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Table of Contents
- 3. Group index
- 4. How to use this manual
- 5. Symbols
- 6. Abbreviations used in this manual
- 8. Wire color
- 9. General information
- 10. General precautions
- 12. Vehicle view
- 13. Fuel, oil and engine coolant recommendat...
- 15. Break-in procedures
- 16. Information labels
- 17. Specifications
- 19. Periodic maintenance
- 21. Lubrication points
- 22. Maintenance and tune-up procedures
- 23. Spark plug
- 24. Spark plug gap
- 25. Valve clearance
- 27. Valve clearance adjustment
- 28. Tappet shim selection table
- 30. Engine oil and oil filter
- 31. Oil filter replacement
- 32. Fuel line
- 33. Throttle valve synchronization
- 34. Throttle cable play
- 35. Cooling system
- 36. Air bleeding the cooling circuit
- 37. Radiator hoses
- 38. Drive chain
- 41. Brake inspection
- 42. Brake pads
- 43. Brake light switch
- 45. Tire tread condition
- 46. Steering
- 47. Exhaust pipe bolt and muffler bolt and n...
- 48. Chassis bolts and nuts
- 50. Compression pressure check
- 51. Oil pressure check
- 53. Engine
- 54. Engine components removable with engine ...
- 55. Engine removal
- 62. Engine installation
- 68. Engine disassembly
- 81. Engine components inspection and service
- 82. PCV hose check
- 84. Cam chain tension adjuster check
- 85. Cam chain tensioner
- 87. Cylinder head distortion
- 88. Valve stem and valve face wear condition
- 89. Valve guide servicing
- 90. Valve seat width inspection
- 91. Valve seat servicing
- 92. Top narrowing cut
- 93. Final seat cut
- 94. Valve spring
- 95. Valve and valve spring reassembly
- 96. Intake pipe
- 97. Clutch drive plates inspection
- 98. Oil pump inspection
- 99. Starter clutch inspection
- 100. Gearshift system inspection
- 101. Oil pressure regulator inspection
- 102. Transmission inspection
- 104. Transmission parts location
- 105. Cylinder check
- 106. Piston and piston ring check
- 107. Piston ring-to-groove clearance
- 108. Crankcase inspection
- 109. Gearshift fork thickness
- 112. Oil jet removal, inspection and cleaning
- 113. Oil jet installation
- 114. Conrod big end side clearance
- 115. Crankshaft and conrod
- 119. Crankshaft journal bearing inspection
- 122. Crankshaft thrust bearing
- 123. Thrust bearing selection table
- 124. Engine reassembly
- 158. FI system diagnosis
- 160. Electrical parts
- 161. Fuse
- 163. Electrical circuit inspection
- 164. Continuity check
- 165. Short circuit check (wire harness to gro...
- 166. Using the multi-circuit tester
- 167. FI system technical features
- 168. Compensation of injection time (volume)
- 169. Injection timing
- 170. FI system parts location
- 172. FI system wiring diagram
- 173. Self-diagnosis function
- 174. Dealer mode
- 176. TPS adjustment
- 177. Fail-safe function
- 179. FI system troubleshooting
- 181. Self-diagnostic procedures
- 182. Malfunction code and defective condition
- 184. "C11" CMP sensor circuit malfunction
- 186. "C12" CKP sensor circuit malfunction
- 188. "C13" IAP sensor circuit malfunction
- 191. "C14" TP sensor circuit malfunction
- 192. "C15" ECT sensor circuit malfunction
- 196. "C21" IAT sensor circuit malfunction
- 198. "C22" AP sensor circuit malfunction
- 201. "C23" TO sensor circuit malfunction
- 203. "C28" STV actuator circuit malfunction
- 205. "C29" STP sensor circuit malfunction
- 208. "C31" GP switch circuit malfunction
- 209. "C32","C33", "C34" or "C35" fuel injecto...
- 211. "C41" FP relay circuit malfunction
- 212. "C49" pair control solenoid valve circui...
