SH125 Service Manual Parts Guide

Paper Book Part No.
62KTF00
HOW TO USE THIS MANUAL CONTENTS

This service manual describes the service procedures for the SH125/
150.
Follow the Maintenance Schedule (Section 3) recommendations to

ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It

compensates for the initial wear that occurs during the break-in period.
Sections 1 and 3 apply to the whole scooter. Section 2 illustrates

procedures for removallinstallation of components that may be required
to perform service described in the following sections.
Section 4 through 20 describe parts of the scooter, grouped according to
location.
Find the section you want on this page, then turn to the table of contents
on the first page of the section.
Most sections start with an assembly or system illustration, service

information and troubleshooting for the section. The subsequent pages
give detailed procedures.
If you don't know the source of the trouble, go to section 22

Troubleshooting.
~~
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 safely information in a variety of forms
including:
Safety Labels - o n the vehicle
Safety Messages - preceded by a safety alert symbol ,.f: and
one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY
HURT if you don't follow instructions.
You CAN be KILLED or SERIOUSLY HURT

if you don't follow instructions.
You CAN be HURT if you don't follow

instructions.
Instructions - how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a
symbol. The purpose of this message IS to help prevent
damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIREC-

TIONS AND SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LAT-
EST 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 OBLI-
GATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITH-
OUT WRllTEN PERMISSION. THIS MANUAL IS
WRllTEN FOR PERSONS WHO HAVE
ACQUIRED BASIC KNOWLEDGE OF MAINTE-
NANCE ON Honda MOTORCYCLES, MOTOR
SCOOTERS OR ATVS.
Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: February, 2005

0 Hnnda Motor Co.. Ltd.
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.
or others to be seriously hurt or killed.
For Your Safety Follow the procedures and precautions in this
Because this manual is intended for the professional service technician, we
do not provide warnings about many basic shop safety practices (e.g., Hot
recommended that you do not attempt to perform the procedures described Failure to properly follow instructions and
in this manual. precautions can cause you to be seriously hurt
or killed.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precautions in this
arise in performing service and repair procedures. Only you can decide manual carefully.
whether or not you should perform a given task.
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 performingany 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.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part@)with new one(s) before assembly.
Use recommended engine oil, unless otherwise specified.

~ ~ ~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1).
Use multi-purposegrease (Lithium based multi-purposegrease NLGl #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGl #2 or
equivalent).
Example: Molykotes BR-2 plus manufactured by Dow Corning U S A .
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl #2 or
equivalent).
Example: Molykotes G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use Fork or Suspension Fluid.

TYPE CODE
Throughout this manual, the following abbreviations are used to identify individual model.
SH125
CODE AREA TYPE
ED EUROPEAN DIRECT SALES
E U.K.
F France
I1 ED EUROPEAN DIRECT SALES: Type I1
I1 E U.K.: Type II
II F France: Type II
I CODE 1 AREATYPE
I EUROPEAN DIRECT SALES I

1 IIED 1 EUROPEAN DIRECT SALES: Type II I
I.GENERAL INFORMATION
SERVICE RULES ............................................ 1-2 FRONJ WHEEL/SUSPENSION/STEERlNG

SPECIFICATIONS............................................ 1-9
REAR WHEEL/SUSPENSION
GENERAL SPECIFICATIONS......................... 1-4 SPECIFICATIONS............................................ 1-9
LUBRICATION SYSTEM BRAKE SYSTEM SPECIFICATIONS............... 1-9

SPECIFICATIONS........................................... 1-6
BATTERYICHARGING SYSTEM
FUEL SYSTEM (Programmed Fuel Injection) SPEClFlCATlONS............................................ 1-9
S PEClFlCATlONS ........................................... 1-6
IGNITION SYSTEM SPECIFICATIONS - - - . * - - - 1-10
COOLING SYSTEM SPECIFICATIONS ......... 1-6
ELECTRIC STARTER SPECIFICATIONS ....*.1-10
CYLINDER HEADIVALVES
SPEClFlCATlONS ........................................... 1-6 LIGHTS/METERS/SWITCHES
SPECIFICATIONS.......................................... 1-10
CYLINDER/PISTON SPECIFICATIONS......... 1-7
STANDARD TORQUE VALUES ................... 1-11
DRIVE AND DRIVEN PULLEYS/CLUTCH
SPEC1FlCATlONS ........................................... 1-8 ENGINE & FRAME TORQUE VALUES........ 1-11
FINAL REDUCTION SPECIFICATIONS ......... 1-8 LUBRICATION & SEAL POINTS ..................1-15
ALTERNATOR/STARTER CLUTCH CABLE & HARNESS ROUTING ...................1-17

SPECIFICATIONS........................................... 1-8
EMISSION CONTROL SYSTEMS ................1-32
CRANKCASE/CRANKSHAFT
SPEClFlCATlONS........................................... 1-8
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's
design specifications may cause damage to the scooter.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the scooter. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown i n the Cable and Harness Routing (page 1-17).
MODEL IDENTlFlCATlON
The registered number plate is attached on the left side of the frame
near the rear shock absorber. The Vehicle Identification Number (VIN)
is stamped on the registered number plate.
1-2
GENERAL INFORMATION
The Vehicle Identification Number (VIN) is stamped on the right side of
the frame near the rear shock absorber.
The engine serial number IS stamped on the crankcase near the rear
. - ... I
wheel.
The throttle body identification number are stamped on the lower side
of the throttle body.
The color label is attached on the luggage box. When ordering color-
coded parts, always specify the designated color code.
1-3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
SH125
SPECIFICATION
DIMENSIONS Overall length 2,020 mm (79.5 in)
Overall w i d th 700 mm (27.6 in)
Overall height 1,140 mm (44.9 in)
Wheel base 1,335 mm (52.6 in)
Seat height 790 mm (31.1 in)
Ground clearance 140 mm (5.5 in)
Curb weight 134 kg (295 Ibs)
Ma x i mu m weight capacity 180 kg (397 Ibs)
FRAME Frame type Unde r-b o n e
Front suspension Telescopic fork
Front axle travel 89 mm (3.5 in)
Rear suspension Power unit swing (swingarm)
Rear axle travel 83 mm (3.3 in)
Front tire size 100/80-16M/C 50P
Rear tire size 120/80-16M/C 60P
Tire brand (Front/Rear) D451 (Dunlop)
Front brake Hydraulic single disc
Rear brake Mechanical d r u m (Leading-trailing)
Caster angle 27" 0 0
Trail length 85 mm (3.3 in)
Fuel tank capacity Z5 liters (1.98 US gal, 1.65 Imp gal)
ENGINE Cylinder arrangement Single cylinder inclined 80" from vertical
Bore and stroke 52.4 x 57.8 mm (2.06 x 2.28 in)
Displacement 124.6 cm3 (7.60 cu-in)
Compression ratio 11 : 1
Va Ive train Chain driven OHC with rocker arms
Intake valve opens 10" BTDC (at 1 mm lift)
closes 30" ABDC (at 1 mm lift)
Exhaust valve opens 35" BBDC (at 1 mm lift)
closes 5" ATDC (at 1 mm lift)
Lubrication system Forced pressure and wet sump
Oil p u mp type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper element
Engine dry weight 31.0 kg (68.3 Ibs)
FUEL DELIV- Tvpe PGM-FI (Programmed Fuel Injection)
ERY SYSTEM Throttle bore 26 mm (1.0 in)
DRIVE TRAIN Clutch system Automatic centrifugal clutch, dry
Gear ratio 2.64 - 0.82
Final reduction 11.423 (47/12 x 35/12)
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulatodrectifier SCR shorted, triple phase full-wave rectification
Lighting system Battery
GENERAL INFORMATION
SH150
ITEM. SPECIFICATION
DIMENSIONS Overall length 2,020 mm (79.5 in)
Overall width 700 mm (27.6 in)
Overall height 1,140 mm (44.9 in)
Wheel base 1,335 mm (52.6 in)
Seat height 790 mm (31.1 in)
Ground clearance 140 mm (5.5 in)
Curb weight 134 kg (295 lbs)
Maximum weight capacity 180 kg (397 Ibs)
FRAME Frame type U nder-bone
Front suspension Telescopic fork
Front axle travel 89 mm (3.5 in)
Rear suspension Power unit swing (swingarm)
Rear axle travel 83 mm (3.3 in)
Front tire size 100/80-16M/C 50P
Rear tire size 120/80-16M/C 60P
Tire brand (Front/Rear) D451 (Dunlop)
Front brake Hydraulic single disc
Rear brake Mechanical drum (Leading-trailing)
Caster angle 27" 00'
Trail length 85 mrn (3.3 in)
Fuel tank capacity 7.5 liters (1.98 US gal, 1.65 Imp gal)
Cylinder arrangement Single cylinder inclined 80" from vertical
Bore and stroke 58.0 x 57.8 mm (2.28 x 2.28 in)
Displacement 152.7 cm3 (9.31 cu-in)
Compression ratio 11 : 1
Valve t ra in Chain driven OHC with rocker arms
Intake valve opens 10" BTDC (at 1 mm lift)
closes 30" ABDC (at 1 mm lift)
Exhaust valve opens 35" BBDC (at 1 mm lift)
closes 5" ATDC (at 1 mm lift)
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper element
FUEL DELIV- Type PGM-FI (Programmed Fuel Iniection)
ERY SYSTEM Throttle bore 26 mm (1.0 in)
DRIVE TRAIN Clutch system Automatic centrifugal clutch, dry
Gear ratio 2.64 - 0.82
Final reduction 10.544 (47113 x 35/12)
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulatorhectifier SCR shorted, triple phase full-wave rectification
Lighting system Batterv
1-5
LUBRICATION SYSTEM SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 0.9 liter (1.0 US qt, 0.8 I m p qt) -
After disassembly 1.0 liter (1.1 US qt, 0.9 Imp qt) -
Recommended engine oil Honda 4-stroke oil or equivalent motor -
oil
API service classification SE, SF or SG
Viscosity: SAE IOW-30
Oil p u m p rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 - 0.20 (0.006 - 0.008) 0.25 (0.010)
Side clearance 0.04 - 0.09 (0.002 - 0.004) 0.12 (0.005)
FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS

