Honda CB900F 919 Service Manual converted

FRONT WHEEL/SUSPENSI

ON/

STEERING

Install the oil seal

its marked

with

side facing up.

Before assembly, wash all parts

non

-flammable

Install a been removed.

I NO

• Be ca

new

TI

refulnot to

forktube

CE I

solvent

damage

and

wipe

bushingifthe

the fork t

coating.

• Do

not

open

the

fork

tube

bushing

necessary.

• Remove the being

Install the new s

da

mage

rem oved.

Remove

being careful

Install seal o

nto

careful

the

burrs fr om th e

the

slider

the

burrs

from

nottopeel

lider

coat

ing

not

to peel

bushing,

fork

slider.

the

bushing

off

bushing being careful

of th e

bush

off

the coating.

back-up

withahigh

them

tube

ube

more

mating

the

coating

ing if it has been

ing mating surface,

ring

flash or

dry.

bushing has

bush

ing

than

surface,

.

and new

not

oil

to

BACK-UP RING

~

If the fork damper

turns together

wit

h the socket

bolt, temporarily

install the fork

sonnq. spring

seat.onto cof/ar

and fork bolt.

tube

sealing

specif

Ibf.f

.

tools

t)

.

bolt

washer

ied

torque.

threads.

.

Install the fork slider into the fork

Drive

the

oil seal in usi ng

TOOL:

Fork sealdriver Fork

seal

Apply

a locking agent to

Install

the

Hold the axle holder in a vise w ith soft jaws or a shop

towel.

Tighten

TORQUE: 20 N

the

driver

socket

fork

weight attachme

bolt

socket

·m

12.0 kgf-rn, 14

the

special

07947-KA50100 07947-KA40200

nt

the

fork socket

withanew

bolt

to the

l.

ATTACH~M~

EN~T

~

o

U;

\ SOCKET BOLT/SEALING WASHR

S

\

SLIDER BUSHING

ATTACHMENT

I

\

13-21

FRONT WHEEL/SUSPENSION/STEERING

Install the fork damper assembly and oil lock piece

into the fork tube.

-

Install the stopper ring into the fork slider groove

securely.

Install the

dust

seal.

/"

DAMPER ASSEMBLY

DUST SEAL

_ _

OIL LOCK

....S..

TOPPER RING

/

PIECE

13-22

Pour the specified amount of recom

into the fork tube.

RECOMMENDED FORK FLUID:

Pro Honda Suspension Fluid

FORK FLUID CAPACITY:

e 2.5 em' 115.7

463 oz)

Pump the dampe r rod several times.

~

55-8

0.08 US oz, 16.3~0.09

men

ded fork fluid

-.

Imp

FRONT WHEEL/SUSPENSION/STEERING

Be sure the oil

is the same

level

both

in

forks.

Measure

while

the

damper

FORK OIL LEVEL: 155 mm 16.1 in)

Pull

the tapered end facing

Screw the

the oil level

compressing

fork

tubeslowly

rod

more

the

damper

from

the

tube

morethan5times

than10times

rod up

and

install

down

rod end

nut

the

all

.

the

fully

topofthe

way

.

the

forkspring

by hand.

after

fork

stroking

and the

tube

with

-

...

NUT

~

OIL LEVEL

Insta ll

Install a

Apply

Hold

the

dampe

Hold the

ified

torque

the

spring

seat and

newO-ringonto

fork f

luid

to the

damper

r rod

fork

rod

unti

litseats on the

bolt and

.

the

new

and sc

tighten

spring

fork bolt.

O-ring.

rew

the lock

collar

the

fork bolt o

damper

.

rod lock nut.

nut

to the spec-

nto

FORK SPRING

SPRING COLLAR

<.

SPRING SEAT

the

TORQUE: 22 Nom 12.2

kgf

om. 16 Ibfoft)

13-23

FRONT WHEEL/SUSPENSI

Screw the fork bolt in to the fork tube.

Install the fork protector onto the fork slider, aligning the protector boss with the groove in the fork slider.

ON/

STEERING

FORK BOLT

-.

PROTECTOR

~

INSTALLATION

Install the

Align the top end of the for k tube with the upper sur-

face of the top

Tighten the

torque.

TORQUE: 39 N'm(4.0 kgf·m. 29 Ibf·ft)

fork

bottom

tube

into

thebottom

bridge

.

bridge pinch bolt to the specified

bridge.

•

13-24

Tighten the fork bolt to the specified torque if it was

removed.

FRONT WHEEL/SUSPENSION/STEERING

TORQUE: 22

Install th e foll

ont

- Fr

- Front wheel (page 13-14)

fender (pag e 2-31

STEERING STEM

REMOVAL

Remove the followi ng:

- Handl ebar (page 13-3)

-

front

wheel

- Combin ation meter (page 19-8)

- Fork (page 13-151

Remove the socket bolts/nuts and headl ight/meter mount stay.

N·m

(2.2

owing

:

(page 13-10)

kqf-m

, 16

Ibf·ftl

Remove the bolt and front brake hose clamp.

Remove the stem nut, washer and the top bridge.

STEERING STEM NUT

13-25

FRONT WHEEL/SUSPENSION/STEERING

Remove the

stem.

Straighten the tabs of the lock

Remove the lock washer and lock nut.

turnsignal

light

bracket from the steering

washe

r.

LOCK NUT

\

Remove the steering stem bearing adjusting nut

using

the special

TOOL:

Steering

Remove th e

- Oust seal

-

- Upper bearing

Upp

er bearin g

stem

tool.

socket

followin

inner

07916-3710101

g:

race

STEERING STEM SOCKET

13-26

FRONTWHEEL/SUSPENSI

ON/

STEERING

Note the installa -

tion direction

the

assembly

base.

Always replace

the bearing races

as a

set

- Steering stem

of

- Lo

wer

bearing

BEARING RACE REPLACEMENT

Replace

ciaI to ol.

TOOLS:

Ball race remover Ball race remover set

- Remover

.

- Driver s

the

upp

attachment

haft

er bearing outer races

07953 07953 07946 07946

using

the

-4250002

-MJ10000

-MJ

10100

- M

J1020

0

spe-

or

~

,--

__

ATTACHMENT

DRIVER SHAFT

/

Replace the cial

tool.

TOOLS:

Ball race remo ver Ball race remover

Tempo stemtoprevent when

lower

rarily

removing

install

stem.

Removethe

equivalent

Remove

the

lower

tool,

dust

bearing

the

bearing

being

seal.

the

threads

lower

careful

outer

steering

frombeing

bear

ing

inner

nottodamage

races

using

07953

-3710500

07953-4250002

stem

nut

onto

damaged

inner

race f

race

with

a chisel or

the

rom

spe-

the

stem.

REMOVER

LOWER INNER RACE

13-27

FRONT WHEEL/SUSPENSION/STEERING

I"-

~

ASSEMBLY

: BEARINGS : BEARING RACES : DUST SEALS

TOP BRIDGE

STEERING STEM NUT

~WASHER

~

_

~

LOCK NUT

LOCK WASHER

~TOPTHREAD

~

• UPPER DUST SEAL

Jfi

. UPPER INNER RACE

UPPER BEARING

UPPER OUTER RACE

- LOWER BEARING

LOWER INNER RACE

~

------

• LOWER OUTER RACE

..

LOWER DUST SEAL

STEERING STEM

Apply grease to the over the steering stem. Install a new lower bearing inner race using a special

tool and a hydraulic press.

TOOL:

Steering stem driver 0794

Remove the lower bearing outer race using the spe-

cial tools.

TOOLS:

Driver handle

Attat

chment

Remove the upper bearing outer race using the spe-

cial tools.

42x47

new

dust seal lips and install it

6-M

BOOOOO

07749-0010000 07749-0010

DUST SEAL

300

13-28

TOOLS:

Driver handle

Attatchment

42x47

0

7749-0010000

07749-0010

300

INNER RACE

Apply

Insert

grease to the

the

steering stem

lower

bearing and bear

into

the steering head pipe.

ing

FRONT WHEEL/SUSPENSION/STEERING

race.

~

LOWER BEARING

..

-$iiiffi

~

Apply

grease to the

dust

seal lip .

Instal l the seal.

Apply

oil to the bearing

Install and

the initial

upper

tighten

torque.

upper

bearing bearing race and

bearing,

the stem bearing

upper

adjustment

inner

nut

race and

threads.

adjust

ing

nut

dust

to

~

J

INNER RACE --_

I

--:c

TOOL:

Steering stem

TORQUE: 25

Move

the steering

fivetimes

Make sure

w

ithout

to seat the bearings .

that

play

soc

ket

N'm

(2.5 kqf-rn, 18

stem

the steering stem

or b

inding;then

07916-3710101

Ibf·ll)

right

and left, lock-to-lock,

moves

loosen the

smoothly,

top

thread.

STEERING STEM SOCKET

13-29

FRONT WHEEL/SUSPENSION/STEERING

Retighten the bearing adjusting nut to the specified

torque.

TORQUE: 25 N·m12.5 kqf -m, 18 Ibf-ttl

Recheck that the stee ring stem out play or binding.

Install the new lock washer onto the steering stem.

Align the tabs of the lock washer with the grooves in the adju stment nut and bend two opposite tabs

(shorter) down into the adjustment nut groove.

Install and Hold the lock nut and

in 1/4 turn (90·) enough to align its grooves w ith the

lock

washer

fing

er tighten the lock nut.

furt

tabs.

her

tig

moves

smoothly

hten the lock

with-

nutwith-

ADJUSTI NG NUT

~

e

~

LOCK WASHER

Bend the lock washer tabs up into the lock nut groove.

Install the turn signal light bracket.

BRACKET

13-30

FRONT WHEEL/SUSPENSION/STEERING

Install the top bridge, stem nut and washer.

Temporarily install the front fork.

Tighten the steering stem nut to the specified torque.

TORQUE: 103

N'm

(10.5

kqf-m,

761bf·1t)

WASHER STEM

..

NUT

Install the

the specified torque.

TORQUE: 12

Install the headlight case/meter mount stay and

en the socket bolt/nut.

Install the

- Front fo rk (page 13-15)

- Handlebar (page

-

Combination

front

brake hose clamp,

N'm

(1.2

following

:

13-51

meter

kgf.m,9Ibf·ltl

(page 19-8)

tighten

the

bolt

tiqht

to

-

13-31

FRONT WHEEL/SUSPENSION/STEERING

STEERING HEAD BEARING PRE-LOAD

Make sure that

no cable

there is

or wire harness

interference.

Jack-up g

Positi on th e stee posi Hook steering

The pre kqf If front bearing

the

motorcycle to raise th e

rou

nd.

ring

stemtothe

tion

.

a sp ring scaletothe fo rk tube and

head bearing pre

-load

-m ),

the

readingsdonot wheel

adj

usting

shouldbewithin

to the

nut.

gro

-load

fall

und

front

w heel offthe

straig

ht ahead

measure

,

10 - 15 Nom (1.0 - 1.5

withinthe

and

limits.

adjust

the

lower

stee

the

ring

13-32

REAR WHEEL/SUSPENSION

____

-<::-~

~

42 Nom (4.3 kqf-m, 31 IbfO"ft).-

...-fYCI

9 Nom (0.9 kgfom, 6.5 lbf-ft)

93 Nom (9.5 kqf-rn , 69 lbf-ft)

~

/

14-0

14.

REAR

WHEEL/SUSPENSION

SERVICE INFORMATION TROUBLESHOOTING REAR WHEEL

14-1 14-2 14-3

SHOCK ABSORBER SWINGARM

SERVICE INFORMATION

GENERAL

A contaminated brake disc or pad reduces s withahigh After

The shock

Before disposalofthe shock abso rber, release the nit When

Use only tires marked "TUBELESS·and tubeless valves on rims marked "TUBELESS TIRE APPLICABLE:'

Use

genu

Refer to section 15

quality

the rear wheel insta llat

abso

servicing the rear

ine Honda replaceme nt

brake degreasing a

rber contains nitrogen

whee

for

brake sys

ion

. check

l and suspens

bolts

tem

information.

topp

gent

.

the

brake o

und

er high pres

ion,support

and

nuts

ing power. Discard con

perationbyapplying

sur

roge

for

all suspens

e. Do not a

n (page 14-13).

the

motorcycle

ion

llow

pivot

tam

inated pads and clean a contaminated disc

the brake pedal.

fire or heat near

usingasafety

and

mount

stand or

ingpoint

the

shockabso

hoist

.

14

-10

14-14

rber.

.

SPECIFICATIONS

Minimum

Cold tire pressure Driver

Axlerunout Wheelrim

Wh

Drive c

tir

e tread depth

runout

eel balanceweight

hain

Dr

Radial

Axial

Sizellink DID DID525VM2-112LE

Slack 25 - 35 (1 - 1-3/8)

Unit:mm

ITEM STANDARD SERVICE LIMIT

only

iver

and passenge r

--

290 kPa (2.90 kgf/em' , 42 psi) 290 kPa (2.90 kgf/em', 42 psi)

--

- -

--

2.0 (0.08)

--

0.2 (0.01)

2.0 (0.08)

2.0 (0.08) 50g (2.1oz)max.

