CBR1000RR 2010

dummytext
27. CBR1000RR/RA-C ADDENDUM

A Few Words About Safety 27-2
LOWER COWL 27-63
INTRODUCTION27-3
MIDDLE COWL 27-64
MODEL IDENTIFICATION 27-4
INTAKE AIR DUCT 27-66
GENERAL SPECIFICATIONS (STANDARD type) 27-7
LEFT REAR UNDER COVER (ABS type) 27-68
GENERAL SPECIFICATIONS (ABS type) 27-8
REARVIEW MIRROR/WINDSCREEN 27-69
LUBRICATION SYSTEM SPECIFICATIONS 27-9
UPPER COWL 27-70
FUEL SYSTEM (PGM-FI) SPECIFICATIONS27-9
REAR CENTER COWL 27-73
COOLING SYSTEM SPECIFICATIONS 27-10
MAINTENANCE SCHEDULE 27-76
CYLINDER HEAD/VALVES SPECIFICATIONS 27-10
AIR CLEANER 27-77
CLUTCH/STARTER CLUTCH/GEARSHIFT
LINKAGE SPECIFICATIONS27-11
SUSPENSION 27-77
OIL COOLER 27-79
CRANKCASE/TRANSMISSION/BALANCER
SPECIFICATIONS 27-11
CRANKSHAFT/PISTON/CYLINDER
FRONT WHEEL/SUSPENSION/STEERING
INTAKE AIR DUCT CONTROL 27-80

FRONT WHEEL 27-81
FORK 27-82
IGNITION SYSTEM DIAGRAM 27-91
REAR WHEEL/SUSPENSION SPECIFICATIONS 27-13
ELECTRIC STARTER SYSTEM LOCATION 27-92
HYDRAULIC BRAKE SPECIFICATIONS 27-13
ELECTRIC STARTER SYSTEM DIAGRAM 27-93
BATTERY/CHARGING SYSTEM SPECIFICATIONS

(STANDARD type) 27-13
ELECTRIC STARTER TROUBLESHOOTING 27-94
BATTERY/CHARGING SYSTEM SPECIFICATIONS

(ABS type)27-14
IGNITION SYSTEM SPECIFICATIONS 27-14
ELECTRIC STARTER SPECIFICATIONS 27-14
LIGHTS/METERS/SWITCHES SPECIFICATIONS
(STANDARD type) 27-14
STARTER RELAY SWITCH 27-95

DIODE 27-96
LIGHTS/METERS/SWITCHES SYSTEM
LOCATION 27-97
HEADLIGHT 27-98
COMBINATION METER 27-99
LIGHTS/METERS/SWITCHES SPECIFICATIONS
(ABS type)27-15
SPEEDOMETER/VS SENSOR 27-101
TORQUE VALUES 27-16
TACHOMETER 27-102
CABLE & HARNESS ROUTING 27-23
EOP SWITCH 27-104
BODY PANEL LOCATIONS 27-59
GEAR POSITION SWITCH 27-104
SEAT/SIDE COVER 27-60
LAP TIMER 27-105
TOP SHELTER 27-60
LAP RELAY 27-107
REAR SEAT COWL 27-61
HISS INDICATOR 27-108
AIR INTAKE COVER27-62
WIRING DIAGRAM (STANDARD type) 27-109
AIR DUCT COVER 27-62
WIRING DIAGRAM (ABS type) 27-110
27
27-1
dummyhead
CBR1000RR/RA-C 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 Customers Safety

Proper service and maintenance are essential to the customers 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 or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual 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 partswear 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

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
Use only a nonflammable solvent, not gasoline, to clean parts.
Never drain or store gasoline in an open container.
Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
27-2
dummyhead
INTRODUCTION
This addendum contains information for CBR1000RR/RA-C.
Refer to CBR1000RR SHOP MANUAL (No. 62MFL00) and CBR1000RR/RA SHOP MANUAL (No. 62MFL00Z and 62MFL00Y) 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
messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
Safety Labels on the vehicle
Safety Messages preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you dont follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you dont follow instructions.
You CAN be HURT if you dont 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
prevent damage to your vehicle, other property, or the environment.
symbol. The purpose of this message is to help
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: August, 2011
27-3
dummyhead
MODEL IDENTIFICATION
STANDARD type:
ABS type:
27-4
dummyhead
DESTINATION CODES
Throughout this manual, the following codes are used to identify individual types for each region.
CBR1000RR (Standard type)
DESTINATION CODE
E, lllE, VE
F, llF, lllF
ED, llED, lVED
U, llU
KO, llKO
lVBR, VBR, VIBR
REGION
U.K.
France, Belgium
European Direct Sales
Australia, New Zealand
Korea
Brazil
CBR1000RA (ABS type)

DESTINATION CODE
E, lllE, VE
F, llF, lllF
ED, llED, lVED
U
llKO
VIBR
REGION
U.K.
France, Belgium
European Direct Sales
Australia, New Zealand
Korea
Brazil
SERIAL NUMBERS
The Vehicle Identification Number (VIN) is stamped on the right side of the
steering head as shown.
VIN
The registered number plate (Except KO, llKO, lVBR, VBR, VIBR) or name
plate (KO, llKO, lVBR, VBR, VIBR types) is located on the left side of the
steering head. The VIN is stamped on the registered number plate.
REGISTERED NUMBER PLATE/NAME PLATE
27-5
dummyhead
The engine serial number is stamped on the front side of the lower
crankcase.
ENGINE SERIAL NUMBER
The throttle body identification numbers are stamped on the side surfaces
of the throttle body.
THROTTLE BODY IDENTIFICATION NUMBER
LABEL
The color label (Except lVBR, VBR, VIBR) is attached on the rear center
cowl under the pillion seat. When ordering color-coded parts, always specify
the designated color code.
Except lVBR, VBR, VIBR:

COLOR LABEL
KO, llKO, lVBR, VBR, VIBR types: The Emission Control Information Label
is attached on the left side of the rear center cowl under the pillion seat.
KO, llKO, lVBR, VBR, VIBR types:
EMISSION CONTROL INFORMATION LABEL
27-6
dummyhead
GENERAL SPECIFICATIONS (STANDARD type)

DIMENSIONS
FRAME
ENGINE
ITEM
Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Curb weight
Maximum weight capacity
Frame type
Front suspension
Front axle travel
Rear suspension
Rear axle travel
Front tire size
Rear tire size
Front tire brand
Rear tire brand
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve
opens
closes
Exhaust valve
opens
closes
Lubrication system
Oil pump type
Cooling system
Air filtration
FUEL
DELIVERY
SYSTEM
DRIVE TRAIN
at 1 mm (0.04 in) lift

Engine dry weight

Firing order
Type
Throttle bore
Clutch system
Clutch operation system
Transmission
Primary reduction
Final reduction
Gear ratio
Gearshift pattern
1st
2nd
3rd
4th
5th
6th
SPECIFICATIONS
2,075 mm (81.7 in)
685 mm (27.0 in)
1,135 mm (44.7 in)
1,410 mm (55.5 in)
820 mm (32.3 in)
396 mm (15.6 in)
130 mm (5.1 in)
200 kg (441 lbs)
Except KO, llKO: 180 kg (397 lbs)
KO, llKO types: 160 kg (353 lbs)
Diamond
Telescopic fork
110 mm (4.3 in)
Swingarm
138 mm (5.4 in)
120/70ZR17 M/C (58W)
190/50ZR17 M/C (73W)
S20F G (Bridgestone), Qualifier ll K (Dunlop)
S20R G (Bridgestone), Qualifier ll K (Dunlop)
Hydraulic double disc
Hydraulic single disc
23 18
96.3 mm (3.79 in)
17.7 liters (4.68 US gal, 3.89 Imp gal)
4 cylinders in-line,
inclined 27.6 from vertical
76.0 x 55.1 mm (2.99 x 2.17 in)
999 cm3 (60.94 cu-in)
12.3 : 1
Chain driven, DOHC
21 BTDC
43 ABDC
41 BBDC
14 ATDC
Forced pressure and wet sump
Trochoid
Liquid cooled
Except KO, IIKO: Paper element
KO, IIKO types: Viscous paper element
62.7 kg (138.2 lbs)
1-2-4-3
PGM-FI
46 mm (1.8 in)
Multi-plate, wet
Cable operating
Constant mesh, 6-speeds
1.717 (79/46)
2.625 (42/16)
2.285 (32/14)
1.777 (32/18)
1.500 (33/22)
1.333 (32/24)
1.214 (34/28)
1.137 (33/29)
Left foot operated return system,
1-N-2-3-4-5-6
27-7
dummyhead
ELECTRICAL
ITEM
Ignition system
SPECIFICATIONS
Computer-controlled digital transistorized with
electric advance
Electric starter motor
Triple phase output alternator
FET shorted/triple phase, full wave
rectification
Battery
Starting system
Charging system
Regulator/rectifier
Lighting system
GENERAL SPECIFICATIONS (ABS type)

DIMENSIONS
FRAME
ENGINE
ITEM
Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Curb weight
Maximum weight capacity
Frame type
Front suspension
Front axle travel
Rear suspension
Rear axle travel
Front tire size
Rear tire size
Front tire brand
Rear tire brand
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve
opens
closes
Exhaust valve
opens
closes
Lubrication system
Oil pump type
Cooling system
Air filtration
FUEL
DELIVERY
SYSTEM
27-8
Engine dry weight

Firing order
Type
Throttle bore

SPECIFICATIONS
2,075 mm (81.7 in)
685 mm (27.0 in)
1,135 mm (44.7 in)
1,410 mm (55.5 in)
820 mm (32.3 in)
396 mm (15.6 in)
130 mm (5.1 in)
211 kg (465 lbs)
Except llKO: 180 kg (397 lbs)
llKO type: 160 kg (353 lbs)
Diamond
Telescopic fork
110 mm (4.3 in)
Swingarm
138 mm (5.4 in)
120/70ZR17 M/C (58W)
190/50ZR17 M/C (73W)
S20F G (Bridgestone), Qualifier ll K (Dunlop)
S20R G (Bridgestone), Qualifier ll K (Dunlop)
Hydraulic double disc
Hydraulic single disc
23 18
96.3 mm (3.79 in)
17.7 liters (4.68 US gal, 3.89 Imp gal)
4 cylinders in-line,
inclined 27.6 from vertical
76.0 x 55.1 mm (2.99 x 2.17 in)
999 cm3 (60.94 cu-in)
12.3 : 1
Chain driven, DOHC
21 BTDC
43 ABDC
41 BBDC
14 ATDC
Forced pressure and wet sump
Trochoid
Liquid cooled
Except KO, IIKO: Paper element
KO, IIKO types: Viscous paper element
62.7 kg (138.2 lbs)
1-2-4-3
PGM-FI
46 mm (1.8 in)
dummyhead
DRIVE TRAIN
ITEM
Clutch system
Clutch operation system
Transmission
Primary reduction
Final reduction
Gear ratio
SPECIFICATIONS
Multi-plate, wet
Cable operating
Constant mesh, 6-speeds
1.717 (79/46)
2.625 (42/16)
2.285 (32/14)
1.777 (32/18)
1.500 (33/22)
1.333 (32/24)
1.214 (34/28)
1.137 (33/29)
Left foot operated return system,
1-N-2-3-4-5-6
Computer-controlled digital transistorized with
electric advance
Electric starter motor
Triple phase output alternator
FET shorted/triple phase,
full wave rectification
Battery
1st
2nd
3rd
4th
5th
6th
Gearshift pattern
ELECTRICAL
Ignition system
Starting system
Charging system
Regulator/rectifier
Lighting system
LUBRICATION SYSTEM SPECIFICATIONS

Engine oil capacity
ITEM
After draining
After oil filter change
After disassembly
Recommended engine oil
Oil pressure at EOP switch

Oil pump
Tip clearance
Body clearance
Side clearance
STANDARD
2.8 liters (3.0 US qt, 2.5 Imp qt)
Honda "4-stroke motorcycle oil" or an
equivalent
API classification: SG or higher (except
oils labeled as energy conserving on the
circular API service label)
Viscosity: SAE 10W-30
JASO T903 standard: MA
590 kPa (6.0 kgf/cm2, 86 psi)
at 6,000 min-1 (rpm)/(80C/176F)
0.15 (0.006)
0.15 0.21 (0.006 0.008)
0.04 0.09 (0.002 0.004)
Unit: mm (in)
SERVICE LIMIT
0.20 (0.008)
0.35 (0.014)
0.17 (0.007)
FUEL SYSTEM (PGM-FI) SPECIFICATIONS

ITEM
Throttle body identification number
Idle speed
Throttle grip freeplay
IAT sensor resistance (at 20C/68F)
Fuel injector resistance
Primary injector
(at 20C /68F)
Secondary injector
PAIR control solenoid valve resistance (at 20C/68F)
IDC solenoid valve resistance (at 20C/68F)
CKP sensor peak voltage (at 20C/68F)
Fuel pressure at idle
Fuel pump flow (at 12 V)
SPECIFICATIONS
GQ23A
1,200 100 min-1 (rpm)
2 6 mm (1/12 1/4 in)
1 4 k
11 13
11 13
23 27
28 32
0.7 V minimum
343 kPa (3.5 kgf/cm2, 50 psi)
3
167 cm (5.6 US oz, 5.9 Imp oz) minimum/10 seconds
27-9
dummyhead
COOLING SYSTEM SPECIFICATIONS

ITEM
Radiator and engine
Reserve tank
Radiator cap relief pressure
Thermostat
Begin to open
Fully open
Valve lift
Recommended antifreeze
Coolant capacity
Standard coolant concentration
SPECIFICATIONS
0.34 liter (0.36 US qt, 0.30 Imp qt)
108 137 kPa (1.1 1.4 kgf/cm2, 16 20 psi)
80 84C (176 183F)
95C (203F)
8 mm (0.3 in) minimum
High quality ethylene glycol antifreeze containing silicate-free
corrosion inhibitors
1:1 (mixture with distilled water)
CYLINDER HEAD/VALVES SPECIFICATIONS

ITEM
IN/EX
IN/EX
IN
EX
IN
EX
IN
EX
IN
STANDARD
1,196 kPa (12.2 kgf/cm2, 174 psi)
at 210 min-1(rpm)
0.16 0.03 (0.006 0.001)
0.30 0.03 (0.012 0.001)
37.34 37.58 (1.470 1.480)
36.58 36.82 (1.440 1.450)
0.020 0.062 (0.0008 0.0024)

25.978 25.993 (1.0228 1.0233)
26.010 26.026 (1.0240 1.0246)
4.475 4.490 (0.1762 0.1768)
3.965 3.980 (0.1561 0.1567)
4.500 4.512 (0.1772 0.1776)
4.000 4.012 (0.1575 0.1580)
0.010 0.037 (0.0004 0.0015)
0.020 0.047 (0.0008 0.0019)
15.1 15.4 (0.59 0.61)
EX
15.7 16.0 (0.62 0.63)
IN/EX
Inner
Outer
0.90 1.10 (0.035 0.043)

35.25 (1.388)
38.93 (1.533)
39.68 (1.562)
Cylinder compression
Valve clearance
Camshaft
Cam lobe height
Valve lifter
Runout
Oil clearance
Valve lifter O.D.
Valve lifter bore I.D.
Valve stem O.D.
Valve, valve
guide
Valve guide I.D.
Valve spring
free length
Stem-to-guide
clearance
Valve guide
projection above
cylinder head
Valve seat width
IN
EX
Cylinder head warpage
27-10
IN
EX
IN
EX
Unit: mm (in)
SERVICE LIMIT
37.32 (1.469)
36.56 (1.439)
0.05 (0.002)
0.10 (0.004)
25.97 (1.022)
26.04 (1.025)
4.465 (0.1758)
3.955 (0.1557)
4.54 (0.179)
4.04 (0.159)
0.075 (0.0030)
0.085 (0.0033)
1.5 (0.06)
34.5 (1.36)
38.2 (1.50)
38.9 (1.53)
0.10 (0.004)
dummyhead
CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE

SPECIFICATIONS
ITEM
Clutch lever freeplay
Clutch
Spring free height
Disc thickness
Plate warpage
A (Two O.D. code
mark)
B (Three O.D. code
mark)
C (Four O.D. code
mark)
Primary driven gear I.D.
Clutch outer
guide
Oil pump drive sprocket guide
Disc A
Disc B
Disc C
I.D.
O.D.
I.D.
O.D.
I.D.
O.D.
Blue
Yellow
Green
I.D.
O.D.
Oil pump drive sprocket I.D.

Mainshaft O.D. at clutch outer guide
Mainshaft O.D. at oil pump drive sprocket guide
Starter driven gear boss O.D.
STANDARD
10 20 (3/8 13/16)
5.70 (0.224)
3.72 3.88 (0.146 0.153)
3.22 3.38 (0.127 0.133)
3.22 3.38 (0.127 0.133)
27.993 28.003 (1.1021 1.1025)

35.007 35.012 (1.3782 1.3784)
27.993 28.003 (1.1021 1.1025)
35.001 35.007 (1.3780 1.3782)
27.993 28.003 (1.1021 1.1025)
34.996 35.001 (1.3778 1.3780)
41.011 41.016 (1.6146 1.6148)
41.005 41.011 (1.6144 1.6146)
41.000 41.005 (1.6142 1.6144)
28.000 28.021 (1.1024 1.1032)
34.975 34.991 (1.3770 1.3776)
35.025 35.145 (1.3789 1.3837)
27.980 27.990 (1.1016 1.1020)
27.980 27.990 (1.1016 1.1020)
45.657 45.673 (1.7975 1.7981)
Unit: mm (in)
SERVICE LIMIT
4.7 (0.19)
3.6 (0.14)
3.1 (0.12)
3.1 (0.12)
0.30 (0.012)
28.012 (1.1028)
35.004 (1.3781)
28.012 (1.1028)
34.998 (1.3779)
28.012 (1.1028)
34.993 (1.3777)
41.019 (1.6149)
41.014 (1.6147)
41.008 (1.6145)
28.030 (1.1035)
34.965 (1.3766)
35.155 (1.3841)
27.96 (1.101)
27.96 (1.101)
45.642 (1.7969)
CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS
M5, M6
C1
C2, C3, C4
M5
M6
C2
C3, C4
M5, C2
M6, C3, C4
M5
C2
at M5
at C2
STANDARD
14.000 14.018 (0.5512 0.5519)
5.93 6.00 (0.233 0.236)
13.957 13.975 (0.5495 0.5502)
31.000 31.025 (1.2205 1.2215)
28.000 28.021 (1.1024 1.1032)
33.000 33.025 (1.2992 1.3002)
30.955 30.980 (1.2187 1.2197)
30.950 30.975 (1.2185 1.2195)
32.955 32.980 (1.2974 1.2984)
32.950 32.975 (1.2972 1.2982)
0.020 0.070 (0.0008 0.0028)
0.025 0.075 (0.0010 0.0030)
27.985 28.006 (1.1018 1.1026)
29.985 30.006 (1.1530 1.1813)
27.967 27.980 (1.1011 1.1016)
29.967 29.980 (1.1798 1.1803)
Unit: mm (in)
SERVICE LIMIT
14.03 (0.552)
5.9 (0.23)
13.95 (0.549)
31.04 (1.222)
28.04 (1.104)
33.04 (1.301)
30.935 (1.2179)
30.930 (1.2177)
32.935 (1.2967)
32.930 (1.2965)
0.10 (0.004)
0.11 (0.004)
28.016 (1.1030)
30.021 (1.1819)
27.957 (1.1007)
29.960 (1.1795)
M5, C2
0.005 0.039 (0.0002 0.0015)
0.06 (0.002)
ITEM
Shift fork
I.D.
Claw thickness
Shift fork shaft O.D.