I ITEM
~ SPECIFICATIONS
Throttle body identifica- SH125 GQMIA
tion number SH150 GQM2A
Idle speed 1,500 f 100 min-' (rpm)
Throttle grip free play 2 - 6 mm (0.08 - 0.24 in)
ECT sensor resistance (at 2OoC/68"F) 2.3 - 2.6 kR
Fuel injector resistance (at 20C /68"F) 11.1 - 12.3 SZ
Fuel pressure 294 kPa (3.0 kgf/cm2, 43 psi)
Fuel pum p f low (at 12 V) 22 cm3 (0.7 US oz, 0.8 I m p oz) minimum/lO seconds
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 0.95 liter (1.00 US qt, 0.84 Imp qt)
I
Reserve tank 0.4 liter (0.42 US at, 0.35 ImD at)
Radiator cap relief pressure 108 - 137 kPa (1.1 - 1.4 kgf/cm2, 16 -'20 psi)
Thermostat Begin to open 80 - 84 "C (176 - 183 OF)
Fully open 95 "C (203 OF)
Valve lift 4.5 mm (0.18 in) mi ni mum
Standard coolant concentration 1:l mixture with distilled water
CYLINDER HEADNALVES SPECIFICATIONS

ITEM STANDARD 1 SERVICE LIMIT
Cvlinder comDression at 600 min-' (rDm)
.. . I 1,373 kPa (14.0 knf/cm2, 199 mi) -
1
r
Camshaft Cam lobe height IN 29.7377 - 29.8177 (1.17077 -'1.17392) 29.637 (1.1668)
EX 29.4953 - 29.5753 (1.16123- 1.16438) 29.395 (1.1573)
Rocker ar m A r m I.D. IN/EX 10.000 - 10.015 (0.3937 - 0.3943) 10.05 (0.396)
Shaft O.D.
-~ INlEX 9.972 - 9.987 (0.3926 - 0.3932) 9.937 (0.3912)
Arm-to-shaft clear- IN/EX 0.013 - 0.043 (0.0005 - 0.0017) 0.063 (0.0025)
ance
Valve clearance IN +
0.16 0.02 (0.006 f 0.0011 -
valve guide EX 0.25 k 0.02 (0.010 f 0.001) -
Valve stem O.D. IN 4.975 - 4.990 (0.1959 - 0.1965) 4.90 (0.193)
EX 4.955 - 4.970 (0.1951 - 0.1957) 4.90 (0.193)
Valve auide
" I.D. IN/EX 5.000 - 5.012 (0.1969 - 0.1973) 5.03 (0.198) J
Stem-to-guide clear- IN 0.010 - 0.037 (0.0004 - 0.001 5) 0.08 (0.003)
ance EX 0.030 - 0.057 (0.0012 - 0.0022) 0.10 (0.004)
Valve guide projection IN/EX 11.35 - 11.65 (0.447 - 0.459) -
above cvlinder head I
Valve seat width I IN/EX I 0.90 - 1.10 (0.035 - 0.043) I 1.8 (0.07)
lenoth I IN/EX 1 36.2 (1.43) I 34.4 (1.35)
roaae I - I 0.05 (0.002) I
1-6
GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS
Oil (side rail) 0.20 - 0.70 (0.008 - 0.028) ~ 0.90 (0.035)

Piston ring-to-ring Top 0.030 - 0.065 (0.0012 - 0.0026) 0.105 (0.0041)
groove clearance Second 0.015 - 0.050 (0.0006 - 0.0020) 0.095 (0.0038)
Cylinder-to-piston clearance 0.010 - 0.040 (0.0004 - 0.0016) 0.10 (0.004)
Connecting rod small end I.D. 14.016 - 14.034 (0.5518 - 0.5525) 14.06 (0.554)
Connecting rod-to-piston pin clearance 0.016 - 0.040 (0.0006 - 0.0016) 0.06 (0.002)

Cylinder I.D. 58.000 - 58.010 (2.2835 - 2.2839) 58.04 (2.2850)
__________
Out-of-round - 0.05 (0.002)
Taper - 0.05 (0.002)
Warpage - 0.05 (0.002)
Piston, Piston O.D. at 10 (0.4)
. . from bottom 57.97 - 57.99 (2.282 - 2.283) 57.90 (2.280)
piston pin, Piston pin hole I.D. 14.002 - 14.008 (0.5513 - 015515) 14.02 (0.552)
piston ring Piston pin O.D. 13.994 - 14.000 (0.5509 - 0.5512) 13.982 (0.5505)
Piston-to-piston pin clearance 0.002 - 0.0014 (0.0001 - 0.0006) 0.02 (0.001)
Piston ring end gap Top 0.10 - 0.25 (0.004 - 0.010) 0.45 (0.018)
Second 0.35 - 0.50 (0.014 - 0.020) 0.70 (0.028)
Oil (side rail) 0.20 - 0.70 (0.008 - 0.028) 0.90 (0.035)
Piston ring-to-ring Top 0.030 - 0.065 (0.0012 - 0.0026) 0.105 (0.0041)
groove clearance Second 0.015 - 0.055 (0.0006 - 0.0021 ) 0.095 (0.0038)
Cylinder-to-piston clearance 0.010 - 0.040 (0.0004 - 0.0016) 0.10 (0.004)
Connectina rod small end I.D. 14.016 - 14.034 (0.5518 - 0.5525) 14.06 (0.554)
I 1
I
Connecting rod-to-piston pin clearance j 0.016 - 0.040 (0.0006 - 0.0016) . 0.06 (0.002)
1-7
GENERAL INFORMATION
DRIVE AND DRIVEN PULLEYSKLUTCH SPECIFICATIONS

Drive belt width 22.5 (0.89) 21.5 (0.85)
Movable Bushing I.D. 23.989 - 24.052 (0.9444 - 0.9469) 24.09 (9.484)
drive face Boss O.D. 23.960 - 23.974 (0.9433 - 0.9439) 23.93 (0.942)
Weight roller O.D. 19.92 - 20.08 (0.784 - 0.791) 19.5 (0.77)
Clutch Clutch outer I.D. 125.0 - 125.2 (4.92 - 4.93) 125.5 (4.94)
Lining thickness 4.0 (0.16) 2.0 (0.08)
Driven pulley Face spring free length 143.3 (5.64) 123.0 (4.84)
Driven face boss O.D. 33.965 - 33.985 (1.3372 - 1.3380) 33.94 (1.376)
Movable driven face I.D. 34.000 - 34.025 (1.3386 - 1.3396) 34.06 (1.341)

Drive belt width 22.5 (0.89) 21.5 (0.85)
Movable Bushing I.D. 24.01 5 - 24.026 (0.9455 - 0.9459) 24.064 (9.4740)
Weight roller O.D. 19.92 - 20.08 (0.784 - 0.791) 19.5 (0.77)
Driven pulley ~-
Face spring free length 143.3 (5.64) 123.0 (4.84)
I Final drive oil capacity