--

RK

RKGB525R

Ol

1-112LE

--

(in)

14-1

REAR WHEEL/SUSPENSI

TORQUEVALUES

ON

Rear brake disc

Final driven sprocket nut

Rear axle nut Rear shock absorber mounting nut

Drive chain slider flange bolt

Swingarm pivot nut

bolt

TOOLS

Bearing Bearing remover head, 20 Driver

Attachment, 32 X 35 Attachment, 42 X 47 Attachment Attachment, 37 X 40 Attachment,

Pilot. 17

Pilot, 20 Pilot, 28 Attachment,

Bearing remover hand le

Bearing remover head

Remover we ight Outer driver, 37

TROUBLESHOOTI

remov

, 52 X 55

22 X 24

mm

28 X 30

er shaft

mm

mm mm mm mm mm

mm

NG

42 Nom (4.3 kqf-rn, 31 lbf-ft} 108 Nom (11.0 kqf-rn, 80 lbf-tt) 93 Nom (9.5 kg10m, 69 lbf-ft ) 42 Nom (4.3 kglom, 31

kqf

9 Nom (0.9 93 Nom (9.5 kqf-rn , 69

07GGD-0010100 0774EHl050600 07749-0010000 0

774EHlOl0l00 0774EHlO10300 0774EHlOl0400 0774EHlOl0 200 0774EHlOl0800 0774EHl040400 0774EHl040500 0774EHl041100 07

94607936-3710100 07936-371060 0 07741-0010201

D-M

07ZM

-rn, 6.5 lbf-ft)

1870100

BW0200

Ibl

lbf

olt)

-ft)

Al

o e bolt: replace

U-nut

If-nut

U-nut AlO

e bolt: replace with a

If-n ut

withanew

new

one

Soft

suspension

Weak shock abso rber

Incorrect suspension adjustment Oil leakage from Insufficient tire pressure

Hard suspension

Incorrect suspension adjustment Damaged rear suspension pivot bearings Bent

damper

Incorrect swingarm pivot fasteners tightening

Tire pressure too high

Rear w heel

Bent rim Wornordamaged

Faulty rear tire

Unbalanced rear tire and Insufficient rear tire pressure Faulty swingarm pivot bearings

Rear

whee Faulty rear w hee l bearings Bent rear axle Rear brake drag Drive chain too tight

rod

wobbl

l turns hard

damper

ing

rear

spring

unit

wheel

bearings

Rear suspension noise

Faulty rear shock absorber loose

rear suspension fasteners

Worn rear suspension pivot bearings

14-2

REAR WH EEL

REM

Supp

hoist, raise the rear

OVAL

ort

themotorcycle using a safety stand or a

whe

el off the ground.

REAR WHE

EL/

SUSPENSION

Remove

Derail thedrive chain

remove the rear w heel.

Remove the right side collar and

wheelright

the

axle

nut

rear axle .

side.

and

washe

from

thedriven sprocket,

r.

then

dust

seal

from

the

Remove the

wheel left side.

left

side collar and dust seal f

rom

the

14-3

REAR WHEEL/SUSPENSION

INSPECTION

Axle

Place the axle in V-blocks and measure the

Act

ual run out is 1/2 the

tota

l indicatorreading.

runo

ut.

Replace the

wheel bearings

pairs.

SERVICE LIMIT: 0.2

Wheel

in

bearing

Turn

the

inn

Be

arings

should turn smoo

Also check t hat

the hu b.

Remove and discard the bearings

not

turn smooth ly and quiet ly, or if they fit

in the

hub

.

Wheelrim Check turn ing stand. Spin dial indica Actual runout is 1/2 the total indicator reading.

runout

the

rimrunout

the

w heel slowly and read the run out using a

tor

mm

10.01

in)

er raceofeach bearing

thl

y and qu

the

bearing oute r race

by pla cing th e wheel in a

.

if the races do

withyour

ietly

.

fit

s t i

loosely

finger

ghtl

.

y in

WHEEL BEARING

the final driven

If

sprocket requires

replacement

inspect the drive

chain and drive

sprocket.

N

ever

install a

new

driv

ona on

sprocket

in

or the replacement

chain

will

e chain

Il\Iom

sprocket

or a worn chain

new

sprockets.

Both

chain

and

must

good

orsprocket

wearrapidly.

be

condition

14-4

SERVICE LIMITS: Radial: 2.0

Axial: 2.0

Driven Check

sprocket

the

con

ditionof

Replace the sprocket

the final d

if

wornordamage

mm

10.08in )

mm

10.08 in)

riv

en sprocket teeth.

DIAL GAUGE

d.

(i

DAM

~R

W

'

:~

M

AL

DISASSEMBLY

REAR WHEEL/SUSPE NSION

If you will be

disassembling the

driven flange.

loosen the driven

sprocket nuts before removing the driven flange

from the

wheel

hub.

Remove

Remove wheel

hub

the

bolts

the

drivenflange

.

and brake disc.

assemblyfrom

the

left

Remove the

Remove

Driven Loosen the

Remove the driven flange f

r

emove

Remove the

the

flange

the

wheel

Ocrinq.

bearing

driven

damper

removal

sprocket nuts.

sprocket

flange

rubbers

bearing and colla r.

.

rom

the w heel hub, then

nuts

and sprocket.

14

-5

REAR WHEEL/SUSPENSION

Wheel bearing removal

Install the bearing remover head into the bearing. From the opposite side install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other

bearing .

TOOLS:

Bearing remover head, 20

Bearing

remover

shaft

ASSEMBLY

108 Nom (11.0 kqf-rn.

31 Ibfoftl

-,

mm

07746-0050600

07746-0050100

DRIVEN SPROCKET

BRAKE DISC

DISTANCE COLLAR

Wheel bearing installation

Drive in a new right bearing .

TOOLS:

Driver

Attachment, Pilot,20mm

42 X 47

mm

07749-0010000 07746-0010300 07746-0040500

~

S

O-RING

LEFT WHEEL BEARING

DRIVEN FLANGE

14-6

REAR WHEEL/SUSPENSION

Never install the

old bearings, once

the bearings have

been removed,

the bearings

be replaced

must

with

newones.

Install

the

Driv

dista nce

e in t he l

eft

side

colla

bear

r

ing using

the

same

too

ls.

Drive the driven flange bearing out using the special

too

ls.

TOOLS:

Driver

Attachment. 28 X 30 mm

Pilot, 20

Driven flangebearing

Drive t he flange using th e spec ial

TOOLS:

Driver

mm

new

installat

driven flange

Attachmen1.52 X 55 mm

Pilot . 20

mm

too

0774~010000

07746-1870100 07746-0040500

ion

bearinginto

ls.

0774~010000

07746-0010400 07746-0040500

the

driven

OUTER DRIVER

the

Install

Apply

wheel

'

oil

to the

groove of the

If

the

driven

sprocket

and

damper

new

whee

l hub.

sprocket

temporarily

rubbe

rs into

the

O-ring and install it

wasremoved,

tighten

the

insta

nuts

wheel

ll the .

into

driven

hub

the

PILOT

.

SPROCKET

14

-7

REAR WHE

EL/

SUSPENSION

Install the d

wheel

TORQUE: 108

Install the brake

facing

Install and

to

rque.

TORQUE: 42 N·m

hub

out

riven

.

N'

.

tig

flange

assembly

m 111.0kgf·m. 80 Ibf·ft)

disc

with

its

hten the

14.

3 k

new

gf.m.

into the left

rotating

boltstothe

31 Ibf·ft)

direction

specified

mark

WHEEL BALANCE

The

wheel

remounted

For

optimum

dot

on the s

stem

. Rem ount the

Note

the

tire .

balance

.

ide

rotatingdirection

must

balance, the

wall)

must

tire

be checked w hen the tire is

tire

balance

be located

if necessary.

marks on

mark(apaint

nexttothe

the

wheel

valve

and

BALANCE

MARK

14-8

ROTATING DIRECTION MARKS

Mount

the

wheel,tire

inspection stand.

Spin

the

wheel, est(heaviest) Do

this

twoorthree

the

wheel

If the

same

To balance

l

ightest

Add stopinthe Do

sideofrim,

just

not

add

enough

allow

partofthe

is balanced, it

position

the

same

more

wheel,

.

weightsothe

posit

than

INSTALLATION

Apply

right

grease and

side.

install

and

brake disc

it to stop, and

wheel

w ith chalk.

timestoverify

will

not

install

balance

the

side

opposite

wheel

ion

when

it is

60 9 (2.1 oz)tothe

the

new

assembly

mark

the

heaviest

stop

consistently

weightsonthe

the chalk marks.

willnolonger

spun.

rear

dust

seal to

the

wheel.

the

REAR WHEEL/SUSPENSION

on an

low-

area.

in

Apply

grease and

install

the

dust

seal to

the

left

side.

/

Apply

grease to the side collars inside and grooves.

Install

the

side

collars

.

14-9

REAR

WHEEL/SUSPENSION

Install the rear brake caliper bracket onto the guide of

the swingarm.

Be careful

damage the brake

not

pads.

to

Place the rear wheel into the swingarm. Install the drive chain over the driven sprocket. Install the rear axle from the left side.

Install the washer and axle nut.

Adjust

thedrive chain slack (page 3-10).

Tighten the axle nut to the specified torque .

TORQU E: 93

N'm

(9.5 kq

f-m,69lb

f-ft]

SHOCK ABSORBER

REMOVAL

Remove

Remove the side cover (page 2-2).

Secure the motorcycle using a hoist or an equivalent.

Loosen the shock absorber reservoir band screw and remove the reservoir from the inner fender.

the

seat (page 2-21.

14-10

BAND SCREW

REAR

WHEEL/

SUSPENSION

Remove the shock abso rber

Remove the shock and

the

shock absorber.

absorber

lower

mou

nting

uppermounting

bolt/nut.

bol

t/nut

UPPER BOLT NUT

MOUN

T

INSPECTION

Check the for Check the

Inspect all the Replace the shock

NEEDLE BEARING REPLACEMENT

Remove the

damper

leakage or

upper

unit, reservoir hose and reservoir

other

pivot

damage

joint

parts

absorber

collar

.

bushing

for

wearordamage

for

wear

or damage.

assembly if necessary.

and

dust

seals.

.

r

\

/

SHOCK ABSORBER

(J

SEALS

o

I

PIVOT COLLAR

"

DUST

14

-11

REAR

WHEEL/SUSPE NSION

Press the needle

bearing into the

lower mount with

the marked side

facing out.

Press out the

absorber

TOOLS:

Driver

Atta

chment, 22 X 24 mm

Pilot, 17

Press a new needle bearing into the lower

that the needle bearing surface is lower 7.4 - 8.0

10.29- 0.32 in)

the s

mm

ame

needle

lower

mount using the special tools .

from

tools.

bearing out of the shock

the

endofthe

04949-3710001 or 0794

6-MJ00100 07746-00 07746-0040400

lower

10800

mount

so

mm

using

ATTACHM ENT DRIVER

ATTACHEMENT HANDL

,

...........

7.4 - 8.0

mm

E

PILOT

Apply grease to the into the lower

Install

the

pivot

mount

collar

new

dust seal lips, install

.

them

o

/ D

DUST SEALS

14-12

SHOCK ABSORBER DISPOSAL

PROCEDURE

REAR WHEEL/SUSPENSION

Remove the da

Release the nitrogen

the valve

I

NOTICE

Po

int

g

ett

ing in your eyes.

Before

core

.

mperreservo

from

ir cap.

the res

ervoir

I

the

valveaway

dispo

salofthe shock absorber, release th e

fro m you to

by depressing

pre

vent

nitrogenbypressing the valve core. Then remove

the

valvefrom

the shock

absorber

res

ervoir

.

INSTALLATION

Install

the

shock absorbe r int o

reserve tan k Install the upper and

Ti

ght

en the upper

torqu

e.

TORQUE: 42

outlet

N'm

14.3

facing to the left.

lowermounting

mount

kqf-m,

ing

nut

31

the

frame with

bolt/n ut.

to the spe

Ibf

·ftl

debris

the

cified

UPPER

MOUNT

BOLT NUT

Tighten the low er

mountingnut

to

the specifi ed

to rque.

TORQUE: 42 Nsm 14.3

Insta ll

the

rese

rvo

ten the

Tigh

Install the removed parts in the reverse order of

removal.

band screwsecur

kgf'm,

31

lbf-ft}

ir intothe reservoir band.

ely

.

BAND SCREW

14-13

REAR WHEEL/SUSPENSION

SWINGARM

REMOVAL

Remove the rear wh eel (page 14-31.

Remove the socket bolts and drive chain case.

Remove the swingarm pivot cover.

CHAIN CASE

SOCKET BOLTS

Remove the swingarm pivot nut and was her.

Remove the swingarm pivot bolt and swingarm.

DISASSEMBLY/ INSPECTION

Remove the bolts and drive chain adjuster.

14-14

~

CHAIN

ADJUST

BOLTS

REAR WHEEL/SUSPENSION

Remove the

Check the

Remove

swinga

Check

fatigue .

the

rm left

the

bolts

drive

dust

chain

pivot

seals and

and

.

drive

slider

collar

chain slider.

for

wearordamage

and

dust

collars

seals

for

from

damage

CHAIN SLIDER -

.

the

or

-~

DUST SEALS ·

BOLT

o

p

Turn

the

inner raceofright

finger

that

.

smoothly

.

the

should

bearing

and

quietly,orifthey

your The bearings

check

hub Remove and discard the bearings if the races do

turn

pivot.

turn

pivot

smooth

outer

bearings w ith

ly and quietly. Also

race

fits

tightlyinthe

fit

looselyinthe

not

SIDE COLLARS

\

DISTANCE COLLAR

14

-15

REAR WHEEL/SUSPENSION

P

IVOT

BEARING REPLACE

MENT

LEFT

PI

DISTANCE

COLLAR

DUST SEAL

(28x 37 x 41

VOT NEEDLE BEARING

~~;;:;:;;;:;:;iiC

Remove the snap ring.