Transmission
Gear I.D.
Gear busing O.D.
Gear-to-bushing
clearance
Gear bushing I.D.
Mainshaft O.D.
Countershaft O.D.
Bushing to shaft
clearance
27-11
dummyhead
CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS
ITEM
Crankshaft
Connecting rod side clearance
Crankpin bearing oil clearance
Main journal bearing oil clearance
Runout
Piston, piston
Piston O.D. at 5 mm (0.2 in)
rings
from bottom
Piston pin bore I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end gap
Top
Second
Oil
(side rail)
Piston ring-to-ring
Top
groove clearance
Second
Cylinder
I.D.
Out-of-round
Taper
Warpage
Cylinder-to-piston clearance
Connecting rod small end I.D.
Connecting rod-to-piston pin clearance
STANDARD
0.15 0.30 (0.006 0.012)
0.030 0.052 (0.0012 0.0020)
0.019 0.037 (0.0007 0.0015)
Unit: mm (in)
SERVICE LIMIT
0.35 (0.014)
0.06 (0.002)
0.05 (0.002)
0.05 (0.002)
75.965 75.985 (2.9907 2.9915)
75.895 (2.9880)
17.002 17.008 (0.6694 0.6696)

16.994 17.000 (0.6691 0.6693)
0.002 0.014 (0.0001 0.0006)
0.22 0.32 (0.009 0.126)
0.40 0.55 (0.016 0.022)
17.030 (0.6705)
16.980 (0.6685)
0.04 (0.002)
0.52 (0.020)
0.74 (0.029)
0.20 0.70 (0.008 0.028)
1.00 (0.040)
0.040 0.080 (0.0016 0.0032)

0.015 0.050 (0.0006 0.0020)
76.000 76.015 (2.9921 2.9927)
0.015 0.050 (0.0006 0.0020)

17.030 17.042 (0.6705 0.6709)
0.030 0.048 (0.0012 0.0019)
0.120 (0.0050)
0.075 (0.0030)
76.025 (2.9931)
0.10 (0.004)
0.10 (0.004)
0.10 (0.004)
0.10 (0.004)
17.048 (0.6712)
0.07 (0.003)
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

ITEM
HESD linear solenoid resistance (at 20C/68F)
Minimum tire tread depth
Cold tire
Driver only
pressure
Driver and passenger
Axle runout
Wheel rim
Radial
runout
Axial
Wheel balance weight
Fork
Spring free length

Tube runout
Recommended fork fluid
Fluid level
Fluid capacity
Pre-load adjuster initial setting

Rebound damping adjuster
initial setting
Compression damping adjuster
initial setting
Steering head bearing pre-load
27-12
STANDARD
10 15
250 kPa (2.50 kgf/cm2, 36 psi)

250 kPa (2.50 kgf/cm2, 36 psi)
229.5 (9.04)
Honda ULTRA CUSHION OIL SS-47

(10W) or equivalent
84 (3.3)
515 2.5 cm3
(17.4 0.08 US oz, 18.1 0.09 Imp oz)
7-1/2 turns from minimum
Unit: mm (in)
SERVICE LIMIT
1.5 (0.06)
0.2 (0.01)
2.0 (0.08)
2.0 (0.08)
60 g (2.1oz)
max.
224.9 (8.85)
0.20 (0.008)
4-3/4 turns out from full hard
12 17 N (1.2 1.7 kgf)
dummyhead
REAR WHEEL/SUSPENSION SPECIFICATIONS

ITEM
STANDARD
290 kPa (2.90 kgf/cm2, 42 psi)

290 kPa (2.90 kgf/cm2, 42 psi)
Minimum tire tread depth

Cold tire
Driver only
pressure
Driver and passenger
Axle runout
Wheel rim
Radial
runout
Axial
Wheel balance weight
Drive chain
Shock absorber
Size/link
DID
RK
Slack
Spring pre-load adjuster standard position
Rebound damping adjuster initial setting
Compression damping adjuster initial setting
DID50VA11-116YB
RK50HFOZ6-116LJFZ
25 35 (1.0 1.4)
4 position from minimum
Unit: mm (in)
SERVICE LIMIT
2.0 (0.08)
0.2 (0.01)
2.0 (0.08)
2.0 (0.08)
60 g (2.1 oz)
max.
HYDRAULIC BRAKE SPECIFICATIONS

Front
ITEM
Specified brake fluid
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
Caliper cylinder I.D.
Caliper piston O.D.
Rear
STANDARD
A
B
A
B
Specified brake fluid

Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
Caliper cylinder I.D.
Caliper piston O.D.
DOT 4
4.4 4.6 (0.17 0.18)
17.460 17.503 (0.6874 0.6891)

17.321 17.367 (0.6819 0.6837)
32.080 32.130 (1.2630 1.2650)
30.280 30.330 (1.1921 1.1941)
31.967 32.000 (1.2585 1.2598)
30.167 30.200 (1.1877 1.1890)
DOT 4
4.8 5.2 (0.19 0.20)
14.000 14.043 (0.5512 0.5529)

13.957 13.984 (0.5495 0.5506)
30.230 30.280 (1.1902 1.1921)
30.082 30.115 (1.1843 1.1856)
Unit: mm (in)
SERVICE LIMIT
3.5 (0.14)
0.20 (0.008)
17.503 (0.6891)
17.321 (0.6819)
32.130 (1.2650)
30.330 (1.1941)
31.967 (1.2585)
30.167 (1.1877)
4.0 (0.16)
0.30 (0.012)
14.043 (0.5529)
13.957 (0.5495)
30.280 (1.1921)
30.082 (1.1843)
BATTERY/CHARGING SYSTEM SPECIFICATIONS (STANDARD type)

Battery
ITEM
Type
Capacity
Current leakage
Voltage
(at 20C/68F)
Charging current
Alternator
Capacity
Charging coil resistance
(at 20C/68F)
SPECIFICATIONS
YTZ7S
12 V 6 Ah
2.0 mA max.
Fully
charged
Needs
charging
Normal
Quick
13.0 13.2 V
Below 12.4 V
0.6 A/5 10 h
3 A/1 h
0.372 kW/5,000 min-1 (rpm)
0.1 1.0
27-13
dummyhead
BATTERY/CHARGING SYSTEM SPECIFICATIONS (ABS type)

ITEM
Type
Capacity
Current leakage
Voltage
(at 20C/68F)
Battery
Charging current
Alternator
SPECIFICATIONS
YTZ10S
12 V 8.6 Ah
2.0 mA max.
Fully
charged
Needs
charging
Normal
Quick
13.0 13.2 V
Below 12.4 V
0.9 A/5 10 h
4.5 A/1 h
0.417 kW/5,000 min-1 (rpm)
Capacity
Charging coil resistance
(at 20C/68F)
0.1 1.0
IGNITION SYSTEM SPECIFICATIONS

ITEM
Spark plug (Iridium)
SPECIFICATIONS
IMR9E-9HES
VUH27ES
0.80 0.90 mm (0.031 0.035 in)
0.7 V minimum
3.3 BTDC at idle
NGK
DENSO
Spark plug gap

CKP sensor peak voltage
Ignition timing ("F" mark)
ELECTRIC STARTER SPECIFICATIONS

ITEM
Starter motor brush length
STANDARD
12.0 (0.47)
Unit: mm (in)
SERVICE LIMIT
6.5 (0.26)
LIGHTS/METERS/SWITCHES SPECIFICATIONS (STANDARD type)

ITEM
Hi
Lo
Position light
Brake/taillight
License light
Turn signal light
Instrument light
Turn signal indicator
High beam indicator
Neutral indicator
MIL
HISS indicator
Low fuel indicator
REV indicator
HESD indicator
Low oil pressure indicator
High coolant temperature indicator
Fuse
Main fuse
Sub-fuse
Tachometer peak voltage
ECT sensor resistance
50C (122F)
80C (176F)
Bulbs
27-14
Headlight
SPECIFICATIONS
12 V 55 W
12 V 55 W
LED
LED
12 V 5 W
12 V 21 W x 4
LED
LED
LED
LED
LED
LED
LED
LED
LED
LED
LED
30 A
10 A x 4, 20 A x 4
10.5 V minimum
6.8 7.4 k
2.1 2.7 k
dummyhead
LIGHTS/METERS/SWITCHES SPECIFICATIONS (ABS type)

ITEM
Hi
Lo
Position light
Brake/taillight
License light
Turn signal light
Instrument light
Turn signal indicator
High beam indicator
Neutral indicator
MIL
HISS indicator
Low fuel indicator
REV indicator
HESD indicator
Low oil pressure indicator
High coolant temperature indicator
Combined ABS indicator
Fuse
Main fuse
Sub-fuse
ABS fuse
Tachometer peak voltage
ECT sensor resistance
50C (122F)
80C (176F)
Bulbs
Headlight
SPECIFICATIONS
12 V 55 W
12 V 55 W
LED
LED
12 V 5 W
12 V 21 W x 4
LED
LED
LED
LED
LED
LED
LED
LED
LED
LED
LED
LED
30 A
10 A x 4, 20 A x 4
30 A x 2, 10 A x 1
10.5 V minimum
6.8 7.4 k
2.1 2.7 k
27-15
dummyhead
TORQUE VALUES
STANDARD TORQUE VALUES
FASTENER TYPE
5 mm bolt and nut
6 mm bolt and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut
TORQUE
Nm (kgfm, lbfft)
5.2 (0.5, 3.8)
10 (1.0, 7)
22 (2.2, 16)
34 (3.5, 25)
54 (5.5, 40)
FASTENER TYPE
5 mm screw
6 mm screw
6 mm flange bolt (8 mm head, small flange)
6 mm flange bolt (8 mm head, large flange)
6 mm flange bolt (10 mm head) and nut
8 mm flange bolt and nut
10 mm flange bolt and nut
TORQUE
Nm (kgfm, lbfft)
4.2 (0.4, 3.1)
9.0 (0.9, 6.6)
10 (1.0, 7)
12 (1.2, 9)
12 (1.2, 9)
27 (2.8, 20)
39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

Torque specifications listed below are for important fasteners.
Others should be tightened to standard torque values (page 27-16).
FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM
Q'TY
Windscreen mounting bolt

Seat rail mounting nut
Seat rail mounting bolt
Seat rail assembly bolt
Vacuum chamber stay mounting screw
Lower cowl mounting special screw
Lower cowl mounting screw
Center cross plate mounting bolt
Exhaust pipe joint nut
Front fender mounting screw
Front reflector mounting nut (AUSTRALIA type)
Rearview mirror mounting nut
Rearview mirror front cover screw
Main step bracket mounting bolt
Pillion step bracket mounting bolt
Exhaust pipe stud bolt
Air duct mounting screw
Air duct cover mounting screw
Heat guard mounting screw
Muffler cover mounting screw
Muffler rear cap mounting screw
Middle cowl mounting screw
Seat mounting special screw
Muffler band bolt
4
2
2
1
2
2
2
4
8
4
2
4
2
4
4
8
2
2
3
4
3
2
2
1
THREAD
DIA. (mm)
5
10
10
8
4
6
5
6
7
6
6
6
5
8
8
8
5
5
6
6
5
5
6
8
TORQUE
Nm (kgfm, lbfft)
1.5 (0.2, 1.1)
54 (5.5, 40)
44 (4.5, 32)
30 (3.1, 22)
1.1 (0.1, 0.8)
10 (1.0, 7)
1.5 (0.2, 1.1)
12 (1.2, 9)
12 (1.2, 9)
12 (1.2, 9)
1.8 (0.2, 1.3)
10 (1.0, 7)
1.0 (0.1, 0.7)
37 (3.8, 27)
27 (2.8, 20)
5.2 (0.5, 3.8)

5.2 (0.5, 3.8)
10 (1.0, 7)
10 (1.0, 7)
4.2 (0.4, 3.1)
1.5 (0.2, 1.1)
4.3 (0.4, 3.2)
17 (1.7, 13)
TORQUE
Nm (kgfm, lbfft)
16 (1.6, 12)
18 (1.8, 13)
REMARKS
See page 3-30
MAINTENANCE
Spark plug
Timing hole cap
4
1
THREAD
DIA. (mm)
10
45
Oil filter cartridge
20
26 (2.7, 19)
Oil drain bolt

Oil filter boss
1
1
12
20
30 (3.1, 22)
Air cleaner element mounting screw

EGCA cable lock nut
2
1
4
10
0.8 (0.1, 0.6)

22 (2.2, 16)
ITEM
27-16
Q'TY
REMARKS
Apply grease to the
threads.
Apply oil to the
threads and O-ring.
See page 4-19
Apply locking agent to
the crankcase side
threads.
dummyhead
LUBRICATION SYSTEM
Oil pump assembly bolt

Oil pump driven sprocket bolt
4
1
THREAD
DIA. (mm)
6
6
Oil cooler bolt

Oil pipe mounting bolt
1
2
20
6
59 (6.0, 44)
12 (1.2, 9)
THREAD
DIA. (mm)
4
5
12
5
4
8
6
12
6
5
5
4
4
4
6
TORQUE
Nm (kgfm, lbfft)
2.0 (0.2, 1.5)
1.1 (0.1, 0.8)
23 (2.3, 17)
5.1 (0.5, 3.8)
2.1 (0.2, 1.5)
22 (2.2, 16)
12 (1.2, 9)
24.5 (2.5, 18)
10 (1.0, 7)
1.1 (0.1, 0.8)
5.0 (0.5, 3.7)
0.8 (0.1, 0.6)
1.8 (0.2, 1.3)
0.8 (0.1, 0.6)
5.5 (0.6, 4.1)
TORQUE
Nm (kgfm, lbfft)
12 (1.2, 9)
12 (1.2, 9)
12 (1.2, 9)
8.4 (0.9, 6.2)
2.7 (0.3, 2.0)
1.0 (0.1, 0.7)
ITEM
Q'TY
TORQUE
Nm (kgfm, lbfft)
12 (1.2, 9)
15 (1.5, 11)
REMARKS
CT bolt
the threads.
the threads.
FUEL SYSTEM (PGM-FI)

ITEM
Bank angle sensor mounting nut
IDC solenoid valve screw
ECT sensor
Primary fuel rail mounting bolt
IACV setting plate torx screw
Knock sensor mounting bolt
Fuel pump mounting nut
O2 sensor
Fuel tank mounting bolt
IAT sensor mounting screw
MAP sensor mounting screw
ECM setting plate screw
Fuel tank cap socket bolt
Air cleaner housing screw
Throttle cable adjuster lock nut
Q'TY
2
2
1
4
2
1
6
1
4
2
1
2
6
14
1
REMARKS
See page 6-71
COOLING SYSTEM
Water pump assembly bolt

Water pump drain bolt
Thermostat housing cover bolt
Fan motor shroud mounting bolt
Left fan motor mounting screw
Left cooling fan mounting nut
4
1
2
6
3
1
THREAD
DIA. (mm)
6
6
6
6
4
3
Right fan motor mounting nut

Right cooling fan mounting nut
3
1
5
5
5.2 (0.5, 3.8)

2.7 (0.3, 2.0)
THREAD
DIA. (mm)
10
12
20
20
12
12
TORQUE
Nm (kgfm, lbfft)
54 (5.5, 40)
64 (6.5, 47)
10 (1.0, 7)
54 (5.5, 40)
64 (6.5, 47)
84 (8.6, 62)
ITEM
Q'TY
REMARKS
CT bolt
CT bolt
CT bolt

the threads.
the threads.
ENGINE REMOVAL/INSTALLATION
ITEM
Drive sprocket bolt
Front engine hanger bolt
Upper engine hanger adjusting bolt
Upper engine hanger lock nut
Upper engine hanger nut
Lower engine hanger nut
Q'TY
1
2
1
1
1
1
REMARKS
27-17
dummyhead
CYLINDER HEAD/VALVES
Cylinder head nut

Camshaft holder bolt
10
20
THREAD
DIA. (mm)
9
6
Cylinder head cover bolt

PAIR check valve cover bolt
4
4
6
6
10 (1.0, 7)
12 (1.2, 9)
Cam sprocket bolt
20 (2.0, 15)
CMP sensor rotor bolt
12 (1.2, 9)
Cam chain tensioner A pivot bolt
10 (1.0, 7)
Cam chain tensioner B pivot bolt

Cam chain guide A bolt
1
1
24
6
74 (7.5, 55)
12 (1.2, 9)
Insulator mounting bolt

Breather plate mounting bolt
6
3
6
6
12 (1.2, 9)
12 (1.2, 9)
Cylinder stud bolt
10
20 (2.0, 15)
TORQUE
Nm (kgfm, lbfft)
128 (13.1, 94)
ITEM
Q'TY
TORQUE
Nm (kgfm, lbfft)
12 (1.2, 9)
REMARKS
See page 9-29
Apply oil to the threads
and seating surface.
the threads.
the threads.
the threads.
the threads.
the threads.
the threads.
CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE
Clutch center lock nut
THREAD
DIA. (mm)
25
Shift drum center bolt
23 (2.3, 17)
Shift drum stopper arm pivot bolt
12 (1.2, 9)
Gearshift spindle stopper pin

Starter clutch mounting bolt
1
1
8
10
23 (2.3, 17)
93 (9.5, 69)
Oil pump drive chain guide mounting bolt
12 (1.2, 9)
Gearshift spindle setting plate bolt
12 (1.2, 9)
THREAD
DIA. (mm)
6
10
TORQUE
Nm (kgfm, lbfft)
12 (1.2, 9)
103 (10.5, 76)
ITEM
Q'TY
REMARKS
Stake the nut.
ALOC bolt; replace with
a new one.
the threads.
the threads.
the threads.
ALTERNATOR
ITEM
Stator mounting bolt
Flywheel bolt
27-18
Q'TY
4
1
REMARKS
dummyhead
CRANKCASE/TRANSMISSION/BALANCER
Mainshaft bearing set plate bolt
THREAD
DIA. (mm)
6
Shift drum bearing set bolt
12 (1.2, 9)
12
3
1
10
7
8
10
9
18 (1.8, 13)
24 (2.4, 18)
39 (4.0, 29)
20 (2.0, 15) + 150
THREAD
DIA. (mm)
8
8
6
TORQUE
Nm (kgfm, lbfft)
27.5 (2.8, 20) + 90
21.6 (2.2, 16) + 90
12 (1.2, 9)
TORQUE
Nm (kgfm, lbfft)
10 (1.0, 7)
ITEM
Crankcase
Q'TY
(7 mm bolt)
(8 mm bolt)
(10 mm bolt)
Main journal bolt
TORQUE
Nm (kgfm, lbfft)
12 (1.2, 9)
REMARKS
the threads.
the threads.
See page 12-23
CRANKSHAFT/PISTON/CYLINDER
ITEM
Crankpin bearing cap bolt
Q'TY
(new)
(retightening)
Oil jet pipe mounting bolt
8
8
2
REMARKS
See page 13-8
See page 13-12
the threads.
FRONT WHEEL/SUSPENSION/STEERING (STANDARD type)
Handlebar weight mounting screw
THREAD
DIA. (mm)
6
Front brake disc bolt
12
20 (2.0, 15)
Front axle bolt