ITEM
After draining
SPECIFICATIONS
190 cm3 (6.4 US oz, 6.9 Imp oz)
. .
I I
Recommended final drive oil Hypoid gear oil, SAE #90 or
Honda 4-stroke oil or equivalent motor oil
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit: mm (in)
Starter driven gear Boss O.D. 39.622 - 39.635 (1.5599 - 1.5604) 39.58 (1.558)
Bushing I.D. 22.026 - 22.045 (0.8672 - 0.8679) 22.10 (0.870)
Starter clutch outer I.D. 56.279 - 56.309 (2.2157 - 2.2169) 56.36 (2.219)
CRANKCASEKRANKSHAFT SPECIFICATIONS
Crankshaft runout - 0.10 (0.004)
Connecting rod big end side clearance 0.10 - 0.35 (0.004 - 0.014) 0.60 (0.024)
Connecting rod bicl end radial clearance 0 - 0.008 (0 - 0.0003) 0.05 (0.002)
1-8
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Minimum tire tread depth - 1.5 (0.06)
Cold tire Driver only 175 kPa (1.75 kgf/cm2, 25 psi) -
pressure Driver and Dassenaer 175 kPa (1.75 kaf/cm2. 25 mi) -
Axle runout - 0.2 (0.01)
Wheel rim Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel balance weight - 70 g (2.502)
max.
:
Fork
Tube runout
257.2 (10.13)
-
__________
252 (9.9)
0.2 (o.oi )
Recommended fork fluid Honda Ultra Cushion Oil 1OW -
or equivalent
Fluid level 106 (4.2) -
Fluid capacity * *
100 1 cm3(3.4 0.03 US 02,3.5 k 0.04 -
Imt, 0 2 )
REAR WHEEL/SUSPENSION SPECIFICATIONS

ITEM STANDARD
Minimum tire tread deoth -
200 kPa (2.00 kgf/cm2, 29 psi) -
1 Wheel rim I Radial I - I 2.0 (0.08) I

runout 1 Axial - 2.0 i0.08)
Shock absorber spring pre-load adjuster Middle position -
BRAKE SYSTEM SPECIFICATIONS

I ITEM STANDARD 1 SERVICE LIMIT
1 Front brake
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
-
~~
3.8 - 4.2 (0.15 0.17)

-
12.700 - 12.743 (0.5000 - 0.5017)
12.657 - 12.684 (0.498390.4994)
3.5 (0.14)
0.3 (0.01)
12.755 (0.5022)
12.645 (0.4978)
t-Rear brake
Caliper cylinder I.D.
Caliper piston O.D.
Brake lever free play
Brake drum I.D.
27.000 - 27.050 (1.0630 - 1.0650)
26.918 - 26.968 (1.0598 - 1.0617)
-
10 20 (2/5 - 3/4)
130 (5.1)
27.06 (1.065)
26.91 (1.059)
-
131 (5.2)
ITEM SPECIFICATION
Battery Capacity 12V-6Ah
Current leakage 0.2 mA max.
Vo Itage Fully charged 13.0 - 13.2 V
(20C/68"F) Needs charging Below 12.3 V
Charging cur- Normal 0.6 N 5 - 10 h
rent Quick 3.0 N1.0 h
Alternator Capacity ~
300 W/5,000 min-' (rpm)
Charging coil resistance (20C/68"F) 0.1 - 0.5 L2
1-9
GENERAL INFORMATION
IGNITION SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug Standard CR8EH-9 (NGK), U24FER9 (DENSO)
For extended high speed riding CR9EH-9 (NGK), U27FER9 (DENSO)
Spark plug gap 0.8 - 0.9 mm (0.031 - 0.035 in)
Ignition coil primary peak voltage 100 V minimum
Crankshaft position (CKP) sensor peak voltage 0.7 V minimum
Ignition timing ("F"mark) 10" BTDC a t idle
ELECTRIC STARTER SPECIFlCAT10NS

Unit: mm [in)
ITEM STANDARD 1 SERVICE LIMIT
ITEM SPECIFICATIONS
Bulb Headlight (highllow beam) 12 V - 60155 W
Brakehaillight 12 V - 211
5' W
License light 12V-5W
Turn signal light 12v-21w x 4
Position light 12v-5 w x 2
Instrument light 12 V - 1.7 W x 3
High beam indicator 12 V - 1.7 W
Turn sianal
" indicator 12 v - 1.7 w x 2
PGM-FI malfunction indicator LED
Engine oil maintenance indicator LED
Fuse Main fuse 30 A
Su b-fuse 15Ax1.10Ax4
1-10
GENERAL INFORMATION
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N - m (kgf.m, Ibf-ft N-m (kgf-m, Ibf-ft)
5 m m bolt and nut 5 (0.5, 3.7) 5 m m screw 4 (0.4, 3.0)
6 m m bolt and nut 10 (1.0,7) 6 m m screw 9 (0.9, 6.6)
8 mm bolt and nut 22 (2.2, 16) 6 m m flange bolt (8 m m head; small flange) 10 (1.0, 7)
10 mm bolt and nut 34 (3.5, 25) 6 m m flange bolt (8 m m head; large flange) 12 (1.2,9)
12 m m bolt and nut 54 (5.5,40) 6 mm flange bolt (10 m m head) and nut 12 (1.2,9)
8 m m flange bolt and nut 27 (2.8, 20)
10 m m flange bolt and nut 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

Torque specifications listed below are for specified fasteners.
Others should be tightened to standard torque values listed above.
NOTE:
1. Apply engine oil to the threads and seating surface.
2. Apply locking agent to the threads.
3. ALOC bolt or screw: replace with a new one.
4. Left-hand threads.
5. U-nut.
ENGINE
FRAME/BODY PANELS/EXHAUST SYSTEM
I ITEM
THREAD TORQUE
N.m (knf-m, Ibf-ft)
REMARKS
Exhaust pipe stud bolt 2 7 9 (0.9, 6.6)
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N.m (kgf-m, Ibf.ft)
Spark plug 1 10 12 (1.2,9)
Valve adjusting screw lo& nut 2 5 10 (1.0,7) NOTE 1
Timing hole cap 1 14 6 (0.6, 4.4)
Engine oil strainer cap 1 30 20 (2.0, 15)
Final drive oil check bolt 1 8 13 (1.3. 10)
LUBRICATION SYSTEM
THREAD TORQUE
ITEM QTY REMARKS
DIA. (mm) N - m (kgf.m, Ibf.ft)
Oil pump cover screw 1 3 2 (0.2, 1.5)
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N - m (kgf-m, I b f W
Throttle body insulator band bolt 2 - page 5-40
Engine coolant temperature (ECT) sensor 1 23 (2.3, 17)
1-11
GENERAL INFORMATION
THREAD TORQUE
REMARKS
ITEM Q'TY DIA. (mm) N-m(kgf-m, Ibf-ft)
Camshaft holder nut 4 8 27 (2.8, 20) NOTE 1
Cam sprocket bolt 2 5 9 (0.9, 6.6)
Cylinder head cover bolt 2 6 12 (1.2,9)
THREAD TORQUE
ITEM REMARKS
'ITY DIA. (mm) N-m (kgf-m. Ibf-ft)
Cylinder stud bolt 4 8 6.6)
9 (0.9,
THREAD TORQUE
ITEM REMARKS
'ITY DIA. (mm) N.m (kgf.m, Ibf-ft)
Clutch lock nut 1 28 54 (5.5,40)
Clutch outer nut 1 12 49 (5.0,36)
Drive pulley face nut 1 12 59 6.0, 44) NOTE 1
Left crankcase cover bolt 5 6 10 (1.0,7)
Belt case air cleaner housing bolt 2 6 - page 10-8
ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
REMARKS
ITEM 'ITY DIA. (mm) N.m (kgfam, Ibf-ft)
Stator bolt 3 6 12 (1.2,9)
Crankshaft position (CKP) sensor bolt 2 5 5 (0.5, 3.7)
Starter clutch outer bolt 3 8 30 (3.1,22) NOTE 2
Flywheel nut - 1 16 116 (11.8,86) NOTE 1
THREAD TORQUE
ITEM REMARKS
'ITY DIA. (mm) N-m (kgf-m, IbfW
C a m chain tensioner pivot bolt 1 6 10 (1.0,7)
1-12
GENERAL INFORMATION
THREAD TORQUE
ITEM REMARKS
*ITY DIA. (mm) N.m (kgf.m, Ibf4tJ
Center stand pivot bolt 2 10 49 (5.0, 36) NOTE 3
Exhaust pipe joint nut 2 7 29 (3.0, 21)
Muffler mounting bolt 3 10 49 (5.0, 36)
Muffler protector bolt 2 5 5.2 (0.53, 3.8)
THREAD
ITEM TORQUE REMARKS
QTY DIA. (mm) N.m (kgf-m, Ibf-ft)
Brake joint cable adjuster lock nut 1 8 6 (0.6, 4.4)
ITEM
THREAD TORQUE
REMARKS
*ITY DIA. (mm) N-m (kgfmm, Ibf4t)
Fuel pump retaining plate nut 7 6 12 (1.2,9) page 5-36
sensor
0 2 1 18 44 (4.5, 32)
Bank angle sensor screw 2 4 1.2 (0.12,0.9)
THREAD TORQUE
ITEM REMARKS
QTY DIA. (mm) N.m (kgf-m, Ibf4t)
Cooling fan motor mounting bolt 2 6 J
8.4 (0.86, 6.2)
ENGINE REMOVAL/INSTALLATlON
___
ITEM THREAD TORQUE REMARKS
QTY DIA. (mm) N-m (kgf-m, Ibf-ft)
Engine hanger bracket bolt (frame side) 2 10 49 (5.0, 36)
I Enaine mountincr nut (enaine side) I l l 10 I 49 (5.0. 36) 1 NOTE 5 I
FRONT WHEEL/SUSPENSION/STEERlNG
I
THR- TORQUE
ITEM Q'TY REMARKS
DIA. (mm)
_____ _ _ N.m _ _ _ ~ IbfW
_ _ _ (kgf.m,
Steering stem lock nut 1 BC 1 68 (6.9, 50)
Steering bearing upper inner race 1 BC 1 - page 14-26
Fork socket bolt 2 8 20 (2.0, 15) NOTE 2
Handlebar post nut 1 10 39 (4.0, 29) NOTE 5
Brake disc bolt 4 8 42 (4.3, 31) NOTE 3
Front axle nut 1 12 68 (6.9, 50) NOTE 5
SDeedometer cable settina screw 1 5 2.2 (0.22. 1.6)
_____
THREAD TORQUE
ITEM REMARKS
QTY DIA.
~.
(mm) N-m(kgf-m, Ibf.ft)
Rear axle nut 1 16 118 (12.0, 87) NOTE 5
BRAKE SYSTEM
THREAD TORQUE
ITEM REMARKS
QTY DIA. (mm) N.m (kgf-m, Ibf-ft)
Caliper bleed valve 1 8 5.5 (0.56,4.1)
Pad pin 2 10 18 (1.8, 13)
Pad pin plug 2 10 2.5 (0.25, 1.8)
Master cylinder reservoir cap screw 2 4 1.5 (0.15, 1.1)
Brake hose oil bolt 7 10 34 (3.5, 25)
Front brake lever pivot bolt 1 6 1 (0.1,0.7)
Front brake lever pivot nut 1 6 6 (0.6, 4.4)
Front brake light switch screw 1 4 1.2 (0.12,0.9)
Master cylinder holder bolt 2 6 12 (1.2,9)
Caliper mounting bolt 2 8 30 (3.1, 22) NOTE 3
Rear brake lever Divot screw 1 5 4.2 (0.43, 3.1 1
1-13
GENERAL INFORMATION
ITEM THREAD TORQUE

