RADIATOR SIPHON HOSE