=if

!-

DUST SEAL

-

(28x 37 x 4)

SIDE COLLAR

DUST SEAL

(27 x 34 x 4)

RIGHT PIVOT BEARING (20

x 37 x 91

DUST SEAL

(28x 37 x 4)

SNAP RING

14-16

Remove the right pivot radial ball bearing using the

special tools .

TOOLS:

Bearing remover handle Bearing remover shaft set, 20mm

Removerweight

07936-3710100 07936-3710600

07741-ll010201

REAR

WHEEL/SUSPENSION

Press the cial

tools

and a hydraulic press.

TOOLS:

Driver

Attachment

Pi

lot

, 28

mm

ASSEMBLY

NEEDLE BEARING

left

pivot

, 32 X 35

DUST SEAL

needle

mm

COLLAR

bear

ing

out using the spe-

07949-3710001 07746-001000 07746-0041

BALL BEARINGS

1

100

COLLAR DUST SEAL

l'

~~""

""

SWING ARM

DRIVER

OUTER DRIVER

PILOT

ousr

CHAIN SUDER

Press the needle

bearing into the

pivot

with

marked side

the

facing out.

ssxt,

~

\a:

~

Pack

Press until

press.

TOOLS:

Driver

Attachment.37mm

Pilot, 28

COLLAR

the

new

the

needle

it seats using

mm

BOLTS

need le bearing w ith grease.

bea

ring

the

into th e

specia l

swingar

tools

andahydra

07749-0010000 07ZMD-MBW0200 07746-0041100

,/

CHAIN ADJUSTER

m left pivot

ulic

OUTER DRIVER

14-17

REAR WHEEL/SUSPENSION

Press the radial ball bearing in using the special too ls and a hydraulic press.

TOOLS:

Driver

Attac

hment

, 32 X 35

P

ilot,20mm

Install the snap ring into the groove securely.

mm

0774~010000

0774lHlOl0l00 0774lHl040500

OUT

ER

DRIVER

PILOT

Apply

grease to the

seals into the left swingarm pivot. Fill the grease up between the inner dust seal and need le bearing. Install the pivot distance colla r.

Apply grease to the dust seal lips, then install the dust

seals and pivot collar into the right swingarm pivot.

Install the bolts and drive chain adjusters.

dust

seal lips,

then

install the

dust

SIDE COLLARS

p

DISTANCE COLLAR

"

14-18

REAR WHEEL/SU SPENSION

Install t he boss on

Install the

swingarm

Install and t ing

TORQUE: 9 Nsm (0.9

drive

the

swingarm

drive

.

igh

boltstothe

chain

ten

specified

the

slider .

slider

new

torque

kqf-rn,

, a

lign

ing

bosses into

drive

chain s

6.5 Ib

f.f

tl

theslitwith

the

hole

lider

mount-

the

in the

~~

;trZBOLT

INSTALLATION

Apply

a

thin

coatofgrease to theswingarm

slid

ing

surface.

Insta ll

the

swingarmonto

Install

theswi

swingarm

Install and ified

to rque.

TORQU E: 93

Install

the

pivot.

tighten

N'm

pivot

ngarm

theswinga rm

(9.5

bolt

the

frame.

pivot

bolt

kqf-m,69Ibf.ftl

collar

.

to

pivot

the

frame

nuttothe

bolt

and

spec-

14-19

REAR WHEEL/SUSPENSION

Install the socket bolts and drive chain case.

Install th e rear w heel (page 14-9),

CHAIN CASE

SOCKET BOLTS

14-20

HYDRAULIC BRAKE

FRO

NT:

15-0

(3 1 kqf-m, 22 lbf-ft)30 Nom .

15. HYDRAULIC BRAKE

SERVICE INFORMATION TROUBLESHOOTING BRAKE

AIR BLEEDING BRAKE PAD/DISC

REAR:

flUID

REPLACEMENT/

15-2 15-3

15-4 15-7

FRONT MASTER CYLINDER REAR MASTER CYLINDER FRONT BRAKE CALIPER REAR BRAKE CALIPER BRAKE PEDAL

10 Nem (1.0 kqf-rn, 7

lbf

15-10 15-15 15-19 15-23 15-26

-ft)

10 N-m (1.0 kqf-rn, 7 lbf-ft l

~

? o.s kqf-rn,

c-:

.f . .

"'"'"'"

15-1

HYDRAULIC BRAKE

SERVICE INFORMATION

GENERAL

A

CAUTION

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.

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contam inated discwith

a high quality brake digreasing agent.

Check the brake syste m by appl ying

Spilled brake fluid w ill 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 front reservoir is horizontal first. Never allow contaminates (dirt, water, Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.

Always use fresh DOT

as they may not be compatible . Always check brake operation before riding the moto rcycle.

4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid

the

brake lever or pedal after the air bleeding .

etc.) to get into an open reservoir.

SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT

Front Specified brake fluid DOT 4

Brake disc thickness Brake disc runout

Master cylinder I.D. Master piston O.D. 13.957 - 13.984 10.5495 - 0.5506) 13.945 (0.5490) Caliper cylinder I.D. A 30.230 - 30.280 11.1902 - 1.1921)

B

Caliper piston 0 .0 . A

B

Rear Specifie d brake fluid DOT 4

Brake disc thickness Brake disc runout Master cylinder 1.0. 12.700 - 12.743 (0.49999 Master piston 0 .0 . 12.657 - 12.684 10.4983 - 0.4994) 12.645 10.49781

Caliper cylinder I.D. 38.180 - 38.230 Caliper piston O.D. 38.098 - 38.148 11.4999 - 1.5019) 38.09 (1

4.3 - 4.7 10.17 - 0

14.000

27.000 - 27.050 (1.0630 - 1.0650) 27.06 (1.065)

30.148 - 30.198 (1.1869 - 1.1889) 30.14 (1.18

26.918 - 26.968 (1.0598 - 1.0617) 26.91 (1.059)

4.8 - 5.2 (0.19 - 0.20) 4.0 (0.16)

-14.04310

Unit

: mm (in)

--

.191

- -

.5512 - 0.5529) 14.055 (0.5533)

3.5 10

.141

0.310.012)

30.29 11.193)

--

0.30 (0.012)

38.24

11.5061 .5001

11

.053 - 1

- -

-0

.5017) 12.755 10.5022)

.5051

71

15-2

TORQUE VALUES

Front

mastercylinder Brake lever pivot Brake lever pivot nut Front bra ke light switch screw Front

maste

r cylinder mou nting bolt Front brake caliper Front brake caliper Rear

maste

r cylinder joint

Rear

master Rear brake caliper bolt Rear brake

cylinder

caliper

reservoir cap screw

bolt

assembly mounting

nut

mounting

bolt

Pad pin Pad pin plug

Brake hose oil bolt Brake caliper bleeder valve

mount

Footpeg brac ket Rear

master

cylinde r hose joint sc

ing bolt

TOOL

torx bolt

flange bolt

bolt

rew

1 Nom (0.1 kqf-rn, 0.7 lbf-ft] 1 Nom (0.1 kgfom, 0.7

lbf-

ft]

6 Nom (0.6 kqf-rn, 4.3 lbf-ft)

1 Nom 10.1 kqf-m, 0.7 lb

f-ft

12 Nom (1.2 kqf-m, 9 lbf-tt)

32 Nom (3.3 kqf-rn, 24 Ibf°ft) 30 Nom (3.1

kqf-rn, 22 lbf-ft)

17 Nom (1.7 kqf-m, 12 lbf-ft) 10 Nom (1.0 kqf-m, 7 23 Nom (2.3 kqf-m, 17

Ibf

lbt

-ft)

-tt)

27 Nom (2.8 kqf-rn, 20 lbf-ft) 17 Nom (1.7 kqf-m, 12

3 Nom (0.3 kqf-rn, 2.2

lbf

-ft)

34 Nom (3.5 kgfom, 25 lbf-tt l 6 Nom (0.6 kqf-rn . 4.3 lbf- ft ) 27Nom12.7 kgfom, 2.0 lbf-ft) 1 Nom (0.1 kgfom, 0.7 lbf-ft)

HYDRAULIC BRAKE

]

Appl

y a lock ing agent to

ALOC bolt

the

thr

eads

Snap ring pliers

TROUBLESHOOTING

Brake lever/ pedal soft or spongy

Air in hydraulic system Leaking hyd raulic system Contaminated brake pad/disc Worn caliper piston seal

master

Worn

Worn brake pad/disc

Contaminated ca

Caliper not sl Low brake fluid level Clogged fluid passage

Warped/defor med brake disc

Sticki

ng/ Sticking Contaminated

Bent brake

Brake leve

Clogged/restricted brake system Sticking

Caliper Clogged/restricted fl uid passage

Worn caliper piston seal

Sticking

Bent brake

cylinder piston cups

liper

iding

prope

worn

caliper piston

/worn

mas

ter

maste

r cylinder

lever

/pedal

r/pedal

/wo

notsliding

/worn

hard

rn calipe r piston

proper ly (rear)

maste r cylinder piston

lever

/pedal

rly (rear)

cylinder piston

07914

-SA

50001

Brake

drags

Con

taminated

ligned

Misa

Clogged/restricted brake hose joint

Warped

Cal

iper Clogged/restricted brake hydraulic system Sticking/w orn calipe r piston

Clogged

wheel

/defo

rmed

not

sliding

mast

er cyl inder po rt

brake pad/disc

brake

disc

properly

(rear)

15-3

HYDRAULIC

BRAKE

BRAKE FLUID REPLACEMENT BLEEDING

I NOTICE I

• Do

not

all

ow fo

reign

material

when

filli

ng the reservoir.

•

Avoid

spilling

part

s. Place a rag

system is serviced.

BRAKE

For the

voir is parallel to the

reservoir ca p.

Remove

Remove the

fron

thescrew

FLUID

t brake,

diaphrag

fluid

on

painted,plas

over

these

DRAINING

turn

the handlebar until the reser-

ground

, before removing the

s and reservoir cap.

m plate and diap

/AIR

to enter the

tic,orrubber

parts

whenever

hragm

system

.

the

SCREWS

\

PLATE/

DIAPHRAGM

=

(0~

I

CAP

the

Remove

Remove th e diaphrag m plate and

reservoir cap.

diap

RESERVOIR CAP

hragm.

15-4

HYDRAULIC BRAKE

Connect

Loosen pedal.

Stop

pumping

flows

a bleed hose to

the

bleed

the

outofthe

bleed valve.

valve

lever

the

caliper

and

pump

or pedal

bleed

valve

the

brake

lever

whennomore

.

or

fluid

Check the fluid

leve!

often

while

bleeding the

brakes to

pum

prevent

air from being

ped

into the

system.

If

air is entering

the bleeder from

around the bleed

valve threads,

seal the threads

with teflon tape.

BRAKE FLUID FILLING/BLEEDING

Close

the

bleed valve.

Fill

the

reservoir

container

.

NOTE:

Use

only

Do

not

compatible

Connectacommercially the

bleed

Pump

the adding der

When turers

Repeat do

Close

fluid

reservoirislow

using

operating

the

not

appearinthe

the

or pedal.

If it still feels

with

DOT 4 brake

mix

different

.

valve

.

brake

bleeder

when

a brake

instructions.

valve

spongy,

DOT 4 brake

fluid

from

typesoffluid.They

available

and loosen

the

fluid

level in

.

bleeding

step

tool,

procedures

plastic hose.

and

operate

bleed

the

system

fluid

from

a sealed

brake

the

master

follow

until

the

brake

again.

bleeder

bleed

the

air

a sealed

container

are

not

valve,

cylin-

manfac-

bubbles

lever

.

to

15-5

HYDRAULIC BRAKE

If a brake bleeder is not available, use the following procedure. Pump up the system pressure with the lever or pedal until lever or pedal resistance is felt.

Do not release

the brake lever or

pedal until the

bleed valve has

been closed.

Connect a bleed hose to

system as follows:

1.Squeeze the brake lever or depress the brake pedal, open the bleed valve 1/2 turn and then close

2. Release the brake lever or pedal until the bleed valve has been closed.

Repeat steps 1 and 2 until bubbles cease to appear in

the fluid coming out of the bleed valve.

the

bleed valve and bleed the

it.

Tighten the bleed valve .

N·m

(0.6

kqf-m,

4.3

TORQUE: 6

Fill the fluid reservoir to the upper level.

Reinstall the

diaphragm

and

IbHt)

diaphragm

plate. PLATE/DIAPHRAGM

UPPERLEVEL

15-6

On the front brake, install the reservoir cap, and tighten the screws to the specified torque.

TORQUE: 2

On the rear brake, install the reservoir cap securely,

N'm

(0.2

kqf-m

, 1.4

Ibf·ftl

REAR FRONT

RESERVOIR

CAP

SCREWS

BRAKE PAD/DISC

Al

ways

the brakepads in

replace

paris to assure

disc pressure.

FRONT BRAKE PAD REPLACEMENT

Remove the pad pin

even

plug

HYDRAULIC BRAKE

.

Check the brake

fluid level in the

brake master

cylinder reservoir

as this operation

causes the level

to rise.

Loosen th e pad pin s. Remove the bolts and brake caliper. Push the cali per pis installation of n Remove the pad pin and pad spring.