REMARKS
'ITY DIA. (mml N.m (kgf.m, Ibf.ft)
Rear brake lever pivot nut 1 5 5.2 (0.53, 3.8)
Rear brake lever equalizer joint screw 1 5 4.2 (0.43, 3.1) NOTE 3
Rear
-_ brake_.__
arm bolt 1 6 10 (1.0,7) NOTE 3
THREAD TORQUE
ITEM REMARKS
'ITY DIA. (mm) N.m (kgfam, Ibf-ft)
License light screw 1 - 1.5 (0.15, 1.1)
I Speedometer cable joint nut 1 12 3.4 (0.35, 2.5)
1-14
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
LOCATION MATERIAL REMARKS
Alternatorkrankshaft position (CKP) sensor wire grommet Sea Iant
seating area
Crankcase mating surface
Starter clutch outer bolt threads Locking agent ~
Water pump shaft journal Molybdenum oil solu- Do not apply to the
tion-(amixture of mechanical seal sliding area
engine oil and molyb- (page 6-12).
Camshaft cam lobes denum disulfide
Starter driven gear inner surface (crankshaft sliding area) grease in a ratio of Avoid getting on the crank-
1:l) shaft and flywheel tapered
areas.
Driven face boss inner surface Multi-purpose grease 7 - 8 g (avoid getting shaft
spline and pulley face when
assemble)
Movable driven face guide grooves (guide pin areas) 2 - 2.5 g
Movable driven face ball and needle bearings
Final shaft groove and outer surface (swingarm fitting
area)
Valve adjusting screw lo& nut threads Engine oil
Final drive oil drain bolt threads and seating surface
Oil pump rotors and shaft sliding surface
Oil pump drive chain
Valve stem seal fitting area
Valve stem sliding surface
Rocker arm shaft sliding surface
Rocker arm slipper and sliding surfaces
Camshaft holder nut threads
Cam sprocket teeth
Cam chain
Piston rings
Piston ring grooves and piston pin hole
Piston pin outer surface
Piston and cylinder wall
Drive pulley face nut threads
Final reduction gear teeth and journals
Starter driven gear teeth and sprag clutch contacting area
Starter reduction gear teeth and sliding surface
Starter reduction gear shaft outer surface
Flywheel nut threads and seating surface
Right crankshaft hole (oil passage)
Connecting rod big end bearing and thrust surfaces 3 cc
Crankshaft main journal bearings 2 cc per eac.. bearing
Timing sprocket teeth
Oil pump drive sprocket teeth
Starter motor pinion teeth
Each bearing rotating area
Each oil seal lips and outer surface
Each 0-rina
GENERAL INFORMATION
FRAME
LOCATION MATERIAL REMARKS
Steering head bearings Urea based multi-pur- 3 - 5 g per each bearing
Steering head dust seal lips pose grease w i th
extreme pressure
(Example: Excelite EP2
manufactured by
Kyodo Yushi, Japan/
Shell Alvania EP2 or
equivalent)
Fuel pum p rubber seal inner surface Engine oil

Seat catch sliding area Multi-purpose grease 1.5 g
Center stand pivots
Front wheel dust seal lips
Speedometer gear retainer seal lips
Speedometer gear box gear teeth and sliding surface
Throttle grip pipe flange cable groove
Swingarm dust seal lips
Rear brake cam dust seal lips
Rear brake cam sliding surfaces and bushing groove 0.5 - 1 g
Rear brake panel anchor p i n 0.5 - 1 g
Rear brake lever pivot
Rear brake lever equalizer joint pivot
Combined brake equalizer link sliding area
Throttle cable boot inside (each end) Silicone grease 0.1 g
Front brake lever and a rm pivots 0.1 g
Front brake lever-to-master piston contacting area 0.1 g
Caliuer Din boot inside 0.4 g per each boot
Brake master piston and cups DOT 3 or DOT 4 brake
Brake caliper piston seal and dust seal fluid
Brake caliper piston outer surface
Fork oil seal lips Honda Ultra Cushion
Fork dust seal liDs Oil 1OW or eauivalent
Speedometer cable Cable lubricant
Throttle cable
Rear brake and joint cables
Handlebar grip rubber inside Honda Bond A or
Brake caliper bracket pad retainer equivalent
Air cleaner connecting tube-to-housing mating area
Air cleaner intake duct-to-housing mating area
Fork socket bolt threads Lockina aclent
1-16
GENERAL INFORMATION
CABLE & HARNESS ROUTING
BRAKE JOINT COMBINED BRAKE

CABLE EQUALIZER
THROTTLE CABLE
CONNECTORS
CO M BINAT1ON METER/
HANDLEBAR SWITCH WIRE
2 mm max.
LEFT FRONT TURN

SIGNAL WIRE
CONNECTORS:
I i If CABLE
. RELAYIFUSE BOX 6P (Black) AND 4P (White) CONNECTORS:

. IGNITION SWITCH 2P (White) . COMBINATION METER/HANDLEBAR
. FAN MOTOR 2P (White) SWITCH 9P (White) AND 6P (White)
. RIGHT TURN SIGNAUPOSITION LIGHT 3P (White) . LEFT TURN SlGNAUPOSlTlON LIGHT 3P (Black)
GENERAL INFORMATION
DIMMER/PASSING SWITCH
4P (Black) CONNECTOR
TURN SIGNAL SWITCH

3P (Red) CONNECTOR
HORN SWITCH 2P (Black)

CONNECTOR
REAR BRAKE
REAR BRAKE LIGHT SWITCH

CONNECTORS
FRONT BRAKE
CABLE HOLDER
STARTER SWITCH 4P (White)

CONNECTOR
1-18
GENERAL INFORMATION
SEAT LOCK
WATER I
SPEEDOMETER
CABLE
1-19
GENERAL INFORMATION
CABLE
GENERAL INFORMATION
BRAKE JOINT
\ CABLE
1-21
GENERAL INFORMATION
FRO"
1-22
GENERAL INFORMATION
REAR BRAKE
CABLE
STARTER MOTOR
---
STARTER RELAY
FLOOR SWITCH WIRE
CABLE
HARNESS
MAIN WIRE
GROUND WIRE
View from the bottom side: I HARNESS
I /
UP
t
-1
Inside 4
.=-
1-23
GENERAL INFORMATION
ALTERNATOR WIRE
1-24
GENERAL INFORMATION
02 SENSOR/PAIR
SOLENOID VALVE WIRE
ENGINE COOLANT CRANKSHAFT POSITION

TEMPERATURE (CKP) SENSOR WIRE
(ECT) SENSOR /
GENERAL INFORMATION
SPARK PLUG WIRE
STARTER -MOTOR
1-26
GENERAL fNFORMATlON
FUEL PUMP/LEVEL
SENSOR WIRE
GROUNDPOINT
1-27
GENERAL INFORMATION
REAR TURN SIGNAUBRAKE/