- 214. Sensors
- 217. Fuel system and throttle body
- 218. Fuel delivery system
- 219. Fuel system
- 220. Fuel pressure inspection
- 221. Fuel pump inspection
- 222. Fuel pump relay inspection
- 223. Fuel pump and fuel filter removal
- 225. Fuel mesh filter inspection and cleaning
- 229. Throttle body construction
- 230. Air cleaner box removal
- 231. Throttle body removal
- 232. Throttle body disassembly
- 234. Throttle body cleaning
- 235. Throttle body reassembly
- 237. Throttle body installation
- 238. Air cleaner box installation
- 239. Fuel injector removal
- 240. Fast idle
- 245. Throttle position sensor (TPS) setting
- 247. Exhaust system
- 248. Precautions for exhaust system
- 249. Exhaust pipe and muffler removal
- 250. Exhaust pipe and muffler installation
- 251. Cooling and lubrication system
- 252. Engine coolant
- 253. Cooling circuit
- 254. Radiator and water hoses
- 255. Radiator installation
- 256. Cooling fan removal
- 257. Cooling fan thermo-switch removal
- 258. ECT sensor removal and inspection
- 259. ECT sensor installation
- 260. Thermostat inspection
- 261. Water pump removal and disassembly
- 264. Water pump inspection
- 268. Lubrication system
- 270. Engine lubrication system chart
- 271. Engine lubrication system diagram
- 274. Chassis
- 276. Exterior parts
- 277. Screen removal and installation
- 279. Body cowling
- 280. Right and left air intake pipes
- 281. Rear seat and seat tail cover
- 282. Front wheel construction
- 283. Front wheel removal
- 284. Axle shaft
- 285. Reassembly and installation
- 286. Brake disc
- 287. Spacer nut
- 288. Front fork construction
- 289. Front fork removal
- 290. Front fork disassembly
- 292. Front fork inspection
- 293. Front fork reassembly
- 294. Damper rod bolt
- 295. Fork spring
- 296. Front fork cap bolt
- 298. Front fork installation
- 299. Suspension setting
- 300. Steering damper construction
- 301. Steering damper installation
- 302. Steering construction
- 303. Steering removal
- 304. Steering inspection
- 305. Steering installation
- 306. Front fork and steering stem upper brack...
- 307. Steering tension adjustment
- 308. Handlebars construction
- 309. Handlebars installation
- 312. Rear wheel construction
- 313. Rear wheel removal
- 314. Rear wheel inspection and disassembly
- 316. Rear wheel reassembly and installation
- 320. Rear shock absorber construction
- 321. Rear shock absorber removal
- 322. Rear shock absorber scrapping
- 324. Rear suspension construction
- 325. Rear suspension removal
- 327. Rear suspension inspection and disassemb...
- 329. Rear suspension reassembly
- 331. Rear suspension installation
- 332. Rear suspension final inspection and adj...
- 333. Front brake construction
- 334. Brake pad replacement
- 335. Brake fluid replacement
- 336. Caliper removal
- 338. Caliper inspection
- 339. Caliper installation
- 340. Brake disc inspection
- 341. Master cylinder removal
- 342. Master cylinder disassembly
- 343. Master cylinder reassembly
- 345. Rear brake construction
- 352. Master cylinder inspection and reassembl...
- 354. Tire removal
- 355. Valve inspection
- 356. Tire installation
- 357. Balancer weight installation
- 358. Drive chain cutting
- 359. Drive chain connecting
- 362. Electrical system
- 364. Cautions in servicing the electrical sys...
- 367. Location of electrical components
- 369. Charging system troubleshooting
- 370. Charging system inspection
- 371. Regulated voltage
- 372. Generator no-load performance
- 373. Starter system and side-stand/ignition i...
- 374. Starter motor removal
- 375. Starter motor disassembly
- 376. Starter motor inspection
- 377. Starter motor installation
- 378. Side stand/ignition interlock system par...
- 379. GP switch check
- 380. Turn signal/side-stand relay
- 381. Ignition system troubleshooting
- 383. Ignition system inspection
- 384. Ignition coil/plug cap resistance
- 385. CKP sensor peak voltage
- 386. CKP sensor resistance
- 387. Combination meter description
- 388. Combination meter removal and disassembl...
- 389. Combination meter inspection
- 390. Engine coolant temperature meter and ind...