Remove

the

tons

ew

brake pads.

all the

way

in to allow

Inst

all the

Ins

tall

shown

new

brake pads.

the

pad spr ing w ith its ar

.

row

mark facing up as

15-7

HYDRAULIC

BRAKE

Push

the

pad sp

ring

, th en

install

the

pad

.

Tighten

TORQUE : 17 Nom

Install and t

TORQUE: 3 Nom 10.3 kgfom ,

the

pad

.

11.7 kgfom , 12 Ibfof1)

ighten

the

pad

plug.

2.2 Ibfof1)

Always

the brake pads

Check the brake

cylinder reservoir

as this operation

replace

paris to assure

even disc

pressure.

fluid level in the

brake ma

ster

causes the leve'

to rise.

REAR

in

Push

BRAKE

the

caliper

PAD REPLACEMENT

pistons

all

the

wayinby

caliper body inwa rd to allow installation of

pads.

the

Remove

pad pin plug.

pus

hing

new

the

brake

15-8

HYDRAULIC BRAKE

Remove Remove

Pivot the calipe r up.

Remove

Install

the

the the

the

new

pad pin. caliper

pad

brakepads

bracket

bolt

.

and brake pads.

.

Make sure the

brake pad spring

is in place.

Low er

the

cal

iperwhile

springsothat

pad

the retainer on

Install

the

pad

the

tighten

pad pin.

Install and

TORQUE: 23 N'm12.3

Tighten

TORQUE: 17 N

the pad

the

cal

.

the caliper bracket bo lt.

'm

11.7 kqf-rn, 12

pushing

ipe

r bracket.

kqf-m,17Ibf·h)

ends

the

are

Ibf·h

pads

posi

l

agai

tio

nst

ned on

• •

the

to

15-9

HYDRAULIC BRAKE

Install and tighten the pad pin plug.

N·m

(0.3

kgf.m

. 2.2

Ibf

TORQUE: 3

·ft)

BRAKE DISC INSPECTION

Visually

Measure the brake disc thickness with a micrometer.

SERVICELIMITS:

Replace the brake disc if th e sma

less than the service

inspect th e bra ke disc

FRONT: 3.5 REAR: 4.0

mm mm

(0.14 in) (0.16 in)

lim

it.

for

damageorcracks.

llest

meas

ure

ment

,.. PAD PIN PLUG

is

Measure

SERVICELIMITS:

Check

warpage

disc if the wheel bearings are

the

brake

FRONT: 0.30 REAR: 0.30

the

wheel

exceeds

disc

wa rpage

mm

10.012 in)

mm

10.012 in)

bearing s for excessive play. If

the

service

FRONT MASTER CYLINDER

REMOVAL

Avoid spilling fluid

on painted, plas-

tic, orrubber

parts. Place a rag

over these parts

whenever the

system is

setvicea.

Drain th e front hydraulic system (page 15-4).

Disc

onn

ect

the

brak

e light

swi

Remove the brake hose

oil

bolt, sealing

brake hose eye let.

limit.

nor

tch

wit

h a dial in

replace

mal.

wire

dicator

the

brake

connectors.

washers

.

the

and

15-10

.

~

...

£ IL BOLT

HYDRAULIC BRAKE

Remove the bolts from the master cylinder holder and remove the master cylinder assembly.

DISASSEMBLY

Remove the pivot bolt/nut and brake lever assembly.

MA

STER CYLNDER

HOLDER

PIVOT BOLT

Remove the screw and brake light switch.

Remove the boot.

BRAKE LEVERASSEMBLY PIVOT NUT

SCREW

BRAKE LIGHT SWITCH

<.

PISTON BOOT

15-11

HYDRAULIC BRAKE

Remove the snap ring from the maste r cylinder body using the special tool as shown .

TOOL:

Snap ring pliers

Remove the master piston and spring.

Clean the inside of the cylinder and reservoir with

brake flu id.

07914-SA50001

SNAP RING

.>

PRIMARY CUP /

PISTON CUP

SNAP RING PLIERS

I

SPRING

MASTER PISTON

SNAP RING

I

cf

INSPECTION

Check the piston boot, primary cup and secondary

cup for fatigue or damage. Check the maste r cylinder and piston for abnormal

scratches.

Measure the master cylinderJ.D.

SERVICE LIMIT: 14.055 mm (0.5533 in)

Measure the master cylinder piston

SERVICE LIMIT: 13.945 mm (0.5490 inl

0.

15-12

HYDRAULIC BRAKE

ASSEMBL

MAS

TER PISTON 0.7 lbf-ft )

Y

SPRING

I

PRIMARY CUP ;

1 Nem (0.1 kqf-rn.

_____

RESERVOIR CAP

SET PLATE

DIAPHRAGM

PIVOT

BRAKE LEVERASSEMBLY

BRAKE LIGHT SW ITCH

Keep the piston.

cups, spring, snap

ring and

set;

boot

do nor substi-

tute

individual

parts.

When instaffing

the cups, do not

allow

the lips to

turn inside

Be certain the

snap ring

is firmly

seared in the

groove.

as a

out

Coat all parts

Dip the p Install the

Install

the

Insta ll the snap

TOOL:

Snap ring pliers 07914-SA50001

iston

spring

piston

with

clean brake

in brake

into

the p

assemblyinto

ring

.

flu

id.

iston

fluid

.

the

before as

master

sembly

cyl

inde

.

SPRING

1

r.

PRIMARY CAP

--,

~

_

//

_

1

-:

MASTER PISTON

SNA

SNAP

RING

P RING

PLIERS

15-13

HYDRAULIC BRAKE

Apply silicon grease to the boot inside.

Install the

boot

.

- §

:00

Install th e brake light

the specified torque.

TORQUE: 1 Nom 10.1 kgfom. 0.7 Ibfoft)

Apply silicone grease to the contact surfaces of the

brake lever and piston tip.

switc

h and ti

ght

en the sc

rew

~.~t;f···}J;

- -

to

.

\9

..-._",0

-'

""""-

-

SCREW

-

PIVOT BOLT

Install the brake lever assembly, tighten the pivot bolt

to the specified torque .

TORQUE: 1 Nom 10.1 kgfom. 0.7 Ibfoft)

Hold the

specified torque.

TORQUE: 6 Nom 10.6 kgfom. 4.3

pivot

bolt and tig hten the

Ibf·ftl

pivot

nut to th e

I

BRAKE LEVER ASSEMBLY

~PI

VOTNUT

15-14

HYDRAULIC BRAKE

Place the master cylinder assembly on the handlebar.

Align the end of the master cylinder with the punch

mark on the handlebar.

Install the master cylinder holder with the "UP" mark facing up.

Tighten the

specified torque .

TORQUE: 12

Install the brake hose eyelet with the oil bolt and sealing washers. Push the eyelet joint against the stopper, then tighten the oil bolt to the specified torque.

TORQUE: 34 N·m(3.5

Connect the brake light switch wire connectors.

Fill the reservoir to the upper level and bleed the

brake

system

upper

bolt

N·m

(1.2

(page 15-4).

first,

kqf-m,

then

9 Ibfoft)

25 Ibfoft)

the

lower

bolt

to the

new

MASTER CYLINDER

HOLDER

SEALING WASHERS

REAR MASTER CYLINDER

REMOVAL

Avoid spilling fluid

on painted, plas-

tic. or rubber

parts. Place

over these parts

whenever the

a rag

system is

serviced.

Drain the rear

Disconnect the brake light switch 2P connector. Remove the rear master cylinder reservoir mounting

bolt/nut

Remove the brake hose oil bolt, sealing washers and brake hose.

Loosen the rear master cylinder mounting bolts. Remove the socket bolts and footpeg bracket assembly.

.

hydraulic

system (page

15-41

RESERVOIR

.

SWITCH CONNECTOR

15-15

HYDRAULIC BRAKE

Remove Remove

Remove

guard

DISASSEMBLY

Disconnect joint.

Remove

master

and

the

and

master

the

cylinder

discard

joint

master

the

screw

pin .

reservoir

.

the

cylinder

and

brake pedal

mounting

.

hose

from

reservoir

the

hose

joint

reservoir

joint

cotte r pin.

bolts,

step

hose

from

the

RESERVOIR

JOINT

Remove

Remove using

TOOL:

Snap ring pliers

Remove

spring

Clean

the

special

the

.

the

insideofthe

boot.

snap

push

ring

from

the

toolasshown

rod,

master

cyl

inder

master

.

07914-SA50001

piston,

w ith brake

cylinder

primary

cup and

fluid

body

.

BOOT

SNAP RING

SPRING

-.

~

SNAP RINGPLIERS

I

,

J

'

,,,8'\

15-16

#'(

PUSH ROD Assy.

\

MAST

ER PITON

INSPECTION

HYDRAULIC BRAKE

RESERVOIR CAP

PLATE

DIAPHRAG M

Check the

cup

Check the

scratches.

Measure

SERVICE LIMIT: 12.755

Measure the

SERVICE LIM IT: 12.645 mm 10.4978 in)

for

piston

fatigue

master

the

boot,primary

or damage.

cylinder

master

mas

ter

and

cylinder1.0.

mm

10.5022 inl

cylinder p

cup and

piston

iston0.0

ASSEMBLY

RESERVOIR JOINT

PUSH ROD

secondary

for

.

~A

e

abnormal

Ii

O·RING

I

MAS

TER CYLIND ER

Keep the piston. Coat all parts w ith clean brake

cups, spring. snap

ring and boot as a

set; do not substi·

tute individual

parts.

When installing

the cups. do

alfow the lips to

turn inside out.

not

thepiston

Dip

Install the

Install

assembly

App

ly si

push rod.

the

.

licone

in brake

spring

to the

spring

grease to the

fluid

primary

/primary

J

.

cup

piston

fluid

cup .

before

and

contact

assemb

master

areaofthe

LOWER

piston

JOINT

ly.

~

1 Nom 10.1

kqf

lbf-ftl

MAS

-rn, 0.7

TER PISTON

--

- MASTER PISTON

- SECONDARY CUP

e--

.

----S

SNAP RING

OOT

15-17

HYDRAULIC BRAKE

Be certain the

snap ring is firmly

seared in the

groov

Install the push rod into the Install the snap ring .

TOOL:

e.

Snap ring pliers

App

ly silicone grease to the boot inside.

Install the

Apply brake fluid to a new O the reservoir joint.

Install the reservoir joint into the maste r cylinder.

boo

t.

maste

r cylinder.

07914-SA50001

·rin

g and install it onto

SNAP RING PLIERS

/

SNAP RING

RESERVOIR HOSE JOINT

/

Install and tighten the screw securely.

Connect the reservoir hose to the reservoir joint.

II the push rod is disassembled, adj ust the push rod

length as shown . After adjustme nt. tighten th e lock nut to the specified torque.

TORQUE: 17 Nom

11.7

kglom, 12 Ibfoft)

LOCK NUT LOWER JO NT

15-18

67.5

mm12.66 in)

INSTALLATION

HYDRAULIC BRAKE

Place the

bracket, install the

Connect the brake peda l to the push rod low er joint.

Install th e jo int pin and secure

Install the

en the socket

TORQUE: 27 Nom (2.8

li

ghten

specified to rque.

TORQUE: 10 Nom (1.0 kgfom, 7 Ibfo

Install the brake hose ing w ashers . Push th e eyelet join t aga

the oil bolt to the specified torqu e.

dr

the

master

iver

bolts

mas

cyl

inder

onto

the main f

master

footpeg

ter cyli

cylinder

it

with

bracket o

to the specified torque.

kqf-m

nder

with

inst

nto

, 20 Ibfoft l

moun

ft)

the oil bolt and new seal-

the s

top

oot

mounting

a new

the frame.

bolts.

cotter

tig

ting bolts to th e

per, then tig hten

peg

pin.

ht-

TORQUE: 34 Nom (3.5 k

Install

bolt/nut to the specified

TORQUE: 10 Nom (1.0

Connect

Fill the reservoi rtothe

brake sys

andtighte

the

brake

tem

(page 15-4).

n the brake reservoirmou nting

lightswit

FRONT BRAKE CALIPER

REMOVAL

Drain

Avoid spilling fluid

on painted, otes-

tic, or rubber

parts. Place a rag

over these parts

whenever the

system is

serviced.

thefront

Remove th e oil bolt. seali ng w ashers and brake hose eyelet j R Remove the brake pads (page 15-7).

oint

emove

brake

.

the cali per

hydraulicsystem

mountingbolt

gf

om, 25 Ibfoftl

torque

.

kqf-rn, 7 Ibfoftl

ch 2P (Black)

uppe

r level

s and cali per.

connector

and

ble

ed th e

(page 15-41.

RESERVOIR SWITCH CONNECTOR

.

15-19

HYDRAULIC BRAKE

DISASSEMBLY

Do not use high

pressure

bring the nozzle

too close to the

81f or

inlet.

Install

betw een the pistons.

Apply

remove

Remove

the

corrugated

small

the

caliper

squirtsofair

pistons

the

fourcaliper

halves

.

cardboard

pressureto

.

assembly

or

soft

the

bolts

wood

fluid

and

sheet

inlet

to

separate

ASSEMBLY BOLTS

Mark the pistons

toensure

Be careful

correct

reassembly.

not

damage the

piston sliding

surface.

Remove the

-

Joint

- Caliper piston A

- Caliper pis

to

Push the

them

out

Clean th e seal

following:

seals

ton

B

dust

seals and piston seals in and

.

grooves

with

clean brake

fluid

PISTONS

lift

.

15-20

PISTON SEAL

HYDRAULIC BRAKE

INSPECTION

kthe

damage.

ure the caliper cylinder 1.0.Meas

SERVICE LI m i1.192 in)

A: 30.29 m (1 065 in)

B: 27.060

other damage.