TAILLIGHT 6P (White) CONNECTOR
GENERAL INFORMATION
FUEL TANK TRAY

ENGINESTOP FUEL PUMP
I RELAY \ RELAY
v
-
SEAT LOCK CABLE
Left side
CABLE
I
I
FLOOR LOWER
COVER
GENERAL INFORMATION
REAR BRAKE CABLE
REAR BRAKE
CABLE
GENERAL INFORMATION
;IGNAUBRAKE/
(White)
LICENSE LIGHT WIRE

GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons. Control of hydrocarbons and
oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when
subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner housing and throttle body. Condensed
crankcase vapors are accumulated in a crankcase breather drain tube which must be emptied periodically (page 3-3).
THROTTLE BODY
CRANKCASE BREATHER HOSE
Fresh Air
1Blow-by Gas
1-32
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a secondary air supply system and PGM-FI system, and no
adjustments should be made. The exhaust emission control system is separate from the crankcase emission control
system.
SECONDARY AIR SUPPLY SYSTEM
The secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn
into the exhaust port by the function of the Pulse Secondary Air Injection (PAIR) solenoid valve.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of
hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.
The PAIR check valve prevents reverse air flow through the system. The PAIR solenoid valve is controlled by the engine
control module (ECM), and the fresh air passage is opened and closed according to the running condition.
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is
recommended.
PAIR SOLENOID VALVE
PAIR 1Exhaust Gas

EXHAUST PORT
THREE-WAY CATALYTIC CONVERTER

This scooter is also equipped with the three-way catalytic converter. The three-way catalytic converter is in the exhaust
system. Through chemical reactions, they convert HC, CO and NOx in the engines exhaust to carbon dioxide (COz),
dinitrogen (N2) and water vapor.
1-33
GENERAL INFORMATION
~ ~~
NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE EMISSION CONTROL SYSTEM IS PROHIBITED: The local law prohibits the following acts or
the causing thereof: (1) The removal or rendering inoperative by any person, other than for the purposes of maintenance,
repair or replacement, of any device or element of design incorporated into any vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate customer or while it is in use; or (2) the use of any vehicle after such device or
element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those
specified by the manufacturer.
1-34
2. FRAME/BODY PANELWEXHAUST SYSTEM
SERVICE INFORMATION .............................. 2-2 FRONT UPPER COVER................................... 2-8
TROUBLESHOOTlNG .................................... 2-2 FRONT LOWER COVER ................................. 2-9
BODY PANEL LOCATIONS ........................... 2-3 FRONT INNER COVER ................................. 2-10
MAINTENANCE LID....................................... 2-4 FLOOR PANEL .............................................. 2-11
SEAT ............................................................... 2-4 FRONT HANDLEBAR COVER ...................... 2-1 1
LUGGAGE BOX ............................................. 2-5 REAR HANDLEBAR COVER ......................... 2-12
FRAME BODY COVER ................................... 2-5 GLOVE BOX INNER COVER ........................ 2-13
REAR FENDER ............................................... 2-7 MUD GUARD ................................................ 2-14
FRONT FENDER ............................................. 2-8 CENTER STAND ........................................... 2-14
FLOOR LOWER COVER ................................. 2-8 EXHAUST SYSTEM...................................... 2-15
2-1
FRAME/BODY PANELWEXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
This section covers removal and installation of the body panels and exhaust system.
When installing the covers, make sure the mating areas are aligned properly before tightening the fasteners.
Always replace the exhaust pipe gasket after removing the exhaust system.
When installing the exhaust system, loosely install all of the fasteners. Always tighten the exhaust joint first, then
tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Center stand pivot bolt 49 N.m (5.0 kgf.m, 36 Ibf.ft) ALOC bolt: replace with a new one.
Center stand spring hook bolt 10 N.m (1.0 kgf.m, 7 Ibf.ft)
Exhaust pipe stud bolt 9 N.m (0.9 kgf.m, 6.6 Ibf.ft)
Exhaust pipe joint nut 29 N.m (3.0 kgf.m, 21 Ibf.ft)
Muffler mounting bolt 49 N.m (5.0 kgf.m, 36 Ibf.ft)
Muffler protector bolt 5.2 N.m (0.53 kgf.m, 3.8 Ibf.ft)
TROUBLESHOOTING
Excessive exhaust noise
Broken exhaust system
Exhaust gas leak
Poor performance
Deformed exhaust system
Exhaust gas leak
Clogged muffler
2-2
FRAMEIBODY PANELSEXHAUST SYSTEM
BODY PANEL LOCATIONS
(1) Maintenance Lid (page 2-4) (7) Front Fender (page 2-8) (12) Floor Panel (page 2-11 1
(2) Seat (page 2-41 (8) Floor Lower Cover (page 2-8) (13) Front Handlebar Cover (page 2-11)
(3) Luggage Box (page 2-51 (9) Front Upper Cover (page 2-81 (14) Rear Handlebar Cover (page 2-12)
(4) Frame body Cover (page 2-5) (10) Front Lower Cover (page 2-91 (15) Glove Box Inner Cover (page 2-13)
(5) Rear Fender A (page 2-7) (11) Front Inner Cover (page 2-10] (16) Mud Guard (page 2-14)
(6) Rear Fender B (page 2-71
BODY PANEL REMOVAL CHART

This chart shows removal order of frame covers by means of arrow.
(11 Maintenance Lid (13) Front Handlebar Cover
(4) Frame Body Cover 4(10) Front Lower Cover I (14) Rear Handlebar Cover
f\ 1
I I
t
I I (11) Front Inner Cover 4 (8) Floor Lower Cover I
(15) Glove Box Inner Cover I (16) Mud Guard
2-3
MAINTENANCE LID
Remove the three tapping screws.
Release the upper tabs from the frame body cover TAPPING SCREWS
and the lower tabs from the floor panel to remove
the maintenance lid. TABS /
Installation is in the reverse order of removal.
SEAT
Unlock the seat lock with the ignition key and open
the seat.
Remove the two nuts while supporting the seat to
remove it.
SEAT
2-4
LUGGAGE BOX
Remove the seat (page 2-4).
Remove the following:
- four bolts (front side; two setting boltshear side;
two washer-bolts)
- tapping screw
- luggage box (release from the two tabs of the
frame cross-bracket)
Installation is i n the reverse order of removal.
TAPPING SCREW
FRAME BODY COVER

- luggage box (page 2-5)
- maintenance lid (page 2-4) FLANGE SCREWS
Remove the two flange screws.
Remove the fuel fill cap. /\ FUELFILL
Release the three tabs of the fuel tank tray from the
frame cross-bracket and disconnect the fuel drain
hose to remove the tank tray.
Install the fuel fill cap.
NOTE:
If the filler neck seal was removed from the tray,
install it with the "UP" mark facing up.
2-5
FRAME/BODY PANELSiEXHAUST SYSTEM
Remove the three bolts and grab rail.
GRAB RAIL
Remove the t w o tri m clips and the tw o tapping

screws.
Raise the front portion of the body cover slightly
and release it fro m the floor panel.
Release the front end tab o n the left body cover
fro m the right body cover, being careful not to break
it.
Pull the rear fender ribs out of the body cover.
Release the body cover fro m the bolt hole stud and
disconnect the 6P (white) connector.
Remove the body cover while spreading the front
portion of it.
NOTE:
For body cover separation, refer to rear combina-
tion light rernovaVinstallation (page 20-6).
2-6
REAR FENDER
FENDER A
Remove the frame body cover (page 2-5).
- license light connectors
- two washer-bolts
- two flange bolts
- two tapping screws
- rear fender A (from between the fender B and
bracket)
Route the license Installation is in the reverse order of removal.
hght wire properly
(page 1-17). FLANGE BOLTS
CONNECTORS
WASHER-BOLTS
FENDER B
Remove the rear fender B (page 2-7).
Support the swingarm securely.
Remove either shock absorber upper mounting bolt
t o get the clearance for fender removal.
Remove the two setting bolts (upper side) and
release the fender off of the bolt hole studs.
Remove the two flange bolts and the rear fender B.
STUDS
SETTING BOLTS
2-7
FRONT FENDER
- speedometer cable guide
- three setting bolts
- front fender
BOLTS
FLOOR LOWER COVER

- fuel drain hose
- fourscrews
Release the rear end tabs from the floor panel.
Slide the floor lower cover forward and release the
center tabs to remove the floor lower cover from the
front lower cover.
NOTE:
Align the mating area of the floor lower cover
and front lower cover properly.
\
SCREWS TAB
FRONT UPPER COVER