- 391. Fuel level indicator switch inspection
- 392. Speedometer
- 393. Lamps
- 394. Headlight beam adjustment
- 395. Relays
- 396. Ignition switch removal
- 397. Switches inspection
- 398. Battery specifications
- 400. Battery servicing
- 401. Servicing information
- 402. Troubleshooting
- 404. Engine will not start or is hard to star...
- 405. Engine idles poorly
- 406. Noisy engine
- 407. Engine runs poorly in high speed range
- 408. Engine lacks power
- 409. Engine overheats
- 410. Radiator (cooling system) troubleshootin...
- 411. Chassis troubleshooting
- 412. Brakes troubleshooting
- 413. Electrical troubleshooting
- 414. Generator does not charge
- 415. Battery troubleshooting
- 416. Wiring harness routing
- 419. Cable routing
- 420. Throttle body hose routing
- 421. Fuel tank drain hose routing
- 422. Cooling system hose routing
- 423. Front brake hose routing
- 424. Rear brake hose routing
- 425. Pair (air supply) system hose routing
- 426. Fuel tank installation diagram
- 427. Fuel tank lower side cover
- 428. Cowling installation
- 429. Frame cover installation
- 430. Under cowling heat shield installation
- 431. Side-stand installation
- 432. Seat lock cable routing
- 433. Handlebar balancer
- 434. Rear combination light installation
- 435. Special tools
- 439. Tightening torque
- 443. Service data
- 444. Camshaft + cylinder head data
- 445. Conrod + crankshaft data
- 446. Oil pump data
- 447. Thermostat + radiator + fan + coolant da...
- 448. FI sensors + seconcary throttle valve ac...
- 449. Throttle body data
- 450. Wattage
- 451. Tire data
- 452. Suspension data
- 453. Fuel + oil data
- 455. Emission control information
- 456. Fuel injection system
- 457. Crankcase emission control system
- 458. Exhaust emission control system (pair sy...
- 459. Noise emission control system
- 460. Pair (air supply) system and emission co...
- 461. Pair control solenoid valve
- 462. Pair (air supply) system diagram
- 465. Wiring diagram
Page 1 of 466
Table of Contents
- 3. Group index
- 4. How to use this manual
- 5. Symbols
- 6. Abbreviations used in this manual
- 8. Wire color
- 9. General information
- 10. General precautions
- 12. Vehicle view
- 13. Fuel, oil and engine coolant recommendat...
- 15. Break-in procedures
- 16. Information labels
- 17. Specifications
- 19. Periodic maintenance
- 21. Lubrication points
- 22. Maintenance and tune-up procedures
- 23. Spark plug
- 24. Spark plug gap
- 25. Valve clearance
- 27. Valve clearance adjustment
- 28. Tappet shim selection table
- 30. Engine oil and oil filter
- 31. Oil filter replacement
- 32. Fuel line
- 33. Throttle valve synchronization
- 34. Throttle cable play
- 35. Cooling system
- 36. Air bleeding the cooling circuit
- 37. Radiator hoses
- 38. Drive chain
- 41. Brake inspection
- 42. Brake pads
- 43. Brake light switch
- 45. Tire tread condition
- 46. Steering
- 47. Exhaust pipe bolt and muffler bolt and n...
- 48. Chassis bolts and nuts
- 50. Compression pressure check
- 51. Oil pressure check
- 53. Engine
- 54. Engine components removable with engine ...
- 55. Engine removal
- 62. Engine installation
- 68. Engine disassembly
- 81. Engine components inspection and service
- 82. PCV hose check
- 84. Cam chain tension adjuster check
- 85. Cam chain tensioner
- 87. Cylinder head distortion
- 88. Valve stem and valve face wear condition
- 89. Valve guide servicing
- 90. Valve seat width inspection
- 91. Valve seat servicing
- 92. Top narrowing cut
- 93. Final seat cut
- 94. Valve spring
- 95. Valve and valve spring reassembly
- 96. Intake pipe
- 97. Clutch drive plates inspection
- 98. Oil pump inspection
- 99. Starter clutch inspection
- 100. Gearshift system inspection
- 101. Oil pressure regulator inspection
- 102. Transmission inspection
- 104. Transmission parts location
- 105. Cylinder check
- 106. Piston and piston ring check
- 107. Piston ring-to-groove clearance
- 108. Crankcase inspection
- 109. Gearshift fork thickness
- 112. Oil jet removal, inspection and cleaning
- 113. Oil jet installation
- 114. Conrod big end side clearance
- 115. Crankshaft and conrod
- 119. Crankshaft journal bearing inspection
- 122. Crankshaft thrust bearing
- 123. Thrust bearing selection table
- 124. Engine reassembly
- 158. FI system diagnosis
- 160. Electrical parts
- 161. Fuse
- 163. Electrical circuit inspection
- 164. Continuity check
- 165. Short circuit check (wire harness to gro...