SERVICE LI

A: 30 .14 m

B: 26.91

. c Iinder for scor

caliper

MITS'

re the caliper piston 0 .0.Measu

MIT

yChec

mm

S'

m i1.1S7 in)

(105

mm

.

9

in)

Ingorother

scoring orfor scratches.k the caliper pistonsChec

......~tA

~

... JOINT SEALS

.II

~I

·

e

PISTON SEAL

~~

ASSEMBLY

°0

nQ)

JlI)

//

DUST SEAL

I CALIPER PISTON A

~~

[)

I

=-----==

~

CALIPER PISTON B

32 Nom (3.3 kg ' ,

f m 24 lbf-ft]

KE BLEED VALVEBRA

15-21

HYDRAULIC BRAKE

Coat the

Coat the new dust seals with silicone grease.

Install the piston and dust seal into the groove of the

calipe r body.

Coat the calipe r pistons w ith clean brake fluid and

install them into the caliper cylinder with their open-

ing ends

Install the

the caliper.

new

piston seals with clean brake fluid.

towa

rd the pad.

new

joint seals into the fluid passages on

PISTON

mble

Asse

Apply

threads.

Install and tighte n the caliper assembly bolts to the

specified to rque.

TORQUE: 32 Nom13.3 kgfom. 24 Ibfoft)

the caliper halves.

a locking agent to

the

caliper assembly

bolt

INSTALLATION

Install the brake pads (page 15-6).

fork

Install the brake caliper onto the

Install and tighten the new caliper mounting bolts to

the specified torque.

TORQUE: 30 Nom13.1 kgfom. 22 Ibfoft)

tall

the brake hose eyelet to the calip er

Ins

two

new sealing washers and the oil bolt.

leg.

body

with

ASSEMBLY BOLTS

SEALING

15-22

Push

the

brakehose

caliper,thentightenthe

torque

.

eyelet

to the stopper on

oil bolt to th e spe

cif

HYDRAULIC BRAKE

the

ied

TORQUE: 34 Nsm 13.5

Fill and bleed the

(page 15-4).

front

REAR BRAKE CALIPER

REMOVAL

Drain

the

rear brake

Avoid

spifJing fluid

on painted, plas-

tic. or rubber

parts. Place a rag

over these parts

whenever the

system

is serviced.

Loosen Remove the rear w heel (page 14-3).

Remo

eyeletjoint

the

caliper bracke t bolt.

ve th e oil b

olt,

.

kgf

.m.

25 Ibfoft)

brake hyd r

hydraulicsystem

sealing

aulicsys

was

hers and brake hose

tem

(page 15-5).

00 not use high

pressure alf or

bring the nozzle

too close to

the

inlet.

DISASSEMBLY

Remove

(page 15

Remove the pad spri ng , co

caliper body.

Remove the cal Remove th e ret

Place a s Position th e calipe r appl rem

the

caliper bracket

-81

.

ipe

r bod y

from

ainer

from

th e cal

hop

towe

l over the

bod

y w it h the piston downand

y sma ll squirts of air press ure to

ove th e pi

sto

n.

bolt

llar

pisto

and

the ca

iperbra

n.

the

brake

bootfrom

liperbra

cket.

the

flui

cket.

d in

pads

the

let

RETAINE R

•

to

15-23

HYDRAULIC BRAKE

Be careful not to Push the

damage the

piston sfiding Clean the seal grooves w

surface.

dust

seal and pis

INSPECTION

Check the

other

Measure

SERVICE LIMIT: 38.24 mm (1.506 inl

calipercylinder

damage.

the cali per cylin

ton

seal in and lift

ith

clean brake

for

scoring

der

I.D.

them

out

.

fluid

.

or

PISTON SEAL

DUST SEAL

for

Check the calipe r pistons

other

damage.

Measu re the ca

SERVICE LIMIT: 38.09 mm (1.500 in)

liperpiston0.0.

scratches, scoring or

/

15-

24

ASSEMBLY

BRAKE PADS

PAD PIN PLUG

~

COLLAR - /

BOOT

r-

-.;:

2\

\0

PAD PIN

~~.

......

II

PISTON SEAL

HYDRAU LIC BRAKE

CALIPER PISTON

~

,

S~

DUST SEAL

PAD SPRING

CALIPER PIN BOLT

Coat Coat th e new

Install the pis

the caliper body.

Coat

insta ll

tow

If the ca orated, repla ce

Ap ply si

boo

Install the bra cket Install the pad

App

ca liper

the

new

the

caliper piston

it into

ard

the pad.

liperand

lico

t.

ly sil icone

bod

y to

~

/

BRACKET BOLT

pisto

n seal w ith clean brake f

dust

seal w ith silicone grease.

to

n seal

and

dust seal

with

thecalipe

ne greasetothe

retainer

greasetothecaliper

bracket

them

pinboot

the

r c

with

into

bracket.

ylinder

new ones .

luid

.

into

thegroove

clean bra ke fluid and

w ith its opening end

boots are hard or deteri-

insid e of th e bracket pin

and co llar

the bracket.

int

o th e caliper.

and insta ll the

BRACKET

of

~~,

S~

COLLAR

DUST SEAL

PAD RETAINER

Install

the

Install

the cal

(page 15-BI.

pad spring into the cali

iper

bracket bolt and brake pads

per

bracket.

15-25

HYDRAULIC BRAKE

INSTALLATION

Install the wheel (page 14·9).

Install the brake caliper/bracket assembly onto the

guideofthe

Install and tighten the caliper bracket bolt to the spec-

ified torque.

TORQUE: 23 N' m (2.3 kgf' m, 17 Iblott)

swingarm (page 14·10).

Install the brake hose eyelet to the caliper

two new sealing washers and oil bolt.

Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified

torque.

TORQUE: 34N'm (3.5 kgf· m. 25

Fill and bleed the rear brake hydraulic system

(page 15·4).

BRAKE PEDAL

REMOVAL

Remove the footpeg bracket mounting bolts and bracket assembly from the frame.

Ibf·ft

body

with

)

15-26

Remove and discard the brake pedal joint cotter pin.

Remove the joint pin.

Unhook the return spring and remove the brake light

switch

from

the step

Unhook

Remove the snap ring and thrust washer.

Remove the brake peda l from the pivot.

the brake pedal return spring .

holder

.

BRAKE LIGHT SWITCH

SWITCH SPRING

MOUNT

SNAP RING/

WASHER

BOLTS

HYDRAULIC BRAKE

~

S

COTTER PIN

INSTALLAT

JOIN

T PIN

STOPPER RING

ION

7'

THRUST WAS HER

BRAKE PEDAL

]J

r SWITCH

I .

/

I

~

//

/ '''-'''"--0

~

BRAKE LIGHT

SW

ITCH SPRING

~

2 7

/ kgfom, 20

o

Nom12.7

lbf-ftl

STEP HOLDER BOLT

A

pply

grease to th e slid ing surface of and footpeg . Install the brake pedal and

pivot.

Secure the pedal pivot with a snap ring.

Hook the brake pedal return spring.

Install the brake

spring.

Connect the brake pedal to the push rod

Install the joint pin and secure it with a

Install the right driver footpeg bracket assembly onto the frame .

light

thrust

switch and hook the switch

the

washer

new

brake pedal

to the pedal

lower

joint .

cotter pin.

BRAKE

10 Nom 11.0 kqf-m . 7 lbf-

~

:

O

~

L1

GHT SWITCH

tt

)

THRUST

ASHER

SNAP RING

COTTER PIN/

JOIN

T PIN

15-27

HYDRAULIC

BRAKE

Install and tighten the right

bolts to the specified torque.

TORQUE: 27 Nom (2.8 kg/om. 20 Ibfoll)

footp

eg bracket socket

15-28

BATTERY/CHARGING SYSTEM

SYSTEM DIAGRAM

AC GENERATOR

BATTERY

8

MA

IN FUSE 130A)

REGULATOR/RECTIFIER

G

il

G G R R

REGULATOR/RECTIFIER

Y Y Y

16-0

AC GENERATOR

16. BATTERY/CHARGING SYSTEM

SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING BATTERY

SERVICE INFORMATION

GENERAL

The

battery

cha

rging

The

battery

cloth

ing

- If elect

- If electrol

Electrolyte is

- If swa immediate

A

lw

ays turn Som e electr ical co tionswitch is ON and current is present.

F

or

extended storage, charge

F

orabattery The maintenance free The batte ry can be

ditions det

erio Battery ly die out . F problems in the and battery

tio

ns,

the

efore

B

fr

equentl

m

oto

rcycl e.

The

battery

revent

p

When checking the chargi ng

F

or

battery cha

rgin

cha

gives

off

exp

.

contains

and a face sh

rolyte

yte

poisonous

llowed,dri

ly.

off

the

stored

remai

contribute

rates after 2-3years.

voltage

or

this

voltage

elect

rolyte

trou bleshoot ing

y under he

will

sulfat

ion

rging,

g tim e may da

sulfur

ield

getsonyour gets

in yo ur eyes, flu shwith

.

nk large

the ignition s

mp

onents may be da

remove

battery

to sh

may

battery

self-discharge

from

every

ning

in a

battery

dam

agedifovercha rgedorunderc

ort

recover a

reason,

itself,

does

not

level

the

avy

load, such as ha

occurr

do not exceed t he c

mage

losive

gases; keep sparks. flam es and

ic acid (electrolyte). Contact

.

skin, flush

quantitiesofwateror

witch

beforedisco

the

battery,give

two

weeks

stored

motor

must

be replaced

ening

the"life span"of

fter

battery

the

charging

which

may

increase,

goes

dow

charg

when

ing

system,alwaysfoll

the battery.

n quickly.

ing

.

the

sys

the

16-0 16-1 16-3

CHARGING SYSTEM INSPECTION

ALTERNATOR CHARGING COIL REGULATOR/RECTIFIER

16-5

A

WARNING

cigarettes

with

skinoreyes m ay cause severe

withwater

mag

.

cycle, disconnect

charg ing, but u

systemisoftensuspectedasthe

appea rtobe an overcharg

reg

tem,

vin

motorcycle

hargi

.

wat

er fo r at least 15

mi lk and call

nnecting

ed if te rminals or con

it a

when

ulator

check

g the headl

ow the steps in the

ng curre nt and

any electrical

full

charge

, and

the it reaches harged , or if lefttodischarge fora long

the

battery

. Even under norm al use,

nder

heavy

/rectif ier

for

is not in use. For this reason, c

supplies

prope r use and

ight

and taillig ht ON for lon g

time

min

your

nectors

store

negat

ive

the

endofits service

load, battery

ing

tro

specified on

away

. Provide adequ ate

utes and call a physician

local Poison

component

are con nected or disc

it in a

battery

prob

symptom

excess

maintenanceof

ubles

Contro

.

cool,

dry

space. For ma ximum se

cable

from

life

voltage

lem

. Battery overcha rge

. If

oneofthe

voltagetothe

the batte ry. Check if

period

harge

hootingflow

the

battery. Use of excess

l Centerora call a p

the

.

theperf

w ill d

batt ery.

s of

the

chart

vent

burns.

imm

battery

period.

rop

battery

(page

Wear

ediately.

onn

ected

termina

These samecon-

orman

ce of the batt

quickly

often

battery

Under

tim

e w itho ut ridi ng t he

every

16-3).

16-8

16-9

ilat

ion

w hen

protective

hys

icia n

whil

e the ig ni-

rvice

l.

and eventual-

resu lts

cells is s

these

the

two

ive

from

horted

condi-

battery is

weeks

current or

lif

ery

e,

~

..:;

to

BATI

ERYTESTING

Refer to

a

Recommended

the

"load" on

instructionofthe

the

batt

ery

battery

so tha t

tester

Operation

theactual

Manual

battery

BM-210-AH or BM-210

for

cond

the

recom mended

itionofthe

load

battery

can be

tester

. The

measured

recommended

.

batt

erytester

puts

16-1

BATTERY

/CHARGING

SPECIFICATIONS

SYSTEM

ITEM

Battery Capacity 12V - 8.6 Ah

Current leakage 1.2

V

olt

age (20'C/68'FI Fully charged 13.0 - 13.2 V

Needs charging

Charging current Norma l 1.2

Quick 5.0

I

Capac Ch

ity

arging

coil resistance (20'C/68'F) O.l

Alternator

SPECIFICA

mA

Below 12.3 V

N5

Al

0.38 kW/5,000

-l

- 10 h

O.5 h

TOOLS

Digital mu ltimeter

Battery tester

Christy battery charger

Com

mercially available

BM-210-AH available through American Honda Tool

MC1012/2

or available through American Honda Tool and Equipm ent Program

and Equipment Program

or BM210

available through and Equipment Program

nONS

max.

min

" (r

pm)

.on

Ame

rican Honda Tool

16-2

TROUBLESHOOTING

BATTERY IS DAMAGED OR WEAK

BATTERY/CHARGING SYSTEM

Remove the ba

Check the battery condition using the recom-

mended

RECOMMENDED BATTERY TESTER:

BM-210-AH or BM-210 (U.S.A.

Install the

Check the battery current leakage (Leak test;

page 16-6).

ttery

(page 16-51.

battery tester.

Correct

battery

(page 16-5).