- two tapping screws (lower)
- two washer-screws (upper) 1 WASHER-SCREWS UPPER
- front upper cover
I TAPPING SCREWS
2-8
FRAMEIBODY PANELWEXHAUST SYSTEM
FRONT LOWER COVER
- front upper cover (page 2-8)
- floor lower cover (page 2-8)
- front wheel (page 14-7)
- front fender (page 2-8)
Remove the ten tapping screws and the setting bolt.
Release the two bosses from the grommets and
raise the front lower cover t o release it from the
retainer on the frame.
While supporting the front lower cover and release
the turn signal and fan motor wires from the wire
guides.
Disconnect the turn signaVposition light 3P connec-
tors and remove the front lower cover.
Route the wires Installation is in the reverse order of removal.
properly
(page 1- 171.
NOTE:
Align the mating areas of the front lower cover
and front inner cover properly.
GUI
GUIDES FAN MOTOR WIRE

TAPPING
FRONT INNER COVER
- front lower cover (page 2-9)
- rear handlebar cover (page 2-12)
- handlebar post lid (by sliding it rearward)
- ignition switch cap (by turning it counterclock-
wise)
- fuse boxhelay 6P (black) and 4P (white) connec-
tors
- two screws and luggage hook
- setting bolt (open the glove box lid)
Raise the lower portion of the inner cover and
release the five tabs from the floor panel.
Remove the front inner cover from the handlebar
post area while spreading the upper portion of it.
LID
CAP INNER COVER I
TABS
FRAMEIBODY PANELWEXHAUST SYSTEM
FLOOR PANEL
- frame body cover (page 2-5)
- front inner cover (page 2-10) ?- STATER RELY SWITCH - -
- battery (page 17-6)

Release the electric cables and wire from the guides
of the floor panel and remove the starter relay
switch.
Remove the two tapping screws and the four
washer bolts
Be careful not to Raise the front portion of the floor panel and release
scratch the floor the rear ends from the footrests t o remove the floor
panel by the panel.
footrest brackets.
Route the cables Installation is in the reverse order of removal.

properl y
TAPPING BOLTS
(page 1-17).
SCREWS
REAR \
FLOOR PANEL
FRONT HANDLEBAR COVER

Remove the front upper cover (page 2-8).
I BOLTS
Remove the two socket bolts. UPPER HANDLEBAR COVER
Becarefulnotto
break the tabs.
Raise the rear end of the upper handlebar cover
slightly, then sliding it forward and release the two
/
tabs to remove the upper handlebar cover.
2-11
FRAME/BODY PANELSIEXHAUST SYSTEM
Remove the two screws.
Push the rear handlebar cover and release the four 1 SCREWS FRONT HANDLEBAR COVER
tabs of the front handlebar cover.
Release the two bosses from the grommet.
Be careful not to Disconnect the headlight 3P connector to remove
scratch the front the front handlebar cover.
inner cover.
NOTE:
Set the throttle cable into the guide groove in the
rear handlebar cover.
REAR HANDLEBAR COVER

Remove the front handlebar cover (page 2-11).
- rearview mirrors
- three tapping screws (meter mount)
- two tapping screws (front side)
- washer-screw (rear side)
Release the rear handlebar cover from the handle-
bar.
Disconnect the following connectors to remove the
handlebar cover:
- starter switch 4P (white)
- dimmedpassing switch 4P (black)
- turn signal switch 3P (red)
- horn switch 2P (black)
Remove the handlebar post cushion.
Route the wires Installation is in the reverse order of removal.
properly (page 1-
17). MIRRORS
REAR HANDLEBAR COVER y

TAPPING
SCREWS
G SCREWS
2-12
GLOVE BOX INNER COVER
Open the glove box lid with the ignition key.
Remove the two tapping screws.
Release the five tabs of the cover from the glove
box.
Remove the relays and the fuse box by pushing the
lock tab to remove the inner cover.
INNER COVER
RELAYS I
TAPPING SCREWS
2-13
MUD GUARD
- washer-screw
- two socket bolts
- mudguard
Ahgn the sht with Installation is in the reverse order of removal.
the tab on the a/r
cleaner housmg
CENTER STAND
Retract the center stand and support the scooter
securely.
Be careful not to Remove the following:
deform the springs. - Springs
- two bolts
- center stand
- pivot collars (from the inside of the stand)
NOTE:
Always replace the pivot bolts with new ones.
Apply grease to the pivot areas.
The springs are installed from the upper side as
shown.
TORQUE: Pivot bolt: 49 N-m (5.0 k9f.m. 36 Ibf4t)

EXHAUST SYSTEM
REMOVAL
- maintenance lid (page 2-4)
- 0 2 sensor (page 5-47)
- two washer-bolts and exhaust pipe protector
- two joint nuts

- three mounting bolts
- muffler
- gasket
INSTALLATION
Check the exhaust pipe stud bolts for looseness or
damage.
Thread two nuts onto the stud and tighten them
together, and use the wrench on them to tighten the
stud butt -ifilis ioosened.
TORQUE: 9 N.m (0.9 kgf.m, 6.6 Ibf.ft)
Always replace the Install a new gasket.

gaskets with new Install the muffler with the mounting bolts and joint
I
one.
nuts by setting the exhaust pipe flange onto the
stud bolts.
Tighten the joint nuts first, then tighten the mount-
ing bolts.
TORQUE:
Joint nut: 29 N.m (3.0 kgf-m, 21 Ibf-ft)
Mounting bolt: 49 N.m (5.0 kgfem, 36 Ibf-ft)
Install the following:
- exhaust pipe protector with the washer-bolts
- 0 2 sensor (page 5-47)
After installation, inspect the exhaust system for

leaks.
Install the maintenance lid (page 2-4).
2-15
-
3. MAINTENANCE
SERVICE INFORMATION .............................. 3-2 BELT CASE AIR CLEANER ........................... 3-12
MAINTENANCE SCHEDULE ......................... 3-3 FINAL DRIVE OIL .......................................... 3-13
FUEL LINE ...................................................... 3-4 BRAKE FLUID................................................ 3-14
THROTTLE OPERATION................................ 3-4 BRAKE SHOES/PADS WEAR ...................... 3-15
AIR CLEANER................................................. 3-5 BRAKE SYSTEM ........................................... 3-15
CRANKCASE BREATHER .............................. 3-6 BRAKE LIGHT SWITCH ................................ 3-17
SPARK PLUG .................................................3-6 BRAKE LOCK OPERATION .......................... 3-17
VALVE CLEARANCE...................................... 3-7 HEADLIGHT AIM .......................................... 3-17
ENGINE OIL.................................................... 3-8 SUSPENSlON ............................................... 3-17
ENGINE OIL STRAINER SCREEN .................3-9 NUTS, BOLTS, FASTENERS........................ 3-18
RADIATOR COOLANT ................................. 3-10 WHEELS/TIR ES ............................................ 3-18
COOLING SYSTEM...................................... 3-1 1 STEERING HEAD BEARINGS ...................... 3-19
SECONDARY AIR SUPPLY SYSTEM.......... 3-12
3-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
Place the scooter on a level ground before starting any work.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
Throttle grip free play 2 - 6 m m (1/12 - 114 in)

Spark plug gap 0.8 - 0.9 m m (0.031 - 0.035 in)
' Valve clearance IN 0.16 k 0.02 m m (0.006 f 0.001 in)
EX 0.25 rt 0.02 m m (0.010 f 0.001 in)
Recommended engine oil Honda 4-stroke oil or equivalent motor oil
Viscosity:
___ __ SAE IOW-30
Engine oil capacity After draining 0.9 liter (1.0 US qt, 0.8 Imp qt)
After disassembly 1.0 liter (1.1 US qt, 0.9 Imp qt)
Engine idle speed 1,500 k 100 min-' (rpm)
Final drive oil 1
After draining 190 cm3 (6.4 US oz, 6.9 Imp oz)
capacity I
After disassembly 220 cm3 (7.4 US oz, 7.7 Imp oz)
Recommended brake fluid DOT 3 or DOT 4
Rear brake lever free play 10 - 20 m m (2/5 - 3/4 in)
Cold tire pressure Driver only Front 175 kPa (1.75 kgf/cm2, 25 psi)
Rear 200 kPa (2.00 kgf/cm2, 29 psi)
Driver and passenger Front 175 kPa (1.75 kgf/cm2, 25 psi)
Rear 225 kPa (2.25 kgf/cm2, 33 psi)
Tire size Front 100/80-16M/C 50P
Rear 12 0 / 8 m / r 6 0 P
Tire brand Front D451 (Dunlop)
Rear D451 (Dunlop)
Minimum tire tread depth Front 1.5 mm (0.06 in)
I Rear I 2.0 m m (0.08 in)
TORQUE VALUES
Spark plug 12 NGm (1.2 kgf.m, 9 Ibf.ft)
Valve adjusting screw lock nut 10 N.m (1.0 kgf.m, 7 Ibf.ft) Apply engine oil to the threads.
Timing hole cap 6 N.m (0.6 kgf.m, 4.4 Ibf.ft)
Engine oil strainer cap 20 N,m (2.0 kgf.m, 15 Ibf.ft)
Belt case air cleaner housing bolt 10 N.m (1.0 kgf.m, 7 Ibf.ft)
Final drive oil check bolt 13 N.m (1.3 kgf.m, 10 Ibf.ft)
Master cylinder reservoir cap screw 1.5 N.m (0.15 kgf.m, 1.1 Ibf.ft)
Brake joint cable adjuster lock nut 6 N.m (0.6 kgf.m, 4.4 Ibf.ft)
3-2
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owners 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 **I m ay require
more technical information and tools. Consult an authorized Honda dealer.
* Should be serviced b y an authorized Honda dealer, unless the owner has proper tools and service data and is
mechanically qualified.
** In the interest of safety, w e recommend these items be serviced only by an authorized Honda dealer.
Honda recommends that an authorized Honda dealer should road test your scooter after each periodic maintenance is
carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding i n rain or at full throttle.
4. Replace every 2 years. Replacement requires mechanical skill.
3-3
MAINTENANCE
FUEL LINE
Remove the luggage box (page 2-5). i
Check the fuel feed hose between the fuel pump
and injector for deterioration, damage or leakage.
Replace the fuel feed hose if necessary.
Also, check the feed hose fittings for damage or
looseness.
THROTTLE OPERATION
Check for any deterioration or damage to the throt-
tle cable. Check the throttle grip for smooth opera-
tion. Check that the throttle opens and automatically
closes in all steering positions.
If the throttle grip does not return properly, lubricate
the throttle cable and overhaul and lubricate the
throttle grip housing.
For cable lubrication; disconnect the throttle cable at
its upper end. Thoroughly lubricate the cable and its
pivot point with a commercially available cable
lubricant or a light weight oil.
If the throttle grip still does not return properly,
replace the throttle cable.
With the engine idling, turn the handlebar all the
way to the right and left to ensure that the idle
speed does not change. If idle speed increases,
check the throttle grip free play and the throttle
cable connection.
Measure the throttle grip free play a t the throttle
grip flange.
FREE PLAY 2 - 6 mm (1112 - 1/4 in)
Minor adjustments are made with the upper adjust-