- 166. Using the multi-circuit tester
- 167. FI system technical features
- 168. Compensation of injection time (volume)
- 169. Injection timing
- 170. FI system parts location
- 172. FI system wiring diagram
- 173. Self-diagnosis function
- 174. Dealer mode
- 176. TPS adjustment
- 177. Fail-safe function
- 179. FI system troubleshooting
- 181. Self-diagnostic procedures
- 182. Malfunction code and defective condition
- 184. "C11" CMP sensor circuit malfunction
- 186. "C12" CKP sensor circuit malfunction
- 188. "C13" IAP sensor circuit malfunction
- 191. "C14" TP sensor circuit malfunction
- 192. "C15" ECT sensor circuit malfunction
- 196. "C21" IAT sensor circuit malfunction
- 198. "C22" AP sensor circuit malfunction
- 201. "C23" TO sensor circuit malfunction
- 203. "C28" STV actuator circuit malfunction
- 205. "C29" STP sensor circuit malfunction
- 208. "C31" GP switch circuit malfunction
- 209. "C32","C33", "C34" or "C35" fuel injecto...
- 211. "C41" FP relay circuit malfunction
- 212. "C49" pair control solenoid valve circui...
- 214. Sensors
- 217. Fuel system and throttle body
- 218. Fuel delivery system
- 219. Fuel system
- 220. Fuel pressure inspection
- 221. Fuel pump inspection
- 222. Fuel pump relay inspection
- 223. Fuel pump and fuel filter removal
- 225. Fuel mesh filter inspection and cleaning
- 229. Throttle body construction
- 230. Air cleaner box removal
- 231. Throttle body removal
- 232. Throttle body disassembly
- 234. Throttle body cleaning
- 235. Throttle body reassembly
- 237. Throttle body installation
- 238. Air cleaner box installation
- 239. Fuel injector removal
- 240. Fast idle
- 245. Throttle position sensor (TPS) setting
- 247. Exhaust system
- 248. Precautions for exhaust system
- 249. Exhaust pipe and muffler removal
- 250. Exhaust pipe and muffler installation
- 251. Cooling and lubrication system
- 252. Engine coolant
- 253. Cooling circuit
- 254. Radiator and water hoses
- 255. Radiator installation
- 256. Cooling fan removal
- 257. Cooling fan thermo-switch removal
- 258. ECT sensor removal and inspection
- 259. ECT sensor installation
- 260. Thermostat inspection
- 261. Water pump removal and disassembly
- 264. Water pump inspection
- 268. Lubrication system
- 270. Engine lubrication system chart
- 271. Engine lubrication system diagram
- 274. Chassis
- 276. Exterior parts
- 277. Screen removal and installation
- 279. Body cowling
- 280. Right and left air intake pipes
- 281. Rear seat and seat tail cover
- 282. Front wheel construction
- 283. Front wheel removal
- 284. Axle shaft
- 285. Reassembly and installation
- 286. Brake disc
- 287. Spacer nut
- 288. Front fork construction
- 289. Front fork removal
- 290. Front fork disassembly
- 292. Front fork inspection
- 293. Front fork reassembly
- 294. Damper rod bolt
- 295. Fork spring
- 296. Front fork cap bolt
- 298. Front fork installation
- 299. Suspension setting
- 300. Steering damper construction
- 301. Steering damper installation
- 302. Steering construction
- 303. Steering removal
- 304. Steering inspection
- 305. Steering installation
- 306. Front fork and steering stem upper brack...