Correct

,

only

)

I

,

Check the alternator charging coil (page 16-7).

f---

Incorrect

-

--'---

--'-----

Incorrect

.-

. Faulty ba

Disconnect the regu lator/rectifier connector and

recheck the battery current leakage.

ttery

I

Correct

L

Incorrect

Shorted wire harness Faulty ignition switch

~

Faulty regulator/rectifier

,

I

STANDARD: 0.1 - 1.0 Q (20'C/6S'F)

I

Correct

I

,

Meas

ure and reco rd the battery voltage using a

digitalmu

Start

Measure the charging voltage (page 16-6).

Compare the measurement to the result of the

following calculat ion .

STANDARD:

Measured battery voltage <

ingvoltage

ltimeter (page 16-5).

the

engine.

< 15.5 V

Incorrect

I

,

Mea

sured charg-

Correct

• F

ault

y battery

16-3

BATTERY/CHARGING SYSTEM

1

Check the voltage and resistance at the regu la-

/rectifier

to r

connector (page 16·7).

I

Correct

Incorrect

Open

Loose

Shortedwi

ault

• F

circuit

in related w ire

or

poor

contactsofrelated terminal

re harness

y regulator/rectifier

16-4

BATTERY

BATTERY/CHARGING SYSTEM

Alway

s turn the

ignition switch

OFF before

removing the

battery.

Connect the

tive terminal first

and then rhe neg-

pos

ative cable.

REMOVAL/INSTALLATION

Remove th e s

Disconnect

from

the

Disconnect the negative

cable, and

Install the

i-

Aft er

install

clean grease.

Install the side

ide

the

battery

remove

battery

ing

cover (page 2-21.

battery

the

cover

band

case.

cabl

the

battery

in the reverse

battery,coat

(page 2-21.

VOLTAGE INSPECTION

and

pull

out

e and

then

the

.

orderofremoval.

the

terminals

the

battery

posi

tiv

witt)

e

NEGATIVE TE

BATTERY

RMINA

L

POSITIVE TERMINAL

t?j

'-Q!)

Measure multi

VOLTAGE:

TOOL:

Digital

the

battery

meter

.

Fully charged: 13.0 - 13.2V Under

charged:

multi

meter

voltage

Below

usingadigital

12.3V

Commercially

available ava

ilable

American

and

EquipmentProg

or through

Honda

Too

••

l

ram

BATTERY

16-5

BATTERY/CHARGING SYSTEM

BATTERY TESTING

For

accurate

results, be sure

the tester's cables

and clamps are in

good

condition and that

a secure connection can be

at the battery,

test

working

made

Remove

Securely connect the tester's positive then connect the negative (

TOOL:

Battery tester B

Set the temperature switch to "HIGH" or "LOW"

depending on the ambient temperature .

the

battery

(page 17-4).

(+) cable first,

-)

cable.

M-2

10-AH

or BM-210IU .S.A.

only)

§

~©©©©©~

TESTER

EO

a

R 8

B©©©©©©©o

BATTERY

BLACK

Ell

For the first

check, DO

charge the

before testing·

test

it in an "ee

is" condition.

NOT

benetv

Push in the appropriate test button for 3 seconds and

read the condition of the battery on the meter.

I NOTICE I

To

avo

id damaging the tester. only

with an Tester damage can result from overheating when :

- The test button is pushed in for more than

- The tester is used without being

amperage

onds.

for

at least 1minute when testing

rating

of

less than 30 Ah.

battery.

-

More

than ten consecuti ve tests are

without allowing at least a 3D-minute cool-down period.

The result of a test on the meter scale is relative to the

amp. hour rating of the battery. Any battery reading in

the green zone is OK. Batteries should only be

chargediftheyregisterinthe

YELLOW or RED zone.

test

allowed

more

performed

batteries

3 sec-

to cool

than one

LJ LJ

HIGH: 15°C (60°F)orhigher LOW: 15°C (60°F) or

R

~8

B©©©©©©©O

YELLOW

RED

(-3,

-2)

1-1)

lower

TEST BUTTONS

Ell

GREEN (+1, +2, +31

16-6

BATTERY CHARGING

BATTERY/CHARGING SYSTEM

Turn the po

O

N/OFF

not

at the at the

charger,

battery terminals.

Remove

I NOTICE I

Make

ti/ated, clearofflammable

heat,

Clean the battery terminals

away

far

Do

not

from the battery

charger.

Do

not

the

air

1.Turn

2. Set

wer

the

for the size of the battery being charged.

TOOL:

Christie

the

battery

sure the

humidity,water

from the charger as the leads will permit.

place batteries belo w the

place batteries on topofthe charger. Be sure

vents are

the

"POWER"

"BATTERY AMP. HR. SELECTOR SWI

batt

ery charger MC101

(page 17-41.

area

around

and

may

corrode and damage the

not

blocked.

switchto"OFF" .

the

chargeriswell

materials,

dust.

and

position the battery as

and

charger

2/2

(U.S.A.

only)

free from

- gases

ven-

TCH"

BATTERY AMP. HR.

WIT

SELECTOR S

5.5

to

3.5 to 5.0

o to 3.0 16.5

Set the appro priate amp . hour rating.

CH

9.0

to

30

Connecting the cables

with

switch

produce

batter

the

elapsed.

the

mode

POWER

turned to "O N "

can

spark which could

ignite or explode

The charger will

automatically

sw itch to the

"Trickle"

after the set

charging time has

3.

Set

the"TIMER" to

Honda Battery Tester; RED-3, RED-2 or YELLOW 1. If

you are charging a new battery, set the switch to the

NEW BATT

4.Attach the clamps to the battery terminals: red to positive, black to negative.

Connect the battery cables only when the "POWER" switch is turned to

a

y.

5.Turn

6.When the timer reaches the "Trickle" position, the charging cycle is complete. Turn the "POWER" switch to "OFF" and disconnect the clamps.

7. Let the battery cool for at least 10 minutes or until gassing subsides after charging.

8. Retest the battery using the Honda battery tester and recharge if necessary using the above steps.

posit

the

"POWER"switchto"ON"

ion.

"OFF".

the

posit

ion indi cated by

.

the

NEW BATT

-,

YELLOW

o

RED

TIMER Trickle

16-7

BATTERY/CHARGING SYSTEM

CHARGING SYSTEM INSPECTION

CURRENT LEAKAGE INSPECTION

Do nor disconnect

the ba

tteryOfany

cable in the charg-

ing

system

out first

off

Failure to follolN

this precaution

can damage the

te

ster

with-

switching

the ignition

switch.

or electrical

comoooents.

Remove the

Turn the

tive

battery

Connect

and the With

the

battery

ignition

the

ammeter(-)

ignition

switch

cable from

ammete

switch

(page 15-5).

off

and disconnect the nega-

the

battery.

r (+)

probetothe

off, check

battery

for

I NOTICE I

When

measur

high

range,

appropriate

range selected may While

measuring on. A sud fuse in th e tester.

SPECIFIED CURRENT LEAKAGE: 1.2

If current leakage exceeds the specified ed circ uit is likely. Locate the short by one and me a

ing

current

and

then

level. Current

blowo

current,donot

den

surgeofcur

disconnectin

suring

the current.

using

a tester, set ittoa

bring

the

range

flow

ut the fuse in t he tester.

rent

mayblowout

g connect ions one by

ground

current

higher

turn

rnA

value

(-)

down

the

max.

cable

terminal.

leakage.

to an

than

the

ignition

the

, a sho rt-

00

BATTERY

CHARGING VOLTAGE INSPECTION

Be sure the ba

rming

fo

arm

up the eng ine to n

W

mperat

te Stop

the engine, and

shown

.

preventashort,

To

posit

the

Restart With on the m

Standard:Measured Measured

5

.000

the

rpm

ttery

is in

this

test.

ure.

connect

make

ive and negative te

engine.

headlight

ultimeter

charging

on Hi beam,

when the

battery

voltage

good

cond

itio

n before per-

orma

l ope rating

the

multimeter

absolutely

rminals

engine

(see above) < 15.5 V at

measure

voltage

certain

or cable.

the

runs at 5,000

(page 16·51 <

whic

00

as

h are

BATTERY

voltage

rpm.

16-8

It is nor necessary

to remove the

statorcoilto

make this test.

BATTERY/CHARGI NG SYSTEM

ALTERNATOR CHARGING COIL

INSPECTION

Remove

Disc

Check the resistance

te

STANDARD: 0.1 - 1.0 n

Check for term There

If read

has conti nuity to ground, replace the alternato r stator.

Refer to section 10 for stator remova l.

onnect

rminals

inals and

should

ings

the

left side

the alternator 3P

.

continuity

Grou

nd.

be no co nti nuity.

are far

beyo

cowl

(page 2·4).

connector

between

all three

lat

20"e/6S"F)

all

three

nd the standard, or if any

REGULATOR/RECTIFIER

SYSTEM INSPECTION

Remove

the

rear cowl (page 2·3).

.

Yellow

wire

3P CONNECTOR

~

3P CONNECTOR

~

Item Terminal Specification

Battery Red

charging and s

line ground

Charging coil Ye

line

Gro

und

line

Disconnect t he regulator/rectifier

it

for

and check

loose

lWhi

te

(+)

1-1

llow

and 0.1-1.0n

Ye

llow

Green and Contin uity

ground

3P.4P

contact or corro

Battery voltage

hould

register

lat 20"C/6S"F)

,

shou

ld exist

connecto

dedterminals.

rs,

4P CONN ECTOR

16-9

BATTERY/CHARGING SYSTEM

If

the

reg

ulatedvoltage

of

the specification,

connec

to r term inals (

If all c

omponents

and there are no loose connections at the regulator/rec-

tifier

connectors, rep lace the

of the cha

REMOVAL/INSTALLATION

read

ing

(see

page

measure

wire

the voltage

harn ess side) as follows:

rging

system are

regulator

/rectifier

16-6) is

between

normal

unit

out

.

o

3P CONNECTOR

~

Disconnect

Disconnect Remove

Installation

the

alternator

the

alternator

two

nuts

is in the reverse o

3P (White)

4P (Wh ite)

and

regulator

connector

connecto

/rectifier.

rderofremoval.

.

4P CONNECTOR

r.

R

EGULA

TOR/RECTIFIER

16-10

MEMO

IGNITION SYSTEM

SYSTEM DIAGRAM

MAIN

SWITCH

CLUTCH SWITCH

IGNITION COIL (#2-#3 COIL)

THROTTLE POSITION SENSOR

-=~-

ENGINE STOP SWITCH

IGNITION COIL (#1-#4 COIL)