Front axle holder bolt
Fork piston rod nut
Fork rod guide case
Fork cap
Handlebar pinch bolt
Top bridge pinch bolt
Bottom bridge pinch bolt
Steering stem adjusting nut
Steering stem adjusting lock nut
Steering stem nut
Compression adjuster plug bolt
HESD mounting bolt
1
4
2
2
2
2
2
4
1
1
1
2
4
18
8
12
40.5
46.5
8
8
8
35
35
33
14
6
79 (8.1, 58)
22 (2.2, 16)
27.5 (2.8, 20)
90 (9.2, 66)
35 (3.6, 26)
26 (2.7, 19)
22 (2.2, 16)
27 (2.8, 20)
137 (14.0, 101)

17 (1.7, 13)
10 (1.0, 7)
Second arm nut

Fork damper rod lock nut
Front brake hose clamp bolt
HESD torque arm nut
2
2
1
1
6
10
6
6
12 (1.2, 9)
20 (2.0, 15)
9.0 (0.9, 6.6)
12.5 (1.3, 9.2)
ITEM
Q'TY
REMARKS
ALOC screw; replace
with a new one.
ALOC bolt; replace
with a new one.
See page 14-40

See page 14-40
ALOC bolt; replace

with a new one.
U-nut
U-nut
27-19
dummyhead
FRONT WHEEL/SUSPENSION/STEERING (ABS type)
Handlebar weight mounting screw
THREAD
DIA. (mm)
6
Front brake disc bolt
12
20 (2.0, 15)
Front axle bolt

Front axle holder bolt
Fork piston rod nut
Fork rod guide case
Fork cap
Handlebar pinch bolt
Top bridge pinch bolt
Bottom bridge pinch bolt
Steering stem adjusting nut
Steering stem adjusting lock nut
Steering stem nut
Compression adjuster plug bolt
HESD mounting bolt
1
4
2
2
2
2
2
4
1
1
1
2
4
18
8
12
40.5
46.5
8
8
8
35
35
33
14
6
79 (8.1, 58)
22 (2.2, 16)
27.5 (2.8, 20)
90 (9.2, 66)
35 (3.6, 26)
26 (2.7, 19)
22 (2.2, 16)
27 (2.8, 20)
137 (14.0, 101)

17 (1.7, 13)
10 (1.0, 7)
Second arm nut

Fork damper rod lock nut
Front brake hose clamp bolt
HESD torque arm nut
Front pulser ring mounting bolt
2
2
1
1
3
6
10
6
6
5
12 (1.2, 9)
20 (2.0, 15)
9.0 (0.9, 6.6)
12.5 (1.3, 9.2)
7 (0.7, 5.2)
TORQUE
Nm (kgfm, lbfft)
42 (4.3, 31)
ITEM
Q'TY
TORQUE
Nm (kgfm, lbfft)
10 (1.0, 7)
REMARKS
ALOC screw; replace
with a new one.
ALOC bolt; replace
with a new one.
See page 14-40

See page 14-40
ALOC bolt; replace

with a new one.
U-nut
U-nut
ALOC bolt; replace
with a new one.
REAR WHEEL/SUSPENSION (STANDARD type)
Rear brake disc bolt
THREAD
DIA. (mm)
8
Driven sprocket nut

Rear axle nut
Shock absorber mounting nut
Shock arm-to-swingarm nut
Drive chain case bolt
Drive chain slider bolt
6
1
2
1
2
3
10
22
10
10
6
6
64 (6.5, 47)
113 (11.5, 83)
44 (4.5, 32)
44 (4.5, 32)
12 (1.2, 9)
9.0 (0.9, 6.6)
Swingarm pivot nut

Shock link nut
1
2
22
10
113 (11.5, 83)

44 (4.5, 32)
TORQUE
Nm (kgfm, lbfft)
42 (4.3, 31)
ITEM
Q'TY
REMARKS
ALOC bolt; replace
with a new one.
U-nut
U-nut
U-nut
U-nut
ALOC bolt; replace
with a new one.
U-nut
U-nut
REAR WHEEL/SUSPENSION (ABS type)
Rear brake disc bolt
THREAD
DIA. (mm)
8
Driven sprocket nut

Rear axle nut
Shock absorber mounting nut
Shock arm-to-swingarm nut
Drive chain case bolt
Drive chain slider bolt
6
1
2
1
2
3
10
22
10
10
6
6
64 (6.5, 47)
113 (11.5, 83)
44 (4.5, 32)
44 (4.5, 32)
12 (1.2, 9)
9.0 (0.9, 6.6)
Swingarm pivot nut

Shock link nut
Rear pulser ring mounting bolt
1
2
4
22
10
5
124 (12.6, 91)

44 (4.5, 32)
7 (0.7, 5.2)
ITEM
27-20
Q'TY
REMARKS
ALOC bolt; replace
with a new one.
U-nut
U-nut
U-nut
U-nut
ALOC bolt; replace
with a new one.
U-nut
U-nut
ALOC bolt; replace
with a new one.
dummyhead
HYDRAULIC BRAKE (STANDARD type)
Reserve tank stopper plate screw

Front brake lever pivot bolt
2
1
THREAD
DIA. (mm)
4
6
Front brake lever pivot nut

Front brake light switch screw
Front master cylinder holder bolt
Front brake caliper mounting bolt
1
1
2
4
6
4
6
10
6.0 (0.6, 4.4)

1.2 (0.1, 0.9)
12 (1.2, 9)
45 (4.6, 33)
Front brake reserve tank stay bolt

Rear master cylinder push rod lock nut
Rear master cylinder mounting nut
Front brake caliper pad pin
Rear brake caliper pad pin
Brake hose oil bolt
Front brake hose clamp nut
Front brake hose 3-way joint bolt
Front brake caliper bleed valve
Rear brake caliper bleed valve
Rear brake hose clamp screw
1
1
2
4
1
5
1
1
2
1
1
2
6
8
6
10
10
10
6
6
8
8
5
5
12 (1.2, 9)
18 (1.8, 13)
10 (1.0, 7)
15 (1.5, 11)
18 (1.8, 13)
34 (3.5, 25)
10 (1.0, 7)
10 (1.0, 7)
8.0 (0.8, 5.9)
6.0 (0.6, 4.4)
4.2 (0.4, 3.1)
4.2 (0.4, 3.1)
TORQUE
Nm (kgfm, lbfft)
1.2 (0.1, 0.9)
1.0 (0.1, 0.7)
ITEM
Q'TY
TORQUE
Nm (kgfm, lbfft)
1.2 (0.1, 0.9)
1.0 (0.1, 0.7)
REMARKS
Apply silicone grease
to the sliding surface.
ALOC bolt; replace

with a new one.
HYDRAULIC BRAKE (ABS type)
Front brake reserve tank stopper plate screw

Front brake lever pivot bolt
1
1
THREAD
DIA. (mm)
4
6
Front brake lever pivot nut

Front brake light switch screw
Front master cylinder holder bolt
Front brake caliper mounting bolt
1
1
2
4
6
4
6
10
6.0 (0.6, 4.4)

1.2 (0.1, 0.9)
12 (1.2, 9)
45 (4.6, 33)
Front brake reserve tank stay bolt

Rear master cylinder push rod lock nut
Rear master cylinder mounting nut
Front brake caliper pad pin
Rear brake caliper pad pin
Brake hose oil bolt
Front brake hose clamp nut
Front brake hose 3-way joint bolt
Front brake caliper bleed valve
Rear brake caliper bleed valve
Rear brake hose clamp screw
Valve unit bleed valve
Power unit bleed valve
1
1
2
4
1
5
1
1
2
1
1
2
4
2
6
8
6
10
10
10
6
6
8
8
5
5
8
8
12 (1.2, 9)
18 (1.8, 13)
10 (1.0, 7)
15 (1.5, 11)
18 (1.8, 13)
34 (3.5, 25)
10 (1.0, 7)
10 (1.0, 7)
8.0 (0.8, 5.9)
6.0 (0.6, 4.4)
4.2 (0.4, 3.1)
4.2 (0.4, 3.1)
5.4 (0.6, 4.0)
5.4 (0.6, 4.0)
THREAD
DIA. (mm)
10
TORQUE
Nm (kgfm, lbfft)
14 (1.4, 10)
TORQUE
Nm (kgfm, lbfft)
12 (1.2, 9)
4.0 (0.4, 3.0)
3.7 (0.4, 2.7)
ITEM
Q'TY
REMARKS
Apply silicone grease
to the sliding surface.
ALOC bolt; replace

with a new one.
COMBINED ABS
ITEM
Brake pipe joint nut
Q'TY
10
REMARKS
Apply brake fluid to
the threads.
ELECTRIC STARTER
Starter motor terminal nut

Starter motor setting bolt
1
2
THREAD
DIA. (mm)
6
5
Negative brush mounting screw
ITEM
Q'TY
REMARKS
ALOC bolt; replace
with a new one.
27-21
dummyhead
LIGHTS/METERS/SWITCHES
EOP switch
THREAD
DIA. (mm)
PT 1/8
EOP switch wire terminal bolt

Combination meter screw
Ignition switch mounting bolt
1
8
2
4
5
8
2.0 (0.2, 1.5)

1.0 (0.1, 0.7)
26 (2.7, 19)
Sidestand switch mounting bolt
10 (1.0, 7)
Right handlebar switch housing screw

Clutch switch mounting screw
2
1
4
3
0.9 (0.1, 0.7)

0.6 (0.1, 0.4)
Combination meter stay mounting bolt
32 (3.3, 24)
THREAD
DIA. (mm)
10
10
8
8
TORQUE
Nm (kgfm, lbfft)
10 (1.0, 7)
29 (3.0, 21)
21.5 (2.2, 16)
22 (2.2, 16)
ITEM
Q'TY
TORQUE
Nm (kgfm, lbfft)
12 (1.2, 9)
REMARKS
Apply sealant to the
threads.
Replace with a new

one.
ALOC bolt; replace
with a new one.
ALOC screw; replace
with a new one.
OTHERS
ITEM
Sidestand pivot bolt
Sidestand pivot nut
Sidestand spring hook bolt
Gearshift pedal pivot bolt
Q'TY
1
1
1
1
Water hose clamp:
0 1 mm (0 0.04 in)
27-22
REMARKS
dummyhead
CABLE & HARNESS ROUTING

STANDARD type:
BANK ANGLE SENSOR
COMBINATION METER
28P (Gray) CONNECTOR
HEADLIGHT 4P (Black)
CONNECTOR
TURN SIGNAL RELAY
HEADLIGHT RELAY
CONNECTORS:
Right position light 1P (White)
Right turn signal 2P (Light blue)
CONNECTORS:
Left position light 1P (White)
Left turn signal 2P (Orange)
BANK ANGLE SENSOR

3P (Black) CONNECTOR
HEADLIGHT HOUSING
VACUUM HOSE
(To one-way valve)
HORN CONNECTORS
HEADLIGHT WIRES
Reverse side of meter stay:

COMBINATION METER
Inside of rearview mirror:
POSITION LIGHT WIRES

TURN SIGNAL WIRES
HORN
27-23
dummyhead
STANDARD type:
LEFT IDC SOLENOID VALVE
SOLENOID VALVE
2P (Gray) CONNECTOR
INTAKE AIR DUCT
VALVE DIAPHRAGM
INTAKE AIR DUCT

CONROL VACUUM
CHAMBER
CLAMP
VACUUM HOSES
SUB-WIRE HARNESS
8P (Gray) CONNECTOR
SUB-WIRE HARNESS
ONE-WAY VALVE
FRONT SUB-WIRE
HARNESS
GUIDE
IDC SOLENOID
VALVE WIRE
VACUUM HOSE
VACUUM HOSES
LEFT HEADLIGHT
WIRE
FRONT
SUB-WIRE
HARNESS
IDC SOLENOID VALVE WIRES

HEADLIGHT WIRES
IDC SOLENOID
VALVE WIRE
RIGHT HEADLIGHT WIRE
VACUUM HOSE
RIGHT IDC
SOLENOID
VALVE
INTAKE AIR
DUCT VALVE
DIAPHRAGM
VACUUM
HOSES
VACUUM HOSE
SOLENOID VALVE 2P (Gray)

CONNECTOR
ONE-WAY VALVE
27-24
GUIDE
dummyhead
STANDARD type:
CLUTCH CABLE
SUB-WIRE HARNESS
AIR DUCT
FRONT SUB-WIRE
HARNESS
FRONT BRAKE HOSE
VACUUM HOSE
SUB-WIRE HARNESS
8P (Gray) CONNECTOR
MIDDLE COWL
RESONATOR
THROTTLE CABLES
CLUTCH
CABLE
IMMOBILIZER
RECEIVER
CLUTCH CABLE
FRONT BRAKE HOSES
27-25
dummyhead
STANDARD type:
IMMOBILIZER RECEIVER WIRE
LEFT HANDLEBAR
SWITCH WIRE
RIGHT HANDLEBAR
SWITCH WIRE
IGNITION SWITCH WIRE

IMMOBILIZER RECEIVER
LEFT HANDLEBAR
SWITCH 10P (Blue)
CONNECTOR
DIODE (2P)
IAT SENSOR 2P (Gray) CONNECTOR
ECM
LAP RELAY
RIGHT HANDLEBAR SWITCH 8P (White)
CONNECTOR
IGNITION SWITCH 2P (Brown) CONNECTOR
LEFT HANDLEBAR
SWITCH WIRE
30
CLUTCH CABLE
10
RIGHT HANDLEBAR
SWITCH WIRE
THROTTLE CABLES
27-26
dummyhead
STANDARD type:
IGNITION SWITCH 2P (Brown)

CONNECTOR
RIGHT HANDLEBAR SWITCH

8P (White) CONNECTOR
ECM 33P (Gray) CONNECTOR
LAP RELAY
ECM 33P (Black) CONNECTOR

DIODE (2P)
LEFT HANDLEBAR
SWITCH 10P (Blue)
CONNECTOR
No. 4
IAT SENSOR
No. 3
No. 2
FUEL RAIL
No. 1
SECONDARY INJECTOR
2P (Gray) CONNECTORS
FUEL HOSE
27-27
dummyhead
STANDARD type:
TP SENSOR WIRE
(SUB-WIRE HARNESS)
FUEL RAIL
IACV 4P (Black)
CONNECTOR
No. 2 PRIMARY
INJECTOR 2P (Gray)
CONNECTOR
No. 1 PRIMARY
INJECTOR 2P (Gray)
CONNECTOR
MAIN WIRE
HARNESS
No. 3 PRIMARY
INJECTOR 2P (Gray)
CONNECTOR
No. 4 PRIMARY INJECTOR 2P (Gray)

CONNECTOR
MAP SENSOR
3P (Blue)
CONNECTOR
O2 SENSOR
4P (Black)
CONNECTOR
EOP SWITCH 1P (White)

CONNECTOR
SIDESTAND SWITCH
2P (Black)
CONNECTOR
SUB- WIRE HARNESS
Up
KNOCK SENSOR 3P (Blue)

CONNECTOR
45
THERMOSTAT
HOUSING
ECT SENSOR 3P (Gray) CONNECTOR
KNOCK
SENSOR
INDEX MARK
0 25
27-28
dummyhead
STANDARD type:
HESD 2P (Brown) CONNECTOR
PAIR CONTROL SOLENOID VALVE
SUB-WIRE HARNESS
RIGHT COOLING FAN

MOTOR WIRE
CMP SENSOR 3P (Blue)

CONNECTOR
VACUUM HOSE
TP SENSOR 3P (Blue)
CONNECTOR
IACV 4P (Black) CONNECTOR

CONNECTOR
SUB-WIRE HARNESS
2P CONNECTOR
(Red/yellow wire)
2P CONNECTOR
(Red/blue wire)
2P CONNECTOR
(Blue/black wire)
2P CONNECTOR
(Yellow/white wire)
No. 1
No. 2
No. 4
No. 3
DIRECT IGNITION COILS
27-29
dummyhead
STANDARD type:
No. 2 DIRECT IGNITION COIL
0 20
Hose clip position:
90
90
90
PAIR CONTROL
SOLENOID VALVE
90
CLUTCH CABLE
SUB-WIRE HARNESS
RIGHT COOLING FAN MOTOR

Bottom of fuel tank:
FUEL PUMP 2P (Brown) CONNECTOR
FUEL RESERVE SENSOR

FUEL TANK DRAIN HOSE
FUEL TANK BREATHER HOSE
27-30
dummyhead
STANDARD type:
BATTERY NEGATIVE
() CABLE
STARTER MOTOR CABLE
BATTERY NEGATIVE () CABLE
0 45
FUEL PUMP 2P (Brown)
CONNECTOR
VS SENSOR 3P (Black) CONNECTOR
GEAR POSITION SWITCH

CKP SENSOR 2P (Red)

CONNECTOR
FUEL RESERVE SENSOR

GROUND POINT
SIPHON HOSE
27-31
dummyhead
STANDARD type:
SIDESTAND SWITCH 2P (Black) CONNECTOR
O2 SENSOR 4P (Black) CONNECTOR
COOLANT OVERFLOW HOSE
ALTERNATOR WIRE
O2 SENSOR
O2 SENSOR WIRE
SIDESTAND
SWITCH WIRE
SIDESTAND SWITCH
O2 SENSOR WIRE
SIDESTAND
BRACKET

5 mm (0.2 in) minimum
LOWER COWL
27-32
dummyhead
STANDARD type:
Inside
Water hose clamp position:

Front
Front
75
45
Front
90
45
Outside
Outside
90
Front
85
135
Inside
Front
OIL
COOLER
O2 SENSOR
WIRE
SIDESTAND
SWITCH WIRE
45
85
Front
135
Inside
Inside
27-33
dummyhead
STANDARD type:
2 mm
(0.1 in)
minimum
Up
COWL
SIPHON HOSE
CLUTCH CABLE
Up
Outside
135
Up
Up
EOP SWITCH
Up
EOP SWITCH WIRE
27-34
dummyhead
STANDARD type:
SUB-WIRE HARNESS
(License/Turn Signal Light)
BRAKE/TAILLIGHT
BATTERY
WIRE
HARNESS
DLC
EGCA 6P (Black)
CONNECTOR
REGULATOR/RECTIFIER
2P CONNECTOR
ALTERNATOR
3P CONNECTOR
BATTERY
NEGATIVE ()
CABLE
STARTER MOTOR CABLE
FUSE/RELAY BOX
EGCA
ALTERNATOR WIRE
BATTERY
STARTER RELAY SWITCH
REGULATOR/RECTIFIER
REAR BRAKE LIGHT SWITCH

REAR BRAKE LIGHT
SWITCH WIRE
GROUND POINT

CKP SENSOR 2P (Red)
CONNECTOR
SIPHON HOSE
STARTER MOTOR CABLE
27-35
dummyhead
STANDARD type:
RADIATOR RESERVE TANK
REAR BRAKE LIGHT

SWITCH WIRE
SIPHON HOSE
BRAKE/TAILLIGHT WIRE
SUB-WIRE HARNESS
CONNECTORS:
License light 3P
RUBBER BAND
EGCA 6P (Black)
CONNECTOR
RUBBER BAND
SUB-WIRE HARNESS
BRAKE/TAILLIGHT
27-36
SUB-WIRE
HARNESS
BRAKE/TAILLIGHT
WIRE
dummyhead
STANDARD type:
EGCA CABLE
REAR BRAKE HOSE
GUIDE
EGCA CABLE
REAR BRAKE LIGHT

SWITCH
27-37
dummyhead
ABS type:
BANK ANGLE SENSOR
COMBINATION METER
HEADLIGHT 4P (Black)
CONNECTOR
TURN SIGNAL RELAY
HEADLIGHT RELAY
CONNECTORS:
Right position light 1P (White)
CONNECTORS:
Left position light 1P (White)
BANK ANGLE SENSOR

HEADLIGHT HOUSING
VACUUM HOSE
(To one-way valve)
HORN CONNECTORS
HEADLIGHT WIRES
Reverse side of meter stay:

COMBINATION METER
Inside of rearview mirror:
POSITION LIGHT WIRES

TURN SIGNAL WIRES
HORN
27-38
dummyhead
ABS type:
LEFT IDC SOLENOID VALVE
SOLENOID VALVE
2P (Gray) CONNECTOR
INTAKE AIR DUCT
VALVE DIAPHRAGM
INTAKE AIR DUCT

CONROL VACUUM
CHAMBER
CLAMP
VACUUM HOSES
SUB-WIRE HARNESS
8P (Gray) CONNECTOR
SUB-WIRE HARNESS
ONE-WAY VALVE
FRONT SUB-WIRE
HARNESS
GUIDE
IDC SOLENOID
VALVE WIRE
VACUUM HOSE
VACUUM HOSES
LEFT HEADLIGHT
WIRE
FRONT
SUB-WIRE
HARNESS
IDC SOLENOID VALVE WIRES

HEADLIGHT WIRES
IDC SOLENOID
VALVE WIRE
RIGHT HEADLIGHT WIRE
VACUUM HOSE
RIGHT IDC
SOLENOID
VALVE
INTAKE AIR
DUCT VALVE
DIAPHRAGM
VACUUM
HOSES
VACUUM HOSE
SOLENOID VALVE 2P (Gray)

CONNECTOR
ONE-WAY VALVE
GUIDE
27-39
dummyhead
ABS type:
CLUTCH CABLE
SUB-WIRE HARNESS
AIR DUCT
FRONT SUB-WIRE
HARNESS
VACUUM HOSE
BRAKE HOSE
SUB-WIRE HARNESS
8P (Gray) CONNECTOR
RESONATOR
MIDDLE COWL
FRONT BRAKE PIPE A
FRONT BRAKE PIPE B
THROTTLE CABLES
CLAMP
CLUTCH
CABLE
CLAMP
IMMOBILIZER
RECEIVER
FRONT WHEEL SPEED

SENSOR WIRE
CLUTCH CABLE
BRAKE HOSE
Front
SENSOR WIRE
FRONT WHEEL SPEED
SENSOR WIRE
27-40
dummyhead
ABS type:
LEFT HANDLEBAR
SWITCH WIRE
RIGHT HANDLEBAR
SWITCH WIRE

LEFT HANDLEBAR
SWITCH 10P (Blue)
CONNECTOR
DIODE (2P)
IAT SENSOR 2P (Gray) CONNECTOR
ECM
LAP RELAY
RIGHT HANDLEBAR SWITCH 8P (White)
CONNECTOR
IGNITION SWITCH 3P (Brown) CONNECTOR
LEFT HANDLEBAR
SWITCH WIRE
30
CLUTCH CABLE
10
RIGHT HANDLEBAR
SWITCH WIRE
THROTTLE CABLES
27-41
dummyhead
ABS type:
IGNITION SWITCH 3P (Brown)

CONNECTOR

ECM 33P (Gray) CONNECTOR
LAP RELAY
ECM 33P (Black) CONNECTOR
DIODE (2P)
LEFT HANDLEBAR
SWITCH 10P (Blue)
CONNECTOR
No. 4
IAT SENSOR
No. 3
No. 2
FUEL RAIL
No. 1
SECONDARY INJECTOR
2P (Gray) CONNECTORS
FUEL HOSE
27-42
dummyhead
ABS type:
TP SENSOR WIRE
(SUB-WIRE HARNESS)
FUEL RAIL
IACV 4P (Black)
CONNECTOR
No. 2 PRIMARY
INJECTOR 2P (Gray)
CONNECTOR
No. 1 PRIMARY
INJECTOR 2P (Gray)
CONNECTOR
MAIN WIRE
HARNESS
No. 3 PRIMARY
INJECTOR 2P (Gray)
CONNECTOR
No. 4 PRIMARY INJECTOR 2P (Gray)

CONNECTOR
MAP SENSOR
3P (Blue)
CONNECTOR
SIDESTAND
SWITCH
2P (Black)
CONNECTOR
EOP SWITCH 1P (White)

CONNECTOR
O2 SENSOR 4P (Black)
CONNECTOR
FRONT POWER UNIT WIRE

SUB- WIRE HARNESS

ABS SUB-WIRE
HARNESS
Up
KNOCK SENSOR 3P (Blue)

CONNECTOR
45
THERMOSTAT
HOUSING
ECT SENSOR 3P (Gray) CONNECTOR
KNOCK
SENSOR
INDEX MARK
0 25
27-43
dummyhead
ABS type:
HESD 2P (Brown) CONNECTOR
PAIR CONTROL SOLENOID VALVE
SUB-WIRE HARNESS
RIGHT COOLING FAN

MOTOR WIRE

CONNECTOR
VACUUM HOSE
TP SENSOR 3P (Blue)
CONNECTOR
IACV 4P (Black) CONNECTOR

CONNECTOR
SUB-WIRE HARNESS
2P CONNECTOR
(Red/yellow wire)
2P CONNECTOR
(Red/blue wire)
2P CONNECTOR
(Blue/black wire)
2P CONNECTOR
(Yellow/white wire)
No. 1
No. 2
No. 4
No. 3
DIRECT IGNITION COILS
27-44
dummyhead
ABS type:
No. 2 DIRECT IGNITION COIL
0 20
Hose clip position:
90
90
90
PAIR CONTROL
SOLENOID VALVE
90
CLUTCH CABLE
SUB-WIRE HARNESS

Bottom of fuel tank:
FUEL PUMP 2P (Brown) CONNECTOR
FUEL RESERVE SENSOR

FUEL TANK BREATHER HOSE
27-45
dummyhead
ABS type:

VS SENSOR 3P (Black)
CONNECTOR
VALVE UNIT DRAIN HOSE
ABS SUB-WIRE HARNESS
ABS SUB-WIRE
HARNESS
STARTER
MOTOR CABLE

HARNESS
PROTECTOR
BATTERY
NEGATIVE
() CABLE
WIRE BAND
ABS SUB-WIRE HARNESS

ALTERNATOR
WIRE
ABS SUB-WIRE
HARNESS
GROUND POINT
SIPHON HOSE
HARNESS
PROTECTOR
27-46
WIRE BAND
CKP SENSOR 2P (Red)

CONNECTOR
dummyhead
ABS type:
STARTER MOTOR CABLE
FUEL PUMP 2P (Brown)

CONNECTOR
45
BATTERY NEGATIVE
() CABLE

VS SENSOR 3P (Black) CONNECTOR
SIPHON HOSE
FUEL RESERVE SENSOR
CKP SENSOR 2P (Red)
CONNECTOR
ABS SUB-WIRE HARNESS 6P

(Black) CONNECTOR
GROUND POINT
O2 SENSOR
FRONT VALVE UNIT 21P (Black)

CONNECTOR
SIDESTAND SWITCH
FRONT BRAKE PIPE B

(To brake caliper)
FRONT BRAKE PIPE A

(To master cylinder)
FRONT VALVE UNIT

27-47
dummyhead
ABS type:
FRONT BRAKE PIPE A

(From master cylinder)
FRONT BRAKE PIPE B

(To brake caliper)
LOWER COWL

O2 SENSOR
FRONT BRAKE PIPE C

(To power unit)
SIDESTAND SWITCH WIRE

O2 SENSOR WIRE
SIDESTAND
SWITCH
27-48
O2 SENSOR WIRE
dummyhead
ABS type:
Inside
Water hose clamp position:

Front
Front
75
45
Front
90
45
Outside
Outside
90
Front
85
135
Inside
Front
OIL
COOLER
45
Front
85
135
Inside
Inside
27-49
dummyhead
ABS type:
2 mm
(0.1 in)
minimum
Up
COWL
SIPHON HOSE
CLUTCH CABLE
Up
Outside
135
Up
Up
EOP SWITCH
Up
EOP SWITCH WIRE
27-50
dummyhead
ABS type:
FRONT BRAKE PIPE B

(To brake caliper)
FRONT BRAKE PIPE A

(From master cylinder)
FRONT WHEEL SPEED

SENSOR WIRE
FRONT BRAKE PIPE C

(To power unit)
FRONT BRAKE PIPE D

(To power unit)
BRAKE PIPE JOINT
FRONT WHEEL SPEED SENSOR

2P (Orange) CONNECTOR
27-51
dummyhead
ABS type:
FRONT POWER
UNIT WIRE
FRONT POWER UNIT 2P (Black)

CONNECTOR
FRONT BRAKE PIPE C

(From valve unit)
BRAKE PIPE JOINT
CLAMP
FRONT BRAKE PIPE D
(from valve unit)
EOP SWITCH WIRE
FRONT POWER UNIT
RADIATOR RESERVE TANK
REAR BRAKE LIGHT

SWITCH WIRE
SIPHON HOSE
27-52
dummyhead
ABS type:
REAR WHEEL SPEED SENSOR

2P (Orange) CONNECTOR

2P (BLACK) CONNECTOR
ALTERNATOR
3P CONNECTOR
STARTER RELAY SWITCH/
FUSE
FRONT ABS MOTOR (30 A)
REAR ABS MOTOR (30 A)
EGCA 6P (Black) CONNECTOR

Front
REAR VALVE UNIT

FUSE BOX
MAIN (30 A)
FI (20 A)
REAR POWER UNIT

BATTERY POSITIVE (+)

CABLE
FUSE/RELAY BOX
BATTERY
COMBINED ABS CHECK

CONNECTOR
5P (Gray) CONNECTOR
COMBINED ABS CONTROL UNIT
27-53
dummyhead
ABS type:
BRAKE PIPE JOINT

(Identification color: Yellow)
STOPPER PIN
REAR VALVE UNIT
REAR POWER UNIT

STOPPER PIN
BRAKE PIPE JOINT
(Identification color: White)
REAR POWER UNIT

FUSE BOX 3P (Brown)
CONNECTOR
FUSE BOX
MAIN (30 A)
FI (20 A)
BRAKE/TAILLIGHT
DLC
SUB-WIRE HARNESS
REGULATOR/RECTIFIER
2P CONNECTOR
27-54
COMBINED ABS CHECK

CONNECTOR
dummyhead
ABS type:
BRAKE/TAILLIGHT WIRE
SUB-WIRE HARNESS
CONNECTORS:
License light 3P
RUBBER BAND
RUBBER BAND
SUB-WIRE
HARNESS
BRAKE/TAILLIGHT
WIRE
CLAMP
EGCA
EGCA CABLE
27-55
dummyhead
ABS type:
REGULATOR/RECTIFIER
CLAMPS
CLAMP
REGULATOR/RECTIFIER
2P CONNECTOR
ALTERNATOR 3P CONNECTOR
ALTERNATOR 3P CONNECTOR
27-56
dummyhead
ABS type:
STOPPER PINS
REAR VALVE UNIT

STOPPER
STOPPER
REAR VALVE UNIT

REAR POWER UNIT
REAR WHEEL SPEED

SENSOR WIRE
BRAKE HOSE
REAR MASTER
CYLINDER
REAR WHEEL SPEED SENSOR
27-57
dummyhead
ABS type:
EGCA CABLE
RUBBER
REAR MASTER
CYLINDER
EGCA CABLE
PROTECTIVE TUBE
CLAMP
27-58
dummyhead
BODY PANEL LOCATIONS

ABS type shown:
WINDSCREEN
PILLION SEAT
SEAT
REARVIEW MIRROR
LICENSE LIGHT STAY
UPPER COWL
SEAT RAIL
AIR INTAKE COVER
LEFT REAR UNDER COVER

(ABS type only)
FRONT FENDER
TOP SHELTER
AIR DUCT COVER
REAR SEAT COWL
SIDE COVER
REAR FENDER A
REAR CENTER
COWL
MIDDLE COWL
REAR FENDER B
SWINGARM COVER (ABS type)
REAR FENDER C (STANDARD type)
LOWER COWL
27-59
dummyhead
SEAT/SIDE COVER
REMOVAL/INSTALLATION
Be careful not to
damage the slit of
the side cover.
Release the side cover boss from the frame grommet,

free the front portion (slit) from the tab of the top shelter
and remove the side cover.
ABS type shown:

PRONGS
Perform the same procedure for the other side cover.

Remove the two special screws and the seat forward to
remove it.
SEAT
LEFT SIDE
COVER
Installation is in the reverse order of removal.

RIGHT SIDE
COVER
Insert the prongs on the seat into the slots and align
the screw holes in the seat and frame properly to
avoid cross-threading when tightening the screws.
TORQUE:
Seat mounting special screw:
4.3 Nm (0.4 kgfm, 3.2 lbfft)
BOSS
BOSS
SCREWS
TAB
SLIT
TOP SHELTER
DISASSEMBLY/ASSEMBLY
TOP SHELTER
RIGHT AIR CLEANER
SIDE COVER
GROMMETS:
TAPPING
SCREWS
TABS:
LEFT AIR CLEANER SIDE COVER
27-60
dummyhead
REAR SEAT COWL

Remove the following:
Seat (page 27-60)
Pillion seat (page 3-6)
SCREWS
Remove the four mounting screws and slide the seat

cowl rearward.
Release either the left or right tab from the center seat
cowl.
Take care not to
scratch the seat
cowl.
Slide
Spread the lower side of the seat cowl and raise it to

clear the grab rail area of the center seat cowl.
Carefully release the other tab and remove the seat
cowl.
REAR SEAT COWL
Remove the special nuts in the seat rail if necessary.

Spread
TAB
GRAB RAIL
AREA
CENTER SEAT COWL
TAB
NUTS
27-61
dummyhead
AIR INTAKE COVER

Remove the three trim clips.
Release the two tabs from the inner middle cowl and
remove the air intake cover.
AIR INTAKE COVER

Align the mating areas of the intake cover and cowls
properly.
TABS
TRIM CLIPS
AIR DUCT COVER

Remove the screw and two tapping screws from the
duct cover.
Remove the screw securing the rear end of the middle
cowl.
SCREW (5 mm) DUCT

COVER
Slide the air duct cover rearward to release the two tabs
from the middle cowl while spreading the cowl outward
slightly and remove the duct cover.
TORQUE:
Middle cowl mounting screw:
1.5 Nm (0.2 kgfm, 1.1 lbfft)
Duct cover mounting screw (5 mm):
5.2 Nm (0.5 kgfm, 3.8 lbfft)
TAPPING
SCREWS
TABS
MIDDLE COWL
SCREW
27-62
dummyhead
LOWER COWL
Release the hoses from the lower cowl.
Support the rear portion of the lower cowl and remove
the four screws.
Be careful not to
break the middle
cowl tabs.
Release either the left or right three tabs on the middle

cowl while sliding the lower cowl rearward, then remove
the lower cowl from the other side tabs.
Remove the special nuts from the stays if necessary.
TORQUE:
Lower cowl mounting screw (front):
1.5 Nm (0.2 kgfm, 1.1 lbfft)
Lower cowl mounting special screw (rear):
10 Nm (1.0 kgfm, 7 lbfft)
HOSES
NUTS
TABS
SPECIAL SCREWS
(6 x 10 mm)
LOWER COWL
SCREWS (5 x 15 mm)
27-63
dummyhead
MIDDLE COWL
REMOVAL
Air intake cover (page 27-62)
Air duct cover (page 27-62)
Remove the trim clip from the inside of the middle cowl.
Be careful not to
break the tabs.
While supporting the bottom of the lower cowl (A), and

holding the lower side of the middle cowl down (B) to
avoid damaging the retaining tabs, disconnect the lower
tabs of the middle cowl by sliding it forward (C).
Be careful not to
scratch the cowls.
Release the stay off of the headlight housing (D), then

turn the middle cowl downward (E) as a pivot point of
the upper end to release the front tabs and remove the
middle cowl.
Remove the screw and cowl stay if necessary.
TABS
(B)
(E)
(C)
MIDDLE
COWL
(A)
TABS
(D)
LOWER
COWL
Pivot Point
STAY
SCREW
NUT
TRIM CLIP
27-64
dummyhead
INSTALLATION
Install the cowl stay, aligning the groove with the frame
tab and tighten the special screw if it was removed.
Do not spread open
the cowl more than
necessary.
1. Install the middle cowl over the intake duct while

spreading the inner side of the middle cowl slightly,
then position the stay onto the headlight housing.
2. Raise the upper cowl end and place the upper tab A
of the middle cowl under the upper cowl.
3. Align the slit in the inner middle cowl with the upper
cowl tab B and set all the front side tabs C properly
by sliding the middle cowl rearward.
4. Insert the three lower tabs D into the slits in the
lower cowl in a straight line while supporting the
bottom of the lower cowl, being careful not to
damage the tabs.
Make sure the mating areas of the middle cowl are
aligned with the air duct and upper cowl properly as
shown, and install the trim clip.
Install the following:
Air duct cover (page 27-62)
Air intake cover (page 27-62)
2.
1.
3.
UPPER COWL
Stay
TAB B
DUCT
TAB A
Slit
MIDDLE COWL
TABS C
(Inner)
4.
Slits
STAY
TABS D
Align
Mating Area:
SCREW
NUT
TRIM CLIP
(Tab is not exposed)
(Flush with duct)
(Connected securely)
27-65
dummyhead
TAPPING SCREWS
LAYER COVER
MIDDLE COWL
TRIM CLIP
LAYER COWL
INNER MIDDLE COWL
INTAKE AIR DUCT

Remove the middle cowl (page 27-64).
Disconnect the 2P (Gray) connector and vacuum hose
from the IDC solenoid valve.
CONNECTOR
Remove the harness clip and the 20P (Black) connector

out of the resonator on the duct.
HOSE
CLIP
CONNECTOR
27-66
dummyhead
Release the following from the wire guide of the duct.
vacuum hoses
solenoid wire
sub-wire harness
TAB
BOSS
Remove the screw.

Release the tab on the headlight housing and the boss
from the frame, and remove the air duct.
Remove the two trim clips and resonator if necessary.
Make sure the mating area of the duct is aligned with
the headlight housing, before tightening the screw.
GUIDE
DUCT
TORQUE: Screw: 5.2 Nm (0.5 kgfm, 3.8 lbfft)
SCREW
GROMMET
TAB FITTING
GROOVE
TRIM CLIPS
RESONATOR
27-67
dummyhead
LEFT REAR UNDER COVER (ABS type)

Remove the left middle cowl (page 27-64).
Remove the bolt and gearshift arm.
Remove the special screws. Release the cover flange
off of the hook and the boss from the grommet, then
remove the left rear under cover.
Install the left rear under cover while aligning its boss
with the grommet, then tighten the special screws
securely.
Install the gearshift arm to the gearshift spindle, aligning
the arm slit with the punch mark on the gearshift
spindle.
Tighten the gearshift arm pinch bolt securely.
Install the left middle cowl (page 27-65).
SPECIAL SCREW
HOOK
BOSS
BOLT
GROMMET
Align
GEARSHIFT ARM
SPECIAL SCREW
LEFT REAR UNDER COVER
27-68
dummyhead
REARVIEW MIRROR/WINDSCREEN
Pull the connector boot out of the stay and disconnect
the position light 1P and turn signal light 2P connectors.
Do not hang the
mirror by the turn
signal/position light
wire.
CONNECTORS
Remove the nuts and washers and pull the wire out of
the stay carefully to remove the rearview mirror.
REARVIEW
MIRROR
Perform the same procedure for the other side mirror.