ter.
Slide the boot off the adjuster.
Loosen the lock nut, turn the adjuster as required
and tighten the lock nut.
Install the rubber boot securely.
3-4
Major adjustments are made with the lower
adjuster o n the throttle body.
Remove the luggage box (page 2-5).
Loosen the lock nut, turn the adjusting nut as
required and tighten the lock nut.
After adjustment, recheck the throttle operation.
AIR CLEANER
NOTE:
The viscous paper element type air cleaner can-
not be cleaned because the element contains a
dust adhesive.
If the scooter i s used in unusually wet or dusty
areas, more frequent inspections are required.
- six screws
- air cleaner cover
- air cleaner element

Replace the element in accordance with the mainte-
nance schedule (page 3-3) or any time it is exces-
sively dirty or damaged.
Clean the inside o f the air cleaner housing and
cover.
Make sure the rubber seals in the housing are i n
position and in good condition.
Install a n e w element and the cover, and tighten the
six screws securely.
3-5
CRANKCASE BREATHER
NOTE:
Service more frequently when ridden in rain, at
full throttle, or after the scooter is washed or
overturned. Service if the deposit level can be
seen in the transparent section of the tube.
Remove the crankcase breather tube plug and drain
the deposits into a suitable container, then reinstall
the plug securely.
SPARK PLUG
Remove the maintenance lid (page 2-4).
Clean around the Disconnect the spark plug cap and remove the spark
spark plug base plug.
with compressed
air before removing
the plug, and be
sure that no debris
is aNowed to enter
into the combustion
chamber
Check the insulator for cracks or damage, and the

electrodes for wear, fouling or discoloration.
Replace the plug if necessary.
RECOMMENDEDSPARK PLUG:
Standard:
CR8EH-9 (NGK), U24FER9 (DENSO)
For extended high speed riding:
CR9EH-9 (NGK), U27FER9 (DENSO)
Clean the spark plug electrodes with a wire brush or
special plug cleaner.
/
SIDE ELECTRODE
INSU LATOR
MAINTENANCE
Check the gap between the center and side elec-
trodes with a wire-type feeler gauge.
I
SPARK PLUG GAP: 0.8 - 0.9 mm (0.031 - 0.035 in)
If necessary, adjust the gap by bending the side
electrode carefully.
Thread the spark plug in by hand to prevent cross-
threading and tighten it with a spark plug wrench.
TORQUE: 12 N-m (1.2 kgf-m, 19 IbfW
Connect the spark plug cap.
Install the maintenance lid (page 2-4).
VALVE CLEARANCE
INSPECTION
NOTE:
Inspect and adjust the valve clearance while the
engine is cold (below 35"C/95"F).
- cylinder head cover (page 8-7)
- belt case air cleaner housing (page 3-12)
Remove the timing hole cap from the right crank-
case cover.
Rotate the drive pulley (crankshaft) counterclock-

wise and align the T mark on the flywheel with the
index notch in the crankcase cover.
The index line on the cam sprocket must be flush
with the cylinder head surface, and the timing mark
"1" is facing up and "2" is facing down (TDC; Top
Dead Center on the compression stroke).
If the timing marks are not above position, rotate
the crankshaft one full turn and align the T mark
again.
MAINTENANCE
When checking the Check the clearances o f each valve by inserting the
clearance, slide the feeler gauge between the adjusting screw and
feeler gauge from rocker arm.
the Inside out in the
djrection of the VALVE CLEARANCE:
arrow. IN: 0.16 f 0.02 mm (0.006 f 0.001 in)
EX: 0.25 k 0.02 mm (0.010 f 0.001 in)
Apply engine oil to Adjust by loosening the lock nut and turning the
thelocknut adjusting screw until there is a slight drag o n the
threads. feeler gauge.
Hold the adjusting screw and tighten the lock nut.
TORQUE: 10 Nnm (1.0 kgfm, 7 Ibf.ft)
After tightening the lock nut, recheck the valve
clearance.
Coat a n e w O-ring with engine oil and install it onto

the timing hole cap.
Install the cap and tighten it.
TORQUE: 6 N.m (0.6 kgf.m, 4.4 Ibf4t)
ENGINE OIL
NOTE:
For engine oil change procedure, see page 3-9
"Engine Oil Strainer Screen".
OIL LEVEL CHECK
Place the scooter o n its center stand o n a level sur-
face.
Start the engine and let it idle for 3 - 5 minutes.
Stop the engine and wait for 2 - 3 minutes.
Remove the oil filler cap/dipstick and wipe the oil
fro m the dipstick with a clean cloth.
Insert the filler cap/dipstick without screwing it in,
remove it and check the oil level.
The level should be between the upper and lower
level lines o n the dipstick.
3-8
MAINTENANCE
If the oil level is below or near the lower level line,
add the recommended oil to the upper level line. OIL VISCOSITIES
RECOMMENDED ENGINE OIL:

API service classification: SE, SF or SG
NOTE:
Other viscosities shown in the chart may be used
when the average temperature in your riding
area is within the indicated range.
Make sure the O-ring is in good condition and install
the oil filler cap/dipstick.
ENGINE OIL STRAINER SCREEN

OIL CHANGE INDICATOR
The oil change indicator illuminates when the dis-
tance covered by the scooter arrives a t the oil
change interval specified in the maintenance sched-
ule. After changing the engine oil, reset the indica-
tor as follows:
1. Turn the ignition switch to OFF.
2. Press the clock setting button and hold it down
while simultaneously turning the ignition switch
to ON.
3. Continue to hold down the button for more than
2 seconds until the indicator switches off.
If the oil is changed before the oil change indicator
illuminates, the indicator must anyway be reset.
In this case, follow the procedure described a t step
l a n d 2, but when you continue to hold down the
button, the indicator will illuminate for 2 seconds
and then switch off.
CLOCK SWITCH
OIL CHANGE AND STRAINER
CLEANING
Change the oil with Start the engine, warm it up and stop it.
the engine warm
Remove the filler cap/dipstick.
and the scooter on
its center stand to Remove the strainer cap, setting spring and oil
assure complete strainer, and drain the engine oil.
and rapid draining
3-9
Wash the strainer screen thoroughly in non-flam-
mable or high flash point solvent until all accumu-
lated dirt has been removed.
Blow dry it with compressed air to clean completely.
The screen mesh should be examined closely for
damage.
Coat a new O-ring with engine oil and install it onto - ,
the strainer cap.
After draining the oil completely, install the oil
strainer (with the round end facing down) and
O-RING
spring.
Install the strainer cap and tighten it.
TORQUE: 20 N-m (2.0 kgf-m, 15 I b f W 1
Pour the recommended oil into the crankcase to the
upper level line on the dipstick (page 3-9).
ENGINE OIL CAPACITY
0.9 liter (1.0 US qt, 0.8 Imp qt) at draining
1.0 liter (1.1 US qt, 0.9 Imp qt) at disassembly
Check the oil level (page 3-8).
Make sure there are no oil leaks.
RADIATOR COOLANT
Place the scooter on its center stand on a level sur-
face.
With the engine running at normal operating tem-
perature and check the coolant level of the reserve
tank.
The level should be between the "UPPER" and
"LOWER" level lines.
If the level is low, remove the reserve tank cap and
fill the tank to the upper level line with a 1:l mixture
of distilled water and antifreeze (coolant prepara-
tion: page 6-7).
Using coolant with silicate corrosion inhibitors may

cause premature wear of water pump seals or
blockage of radiator passages. Using tap water may
cause engine damage.
Check to see if there are any coolant leaks when the
coolant level decreases very rapidly.
If the reserve tank becomes completely empty, there
is a possibility of air getting into the cooling system.
Be sure to remove all air from the cooling system
(page 6-8).
MAINTENANCE
COOLING SYSTEM
Check for any coolant leakage from the water hoses
and hose joints.
Check the water hoses for cracks or deterioration
and replace if necessary.
Check that all hose clamps are tight.
Check the radiator air passage for clogs or damage.