BANK ANGLE SENSOR

~~~

ENGINE CONTROL MODU LE (ECM)

/

/_-

CAM PULSE GENERATOR

BI/W- - - - - - -

DIODE

r--

NEUTRA L SWITCH

~~--

NEUTRAL SWITCH

SIDESTAND SWITCH

U~G/W~/Wf-

O

-=

~

QOWN

.......

>-Bl

---o

""""-o---e

T CLUTCH SW ITCH

-IB

I/W---

IGNITION COIL

SIDE STAND SWITCH

G G-

2P (G)

l

~-<

----++

-----,

I

BuIY

GJR

ENGINE CONTROL

~

H

V/G RN YIR

MOD

ULE (ECMj

MA

IN FUSE 30A

~

BANKANGLE SENSOR

,-t==

r---+-'

y

PGM-fI FUSE lOA

::=:::,=====t--,

~

,

l.D

[~

BATTERY _

L

I

17-0

00 00

_L i

- -

-±--±-

- - - -

--

CAM PU LSE GENERATOR CRANK PU LSE GENERATOR

17.

IGNITION SYSTEM

SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING IGNITION SYSTEM INSPECTION

SERVICE INFORMATION

GENERAL

Some

electrical

tion

switch

When

servicing

This motorcycle's

The

ignition

The ECM

age

may

A

faulty

ignition

batteryisadequately

well

as no spark at the spark plug .

Use

spark

Refertosection5for

components

is ON and

the

ignition

Ignition

timing

does

maybedamagedifdropped.Alsoifthe

damage

the

systemisoften

plugofthe

module.Always

charged.

Throttle

maybedamagedifterminalsorconnectors

currentispresent

system,

Control

not

normally

relatedtopoor

Using

correct

heat range.

Position (TP) sensor,

.

always

Module

needtobe

turn

the

follow

(ICM) is

off

starter

Using

17-0 17-1 17-3 17-4

the

built

adjusted

connectorisdisconnected

the

ignition

connections

motor

spark

cam

ICGNITION COIL IGNITION PULSE GENERATOR

IGNITION TIMING

ECM (ENGINE CONTROL MODULE)

steps in

into

withaweak

plug

pulse

the

troubleshooting

the Engine Control

since

the

switch

before

. Check

withanincorrect

those

generator

ECM is

battery

and

are

connectedordisconnected

Module

factory

when

currentisflow servicing connections

.

results in a

heat range can

ECM

inspection.

sequence

preset.

before

on page 17-3.

IECM!.

proceeding.Make

slower

damage

ing,

engine

while

the

excessive

cranking

the

engine.

17-7 17-7 17

-10

17-11

the

sure

speed as

igni-

volt-

the

SPECIFICATIONS

ITEM SPECIFICATIONS

Spark plug

Spark plug gap 0.80 - 0.90

Ignition Ignition

Ignition

(Iridium!

coil

pulse

timing

peak

voltage

generator

I"F"

NGK

DENSO

peak

voltage

mark) 8"BTDC at idle

CR8

EH·9IStandard!/

U

24f

ER9IStandard!/ U27F

CR9EH

·9 (Forextended high speedrunning!

ER9

(Forextendedhigh speedrunning!

mm

10.031 - 0.035 in!

100 V

minimum

0.7 V

minimum

17-1

IGNITION SYSTEM

TORQUE VALUES

Timing hole cap

Spark

plug

Ignition pulse generator cove r Ignition pulse generator rotor special bolt

TOOLS

Peak vo

Peak voltage adaptor

ltage

tester IU.S.A. only)

18 Nom (1.8 12 Nom (1.2 kqf-rn, 9 lbf-ft) 10 Nom (1.0 kqf-m, 7 lbf-ft} 59 Nom 16.0

07HGJ-0020100 (not avail able in U.S.A.)

commercially ava ilable digital multi minim um)

kqf-m

, 13 Ibfoft)

kqf

-rn, 43 Ibfoft)

Apply greasetothe

App

ly sealanttothe th reads

meter

thr

eads

with

(impedance 10 M.Q/DCV

17-2

TROUBLESHOOTING

IGNITION SYSTEM

Inspect

- F

- Loose spa rk plug caporspark

If

the

followingbeforediagnos

aul

ty spa rk p

Waterinthe

there

is no spark at

lug

direct

ign

eithe

ition

r cyl

test.

If

the

re is spark,

"Initial v

(The

Ignition primary voltage

Ignition pulse Peak genera

olta

engine

coil

tor

the

excha

nged

ge"oftheignition

is not cranked by

Unusual

No

init engine cal components are

Initial vo

down engi ne.

Initial

voltage

Initial age is lowe r

I

Init

ial and peak

do

es not spark.

val ue.

No peak vo ltage.

condition

ial

voltage

stop

ltage

to 2 - 4 V w hile cranking

vol

tage is norm al, but no peak 2. Faulty peak

while

voltageisnormal,but

voltageislower

swi

than

ing th e system.

plug

wire

connection

coil

(leaking ignition coil

inder,temporar

igniti on

primary

the

tches ON.

is no rm al,

cranki ng the eng ine.

coil is

starter

w ith ignition

normal)

standard

voltage

tha

ily

coi

l is faulty.

the

motor

(Other

butitdro

peak

value. 2.

are

normal,

n standa rd MQl DCV.

exchange

battery

).

and

electrl-

ps

the

volt

secondary

voltage

-

but

voltage)

the

ignition

w ith

Fa ulty

l.

2. An

coil

3. l oose terminal,oran ECM connecto r).

4.

Faulty ECM(when th e in itial vo

conne

l. Incorrect peak vol

Underc

2.

3. No vol gro connect

4. An ope n

5. An open circuit or

Yellow/blue

6. Sh

7. Faulty side stan d

An

8.

c

.

9. Fa

age). Fa

10.

l.

Fa

3. Faulty ECM (in case w hen above

l. The m

MQl Cranking

3. The were voltage is

4. Faulty ECM (in case

l. Faultysparkplugorleakin g

rent Faulty ignition

2.

The

l.

2. Cra

3. The we re not sy nchronised vol FaultyECM

4.

l. Fau

Faulty

2.

coil

withaknown-good

the

ignition

Probable

engine

opencircuit

and

or

cting

harged

tage

und

ort

cir

ope

n circuitorl

ult

w ires. Side s Neutralswitch line:

ultyignition ult

y ECM (in casewhen

ult

y peak

ulti

DCV.

samplingtimingof

not

ampe

multimeterimp

nking

sampling

tage is

lty

peak voltage adaptor. ignit

cause (Check in

stop

eng

(-) at th e ECM multi-co

ion.

cuitinignition

tandswi

in Black/White

inestopswitch.

poor

con

opencircuitinprimary

ECM

connec

battery.

between the Black/white

cir

cuitorloos

wires

tch

pulse

voltag voltageadaptor

meter

speedistoo

synchronised

over

thestandard

re.

coil

speed is

tim ing of the tester and mea

over

the

(whe

ion

pulse

switchONand

switch.

nectofthe

tor)

tage

adapto

r connections.

e co nn

loose

between

switch

oose

lin

genera

e ad

aptor

impeda

low

when

(s).

too

standa rdvoltage

n above N

generator.

ectio

connectio n in Blue/black

theigniti

prim

ary

or n

eutr

connectio n in No.7 related cir-

e: Green/w hitewire

li

ght green w ire

tor

above

connectio ns.

.

nce is

(battery

the

tester

(system is

voltage at least once).

aboveNo.1

ign

edance is low (

battery

(system

o.1

one

and

perform

engine

numerical

wire ign

ltageisnor

coil.

al sw itch.

(measu re the peak volt-

ition

- 3 are normal ).

stop

order)

between

itio n

coil

mal

nnec

No. 1 - 9 are normal).

No

is no

(+)

tor

or

n in Green w ire.

on coils and ECM.

.1, 2 are no

low;below

too

unde

r-charged) .

and

measured

normalif

- 3 are

coil

secondary

low ; be

too

undercharged)

rmalif

at least once).

the spa rk

switch

the

ignition

pri

marywire

(Check at the

whil

and Body

loose

rmal)

measu

normal).

low

.

suredpulse

measured

at RUN

e dis-

ECM

and

.

10

pulse

red

cur

10

-

17-3

IGNITION SYSTEM

IGNITION SYSTEM INSPECTION

If there is no spark at any plug, check all con nec-

tions for loose or poor contact before measuring

each peak voltage. Use a rec

cially available digital mu ltimeter with an imped-

ance of 10 M O/DCV minimum.

The display value differs depending upon the inter-

nal impedance of the multimeter. If the Imrie diagnostic tester (model 625) is used,

follow the manufacturer's instruction.

Connect the peak voltage tester or peak voltage adap-

tor to the digital multimeter.

TOOLS:

Peak Peak

with

(impedance 10

omm

ended digital multimeter or commer-

voltage voltage

commercially available digital

tester adaptor

MQ/DCV

IU.S.A.

minimum)

only

)

07HG~020100

Inotavailable in U.S.A.)

multimeter

DIGITAL MULTIMETER

I

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 cylinde r comp ression and check that the spark plugs are installed correctly.

Open and supp (page 3-4).

Shift the transmission into neutral and disconnect all

the spark plug caps f

Connect known good spark plugs to the spark plug

caps and gr

as done in a spark test.

ort

the f

ront

end of the fu el tank

rom

the spark

oun

d the spark plugs to the cylind er head

plug

.

KNOWN-GOOD SPARK PLUG

17-4

Avoid touching

the spark plugs

and tester probes

to prevent electric

shock.

With

the

ignit ion

the

peak

voltage

coil.

CONN

ECTION:

.l/NO

No

Turn to

"RUN". Check f The If

the

powersupply

.4 coil:

Yellow/

B

battery

Blue

.2/NO.3

lue/Yellow

the

coi

ignitionswitch " ON"and

or

initial

voltage

initialvoltage

circuit

17-31.

Shift

the

transmission

Crank

the

eng ine

tion

coil

primary

PEAK

VOLTA

GE: 100V

If

the

peak

voltageisabnormal circuit Blue/y If no defects are troubleshooting

or

ellow

poor

wires.

coil

primary

adaptororImrie

terminal

l:

terminal

voltageatthis

should

cannotbemeasured,

(refer to

with

peak

connection

found

chart

wire

!+l

- Body

(+1-

be measured.

Troubleshooting,

into

neutral.

the

starter

voltage.

minimum

in th e harness, refer to

on page 17-3.

connected,connect

tester to

Body

engine

time

moto

, check

in

the

ground

stop

.

r and read

foranopen

Yellow

H

check

/blue

ignition

switch

the

page

igni

and

the

IGNITION SYSTEM

00

PEAK VOLTAGE ADAPTOR

-

IGNITION PULSE GENERATOR PEAK VOLTAGE

Check all the

mightbemeasured Check spark

Disconnect (page

system

sys

temisdisconnected,

cylinder

plugs

the

connecti

compression

are

installed

22P (Gray)

.

5-761.

ons

before

incorrect

and check

correctly

connector

inspection.

.

from

peak

voltage

that

the

ECM

If

the

ECM

22P (GRAYI CONN ECTOR

17-5

IGNITION SYSTEM

Avoid touching

the spark plugs

and

tester

probes

to prevent electric

shock.

Connect

tor

ness side and g

TOOLS: Peak Peak

with

(impedance

CONNECTION:

Sh Crank the e peak voltage.

PEAK VOLTAGE : 0.7 V

If nector is igniti on

Remove

Disc

nect (Yellow and W hite/yellow) . In the same sure the peak vo l

m

the

peak

vol

tage

tes

probestothe

voltage voltage

commercially

Yellow

the

easur

terminal

ift

the t ra

peakvoltage m easured at the ECM

abnorma

pulse

the

onn

ect

or

and connect the teste r

ed at th e ECM connector.

connector

roun

d.

tester

(U.S.A. on ly)

adaptor

available

10 M

Q/DCV

nsmis

nginewith

genera

right

theignit

man

ner as at the ECM connector, mea -

min

(+) -

White/yellow

sion intoneutral.

the

starter motor

minimum

l, measure the peakvoltageatthe

tor

connector

side

cover (page 2-2).

ion

pul

tage

and com pare it to the vo ltage

terorpeak term ina lofthe w ire her-

07HGJ-0020100 (not

digital multi

imum)

voltage

available in U.S.A.)

adap-

meter

H

and

read

the

multi

-con -

.

se generator 2P (Redl co n-

pro

bestotheterm

inal

PEAK VOLTAGE A DAPTOR

22P (LIGHT GRAY) CONN ECTOR

2P (RED

PEAK VOLTAGE ADAPTOR

ICONNECTOR

If th e peak mal gene circuitorloose If th e peak voltage is follow chart (

Install th e rem oved parts in

removal.

volt

age

measuredatthe

and

the

one

measuredatthe

rato

r is normal, the w ire

con

nectio

n.

lower

the checks described in th etroubleshoo

page

17-3).

ECM is

ignition

harness

than standa rd value,

the

reverseorder

abnor

pulse

has an

ope

tin

-

n

g

of

17-6

IGNITION SYSTEM

IGNITION COIL

REMOVAL/INSTALLATION

NO.1/NO.4 Open and support the f (page 3-4).

Remove

onn

Disc Remo

ve th e bolts, c

igni

tion coil.

Install ation is in the reverse

NO.2/NO.3coil Open and suppo rt th e fr (page 3-4).

Remove the spark plug cap.

Disconnect the i Remove the Remove the

ignition coil.

Installation is in the re

coil

the

spark

ect the i

boltsand bolts

ront

end

of the fu el

plug

cap.

gnitionprimar

lamp,

gni

tion

ignition coil asse m bly.

. spacer and bracket from th e

ver

y w ires.

spacers, collars, and

orderofremo

ont

end of th e fue l tank

prim

ary w ires.

se order of rem oval.

tan

val.

IGNITION COIL

k

PLUG CAP

IGNITION COIL

IGNITION PULSE GENERATOR

REMOVAL

Remove th e s ide

Disconnect t he ig nitio n pu lse gene

connector.

Remove th e bo lt s and

cov

er (page3·4).

igni

tio n pulse gener ato r cov er.

rator

SPARK PLUG CAP

2P (RED) CONN ECTOR

2P (Red)

17-7

IGNITION SYSTEM

Remove the dow el pin s and gasket.

If

the engine is

our of the frame,

remove the alter·

nator cover (page

10-2) and

flywheel

I07725-{)040000),

hold

the

with

the

flvwheel holder

then remove the

bolt.

Remove the w ire Remove the bolts and ignit

grommet

from

the cove r.

io

n pulse generato r.

Shift thetransm ission into 6th gear and apply the rear

brake,

Remove the ignition pulse

generator

roto

r bolt.

17-8

INSTALLATION

Install the ig

the wide groove

Install the

nit

ion pulse generator

withthe

wash

er and

rot

or by aligning

wide teeth of the crankshaft .

rotorbolt

.

IGNITION SYSTEM

If the engine is

outofframe,

remove the alter-

nator cover (page

10·2) and hold the

flyw

heel

with

flywheel

(07725-0040000

then t

holder

ighte

t

heboll.

the

Sh

ift

the

transmission brake. Tight en the ig specifie d torque.

TORQUE: 59 N·m 16.0

1. n

the

Install App

igniti

ly sealant to the w ire

th e groove of th e

into 6th

nit

ion pulse generato r

kgf.m, 43 Ibf·ft

on pulse gener a

gromm

cove

r.

gear

and apply th e rear

rot

or bolt to

l

tor

into

the cove r.

et, then install it

int

the

o

Ap ply sealant to th e crankcase as s

Appl

y sealant to th e bo lt

into th e

mar

k of

the

thr

eads, th en install the bolts

ignit

ion pulse

how

gene

n.

rator

cove

r.

MARKS

COVER

17-9

IGNITION SYSTEM

Install

Insta ll and

bolts to spec

the

right crankcase cover.

tighten

ified

the

torque

igni

.

tio

n pulse

generatorcove

r

TORQUE: 10

Route the

nect

the

Install the rem oved

remo

val.

N'm

ignit

ion

2P (Red)

(1.0

connector

pulse

kg!·m

generator

.

part

s in the re

. 7 Ibfoltl

wire

properly

verseorder of

, con-

2P(RE

DICONN

ECTOR

IGNITION

Read the instruc- Connect the t

tlons for riming

light

ooereuon

TIM

ING

Warm up the eng Stop the en

.

ine

.

gine

and rem ove th e

iminglight

tim

ing

hole

cap.

to the No.2 spark plug wi re.

17-10

Start the engi ne and let it id le.

IGNITION SYSTEM

IDLE SPEED: 1,200~100

The

ign

ition

timin

g is correctifthe

nition

ig line pulse

Increase the engine speed by tu screw coun

Check

necessary.

Apply grease to the tim

install

Tighten the timi ng

TORQUE: 18

pulse gen

of

the "F" mark and center line on the ignition

generator

and

terclo

that

theO-ring

rot or.

make

sure the " Fit

ckwise.

the O-ring is in

and

Nsm

min"(rpm

erator

cover

good

ing

timing

hole

cap to the specified

(1.8

kqf-m,13Ibf·ftl

)

index

mark

on the

align with the index

rning

the

throttle

mark

beginstomove

condition, replace if

hole cap

cap.

threads

tor

que

stop

and

.

ECM (ENGINE CONTROL MODULE )

REMOVAL/ INSTALLATION

Remove Remove the rear side bolts

Disconnect the ECM 22P(black), 22P(Gray)

connectors.

Remove the ECM.

Install the removal.

the

removed

rear

cowl

(page 2-2).

of

parts

in the reverse

the rear

fender

.

orderof

SPARK UNI T

1

>-....

22P (GRAY)

CONNECTOR

:v\

22P (GRAY) CONNECTOR

""

17-11

ELECTRIC STARTER

SYSTEM DIAGRAM

IGNTION SWITC H

STARTER RELAY SW ITCH

STARTER MOTOR

IGNTION SWITCH

?r

RlBl R

~~:E~~:E

Pi

8W

' 8

L.o----

NE

UTRAL

INDICATOR CLUTCHSWITCH DIODE

STARTER

L

O

SWITCH SWITCH

~

BATIER

Y

e

MAIN

-e- FUSE

30A

ViR

~

LG

NEUTRAL

SW

ITCH

TARTER

S

SWIT

RELAY

CH

VIR

I CLUTCH

Gffi

---L

iR

STARTER MOTOR

~0-----j

81 81

iR~

GM!

18-0

SIDE STANO SWITCH

18. ELECTRIC STARTER

SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING

SERVICE INFORMATION

GENERAL

A

lwa

ys turn

seri

ous

Whe n checking the s

A

weak

cur

If th e

maybedamaged

See se See section 19 fo r foll o

- Ignition

- Engine

- Starter

-

Neutral

-

Side

- CIutch s

SPECIFICAT

the

ignition

injury.

tarter

battery

ction10forstarter

stand

may be un able to t urn

rent is kept f

sw

itch

stop

switch

lowi

.

switch

wi

tch

wing

ION

switch

system, always

ng t

clutch

hro

servicing

com p

OFF

ugh

one

the

before

the

nts:

18-0 18-1 18-2

servicingthestarter

follow

the steps in the

sta

rtermoto

starter

.

moto

r to t

STARTER MOTOR STARTER RELAY SWITCH

DIODE

moto

r. Themotor

troubleshoot

r quickly

enoug

urnitwhile

h, or supp ly adequate i

the engine is not cranking over, the startermotor

could

suddenlystart

ing flowchart (page

gniti

18-21

.

on current.

18-4 18-10 18-11

, causing

Unit: mm (in)

Starter

motorbrushlength

TORQUE

Starter

motorterminal

VA LUE

ITEM STANDARD SERVICE LIMIT

nut

12.0 - 13.0 (0.47 - 0.51)

12 Nom (1.2 kqf-rn, 9

lbf

-ft)

4.5 (0

.181

18-1

ELECTR

IC STARTER

TROUBLESHOOTING

Starter

• Make sure the

motor

Check

forablown

Check the You starter switch

starter

should

does

not

turn

mai n or

batteryisfully

relay

hear the relay "CLICK"

butt

on is dep ressed.

switch

sub

fuse before serv

charged

operation.

icing

.

and in

good

condition

"CLICK" heard

when

the Iy and check th e ope

.

Apply battery vol

1N

orm

,

.

Poorly connected

start

er motorcable

.

" "

CLICK

D

isconnect

and check the relay coil ground wire lines as Faulty neutral

below

1. Green/red ter

tralswitch line(with tral and

2. Green/red te r switch line (in any gea r except neu

wi

stand up.I

the

starter

for

continuity

clutchlever

th t he clutch leve r pulled in and th e side

not

heard

I

,

relay

switch

: Faultyclutch

mina

l-clutch

minal/c

switc

the

transmission

released). Looseorpoor co

lutch

swi

connector

h diode-nee- Faulty clutch/side stand diode

tch-side

tr

, 1--

in ne u- Faulty sid e

stand

al, and

Abnormal

-"

= =

="-

- ... Faul

Faultystarte

switc

h (page 18-101

ty

neut

Open circuit in w ire harn ess

tagetothestart

ration

al

r re ay

I

ralswitch

diode

switch

stand

switc

ntact

.

I

Abn

,

.

Faulty

(page 18-4)

(page 19-

h

con nector

er motor direct-

ormal

starter

motor

201

Connect With switch age at

Yellow

Check the