Remove the four bolts, plastic washers, and rubber
washers.
Take care not to

scratch the
windscreen surface.
Slightly press both ends of the windscreen inward and

remove it.
NUTS AND
WASHERS
Remove the four special nuts and two grommets from

the windscreen.
Align the windscreen tab with the cowl groove and
the two grommets with the cowl bosses.
Route the turn signal/position light wires through the
stay before installing the windscreen, being careful
not to break the tabs on the upper cowl.
TORQUE:
Windscreen mounting bolt:
1.5 Nm (0.2 kgfm, 1.1 lbfft)
Rearview mirror mounting nut:
WINDSCREEN
SPECIAL NUTS
UPPER COWL
WINDSCREEN
UPPER COWL
STAY
BOLTS
PLASTIC WASHERS
WINDSCREEN
RUBBER WASHERS
Align
Align
COWL TABS
27-69
dummyhead
UPPER COWL
Middle cowls (page 27-64)
Intake air duct (page 27-66)
Disconnect the sub-wire harness 8P (Black), 8P (Gray)
and 20P (Black) connectors.
Disconnect the vacuum hose (that goes to the chamber
on the headlight housing) from the one-way valve.
Cover the front
fender with clean
shop towels to
prevent the upper
cowl from falling
onto the fender.
Route the wires
properly (page 2723).
Remove the rearview mirrors and windscreen (page 2769).

Release the two cowl bosses off of the stay grommets
and disconnect the meter 28P (Gray) and horn
connectors to remove the upper cowl.
GROMMETS
METER 28P CONNECTOR
UPPER COWL
HORN CONNECTORS
BOSSES
VACUUM HOSE
8P (Gray) CONNECTOR
ONE-WAY VALVE
27-70
dummyhead
DISASSEMBLY
RELAYS
TAB
TAB
turn signal and headlight relays (from the headlight

housing)
flange screw and two washer screws
upper cowl (by releasing the two tabs)
SCREWS (Washer)
SCREW (Flange)
vacuum chamber (from the stay)

CHAMBER
two tapping screws and stay (from the headlight
housing)
angle sensor 3P (Black) connector and wire clip (to
remove the stay)
two nuts and bank angle sensor (disconnect the 3P
connector)
headlight 4P (Black) connector
sub-wire harnesses (from the clamp)
COWL
3P CONNECTOR
CLIP
SCREWS
STAY
CLAMP
SENSOR
HARNESS
NUTS
4P CONNECTOR
27-71
dummyhead
ASSEMBLY
TURN SIGNAL RELAY
HEADLIGHT RELAY
UPPER COWL
WASHER SCREWS
2 Nm (0.2 kgfm,
1.5 lbfft)
VACUUM CHAMBER
TABS
FLANGE SCREW
BANK ANGLE
SENSOR
GROOVES
CHAMBER STAY
HEADLIGHT ASSEMBLY
Route the wires

Place the sub-wire harness between the headlights and

connect the 4P (Black) connector.
1.1 Nm (0.1 kgfm,

0.8 lbfft)
SENSOR
Install the bank angle sensor with the two nuts.

TORQUE: 2 Nm (0.2 kgfm, 1.5 lbfft)
Connect the 3P (Black) connector.
HARNESS
Install the wire clip and 3P connector onto the chamber

stay and install it with the two tapping screws.
NUTS
TORQUE: 1.1 Nm (0.1 kgfm, 0.8 lbfft)

Install the vacuum chamber into the stay and secure the
wires and vacuum hose with the clamp.
4P CONNECTOR
3P CONNECTOR
CHAMBER
STAY
CLIP
SCREWS
HOSE
CLAMP
27-72
dummyhead
Place the upper cowl onto the headlight housing by
aligning the four lower grooves with the tabs of the
housing and set the two upper tabs into the grooves to
secure the cowl.
TAB
RELAYS
TAB
Install the three screws and tighten them.

Install the turn signal and headlight relays onto the
stays.
SCREWS (Washer)
SCREW
(Flange)
TABS
REAR CENTER COWL

STANDARD type
Rear seat cowl (page 27-61)
License light stay (page 26-27)
Disconnect the brake/taillight 3P connector.
Remove the fuse/relay box.
Remove the tapping screw located under the fuse/relay
box.
Remove the four bolts and washers while supporting
the cowl.
Release the wire out of the rear fender B and remove
the rear center cowl assembly.
Remove the setting collars.
SCREW
FUSE/RELAY BOX
COLLARS
3P CONNECTOR
BOLTS AND
WASHERS
REAR CENTER COWL
27-73
dummyhead
ABS type
Remove the rear seat cowl (page 27-61).
Remove the fuse/relay box.
Disconnect the 3P and 4P connectors (that goes to the
brake/taillight and turn signal lights).
Remove the trim clip and the bolt located under the
fuse/relay box.
Remove the four bolts and washers while supporting
the cowl.
Release the wires out of the rear fender B and remove
the rear center cowl assembly.
Remove the setting collars.
FUSE/RELAY BOX
COLLARS
WASHERS
CONNECTORS
BOLTS (6 x 18 mm)
REAR CENTER COWL
TRIM CLIP
27-74
BOLT (6 x 14 mm)
dummyhead
STANDARD type:
TAPPING SCREWS
SCREWS
WASHERS
GROOVE
BRAKE/
TAILLIGHT
COLLARS
RUBBERS
SLOT
EDGE
TAB
ABS type:
WASHER BOLTS
TAPPING SCREWS
BRAKE/
TAILLIGHT
WASHERS
SCREWS
GROOVE
COLLARS
RUBBERS
LICENSE LIGHT STAY
SLOT
EDGE
COLLARS
TAB
27-75
dummyhead
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 a dealer.
ITEMS
NOTE
* FUEL LINE
*
*
*
*
*
THROTTLE OPERATION
AIR CLEANER (KO, IIKO types)
AIR CLEANER (Except KO, IIKO)
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FILTER
* ENGINE IDLE SPEED
RADIATOR COOLANT
* COOLING SYSTEM
* SECONDARY AIR SUPPLY SYSTEM
** EGCA CABLE
I
NOTE2
NOTE2
R
R
I
NOTE3
DRIVE CHAIN
DRIVE CHAIN SLIDER
BRAKE FLUID
BRAKE PADS WEAR
BRAKE SYSTEM
BRAKE LIGHT SWITCH
HEADLIGHT AIM
CLUTCH SYSTEM
SIDESTAND
* SUSPENSION
* NUTS, BOLTS, FASTENERS
** WHEELS/TIRES
** STEERING HEAD BEARINGS
FREQUENCY (NOTE 1)
x 1,000 km 1 12 24 36
x 1,000 mi 0.6 8 16 24
I
I
I
NOTE3
R
R
I
I
I
I
I
R
I
I
I
R
R
I
I
I
I
I
48
32
I
R
R
I
I
I
I
EVERY 1,000 km
(600 mi) I, L
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
R
I
R
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
REFER
ANNUAL REGULAR
TO
CHECK REPLACE PAGE
I
4-5,
25-66
I
4-8
27-77
27-77
4-10
4-12
R
4-17
R
4-17
I
6-87
I
3 years
4-20
I
4-20
I
4-21
4-31,
25-69
4-22,
25-69
4-27
I
2 yeas
4-27
I
4-28
I
4-29
I
4-30
I
4-30
I
4-30
I
4-34
I
4-34,
27-77
I
4-37
I
4-38
I
4-39
* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer reading, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replacement requires mechanical skill.
27-76
dummyhead
AIR CLEANER
Remove the air cleaner element (page 4-8).
Except KO, IIKO:
Clean the air cleaner element using compressed air

from the throttle body side any time it is excessively
dirty.
KO, IIKO types:
Replace the air cleaner element in accordance with the

maintenance schedule or any time it is excessively dirty
or damage.
The viscous paper element type air cleaner (KO,
IIKO types) cannot be cleaned because the element
contains a dust adhesive.
TORQUE:
Air cleaner element mounting screw:
0.8 Nm (0.1 kgfm, 0.6 lbfft)
ECM setting plate screw:
0.8 Nm (0.1 kgfm, 0.6 lbfft)
SUSPENSION
FRONT SUSPENSION ADJUSTMENT
SPRING PRE-LOAD ADJUSTER
Spring pre-load can be adjusted by turning the adjuster.
TURN CLOCKWISE:
Increase the spring pre-load
TURN COUNTERCLOCKWISE:
Decrease the spring pre-load
PRE-LOAD ADJUSTER ADJUSTABLE RANGE:
15 turns
PRE-LOAD ADJUSTER STANDARD POSITION:
7-1/2 turns clockwise from minimum
PRE-LOAD ADJUSTER
COMPRESSION AND REBOUND DAMPING

ADJUSTERS
Do not turn the adjusters more than the given positions

or the adjusters may be damaged.
All damping adjustments are referenced from the
fully hard position.
The compression and rebound damping can be
To adjust both sides adjusted by turning the adjusters.
equally, set the right
and left damping
adjusters to the
same position.
COMPRESSION
ADJUSTER
DIRECTION H: Increase the damping force (harder)

DIRECTION S: Decrease the damping force (softer)
Turn the compression adjuster clockwise until it stops
(fully hard position), then turn the adjuster
counterclockwise.
COMPRESSION ADJUSTER ADJUSTABLE RANGE:
7 turns
COMPRESSION ADJUSTER STANDARD POSITION:
5-1/2 turns out from fully hard
27-77
dummyhead
Turn the rebound adjuster clockwise until it stops (fully
hard position), then turn the adjuster counterclockwise.
REBOUND ADJUSTER ADJUSTABLE RANGE:
5-1/2 turns
REBOUND ADJUSTER STANDARD POSITION:
REBOUND
ADJUSTER
REAR SUSPENSION ADJUSTMENT

SPRING PRE-LOAD ADJUSTER
Spring pre-load can be adjusted by turning the adjuster.
PRE-LOAD ADJUSTER
PRE-LOAD ADJUSTER ADJUSTABLE RANGE:

10 positions
PRE-LOAD ADJUSTER STANDARD POSITION:
4 position from minimum
COMPRESSION AND REBOUND DAMPING

ADJUSTERS
Do not turn the adjusters more than the given positions

or the adjusters may be damaged.
All damping adjustments are referenced from the
fully hard position.
The compression and rebound damping can be
adjusted by turning the adjusters.
DIRECTION H: Increase the damping force
DIRECTION S: Decrease the damping force
Turn the compression adjuster clockwise until it stops
(fully hard position), then turn the adjuster
counterclockwise.
COMPRESSION ADJUSTER ADJUSTABLE RANGE:
4-1/2 turns
COMPRESSION ADJUSTER STANDARD POSITION:
27-78
COMPRESSION ADJUSTER
dummyhead
Turn the rebound adjuster clockwise until it stops (fully
hard position), then turn the adjuster counterclockwise.
REBOUND ADJUSTER
REBOUND ADJUSTER ADJUSTABLE RANGE:

4 turns
REBOUND ADJUSTER STANDARD POSITION:
OIL COOLER
INSTALLATION
Apply oil to a new O-ring and install it into the oil cooler
groove.
Apply oil to the seating surface of a new sealing
washer.
Do not stagger the
arrows more than
4 mm (0.2 in).
WASHER
Place the oil cooler onto the crankcase by aligning the

arrows with the edges of the crankcase boss. Install the
oil cooler bolt with the sealing washer and temporarily
tighten it.
O-RING
Hold the oil cooler by your hand securely to prevent

misalignment of the arrow position and tighten the bolt
to the specified torque.
OIL COOLER
TORQUE: 59 Nm (6.0 kgfm, 44 lbfft)
BOLT
Make sure the arrows are in alignment with the boss.

BOSS
4 mm
max.
ARROWS
4 mm
max.
Align
Connect the water hoses and tighten the hose clamp

screws (page 27-22).
Install the exhaust pipe (page 3-29).
Fill the crankcase with the recommended oil (page 417).
Check for coolant and oil leaks.
HOSES
27-79
dummyhead
INTAKE AIR DUCT CONTROL

INTAKE AIR DUCT VALVE
DIAPHRAGM
INSPECTION
Remove the air duct cover (page 27-62).
VACUUM PUMP
Disconnect the vacuum hose from the diaphragm.

Connect a vacuum pump to the diaphragm and apply
specified vacuum.
DIAPHRAGM
SPECIFIED VACUUM: 250 mm Hg (9.8 in Hg)

The vacuum should hold and the air duct valve should
remain open.
AIR DUCT VALVE
Remove the middle cowl (page 27-64).
Disconnect the vacuum hose.
RETAINERS
DIAPHRAGM
Turn the diaphragm counterclockwise while holding

down it to release the retainers from the duct.
Disconnect the rod from the valve and remove the
diaphragm.
ROD

When connecting the rod, insert the rod into the
valve from the inside.
Set the diaphragm so its hose joint is facing the duct
elbow (rearward).
VALVE
HOSE
IDC SOLENOID VALVE

Remove the air duct cover (page 27-62).
Disconnect the 2P (Gray) connector.
Remove the tapping screw and solenoid valve from the
air duct.
HOSES
SCREW
Disconnect the vacuum hoses to remove the IDC

solenoid valve.
Route the hoses
and wire properly
(page 27-23).

TORQUE: Screw: 1.1 Nm (0.1 kgfm, 0.8 lbfft)
SOLENOID
VALVE
CONNECTOR
27-80
dummyhead
FRONT WHEEL
INSPECTION
Wheel balance
Wheel balance directly affects the stability, handling
and overall safety of the motorcycle. Always check
balance whenever the tire has been removed from
the rim.
For optimum balance, the tire balance mark (a paint
dot on the side wall) must be located next to the
valve stem. Remount the tire if necessary.
Mount the tire with the arrow mark facing in the
direction of rotation.
Stick-type balance weights should be used on this
motorcycle. Use genuine Honda balance weights.
Before installing the weights, remove any
adhesive from the rim thoroughly and clean the
area where new weights are to be placed with
degreasing agent. Take care not to scratch the rim
surface.
Do not touch the adhesive surface of the weight
with your bare hands when installing.
The balance weights are always replaced with
new ones whenever they are removed. Do not
reuse them.
BALANCE MARK
VALVE STEM
ARROW
Wheel Rotating Direction
Mount the wheel, tire and brake discs assembly in an

inspection stand.
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) point of the wheel with a chalk.
Do this two or three times to verify the heaviest area.
If the wheel is balanced, it will not stop consistently in
the same position.
INSPECTION
STAND
To balance the wheel, install the wheel weights on the

highest side of the rim, on the side opposite the chalk
marks. Add just enough weight so the wheel will no
longer stop in the same position when it is spun.
Do not add more than 60 g to the wheel.
Press the weights by your hands firmly and make sure
they are not come off the rim.
The weights are attached to the position at 5 mm
(front)/7.5 mm (rear) from the side surface of the rim
in the direction as shown.
If the weight exceeds 10 g, install same amount of
the balance weights on the right and left symmetrical
position.
Front Wheel:
5 mm (0.2 in)
Rear Wheel:
7.5 mm (0.3 in)
WEIGHTS
27-81
dummyhead
FORK
REMOVAL
FORK CAP
WRENCH
intake air duct (page 27-66)

front wheel
STANDARD type (page 14-17)
ABS type (page 25-103)
front fender
Loosen the pinch bolts of the handlebar and top bridge.
Take care not to
scratch the cap
head.
Keep the master

cylinder reserve
tank upright to
prevent air from
entering the
hydraulic system.
When the fork leg will be disassembled, loosen the fork

cap, but do not remove it yet.
TOOL:
Lock nut wrench
PINCH BOLTS
07SMA-GBC0100
While holding the fork leg, loosen the bottom bridge

pinch bolts. Pull the fork leg down and remove it out of
the fork bridges.
PINCH
BOLTS
FORK
DISASSEMBLY
Turn the spring pre-load adjuster counterclockwise to
the softest position (be sure to record the number of
turns from the starting position).
Remove the collars.
COLLARS
PRE-LOAD
ADJUSTER
Remove the stopper ring, being careful not to scratch

the outer tube.
Do not clamp the
tube too tight or it
could get damaged.
Take care not to
scratch the cap
head.
Place the outer tube in a vise with soft jaws or shop

towels.
Loosen the fork cap and remove it from the outer tube.
TOOL:
Lock nut wrench
07SMA-GBC0100
Lower the outer tube slowly and rest it onto the axle
holder.
Remove the O-ring from the fork cap.
27-82
FORK CAP
OUTER
TUBE
STOPPER RING
dummyhead
Hold the axle holder on the slide pipe in a vise with soft
jaws or shop towels.
GUIDE CASE
WRENCH
Loosen the rod guide case using the special tool.

The piston rod
assembly is under
spring pressure;
hold the fork cap
securely when
removing.
Remove the rod guide case from the slide pipe by

turning the tool by hand.
TOOL:
Rod guide case wrench
070MB-MGP0100
ROD GUIDE CASE

piston rod assembly
PISTON ROD
spring collar B
fork spring
COLLAR B
Be careful not to
scratch the slide
pipe.
dust seal
stopper ring
FORK SPRING
DUST SEAL
STOPPER RING
27-83
dummyhead
Using quick successive motions, pull the slide pipe out
of the outer tube.
Remove the following from the slide pipe:
slider bushing
guide bushing
back-up ring
oil seal
stopper ring
dust seal
GUIDE
BUSHING
SLIDER
BUSHING
BACK-UP
RING
DUST
SEAL
OIL SEAL
Take care not to

scratch the cap
head.
STOPPER
RING
Loosen the piston rod nut while holding the fork cap
with the special tool.
TOOL:
Lock nut wrench
NUT
07SMA-GBC0100
Remove the fork cap.

FORK CAP
WRENCH
INSPECTION
Fork Spring
Measure the fork spring free length.
SERVICE LIMIT: 224.9 mm (8.85 in)
27-84
dummyhead
Outer Tube/Slide Pipe
Check the outer tube for damage or deformation.
Check the slide pipe for score marks, scratches, or
excessive or abnormal wear.
SLIDE PIPE
OUTER TUBE
Set the slide pipe in V-blocks and measure the fork tube
runout with a dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT: 0.20 mm (0.008 in)
SLIDE PIPE
Bushing/Back-up Ring
Visually inspect the guide and slider bushings.
Replace the bushings if there is excessive scoring or
scratching, or if the teflon is worn so that the copper
surface appears on more than 3/4 of the entire surface.
BUSHING
Check the back-up ring; replace it if there is any

distortion at the points shown.
BACK-UP RING
CHECK POINTS
COPPER SURFACES
Piston Ring
Check the piston rings for wear or damage.
RING A
RING B
27-85
dummyhead
ASSEMBLY
OUTER TUBE
PISTON RING B
NUT
27.5 Nm (2.8 kgfm, 20 lbfft)
STOPPER RING
SLIDER BUSHING
O-RING
FORK CAP
GUIDE BUSHING
O-RING
BACK-UP RING
INNER ROD PIPE

OIL SEAL
ROD GUIDE CASE
STOPPER RING
REBOUND SPRING
DUST SEAL
ROD PIPE
SLIDE PIPE
PISTON ROD
PISTON RING A
SPRING COLLAR B
FORK SPRING
SPRING COLLAR A
Assemble the piston rod and rod guide case.