- 307. Steering tension adjustment
- 308. Handlebars construction
- 309. Handlebars installation
- 312. Rear wheel construction
- 313. Rear wheel removal
- 314. Rear wheel inspection and disassembly
- 316. Rear wheel reassembly and installation
- 320. Rear shock absorber construction
- 321. Rear shock absorber removal
- 322. Rear shock absorber scrapping
- 324. Rear suspension construction
- 325. Rear suspension removal
- 327. Rear suspension inspection and disassemb...
- 329. Rear suspension reassembly
- 331. Rear suspension installation
- 332. Rear suspension final inspection and adj...
- 333. Front brake construction
- 334. Brake pad replacement
- 335. Brake fluid replacement
- 336. Caliper removal
- 338. Caliper inspection
- 339. Caliper installation
- 340. Brake disc inspection
- 341. Master cylinder removal
- 342. Master cylinder disassembly
- 343. Master cylinder reassembly
- 345. Rear brake construction
- 352. Master cylinder inspection and reassembl...
- 354. Tire removal
- 355. Valve inspection
- 356. Tire installation
- 357. Balancer weight installation
- 358. Drive chain cutting
- 359. Drive chain connecting
- 362. Electrical system
- 364. Cautions in servicing the electrical sys...
- 367. Location of electrical components
- 369. Charging system troubleshooting
- 370. Charging system inspection
- 371. Regulated voltage
- 372. Generator no-load performance
- 373. Starter system and side-stand/ignition i...
- 374. Starter motor removal
- 375. Starter motor disassembly
- 376. Starter motor inspection
- 377. Starter motor installation
- 378. Side stand/ignition interlock system par...
- 379. GP switch check
- 380. Turn signal/side-stand relay
- 381. Ignition system troubleshooting
- 383. Ignition system inspection
- 384. Ignition coil/plug cap resistance
- 385. CKP sensor peak voltage
- 386. CKP sensor resistance
- 387. Combination meter description
- 388. Combination meter removal and disassembl...
- 389. Combination meter inspection
- 390. Engine coolant temperature meter and ind...
- 391. Fuel level indicator switch inspection
- 392. Speedometer
- 393. Lamps
- 394. Headlight beam adjustment
- 395. Relays
- 396. Ignition switch removal
- 397. Switches inspection
- 398. Battery specifications
- 400. Battery servicing
- 401. Servicing information
- 402. Troubleshooting
- 404. Engine will not start or is hard to star...
- 405. Engine idles poorly
- 406. Noisy engine
- 407. Engine runs poorly in high speed range
- 408. Engine lacks power
- 409. Engine overheats
- 410. Radiator (cooling system) troubleshootin...
- 411. Chassis troubleshooting
- 412. Brakes troubleshooting
- 413. Electrical troubleshooting
- 414. Generator does not charge
- 415. Battery troubleshooting
- 416. Wiring harness routing
- 419. Cable routing
- 420. Throttle body hose routing
- 421. Fuel tank drain hose routing
- 422. Cooling system hose routing
- 423. Front brake hose routing
- 424. Rear brake hose routing
- 425. Pair (air supply) system hose routing
- 426. Fuel tank installation diagram
- 427. Fuel tank lower side cover
- 428. Cowling installation
- 429. Frame cover installation
- 430. Under cowling heat shield installation
- 431. Side-stand installation
- 432. Seat lock cable routing
- 433. Handlebar balancer
- 434. Rear combination light installation
- 435. Special tools
- 439. Tightening torque
- 443. Service data
- 444. Camshaft + cylinder head data
- 445. Conrod + crankshaft data
- 446. Oil pump data
- 447. Thermostat + radiator + fan + coolant da...
- 448. FI sensors + seconcary throttle valve ac...
- 449. Throttle body data
- 450. Wattage
- 451. Tire data
- 452. Suspension data
- 453. Fuel + oil data
- 455. Emission control information
- 456. Fuel injection system
- 457. Crankcase emission control system
- 458. Exhaust emission control system (pair sy...
- 459. Noise emission control system
- 460. Pair (air supply) system and emission co...
- 461. Pair control solenoid valve
- 462. Pair (air supply) system diagram
- 465. Wiring diagram
File size: 59.13 MB
Created: March 10, 2023
Last updated: March 29, 2023
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