~~~~~~~~

L

the

starter

ignition

pushed,measure

the

starter

/red 1+)and g

Battery voltage reg istered

starter

Normal

I

,

relay

round

switch

ON

and

the

starterrelay

connector

H .

switch

I .

I

relayswitch o

::"

~~~~~~~

Abnormal

L

connector.

the

starter

(between

per

atio

n.

volt-

__

--.1

- -

No

voltage

Norma

--'=="-'-

l

Faultyignitionswitch Faultystarter Blown Looseorpoo Open circuit in w ire harness

- --" . Loose or

connecto r

..

. Faul

ty

switch

out

mainorsub-fuse

r co n

poor

contact

starter

relay

tact

of connec

starter relay switch

switch

tor

18-2

ELECTRIC

START

ER

The startermotor

neutral ,

with

Check th e cl

Check the side stand s

Starter motor

Low ba Poorly connected

P

Faulty

Poo

tteryvoltage

oorly

connected starter

start

rly

conn

turns

the side stand up and th e clutch lever pulled in.

utc

h switch operati on .

turns

er m

otor

ected

w hen

Norma l

wit

Nor

engine

battery

the

transmiss

ch.

mal

-

------------------

slowly

terminal

moto

r cable

gro und cable

cable

ion

is in neutral, but does not tu rn

ormal

N

No

rmal

...

with

Open cir

Loose or

thetransmi ssio n in

cuit

in wire harness

poor

contact

connector

any

posi

tion exc

ept

Starter

Sta

• Cr

motor

turns,

St

art

er motor is run

- Case asse

- Term inals connected

Faulty start er clu Dama gedorfaul ty s

rt

er relay

ankshaft

mbledimproperly

switch"Click

doe

s not turn due to en

but

nin

tch

tarterdrive

enginedoes

g backwards

impro

perly

gear

s, "

but

eng

not

ine

gine

turn

does

prob

not

lems

turn

over

18-3

ELECTRIC STARTER

STARTER MOTOR

RE

MOVAL

With the ignition switch

rumed to

uOF

FN.

remove

the negative cable

at the

befor

battery

e servicing

the staner motor.

Remove

With

cable at

Remove

the

air

cleaner

housing

(page 5·53).

the ignition switch OFF, remove the negative

the

battery

the

nut

and

befo

the

re ser

start

vicing

er m

otor

the

cable

starte r motor.

Remove cable.

Pull the s

the

starter

motor

mount

tarte

r motorout of th e crankcase.

ing

bolts

startermoto

from

and g

round

r.

the

Record the toes-

tion and number

of

shims.

DISASSEMBLY

Remove the

- Start er

- Rear cover

-

Front

- Seal

- Lock Insulated

-

- Shims

- A

rmat

motor

cover ring washe

washe

ure

followi

case bo lts

r

MOTOR CASE

ng:

CASE BOLTS

r

18-4

INSPECTION

ELECTRIC STARTER

Check for continuity between the brush and cable

minal (the indigo colored wire on the insulated brush

holder).

There should be continuity.

Check for continuity between the motor case and

cable terminal. There should be no continuity.

ter

-

MOTOR CASE

Inspect the brushes for damage and measure the

brush

length

.

SERVICE LIMIT: 4.5

Check the bushing in the rear cover for damage.

mm

(0.18 in)

wear

or

BUSHING

REAR COVER

18-5

ELECTRIC

STARTER

Donot use e

or sand paper on

the

me

commutator.

Check the oil seal and needl e bearing in the

det

cover for

ry

Check th e c discolorati on.

eriorat ion, w ear or damage.

omm

utator barsofthe armature

for

fro

nt

FRONT COVER

/

NEEDLE BEARING

COM

MUTATOR

I

Check for bars.

There should be cont

Check for contin uitybetwe

and the

Thereshould

cont

armatur

be no conti n

inu

ity

e shaft .

between

inui

ty.

pairsofcommutat

en each commuta

uit

y.

tor

or

bar

18-6

ELECTRIC STARTER

Remove the

-

Nut

- Washer

- Insu lato rs

-

a-r

ing

- Brush ho

- Brushltermi nal

ASSEMBLY

followi

lderassembly

ng:

INSULATED WASHER

SEAL RINGS

BRUSH HOLDER

I

a -RING

INSULATORS

WASHER

oo~7

0

/

N U T

Align the terminal

holder boss with

the groove in the

motor case.

WASHER

INSULATORS - _

O

-RING---~

Install the brushes i

Install the cable

rear

cover,aligning

groove.

--

terminal

_

nto

the brush holder.

and brush

the

holder

tab

with

holder

the

into the

rear

cover

18-7

ELECTRIC STARTER

Instal! the insufa

tors prop

The coil

magnet

armature against

Install the shims

properly as

during removal.

damaging the oil

erly

noted

during

removal.

may

damageifthe

ouus the

the

case.

noted

When installing

the cover; take

care to prevent

sea/lip with

the shaft.

Install the

w

New

-

as

- Insu lated

- Washer

- Nut

Install

be

Wh en installi ng

hold case

O-r

the

from

following ing

was

armature

pullin

INOTICE I

The

coil

may

armature against the case.

hers

the

g the

be

:

in the

armature

tig

htly to keep arma

damaged

motor

ture

if the

case.

into

the

motor

the

magnetofthe

agai nst it.

magnetpulls the

case,

I

BRUSH HOLDER

MOTO

O-RING

<.

R CASE

SULA

IN

TORS

IWASHER

Install the shims

pr

operty as noted

during

remov

I

nst

all the s

as

notedduring Install a new seal r Apply a th in coat of grease to the armature

Install int

o the brush

tab

with

Install the sh ture shaft.

al.

Install a Apply grease to the oil seal lip and needle bearing in the fr

Inst

all

Install the f

ame

the

rear

the

new

ont

cover

the

lock wa sher o

ront

number of shims in the same

disassembly.

ing

onto

the motor case.

cover,whi

hold

mot

or case

ims

and insulated

seal ring

.

cover

le push

er and align

gro

ove .

onto

the

nto

the

.

ing

washe

moto

fro nt

in the brushes

the brush holder

r onto th e arrna-

r case.

cov

er.

location

shaft

end.

18-8

FRONT COVER

Make

sure

the

index li nes are

aligned.

ELECTRIC STARTER

INDEX LINES

Be careful not to

damage the water

hose.

Install and tighte n

INSTALLATION

Coat a

newO-ring

moto

r g

roove

Install th e sta

with

.

rtermotorint

the

case bolts securely.

oil

and

installitinto

o th e crankcase.

the

CASE BOLTS

starter

Route the Install

theground

and

tigh

starter

ten th e b

motor

cable

cable and m

olt

s secure ly.

and g

ounting

roundcab

bo lts,

le.

18-9

ELECTRIC STARTER

Install the sta nal

nut

TORQUE: 12

Inst

all th e

rtermoto

to th e specified torque.

N-m

rubber

r cabl e, th en ti

(1.2

kgf-m

cap se

curely

STARTER RELAY SWITCH

OPERATION INSPECTION

Remove

Shift th e transmission into neutral.

Turn th e to

Push the sta

The coil is

the

rig ht side cover (

ignitionswitch ON

RUN.

rter

norma

switch

l if the

butt on.

start

. 9

Ibl-ttl

.

page

and

er relay

ght

2-2),

eng ine

switch

en th e

ter

stopswitch

clic

ks.

mi-

If

yo

u don't hear the switch "CLICK, " inspect the relay

switc

h using

GROUND

Dis

connectthe

Check for continu

(gro und Iinel and

If there is continui tr

al or w hen the clutch is disengaged and the side

s

tan

d s (In neut ral, there is a s d

iode

).

the

procedure below.

LINE INSPECTION

starter relay

ity

gro

und

tywhen th etran

wit

ch is retracted,

swit

ch 4P

connecto

r.

between the Green/red wire

.

smi

ssion is in neu-

the

gro

und

circu it is no rma l

lightresist

ance due to

the

STARTER RELAY VOLTAG E INSPECTION

C

onnect

Shift Mea minal

the starter rela y

the

transmi

sure

thevoltagebetwe

(+) and

gr

swit

ch 4P connector.

ssion intoneutral.

en the

ound H .

Yellow

/red

wire

ter-

STARTER RELAY SWITCH 4P CONNECTOR

=

I

~

00

18-10

If

the

batt

ery

swit

ch is pushed

eng ine stop s

vol

tage appears onlywhen

with

the

ignitionsw

witc

h at RUN, it is normal.

the

starter

itch ON and

STARTER RELAY SWITCH 4P CONNECTOR

Honda CB900F 919 Service Manual converted

Specifications and Main Features

Frequently Asked Questions

User Manual