Install the fork cap onto the piston rod and screw it until
the cap just touches the rod end.
Take care not to
scratch the cap
head.
NUT
Hold the fork cap with the special tool and tighten the
rod nut.
TOOL:
Lock nut wrench
07SMA-GBC0100
FORK CAP
TORQUE: 27.5 Nm (2.8 kgfm, 20 lbfft)

WRENCH
27-86
dummyhead
Cover the slide pipe end with a plastic wrap or
equivalent to avoid damaging the seals on the edges.
STOPPER
RING
OIL SEAL
Apply fork fluid to the lips of new dust and oil seals.
Install the following onto the slide pipe:
DUST SEAL
dust seal
stopper ring
oil seal (with the marked side facing the axle holder)
Remove the plastic wrap.
WRAP
(Mark)
Remove the burrs from the slider bushing mating

surface, being careful not to peel off the coating.
Be careful not to back-up ring (with the groove facing the outer tube)
damage the coating guide bushing
on the bushing. Do slider bushing
not spread open the
bushing more than
necessary.
Axle holder side
BACK-UP RING
(Groove)
Install the slide pipe into the outer tube.
GUIDE BUSHING
SLIDER BUSHING
Drive the guide bushing into place, using the special

tool.
TOOL:
Fork seal driver
OIL
SEAL
07YMD-MCF0100
Drive the oil seal until the stopper ring groove is visible,
using the same tool.
BACK-UP
RING
GUIDE
BUSHING
Do not scratch the
fork tube sliding
surface.
Install the stopper ring into the groove in the outer tube.
DRIVER
DUST SEAL
Make sure the stopper ring is securely set in the

groove.
Install the dust seal securely.
STOPPER RING
27-87
dummyhead
Lower the outer tube and rest it onto the axle holder.
Note the installation
direction of the
collars.
COLLAR B
Insert the following into the slide pipe:

spring collar A (with the round side facing down)
fork spring
spring collar B (with the flange side facing down)
FORK
SPRING
COLLAR A
After installing the
piston rod
assembly, pour the
total amount of fluid
as described in the
later step.
Pour the recommended fork fluid up to the side holes in

the slide pipe with the fork leg compressed.
Do not extend the

outer tube more
than 25 cm (10 in)
from the axle
holder. The fork
fluid will spill out of
the side holes in the
slide pipe.
Slowly pump the outer tube 8 10 times to remove any

trapped air completely.
RECOMMENDED FORK FLUID:

Honda ULTRA CUSHION OIL SS-47 (10W)
or equivalent
FORK FLUID CAPACITY:
515 2.5 cm3 (17.4 0.08 US oz, 18.1 0.09 Imp oz)
25 cm (10 in) max.
Be careful not to
damage the piston
ring B on the rod
guide case on the
edge or threads.
Insert the piston rod assembly into the slide pipe while
extending the outer tube with the fork cap held down.
THREADS
PISTON
Using the special tool, screw the rod guide case by ROD
hand to install it into the slide pipe with the outer tube
lifted up.
TOOL:
Rod guide case wrench
070MB-MGP0100
RING B
WRENCH
OUTER TUBE
27-88
GUIDE
CASE
dummyhead
Hold the axle holder on the slide pipe in a vise with soft
jaws or shop towels.
Tighten the rod guide case to the specified torque.
WRENCH
GUIDE CASE
Fill the rod guide case with the remaining fork fluid.
RECOMMENDED FORK FLUID:
Honda ULTRA CUSHION OIL SS-47 (10W)
or equivalent
Hold the fork cap down, then pump the outer tube
several times to remove any trapped air completely.
84 mm
(3.3 in)
Compress the outer tube fully and measure the fluid

level from the top of the outer tube by supporting the
fork leg vertically.
FORK FLUID LEVEL: 84 mm (3.3 in)
OUTER TUBE
Adjust the fluid level as required.

Do not clamp the
tube too tight or it
could get damaged.
Take care not to

scratch the cap
head.
Place the outer tube in a vise with soft jaws or shop

towels.
O-RING
Coat a new O-ring with fork fluid and install it into the
fork cap groove.
FORK
CAP
Install the fork cap into the outer tube and tighten it.
TOOL:
Lock nut wrench
07SMA-GBC0100
TORQUE: Actual: 35 Nm (3.6 kgfm, 26 lbfft)

Indicated: 31 Nm (3.2 kgfm, 23 lbfft)*
STOPPER RING
*Using a deflecting beam type torque wrench 20 inches long

Install the stopper ring into the outer tube groove.
Install the collars.
Return the pre-load adjuster to the original position as
noted before disassembly.
COLLARS
PRE-LOAD
ADJUSTER
27-89
dummyhead
INSTALLATION
Route the wires,
cables and hose
Install the fork leg into the bottom bridge, handlebar and
top bridge.
Align
Align the top of the outer tube with the upper surface of
the top bridge and parallel the adjusters on the fork cap
to the top bridge (rider can be read characters) as
shown, then tighten the bottom bridge pinch bolt to
determine the fork position.
FORK CAP
Front
Tighten the bottom bridge pinch bolts to the specified

torque.
PINCH
BOLTS
FORK
Tighten the top bridge pinch bolt.

TOP BRIDGE
PINCH BOLT
Be sure to align the handlebar stopper pin with the hole

in the top bridge. Tighten the handlebar pinch bolt while
seating the handlebar against the bridge.
PIN
Install the following:

front fender
front wheel
intake air duct (page 27-66)
27-90
HANDLEBAR
PINCH BOLT
dummyhead
IGNITION SYSTEM DIAGRAM

FUSE 10A
(START)
W/Y
G
IGNITION
SWITCH
R/Bl
MAIN FUSE
30A
R
R/Bu
W/Y
W/Bl
Bl
Bl
BATTERY
ENGINE STOP
SWITCH
Bl/G Bl/Br Bl
BANK
ANGLE
SENSOR
FUSE 20A (FI)

R/W
ENGINE STOP
RELAY
Bl/W
Bu/Bl
Bl/W
Bl/W
Y/W
R/Bu
Bl/W
R/Y
Bl/W
DIRECT
IGNITION COILS
No.1
No.2
No.3
G/P
Bl/W
No.4
G/P
G/P
ECM
UP
SIDESTAND
SWITCH
G/W
DOWN
To Combination
Meter
Gr/R
Gr/Bl
Gr/Bl
Bu/Y
R: Red
G: Green
Y: Yellow
Lg: Light green
Gr: Gray
Bl: Black
Bu: Blue
W: White
O: Orange
P: Pink
Gr/Bl
Y/R
Lg/Y
Gr/Bl
Gr/Bu
Y/R
Y/R
Bu/Y
G/W
Bl
G/R
Bl
Gr/Bl
Y/R
Bu
O
W/Y
Gr
G/R
DIODE
ECT
SENSOR
MAP
SENSOR
IAT
TP
SENSOR SENSOR
KNOCK
CMP
CKP
SENSOR SENSOR SENSOR
CLUTCH
SWITCH
Lg
3
2
5
6
Lg
GEAR POSITION
SWITCH
27-91
dummyhead
ELECTRIC STARTER SYSTEM LOCATION

STANDARD type:
STARTER/LAP SWITCH
LAP RELAY
IGNITION
SWITCH
DIODE (2 terminals)
DIODE (3 terminals)
CLUTCH SWITCH
STARTER MOTOR
GEAR POSITION
SWITCH
SIDESTAND SWITCH
BATTERY
ABS type:
STARTER/LAP SWITCH
LAP RELAY
IGNITION
SWITCH

DIODE
(2 terminals)
BATTERY
CLUTCH SWITCH
DIODE (3 terminals)
STARTER MOTOR
GEAR POSITION
SWITCH
SIDESTAND SWITCH
27-92
dummyhead
ELECTRIC STARTER SYSTEM DIAGRAM

STANDARD type:
STARTER
MOTOR
MAIN
FUSE
30A
BATTERY
IGNITION
SWITCH
CLUTCH
SWITCH
G/R
G/R
W/Y
R/Bl
DIODE
LAP RELAY
G/R
Bl
FUSE 10A
(START)
Y/R
R
Bl
R: Red
W: White
Y: Yellow
G: Green
Bl: Black
Lg: Light green
P: Pink
O: Orange
G/W
STARTER/LAP SWITCH
Y/P
DIODE
Lg
UP
Y/R
Bl/R
Y/P
DOWN
SIDESTAND
SWITCH
W/Y
Lg
4 3
Bl/O
5
6
G
To combination meter
(LAP timer input signal)
GEAR
POSITION
SWITCH
(LAP relay output)
ABS type:
R: Red
W: White
Y: Yellow
G: Green
Bl: Black
Lg: Light green
P: Pink
O: Orange
STARTER
MOTOR
MAIN
FUSE
30A
BATTERY
IGNITION
SWITCH
CLUTCH
SWITCH
G/R
R
Bl
G/R
R/Bl
W/Y
DIODE
LAP RELAY
G/R
Bl
FUSE 10A
(START)
Y/R
G/W
DIODE
Lg
UP
STARTER/LAP SWITCH
Y/P
Y/R
Bl/R
Y/P
DOWN
SIDESTAND
SWITCH
G
Bl/O
2
6
W/Y
Lg
4 3
5
GEAR
POSITION
SWITCH
(LAP timer input signal)
(LAP relay output)
27-93
dummyhead
ELECTRIC STARTER TROUBLESHOOTING

Make sure the battery is fully charged and in good condition.
Check the ignition switch and its circuit if all systems do not function when the ignition switch is turned ON.
Check for a blown main fuse (30 A) or sub-fuse (START; 10 A). (Check for a short circuit in the related wires
if the fuse is blown again)
The starter motor should operate with the following conditions.
transmission is in neural or
clutch lever squeezed with sidestand retracted
ignition switch turned ON
starter/lap switch pushed
This model is equipped with a lap timer. The starter switch is used for timer operation as well as for starting
the engine. These two functions of the switch are changed automatically depending upon the mode of the
combination meter. The change is made via the lap relay (page 27-107).
The starter/lap switch functions as the lap timer switch when the combination meter is in lap time mode and
with the engine running. The switch reverts to its primary starting function when the combination meter is
displaying standard information or when the engine is stopped.
Starter motor does not turn
1. Starter Relay Switch Operation Inspection
Check the operation of the starter relay switch as above starting conditions.
Does the starter relay switch click?
YES
GO TO STEP 2.
NO
GO TO STEP 3.
2. 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?
YES
Poorly connected starter motor cable

Faulty starter relay switch (page 19-15)
NO
Faulty starter motor (page 19-6)
3. Relay Coil Ground Line Inspection

Check the ground line of the starter relay switch (page 19-15).
Is the ground line normal?
NO
Faulty gear position switch (page 27-104)

Faulty clutch switch (page 20-19)
Faulty sidestand switch (page 20-21)
Faulty diode (3 terminals) (page 19-16)
Loose or poor contact of the related connector terminal
Open circuit in the wire harness
YES
GO TO STEP 4.
4. Starter Coil Power Input Line Inspection

Check the power input line of the starter relay switch (page 27-95).
Is the input line normal?
27-94
NO
Faulty starter/lap switch (starter switch; page 20-17)

Faulty diode (2 terminals) (page 27-96)
Loose or poor contact of the related connector terminal
Open circuit in the wire harness
Faulty lap timer circuit (page 27-95)
YES
GO TO STEP 5.
dummyhead
5. Starter Relay Switch Continuity Inspection
Check the function of the starter relay switch (page 19-15).
Does the starter relay switch function properly?
NO
Faulty starter relay switch
YES
Loose or poor contact starter relay switch connector terminal
Starter motor turns engine slowly

Low battery voltage
Poorly connected battery cables
Poorly connected starter motor cable
Faulty starter motor
Starter motor turns, but engine does not turn
Starter motor is running backwards
Case assembled improperly
Terminals connected improperly
Faulty starter clutch
Damaged or faulty starter drive gear, driven gear, idle gear and/or reduction gear
Starter relay switch "CLICK", but engine does not turn over
Crankshaft does not turn due to engine problems

INPUT LINE INSPECTION
Disconnect the starter relay switch 4P connector.
STANDARD type:
Check for continuity between the Red and Yellow/red

terminals of the 4P connector.
There should be continuity when the ignition switch is
ON and the starter/lap switch is pushed. (There is a
slight resistance due to the diode)
ABS type:
STANDARD type:
Red (+)
ABS type:
Yellow/red ()
(+)
Yellow/red
()
Turn the ignition switch ON. Measure the voltage

between the Yellow/red terminal (+) and ground ().
There should be battery voltage when the starter/lap
switch pushed.
STARTER RELAY SWITCH 4P CONNECTOR

(Viewed from the terminal side)
If the power input line is abnormal, check the following.

starter/lap switch (starter switch; page 20-17)
diode (2 terminals) (page 27-96) and its wires
lap timer circuit as follows
1. Lap Relay Inspection
Check the lap relay (page 27-107).
Is the relay normal?
NO
Faulty lap relay (stuck on).
YES
GO TO STEP 2.
27-95
dummyhead
2. Lap Relay Coil Output Line Short Circuit
Inspection
Check for continuity between the Black/orange wire
terminal of the relay 4P connector and ground.
LAP RELAY 4P CONNECTOR

Is there continuity?
YES
Short circuit in Black/orange wire between

the relay and combination meter.
NO
Replace the combination meter with a new

one and recheck.
Black/orange
DIODE
2 terminals
Lift and support the fuel tank.
DIODE
Remove the diode from the main wire harness (near the
lap relay).
INSPECTION
Check for continuity between the diode terminals.
When there is continuity, a small resistance value will
register.
If there is continuity in one direction, the diode is
normal.
DIODE
27-96
dummyhead
LIGHTS/METERS/SWITCHES SYSTEM LOCATION

STANDARD type:
IGNITION SWITCH
FRONT BRAKE LIGHT SWITCH
TURN SIGNAL RELAY
HEADLIGHT RELAY
LAP RELAY
FUEL RESERVE SENSOR

FUSE/RELAY BOX
CLUTCH SWITCH
LEFT HANDLEBAR
SWITCH
HORN
VS SENSOR
ECT SENSOR
SIDESTAND
SWITCH
EOP SWITCH
ABS type:
IGNITION SWITCH
FRONT BRAKE LIGHT SWITCH

TURN SIGNAL RELAY

HEADLIGHT RELAY
LAP RELAY
FUEL RESERVE SENSOR
FUSE/RELAY BOX
CLUTCH SWITCH
LEFT HANDLEBAR
SWITCH
HORN
VS SENSOR
ECT SENSOR
SIDESTAND
SWITCH

EOP SWITCH
27-97
dummyhead
HEADLIGHT
INSPECTION
The power source for both the low and high beams
of the headlight are supplied via the headlight relay
and which is controlled by the combination meter.
The headlights go off while the starter/lap switch is
pushed for starting.
Check the following before troubleshooting:
bulbs
battery condition
fuse (HEADLIGHT; 20 A)
Check for short circuit in related wires (Black/red)
if the fuse is blown.
The headlights do not light with the ignition switch
turned ON
1. Relay Inspection
Check the headlight relay (page 20-23).
YES
GO TO STEP 2.
NO
Faulty headlight relay.
2. Relay Signal Line Open Circuit Inspection

Check the Black/blue wire for continuity between the
meter 28P and headlight relay 4P connectors.
METER 28P CONNCTOR
Is the there continuity?

NO
Open circuit in the Black/blue wire.
YES
GO TO STEP 3.
Black/
blue
Black/blue
RELAY 4P CONNECOTR
3. Relay Input Voltage Inspection

Support the
upper cowl
securely to
avoid damaging
the wire
harness.
27-98
Connect the sub-wire harness 8P (Black) connector

on the upper cowl.
Measure the voltage between each Black/red wire
terminal (+) of the headlight relay 4P connector and
ground () with the ignition switch turned ON.
Is there battery voltage?
NO
Open circuit in the Black/red wire(s).
YES
GO TO STEP 4.
RELAY 4P CONNCTOR
Black/red
Black/red
dummyhead
4. Headlight Input Line Open Circuit Inspection
Turn the ignition switch OFF.
Check for continuity between the Blue/white wire
terminal of the relay 4P connector and ground with
the bulbs installed.
RELAY 4P CONNCTOR
NO
Open circuit in the Blue/white wire.
YES

one, and recheck.
Blue/white
The headlights stays on during engine starting

Faulty headlight relay (stuck on) (page 20-23).
Short circuit between the headlight relay and
combination meter (Black/blue wire).
Faulty combination meter.
COMBINATION METER
POWER/GROUND LINE INSPECTION
Support the upper
cowl securely to
avoid damaging the
wire harness.
Remove the upper cowl from the stay with all the
connector connected (page 27-70).
Disconnect the combination meter 28P (Gray)
connector and check the following at the wire harness
side connector terminals:
28P CONNECTOR
Power Input Line

Measure the voltage between the Brown/white wire
terminal (+) and ground ().
There should be battery voltage with the ignition switch
turned ON.
If there is no voltage, check the fuse (METER ILLUMI
10 A) and Brown/white wire for a loose connection or an
open circuit.
28P CONNECTOR
Brown/white
27-99
dummyhead
Back-up Line
Measure the voltage between the Red/green wire
terminal (+) and ground ().
There should be battery voltage at all times.
If there is no voltage, check the fuse (CLOCK/TURN 10
A) and Red/green wire for a loose connection or an
open circuit.
28P CONNECTOR
Red/green
Ground Line
Check for continuity between the Green/black wire
terminal and ground.
There should be continuity at all times.
If there is no continuity, check for open circuit in the
Green/black wire.
28P CONNECTOR
Green/black
Remove the eight screws.
Place the meter assembly with the lower case down
and remove the following:
upper case
combination meter (printed circuit board)
METER
UPPER CASE
Assemble the meter in the reverse order of removal.

TORQUE: 1.0 Nm (0.1 kgfm, 0.7 lbfft)
LOWER CASE
27-100
SCREW
dummyhead
DIGITAL CLOCK SETTING
PROCEDURE
Turn the ignition switch ON.
The control is
automatically
switched from the
setting mode to the
ordinary display if
the button is not
pressed for about
30 seconds.
1. Press and hold the SEL and SET buttons until the
hour digits starts flashing.
2. Press the SEL button until the desired hour is
displayed (press and hold to advance the hour fast).
3. Press the SET button. The minute digits start
flashing.
4. Press the SEL button until the desired minute is
displayed (press and hold to advance the minute
fast).
5. Press the SET button. The hour and minute digits
starts flashing.
If necessary, press the SEL button to select the
second display.
6. Press the SET button. The clock is set, and then the
display moves to the backlight brightness
adjustment ("ooooo" is indicated).
SEL
SET
CLOCK
Clock setting display flow:
1.
2.
3.
4.
5.
6.
SPEEDOMETER/VS SENSOR
SYSTEM INSPECTION
Before performing this inspection, check that the
ECM has stored the DTC 11-1 (11) (page 6-10). If
stored, follow the DTC (MIL) troubleshooting.
Speedometer does not operate
1. Meter Function Inspection
Check that the tachometer and coolant temperature
meter function.
Do they operate normally?
YES
GO TO STEP 2.
NO
Check the power/ground line (page 27-99).
27-101
dummyhead
2. Related Connector Check
Remove the upper cowl (page 27-70).
Check for loose or poor contact terminals of the
meter 28P (Gray) and sub-wire harness 20P (Black)
connectors.
Are the connector terminals in good condition?
YES
GO TO STEP 3.
NO
Repair the faulty part.

28P CONNECTOR
20P CONNECTOR
3. VS Sensor Pulse Inspection

Support the
upper cowl
securely to
avoid damaging
the wire
harness.
Connect all the sub-wire harness and meter

connectors on the upper cowl.
Raise the rear wheel off the ground, shift the
transmission into neutral and turn the ignition switch
ON.
Measure the voltage between the Pink/green wire
terminal (+) of the meter 28P connector and ground
() while slowly turning the rear wheel by hand.
Is there 0 to 5 V pulse voltage?
YES
Replace the combination meter.
NO
Open or short circuit in Pink/green wire

between the meter and VS sensor. If wire
is OK, faulty VS sensor.
TACHOMETER
SYSTEM INSPECTION
Tachometer does not operate
1. Meter Function Inspection
Check that the speedometer
temperature meter function.
and
coolant
Do they operate normally?
27-102
YES
GO TO STEP 2.
NO
Check the power/ground line (page 27-99).
Pink/
green
28P CONNECTOR
(Viewed from the wire harness side)
dummyhead
2. Tachometer Signal Voltage Inspection
Support the
upper cowl
securely to
avoid damaging
the wire
harness.
Remove the upper cowl from the stay with the front
sub-wire harness connectors connected (page 2770).
Connect the peak voltage tester or adaptor probes
to the Yellow/green terminal (+) of the meter 28P
connector terminal and ground ().
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor
07HGJ-0020100
with commercially available digital multimeter
(impedance 10 M/DCV minimum)
Start the engine and measure the tachometer signal
peak voltage.
Is there 10.5 V or more?
YES
Replace the combination meter.
NO
Less than 10.5 V: Faulty ECM

No voltage: GO TO STEP 3.
SUB-WIRE
HARNESS
CONNECTORS
28P CONNECTOR
Yellow/green
PEAK VOLTAGE ADAPTOR
3. Signal Line Open Circuit Inspection

Disconnect the ECM 33P (Gray) connector (page 68).
Check the Yellow/green wire for continuity between
the meter 28P connector and ECM 33P (Gray)
connector terminals.
TOOL:
Test probe
07ZAJ-RDJA110
28P CONNECTOR
Yellow/green
YES
GO TO STEP 4.
NO
Open circuit in the Yellow/green wire.
Yellow/green
(B17)
4. Signal Line Short Circuit Inspection

Check the Yellow/green wire for continuity between
the meter 28P connector and ground.
28P CONNECTOR
YES
Short circuit in the Yellow/green wire.
NO
Loose or poor contact of the related

Replace the ECM with a known-good
one, and recheck.
Yellow/green
27-103
dummyhead
EOP SWITCH
INSPECTION
The oil pressure indicator should come on when the
ignition switch is turned ON with the engine stopped
and goes off while the engine is running in normal
operating pressure.
Indicator does not come on when the ignition
switch is turned ON
Remove the dust cover, and disconnect the switch wire
by removing the terminal bolt (page 20-14).
Ground the wire terminal with a jumper wire.
Turn the ignition switch ON and check the oil pressure
indicator. The indicator should come on.
If the indicator comes on, replace the EOP switch.
If the indicator does not come on, check for an open
circuit in the Black and Blue/red wires between the
switch and combination meter. If wires are OK,
replace the combination meter.
OIL PRESSURE INDICATOR
BOLT
Indicator stays on while the engine is running

Check the engine oil pressure (page 5-5). If it is normal,
inspect as follows.
Start the engine with the EOP switch wire disconnected
and check the oil pressure indicator.
If the indicator does not come on, replace the EOP
switch.
If the indicator stays on, check for a short circuit in
the Black and Blue/red wires between the switch
and combination meter. If wires are OK, replace the
combination meter.
WIRE
EOP SWITCH
DUST COVER

INSPECTION
When malfunction occurs in the gear position switch
or its circuit, the gear position indicator blinks ""
constantly.
Remove the fuel tank (page 6-72).
Disconnect the gear position switch 8P (Black)
connector in the connector boot.
Check for continuity at the switch side connector
terminals.
There should be continuity in each gear position as
follows.
Gear position
1st
Neutral
2nd
3rd
4th
5th
6th
27-104
Connection
Brown ground
Light green ground
Red ground
Black/yellow ground
Yellow ground
Black ground
Blue ground
8P CONNECTOR
dummyhead
Shift the transmission into neutral and remove the
following.
BOLT
STANDARD type: gearshift arm (page 10-27)

ABS type:
left rear under cover (page 27-68)
drive sprocket cover and guide plate (page 4-23)
SWITCH
Disconnect the gear position switch 8P (Black)

connector (page 27-104).
Release the switch wire out of the frame.
Remove the bolt and the position switch. Remove the
O-ring.
O-RING
Align
MARK
PIN
Coat a new O-ring with engine oil and install it into the
switch groove.
Align the long end of the switch pin with the paint mark
on the switch body (neutral position).
Take care not to
damage the switch
pin.
Be sure the transmission is in neutral and install the

gear position switch.
Install the bolt and tighten it.
Route the switch wire properly and connect the 8P
Install the following.
STANDARD type: gearshift arm (page 10-30)
ABS type:
drive sprocket cover and guide plate (page 4-24)
left rear under cover (page 27-68)
Install the fuel tank (page 6-73).
LAP TIMER
INSPECTION
The starter switch is used for timer operation as well
as for starting the engine. These two functions of the
switch are changed automatically depending upon
the mode of the combination meter. The change is
made via the lap relay.
Lap timer cannot be operated with the starter/lap
switch
1. Switch Signal Input Voltage Inspection
Support the
upper cowl
securely to
avoid damaging
the wire
harness.
Start the engine. Turn the combination meter to the
lap time mode (by pressing the SEL and SET
buttons at the same time).
Measure the voltage between the Yellow/pink wire
terminal (+) of the meter 28P (Gray) connector and
ground () while operating the starter/lap switch.
28P CONNECTOR
Yellow/pink
Switch released: Less than 6 V

Switch pushed: 10 16 V
Are the voltages within the specified value?
YES
The input signal is OK. Check for loose or

poor contact of the related connector
terminals.
NO
GO TO STEP 2.
27-105
dummyhead
2. Switch Signal Input Line Continuity Inspection
Disconnect the right handlebar switch 8P (White)
Disconnect the meter 28P connector.
Check the Yellow/pink wire for continuity between
the wire harness side switch 8P and meter 28P
connectors.
8P CONNECTOR
YES

one, and recheck.
NO
Open circuit in Yellow/pink wire between

the starter/lap switch and combination
meter.
8P CONNECTOR
Yellow/pink
28P CONNECTOR
Yellow/pink
Starter motor turns when pressing the starter/lap

switch for lap timer operating with the engine
running (Lap timer does not operate)
1. Lap Relay Inspection
Check the lap relay (page 27-107).
NO
Faulty lap relay (stuck off).
YES
GO TO STEP 2.
2. Lap Relay Coil Input Voltage Inspection

Measure the voltage between the White/yellow wire
terminal (+) of the lap relay 4P connector and
ground ().
RELAY 4P CONNECTOR
Is there battery voltage?
27-106
YES
GO TO STEP 3.
NO
Open circuit in White/yellow wire between

the fuse/relay box and relay.
White/yellow
dummyhead
3. Lap Relay Coil Output Voltage Inspection
Install the lap relay onto the connector.
Start the engine.
Measure the voltage between the Black/orange wire
terminal (+) of the lap relay 4P connector and
ground () while operating the SEL and SET buttons
at the same time.
Ordinary mode: Less than 2 V
Lap time mode: 10 16 V
4P CONNECTOR
Black/orange
Are the voltages within the specified value?

YES
The relay coil output voltage is OK. Check

for loose or poor contact of the related
NO
GO TO STEP 4.
4. Lap Relay Coil Output Line Inspection

Disconnect the combination meter 28P (Gray)
connector and remove the lap relay.
Check the Black/orange wire for continuity between
the relay 4P and meter 28P connectors.
Support the
upper cowl
securely to
avoid damaging
the wire
harness.
Black/orange
28P CONNECTOR
4P CONNECTOR
YES

one, and recheck.
NO
Open circuit in Black/orange wire between

the lap relay and combination meter.
Black/orange
LAP RELAY
INSPECTION
Remove the top shelter (page 3-7).
LAP RELAY
Remove the lap relay.

Check for continuity between the No. 1 and No. 2
terminals, and between No. 1 and No. 4 terminals.
Connect a fully charged 12 V battery (+) terminal to the
relay No. 5 terminal and the () terminal to the No. 3
terminal.
There should be continuity between the No. 1 and
No. 2 terminals while the battery is connected.
There should be continuity between the No. 1 and
No. 4 terminals when the battery is disconnected.
27-107
dummyhead
HISS INDICATOR
Support the upper
cowl securely to
avoid damaging the
wire harness.
Perform the following inspections at the combination
meter connector.
POWER INPUT LINE INSPECTION

Measure the voltage between the Red/green (+) and
Green/black () wire terminals of the combination meter
connector.
There should be battery voltage at all times.
28P CONNECTOR
Green/black
Red/green
(Viewed from the wire side)
HISS INDICATOR LINE INSPECTION

Measure the voltage between the White/red (+) wire
terminal and ground () of the combination meter
connector.
There should be battery voltage.
28P CONNECTOR
White/red
(Viewed from the wire side)
27-108
dummytext
WIRING DIAGRAM
WIRING DIAGRAM (STANDARD type)

WIRING DIAGRAM
IACV 2A
U-INJ3
PG
PG
PG
EX-AI
FLR
WARN
IACV 1A
SG
L-INJ1
IACV 2B
U-INJ2
U-INJ4
U-INJ1
IG1
MOM
MOP
VCC
L-INJ3
L-INJ4
L-INJ2
IGP1
IGP2
IG4
IG3
IG2
O2 SENSOR
EGCA
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-11
A-10
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
PCM
FAN1
K-LINE
IACV 1B
SSTAND
IMOID
TW
IMOIND
LININD
LINSOLP
PB
LINSOLM
FAN2
IDC2
FLCNT
LG
IDC1
O2HT
M
W
Gr
4P
(Bl)
Bl/W
W
Bl/R
Gr/Bl
Bl/R
R
Bu
W/Y
Gr/Bu
O/W
Bl/O
Bl/R
Y/G
G/P
G/P
G/P
Y/Bu
Br/Bl
W/Bu
Bl/Y
Gr/Bl
P/Y
Bl/Bu
Y/Bu
Y/Bl
Y
Bu/Bl
Bu
R
Y/R
P/G
P/Bl
P/Bu
Bl/W
Bl/W
R/Y
R/Bu
Y/W
P
W/R
W/G
W/Bu
Y/Bu
G
W
O
Bu
Br
Y/G
G/W
Bu/Y
Gr/W
Lg/Y
Gr/Bl
P/Bl
Y/Bl
Y
Bl/R
Lg/Bl
P/G
Bu/O
W
Bl
33P
(Bl)
Gr
Bu/Y
Gr/Bu
G/R
33P
(Gr)
G
Y/R
KNVCC
PCP
KNOCK
O2
SCS
POT
TACHO
TA
VSP
NLSW
B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-11
B-10
B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1
CYLP
IMOAU
TH
ECM
6P (Bl)
Y/R
R
Gr/Bl
Br
Bl/W
Y/R
O/W
G
Bu
O
Bu
Bl/R
Y/R
R
G
Y/R
Gr/Bl
Bu/Y
Bu
Lg/Bl
Y/G
SHIELD WIRE
2P
(Gr)
PRIMARY FUEL INJECTORS
2P
2P
#2
KNVCC
VCC
KNOCK
Bl/W
#3
PAIR CONTOROL
SOLENOID VALVE
#4
2P
(Bl)
P/G
G/Bl
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
VS SENSOR
W/G
JUNCTION
ENGINE STOP
SWITCH
2P
V
2P
(Br)
Y/Bu
IGNITION COILS
IDC SOLENOID VALVES
(RIGHT) (LEFT)
2P
KNOCK
SENSOR
3P (Bl)
HESD
2P
Bl/W
#1
6P (Bl)
W/Bu
2P
Bl/W
Bl/W
LOW
#4
SHIELD WIRE
Bu/Bl
Y/W
R/Bu
R/Y
Bl/W
R/Y
LOW
#3
Bl/W
Bl/W
Bl/W
LOW
#2
2P
(Gr)
R/Bu
LOW
#1
2P
(Gr)
Y/W
2P
(Gr)
Bu/Bl
2P
(Gr)
TP SENOR
Bu/Bl
Y/W
R/Bu
R/Y
Bl/W
P/Bl
P/Y
SECONDARY FUEL INJECTORS
Bl/W
UP
#4
P/G
UP
#3
DLC
3P (Bu)
Bl/W
UP
#2
Bl/W
Bl/W
2P
(Gr)
P/Bu
VCC
SG
TH
1B
2A
1A
2B
IACV
2P
(Gr)
UP
#1
3P
(Bu)
4P
(Bl)
Y/Bl
Y/Bu
Y
Bl/O
Bl/Y
BlR
Bl/Bu
Y/R
Gr/Bl
Bu/Y
2P
(Gr)
4P (R)
Bl/W
Bl/W
3P
(Bl)
IGP2
IGP1
INJ2
INJ3
IGN
INJU1
INJU2
INJU3
EX-AI
FANL
FANR
FUEL
INJU4
G
Br/W
Lb
1P
(W)
4P (Bl)
Y/Bu
W/Y
Gr/R
P/Bl
Y/G
G/Bl
Lg/Bl
W/R
V
R/Bu
20P (Bl)
8P (Bl)
COLOR
HAZARD SWITCH
W
Gr
Lb
ENGINE STOP SWITCH

IG BAT4
ST
COLOR Bl/R
Y/R
FREE
ON
FREE
OFF
PUSH
Lb
COLOR
Bl
W/Bl
Bu
BAT5
PUSH
COLOR Gr
Bl
G
Lb
G/R
R
LEFT REAR TURN SIGNAL LIGHT

12V 21W
G
2P (Lb)
Lb
Lb
W/Y
COLOR Bu/W
STARTER/LAP SWITCH
IGNITION SWITCH
CLUTCH SWITCH
HAZARD SWITCH
TURN SIGNAL SWITCH
Y
W/Y
Br/W
R/Bl
W/G
W/G
Br/W
Bl/R
R/Bl
W/Y
W/Y
Bu/R
R/G
R
Bu
R/G
Lg/Bl
G/R
Lg
Br
Bl/W
Br/Bl
Bl/W
Bl/R
Bl/W
Gr/Bl
Bu/R
Bl/W
Bl/W
R/Bu
Bl
R/W
Bl/Bu
Bl/W
Gr/Bu
Bu
G
G
G/P
G/Bl
R
Br
Bl
3P (Bu)
W/G
BAT3
HORN SWITCH
DIMMER SWITCH
PASSING SWITCH
A
SIDESTAND
SWITCH
FUSE/RELAY BOX
A:
B:
C:
D:
E:
FUSE/RELAY BOX
FAN (R) MOTOR RELAY
FAN (L) MOTOR RELAY
ENGINE STOP RELAY
FUEL PUMP RELAY
DIODE
DOWN
G/W
R
Br
GEAR POSITION
SWITCH
UP
2
N
R
Y
Y
Lg
Bl
Y
Bl/Y
4
Bu
CKP SENSOR
ECT SENSOR
MAP SENSOR
Bl/Gr
Bu/W
LO
HL
HO
Bu/W
BAT2
LEFT FAN
MOTOR
COLOR Bu/W Bu
R/Bl
(N)
IG
LOCK
G/W
Bu
Y
Bl/Y
Lg
Y/R
Gr/Bl
Lg/Y
Gr/Bl
Gr/R
Bu/Y
2P (Bl)
Bu
Hi
HI
Lo
HL
Gr
Lb
Gr
Lb
O
Bl
PUSH
KEY OFF
LOCK
O
G
LICENSE LIGHT
12V 5W
R
Br
Bl
Gr/Bl
Gr/Bl
Y/R
Gr
DIMMER SWITCH
KEY OFF
Br/W
Lb
W/Y
R
L
W
OFF
O
G
Bl/Br
G/W
3P (Gr)
8P (Bl)
Bu
Y
Bl/Y
Lg
Bu
IAT
SENSOR
CMP SENSOR
Bl
Hi
BRAKE/TAILLIGHT (LED)
2P (R)
2P (Gr)
Bl
Gr
Bl/Gr
Bu/W
W/G
Bl
Lb
O
3P
(Bu)
Gr/Bu
Bu/R
10P
(Bu)
Bl
2P
(Br)
Bl
1P (W)
G/W
Gr
Bl
Bu/W
W/G
2P
(Bl)
Bu
G/R
Lb
O
R/Bl
Bl/R
G
Bl/G
Bl/Br
Bl
HORN
BANK ANGLE
SENSOR
TURN SIGNAL
RELAY
TURN SIGNAL SWITCH
Bl/Y
Bl
RIGHT REAR TURN SIGNAL LIGHT

12V 21W
BAT1
FREE
COLOR Bl/Gr W/G
Bl
G/Y
Br/W
Lb
4P (Bl)
Bl/R
O
Bu
G
Lb
Bu/W
Br/W
Gr
Bu
KEY ON
2P (O)
Bl
ON
Ho BAT3
W/G
Br
G
W/G
Bl
R/Bl
BAT2
KEY
Bl/W
Br/W
HEADLIGHT
RELAY
PASSING SWITCH
G/Y
G
3P
HORN SWITCH
R/G
Br/W
O
Gr/Bl
Y/R
P
Bu/O
G/Y
Bl
Y/P
3P (W)
EOP SWITCH
BATTERY
12V 6Ah
Br/W
SWITCH CONTINUITY
COLOR
4P
Y/Bl
Br/Bl
Gr/W
P/G
Bu/R
R/G
W/Bu
4P
BATT
VCC
OUT
GND
BAT1 IG
STARTER
MOTOR M
Y/P
R
Y
Bu
Bu
4P
(Bl)
GND
VCC
OUT
R/G
W/G
G
R/G
Gr
Bl/R
Bl/R
Bl/Bu
Bu/W
O
G
POSITION LIGHT (LED)
IGNITION SWITCH
6P
2P
(Bl)
Y/R
R/W
Y/R
O/Bu
G/O
P
Y
Bl/O
Y/P
W/Y
Y/R
F/P
2P
(Br)
Br/Bl
Y/R
GND
VCC
RXDT
TXCT
HL
ST
BAT5
IG
BAT4
W/G
G/Y
Bl
Y/R
4P
(Bl)
MAIN FUSE (30A)

FI FUSE (20A)
Bl
G
O
Br/W
3P
(Bl)
2P
(O)
Bl/Bu
LEFT FRONT TURN SIGNAL LIGHT

12V 21W
Bl/Bu
Y/Bl
Br/Bl
Gr/W
P/G
Bu/R
R/G
W/Bu
O/G
W/G
Bl
Bl/R
O
Bu
G
Lb
Bu/W
Br/W
Gr
G
Bu/W
1P
(W)
FUEL
PUMP
G
W/Y
R/Bu
Bu
G
G
W
Bl/O
Br
Bl/Y
Bl
Y/P
R
Y
Bu
R/Bl
2P
(Lb)
G
Bu
Bu
G
W/G
W/Y
W/Y
Lb
Y/Bu
W/Y
Gr/R
P/Bl
Y/G
G/Bl
Lg/Bl
W/R
V
R/Bu
G
Bl/Bu
HEADLIGHT (HIGH)
12V 55W
G
W
FUEL RESERVE
SENSOR
8P (Gr)
Bl/O
Br
Bl/Y
Bl
Lb
HEADLIGHT (LOW)
12V 55W
2P
(Gr)
8P
(W)
Bl/Bu
RIGHT FRONT TURN SIGNAL LIGHT

12V 21W
REAR BREAKE
LIGHT SWITCH
LAP RELAY
DIODE
2P
(Bl)
V
W/R
O
W/Bu
Lg/Bl
G/Bl
Bl/Bu
P/G
Gr/W
Br/Bl
Bl
Bl/Y
Br
Bl/O
IMMOBILIZER
RECEIVER
STATER/LAP
SWITCH
W/G
W/Bl
Bl/R
Bl/Bu
Lb
Bu
R/G
Bu/R
Y/G
P/Bl
Gr/R
Bu
Y
R
Y/P
Br/W
O/G
W/Bl
Bl
IGN
SP-VCC
NO USE
HISS
NO USE
TURN L
TURN R
FI
HIGHBEAM
NEUTRAL
BATT
GND
IOIL
H/L RELAY
TA-SIG
SP-SIG
IFUEL PULSE
HESD
TEMP
FUEL
6TH
5TH
4TH
3RD
2ND
1ST
LAP
LAP RELAY
28P
(Gr)
Bl/Bu
Bl
G/Y
RIGHT FAN
MOTOR
COMBINATION METER
Bl/R
W/Y
Y/Bl
Y/Bu
W/Y
14P
FRONT BRAKE
LIGHT SWITCH
ALTERNATOR
F:
G:
H:
I :
J:
K:
L:
10A........CLOCK/TURN
20A........FAN (R)
20A........FAN (L)
20A........HEADLIGHT
10A........START
10A........METER ILLUMI
10A........STOP/HORN/WINK RLY
2P (Bl)
3P (Bl)
REGULATOR/
RECTIFIER
Bl
Y
Bu
G
R
W
V
:
:
:
:
:
:
:
BLACK
L
YELLOW
BLUE
GREEN
RED
WHITE
VIOLET
Br
O
Lb
Lg
P
Gr
:
:
:
:
:
:
BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK
GRAY
27-109
dummytext
WIRING DIAGRAM
WIRING DIAGRAM (ABS type)
Y/G
SHIELD WIRE
2P
(Gr)
KNVCC
VCC
KNOCK
2P
(Bl)
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
Bl/W
SHIELD WIRE
Bl
Lb
Y/Bu
W/Y
Gr/R
P/Bl
Y/G
G/Bl
Lg/Bl
W/R
V
R/Bu
G
Bl/Bu
G
Br/W
Lb
1P
(W)
4P (Bl)
Bl/R
O
Bu
G
Lb
Bu/W
Br/W
Gr
G
Bu/W
20P (Bl)
8P (Bl)
HORN SWITCH
PUSH
COLOR Bl/Gr W/G
27-110
HAZARD SWITCH
W
Gr
Lb
ENGINE STOP SWITCH
OFF
STARTER/LAP SWITCH
BAT5
ST
PUSH
O
COLOR
Bl
W/Bl
RRSOLM3
RRSOLP2
RRSOLP1
RFSP
RMCP2
VCC2
RCCP2
Lg/Bl
Bu/P
Bu/R
Bl
Br
R
Y
Bl
R
RRSOLP3
RRSOLM2
RRSOLM1
SLD2
RCCP1
SGND2
RMCP1
RVMP
RVBMB
MAIN
PGND
RVMM
F
G
H
I
J
Bu
G
R
O/Bl
B
RCCP2
VCC2
RMCP2
RCCP1
SLD2
RMCP1
SGND2
RFSP
SLD1
FMCP2
VCC1
FCCP1
FMCP1
SGND1
FCCP2
FFSP
FRPFVWV+
SCS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
R
W
Bu
Bl
Br
R/W
R/Bu
W
W
Br
G/P
G/O
G/R
Y
Br
G
R
Bl
Y
Bu
W
Bu
Bl/R
Bl/P
Bl/O
RRP-
RVWV+
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
FRSOLM2
FRSOLP1
FRSOLM3
FRSOLP2
FRSOLM1
FRSOLP3
RRSOLM2
RRSOLP1
RRSOLM3
RRSOLP2
RRSOLM1
RRSOLP3
FVMP
FVBMB
INDSIG
PGND
FVMM
W
G
R
O/G
Bl
Bu/O
Lg//W
Lg/R
W
G
Bu
BRAKE/TAILLIGHT (LED)
Bl/Br
LICENSE LIGHT
12V 5W
LEFT REAR TURN SIGNAL LIGHT

12V 21W
G
Bl
Bu
Bl
G
Lb
W/G
G/Y
G/R
W
2P (Lb)
Lb
Lb
W/Y
Bu
FREE
Lb
O
G
Y
Y
W/Y
R
R/W
O/Bl
O/Bu
Br/W
R/Bl
W/G
W/G
Br/W
Bl/R
R/Bl
W/Y
W/Y
Bu/R
R/G
R
Bu
R/G
Lg/Bl
G/R
Lg
Br
Bl/W
Br/Bl
Bl/W
Bl/R
Bl/W
Gr/Bl
Bu/R
Bl/W
Bl/W
R/Bu
Bl
R/W
Bl/Bu
Bl/W
Gr/Bu
Bu
G
G
G/P
G/Bl
2P (R)
G/W
R
Br
Bl
Bu
Y
Bl/Y
Lg
R
R/W
COLOR Bu/W
IG BAT4
ON
COLOR Gr
COLOR Bl/R
Y/R
IGNITION SWITCH
CLUTCH SWITCH
HAZARD SWITCH
TURN SIGNAL SWITCH
GEAR POSITION
SWITCH
R/W
G
G/W
FUSE/RELAY BOX
A:
B:
C:
D:
E:
FUSE/RELAY BOX
FAN (R) MOTOR RELAY
FAN (L) MOTOR RELAY
ENGINE STOP RELAY
FUEL PUMP RELAY
DIODE
FUSE BOX
N : 30A....................MAIN
O: 20A....................FI
F:
G:
H:
I :
J:
K:
L:
M:
10A........CLOCK/TURN
20A........FAN (R)
20A........FAN (L)
20A........HEADLIGHT
10A........START
10A........METER ILLUMI
10A........STOP/HORN/WINK RLY
10A........ABS MAIN
R
Y
Y
DOWN
SIDESTAND
SWITCH
G
R
Y
UP
2
N
R
R/W
3
1
R
Br
Bl
Y
Bl/Y
4
6
3P
2P
ALTERNATOR
R
Y
Y
W/G
BAT3
Bu
Bu/W
LO
HL
HO
Bu/W
HI
Gr
Bl/Gr
HORN SWITCH
DIMMER SWITCH
PASSING SWITCH
W/Y
CKP SENSOR
COLOR
BAT2
LEFT FAN
MOTOR
COLOR Bu/W Bu
Ho BAT3
FREE
(N)
R/Bl O/R
Br/W
Lb
O
G
3P (Br)
3P (Bu)
ECT SENSOR
MAP SENSOR
LOCK
R/G
Br/W
O
Br
G
Hi
Lo
Lb
Gr
Lb
O
HL
R
L
W
Bl
Bl
Bl/Y
Bl
2P (Bl)
Lg
DIMMER SWITCH
BAT1
Hi
G/W
Bu
Y
Bl/Y
Lg
Y/R
Gr/Bl
Lg/Y
8P (Bl)
Bu
TURN SIGNAL SWITCH
R
Br
Bl
Gr/Bl
Gr/Bl
Y/R
Gr
Gr/Bu
3P (Gr)
Gr/Bl
Gr/R
Bu/Y
Bl
2P (Gr)
IAT
SENSOR
Bu
Bl
Lb
O
3P
(Bu)
CMP SENSOR
O/R
PUSH
KEY OFF
LOCK
COLOR
Br/Bl
Gr/Bl
Y/R
P
Bu/O
Bu/R
Bu
10P
(Bu)
Bl
Gr
Bl/Gr
Bu/W
W/G
TURN SIGNAL
RELAY
1P (W)
G/W
Gr
Bl
Bu/W
W/G
3P
(Br)
Bu
2P
(Bl)
G/R
Lb
O
R/Bl
O/Bu
R
Bl/R
G
Bl/G
Bl/Br
Bl
HORN
BANK ANGLE
SENSOR
R/Bl
R
KEY OFF
Bl/W
RIGHT REAR TURN SIGNAL LIGHT

12V 21W
IG2
IG1
OFF
Y/R
O/Bu
G/O
P
Y
Bl/O
Y/P
W/Y
Y/R
Y
G/Y
Bl
Y/P
Br/W
Lb
Bu
FREE
G/Y
G
Br/W
4P (Bl)
Bl/R
O
Bu
G
Lb
Bu/W
Br/W
Gr
Bl
KEY ON
REAR WHEEL
SPEED SENSOR
2P (O)
ON
BATTERY
12V 8.6Ah
EOP SWITCH
PASSING SWITCH
BAT2
4P
3P
HEADLIGHT
RELAY
KEY
2P
(O)
3P (W)
SWITCH CONTINUITY
IG1
2P
(Bl)
Br/W
4P
BATT
VCC
OUT
GND
GND
VCC
OUT
R/G
W/G
G
4P
(Bl)
BAT1 IG2
2P
(O)
STARTER
MOTOR M
Y/Bl
Br/Bl
Gr/W
P/G
Bu/R
R/G
W/Bu
O/G
W/G
Bl
Bl
R/G
Gr
Bl/R
Bl/R
Bl/Bu
Bu/W
Bl/Bu
LEFT FRONT TURN SIGNAL LIGHT

12V 21W
IGNITION SWITCH
6P
Bl
G
O
Br/W
3P
(Bl)
2P
(O)
1P
(W)
Y/Bu
W/Y
Gr/R
P/Bl
Y/G
G/Bl
Lg/Bl
W/R
V
R/Bu
GND
VCC
RXDT
TXCT
HL
Y/R
ST
BAT5
IG
BAT4
W/G
G/Y
Bl
Y/R
F/P
REAR ABS MOTOR (30A)

FRONT ABS MOTOR (30A)
G
W/Y
R/Bu
Bu
G
Y/Bl
Br/Bl
Gr/W
P/G
Bu/R
R/G
W/Bu
O/G
W/G
Bl
COMBINED
ABS CHECK
CONNECTOR
O/G
W
G/R
2P
(Br)
Y/P
R
Y
Bu
O/R
2P
(Lb)
Bl/O
Br
Bl/Y
Bl
Y/P
R
Y
Bu
O/Bl
Bu
Y/R
O/G
W
G/R
FRONT WHEEL
SPEED SENSOR
R/Bl
R
HEADLIGHT (HIGH)
12V 55W
Bl/Bu
FUEL
PUMP
8P (Gr)
Bl/O
Br
Bl/Y
Bl
Lb
Br
SHIELD WIRE
W/G
W/Y
W/Y
G
Bl/Bu
RIGHT FRONT TURN SIGNAL LIGHT

12V 21W
3P (R)
FUEL RESERVE
SENSOR
4P
(Bl)
8P
(W)
2P
(Bl)
V
W/R
O
W/Bu
Lg/Bl
G/Bl
Bl/Bu
P/G
Gr/W
Br/Bl
Bl
Bl/Y
Br
Bl/O
2P
(Gr)
O/Bl
Bu
Y/R
REAR BREAKE
LIGHT SWITCH
LAP RELAY
DIODE
Bl
2P (Gr)
6P (Bl)
IMMOBILIZER
RECEIVER
STATER/LAP
SWITCH
W/G
W/Bl
Bl/R
Bl/Bu
Lb
Bu
R/G
Bu/R
Y/G
P/Bl
Gr/R
Bu
Y
R
Y/P
Br/W
O/G
W/Bl
Bl
IGN
SP-VCC
ABS
HISS
NO USE
TURN L
TURN R
FI
HIGHBEAM
NEUTRAL
BATT
GND
IOIL
H/L RELAY
TA-SIG
SP-SIG
IFUEL PULSE
HESD
TEMP
FUEL
6TH
5TH
4TH
3RD
2ND
1ST
LAP
LAP RELAY
28P
(Gr)
G
W
Bl
G/Y
RIGHT FAN
MOTOR
Bl/R
W/Y
Y/Bl
Y/Bu
W/Y
FRONT BRAKE
LIGHT SWITCH
COMBINATION METER
Bu
G
G/O
Bl/R
Br
Y
Bu
IGP2
IGP1
INJ2
INJ3
IGN
INJU1
INJU2
INJU3
EX-AI
FANL
FANR
FUEL
INJU4
W/G
Y/Bu
JUNCTION
14P
G
W
FRSOLM3
FRSOLP2
FRSOLP1
FFSP
FMCP2
VCC1
FCCP2
FRSOLP3
FRSOLM2
FRSOLM1
SLD1
FCCP1
SGND1
FMCP1
Bl
VS SENSOR
2P
(Br)
ENGINE STOP
SWITCH
2P
P/G
G/Bl
#4
#3
PAIR CONTOROL
SOLENOID VALVE
R/W
#2
3P (Bl)
HESD
2P
#1
Bl/W
R/Y
2P
KNOCK
SENSOR
Y/R
Bu
2P
Bl/W
2P
HEADLIGHT (LOW)
12V 55W
2P
(Bl)
21P
(Bl)
DLC
6P (Bl)
IGNITION COILS
IDC SOLENOID VALVES
(RIGHT) (LEFT)
G
Bu
5P
(Gr)
SHIELD WIRE
Bu/Bl
Y/W
R/Bu
R/Y
Bl/W
W/Bu
2P
Bl/W
Bl/W
LOW
#4
R/Bu
LOW
#3
Y/W
LOW
#2
2P
(Gr)
Bu/Bl
2P
(Gr)
Bl/W
Bl/W
P/Bl
Bl/W
Bl/W
2P
(Gr)
P/G
P/Y
2P
(Gr)
TP SENOR
Bu/Bl
Y/W
R/Bu
R/Y
Bl/W
PRIMARY FUEL INJECTORS
21P
(Bl)
UP
#4
Bl/W
UP
#3
LOW
#1
Bl/Bu
21P
(Gr)
3P (Bu)
P/Bu
UP
#2
Bl/W
Bl/W
2P
(Gr)
SECONDARY FUEL INJECTORS
VCC
SG
TH
1B
2A
1A
2B
IACV
2P
(Gr)
UP
#1
3P
(Bu)
4P
(Bl)
Y/Bl
Y/Bu
Y
Bl/O
Bl/Y
BlR
Bl/Bu
Y/R
Gr/Bl
Bu/Y
2P
(Gr)
5P
(Bl)
REAR VALVE UNIT
4P (R)
Bl/W
Bl/W
3P
(Bl)
Bl/O
G/P
G/R
R/W
R/Bu
Bl
O/W
G
Bu
O
Y/R
R
G
Bl/W
W
Bl/R
Gr/Bl
Br
Bl/W
Y/R
Bu
Bl/R
21P
(Bl)
Y/R
Gr/Bl
Bu/Y
Y/R
R
Gr/Bl
COMBINED ABS CONTROL UNIT
A
B
C
D
E
W
Bl
W
Gr
G
Y/R
6P (Bl)
Bu
Lg/Bl
2P
4P
(Bl)
Bl/R
R
Bu
W/Y
Gr/Bu
O/W
Bl/O
Bl/R
Y/G
G/P
G/P
G/P
Y/Bu
Br/Bl
W/Bu
Bl/Y
Gr/Bl
P/Y
Bl/Bu
Y/Bu
Y/Bl
Y
Bu/Bl
Bu
R
Y/R
P/G
P/Bl
P/Bu
Bl/W
Bl/W
R/Y
R/Bu
Y/W
P
W/R
W/G
W/Bu
Y/Bu
G
W
O
Bu
Br
Y/G
G/W
Bu/Y
Gr/W
Lg/Y
Gr/Bl
P/Bl
Y/Bl
Y
Bl/R
Lg/Bl
P/G
Bu/O
FRONT VAVE UNIT

M
Lg/W
Bu/R
Lg/Bl
Bu/P
Lg/R
Bu/O
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-11
A-10
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
33P
(Bl)
Gr
Bu/Y
Gr/Bu
G/R
33P
(Gr)
REAR POWER
UNIT
FRONT POWER
UNIT
EGCA
Bl/P
W
R
IACV 2A
U-INJ3
PG
PG
PG
EX-AI
FLR
WARN
IACV 1A
SG
L-INJ1
IACV 2B
U-INJ2
U-INJ4
U-INJ1
IG1
MOM
MOP
VCC
L-INJ3
L-INJ4
L-INJ2
IGP1
IGP2
IG4
IG3
IG2
O2 SENSOR
PCM
FAN1
K-LINE
IACV 1B
SSTAND
IMOID
TW
IMOIND
LININD
LINSOLP
PB
LINSOLM
FAN2
IDC2
FLCNT
LG
IDC1
O2HT
KNVCC
PCP
KNOCK
O2
SCS
POT
TACHO
TA
VSP
NLSW
B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-11
B-10
B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1
CYLP
IMOAU
TH
ECM
NO
FUSE BOX
REGULATOR/
RECTIFIER
Bl
Y
Bu
G
R
W
V
:
:
:
:
:
:
:
BLACK
L
YELLOW
BLUE
GREEN
RED
WHITE
VIOLET
Br
O
Lb
Lg
P
Gr
:
:
:
:
:
:
BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK
GRAY

CBR1000RR 2010

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CBR1000RR 2010

Uploaded by

Copyright:

Available Formats

dummytext

27. CBR1000RR/RA-C ADDENDUM

LOWER COWL 27-63

MIDDLE COWL 27-64

MODEL IDENTIFICATION 27-4

INTAKE AIR DUCT 27-66

GENERAL SPECIFICATIONS (STANDARD type) 27-7

LEFT REAR UNDER COVER (ABS type) 27-68

GENERAL SPECIFICATIONS (ABS type) 27-8

REARVIEW MIRROR/WINDSCREEN 27-69

LUBRICATION SYSTEM SPECIFICATIONS 27-9

UPPER COWL 27-70

FUEL SYSTEM (PGM-FI) SPECIFICATIONS27-9

REAR CENTER COWL 27-73

COOLING SYSTEM SPECIFICATIONS 27-10

MAINTENANCE SCHEDULE 27-76

CYLINDER HEAD/VALVES SPECIFICATIONS 27-10

AIR CLEANER 27-77

INTAKE AIR DUCT CONTROL 27-80

REAR WHEEL/SUSPENSION SPECIFICATIONS 27-13

ELECTRIC STARTER SYSTEM LOCATION 27-92

HYDRAULIC BRAKE SPECIFICATIONS 27-13

ELECTRIC STARTER SYSTEM DIAGRAM 27-93

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ELECTRIC STARTER TROUBLESHOOTING 27-94

BATTERY/CHARGING SYSTEM SPECIFICATIONS

STARTER RELAY SWITCH 27-95

SPEEDOMETER/VS SENSOR 27-101

TORQUE VALUES 27-16

CABLE & HARNESS ROUTING 27-23

EOP SWITCH 27-104

BODY PANEL LOCATIONS 27-59

GEAR POSITION SWITCH 27-104

SEAT/SIDE COVER 27-60

LAP TIMER 27-105

TOP SHELTER 27-60

LAP RELAY 27-107

REAR SEAT COWL 27-61

HISS INDICATOR 27-108

AIR INTAKE COVER27-62

WIRING DIAGRAM (STANDARD type) 27-109

AIR DUCT COVER 27-62

WIRING DIAGRAM (ABS type) 27-110

A Few Words About Safety

For Your Customers Safety

Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

symbol. The purpose of this message is to help

CBR1000RA (ABS type)

REGISTERED NUMBER PLATE/NAME PLATE

ENGINE SERIAL NUMBER

THROTTLE BODY IDENTIFICATION NUMBER

Except lVBR, VBR, VIBR:

KO, llKO, lVBR, VBR, VIBR types:

EMISSION CONTROL INFORMATION LABEL

GENERAL SPECIFICATIONS (STANDARD type)

at 1 mm (0.04 in) lift

Engine dry weight

GENERAL SPECIFICATIONS (ABS type)

Engine dry weight

at 1 mm (0.04 in) lift

LUBRICATION SYSTEM SPECIFICATIONS