Straighten bent fins with a small, flat blade screw- RADIATOR FIN
driver and remove insects, mud or other obstruc-
tions with compressed air or l o w pressure water.
Replace the radiator if the air fl ow is restricted over
more than 20% of the radiating surface.
3-1I
MAINTENANCE
Remove the following :
Check the air supply hoses between the air cleaner
housing and pulse secondary air injection (PAIR)
check valve for cracks, deterioration, damage or
loose connections.
n
HOSES
PAIR SOLENOID
VALVE
If the air supply hoses show any signs of heat dam-

age, inspect the PAIR check valve (page 5-51).
For secondary air supply system inspection, see
page 5-49.
VALVE PORT
BELT CASE AIR CLEANER

Remove the floor lower cover (page 2-8).
Remove the fo Ilowi n g :
- t w o bolts
- belt case air cleaner housing
- O-ring
Release the t w o tabs and remove the air cleaner

base.
3-12
MAINTENANCE
Remove the air cleaner element from the base.
DO not apply oil to Wash the element in non-flammable or high flash
the element. point solvent.
Squeeze out the solvent and let it dry thoroughly,
then install it onto the base core.
Replace the 0-rmg Install the air cleaner housing in the reverse order of
with a new one. removal.
TORQUE: 10 N.m (1.0 kgf-m, 7 Ibf-ft)
FINAL DRIVE OIL

OIL LEVEL CHECK
Place the scooter on its center stand on a level sur-
face.
Remove the oil check bolt.
Check that the oil level is up to the lower edge of the
filler hole.
Check for leaks if the oil level is low.
Pour the recommended oil through the oil filler hole
until it reaches the lower edge of the hole.
RECOMMENDED FINAL DRIVE OIL:
Hypoid gear oil, SAE #90 or
API service classification:SE, SF or SG
Install the check bolt and tighten it.
TORQUE: 13 N.m (1.3 kgf-m, 10 Ibfaft)
OIL CHANGE
Remove the oil check bolt and drain bolt, slowly
turn the rear wheel and drain the oil.
After the oil is completely drained, install the drain
bolt with a new sealing washer and tighten it
securely.
Fill the gear case with recommended oil up to the
correct level (page 3-13).
OIL CAPACITY:
190 cm3 (6.4 US oz, 6.9 Imp 0 2 ) at draining
220 cm3(7.4 US 02.7.7 Imp oz) at disassembly
3-13
MAINTENANCE
BRAKE FLUID
I NOTICE I
Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE:
Do not mix different types of fluid, as they are
not compatible with each other.
Do not allow foreign material to enter the system
when filling the reservoir.
When the fluid level of the front master cylinder
is low, check the brake pads for wear (page 3-15).
A low fluid level may be due to wear of the brake
pads. If the brake pads are worn, the caliper pis-
ton is pushed out, this accounts for a low reser-
voir level. If the brake pads are not worn and the
fluid level is low, check entire system for leaks
(page 3-15).
Turn the handlebar to the left so the reservoir is
level and check the brake reservoir fluid level
through the sight glass.
If the fluid level is near the LOWER level mark,

remove the reservoir cap, set plate and diaphragm,
and fill the reservoir with DOT 3 or DOT 4 brake fluid
from a sealed container to the casting ledge.
Install the diaphragm, set plate and reservoir cap
and tighten the cap screws.
TORQUE: 1.5 N.m (0.15 kgf-m, 1.1 IbfW
3-14
MAINTENANCE
BRAKE SHOEWPADS WEAR
FRONT BRAKE PADS
J
Check the brake pad for wear.
Replace the brake pads if either pad is w orn t o the
wear limit line.
See page 16-9 for brake pad replacement.
I WEAR LIMIT LINES
REAR BRAKE SHOES

Check the wear indicator position when the rear
brake lever is squeezed.
If the indicator aligns with the reference mark,
inspect the brake drum (page 16-18).
Replace the brake shoes if the drum I.D. is within the
service limit.
BRAKE SYSTEM
FRONT BRAKE (HYDRAULIC SYSTEM)
Firmly apply the front brake lever, and check that n o
air has entered the system.
If the lever feels soft or spongy when operated,
bleed the air fro m the system.
See page 16-8 for air bleeding procedures.
Inspect the brake hose and fittings for deterioration,
cracks, damage or signs of leakage.
Tighten any loose fittings.
Replace hose and fittings as required.
MAINTENANCE
REAR (COMBINED) BRAKE
REAR BRAKE LEVER FREE PLAY
Check the rear brake lever free play.
FREE PLAY 10 - 20 mm (2/5 - 3/4 in)
Adjust the free play by turning the adjusting nut.

Make sure the cutout of the adjusting nut is seated
on the brake arm pin.
Check that the rear wheel turns smoothly and the
brake is not dragging.
If the free play cannot be obtained, check the brake
shoes for wear (page 3-15).
After adjusting the free play, check the brake lock
operation (page 3-17).
BRAKE JOINT CABLE FREE PLAY

Check that there is no tension of the brake joint
cable.
Make sure the clearance between the cable end and
joint inner surface is 0 - 1 m m when pushing the
cable joint inward.
Adjust by loosening the lock nut and turning the
adjuster.
After adjustment, tighten the lock nut.
TORQUE: 6 N.m (0.6 kgf-m, 4.4 Ibf4t)
Operate the rear brake lever and recheck the free
Play.
3-16
MAINTENANCE
BRAKE LIGHT SWITCH
NOTE:
The brake light switches cannot be adjusted. If
the brake light switch actuation and brake
engagement are not synchronized, either replace
the switch unit or the malfunctioning parts of the
system.
Check that the brake light comes on just prior to the
brake actually being engaged.
See page 20-14 for brake light switch inspection.
BRAKE LOCK OPERATION

Pull the lock lever while squeezing the rear brake
lever to lock it.
Check that the rear wheel locks securely.
To release the brake lock, squeeze the rear brake
lever again.
If the brake does not lock properly or the lock lever
does not return smoothly, lubricate and adjust the
rear brake system.
HEADLIGHT AIM
Support the scooter upright on a level surface.
Adjust the headhght Adjust the headlight beam vertically by turning the
beam as specified adjusting screw.
by local laws and
regulabons.
SUSPENSION
FRONT
Check the action of the front suspension by operat-
ing the front brake and compressing it several
times.
Check the entire assembly for damage or loose fas-
teners.
Replace damaged components which cannot be
repaired.
Tighten a l l fasteners.
Refer to page 14-12 for front fork service.
MAINTENANCE
REAR
Check the action o f the shock absorber b y com-
pressing it several times.
Check the entire shock absorber assembly for dam-
age or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all fasteners.
Refer to page page 15-8 for rear shock absorber ser-
vice.
Raise the rear wheel off the ground by placing the

scooter o n its center stand.
Check for w o r n engine hanger bushings by grab-
bing the rear wheel and attempting to move the
wheel side t o side.
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-1 1).
Check that all cotter pins, safety clips, hose clamps
and cable stays are in place and properly secured.
W HEELS/TIRES
Check the tire pressure with a tire pressure gauge
when the tires are cold.
RECOMMENDED TIRE PRESSURE:

Driver only:
Front: 175 kPa (1.75 kgf/cm2, 25 psi)
Rear: 200 kPa (2.00 kgf/cmz, 29 psi)
Driver and passenger:
Front: 175 kPa (1.75 kgf/cm2, 25 psi)
Rear: 225 kPa (2.25 kgf/cm2, 33 psi)
Check the tires for cuts, embedded nails, or other
damage.
Check the front and rear wheels for trueness.
Measure the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the
following limits.
MINIMUM TREAD DEPTH: Front: 1.5 m m (0.06 in)
Rear: 2.0 m m (0.08 in)
MAINTENANCE
STEERINGHEADBEARINGS
Raise the front wheel off the ground and support
the scooter securely.
Check that the handlebar moves freely from side to
side, Make sure the control cables do not interfere
with the handlebar rotation.
If the handlebar moves unevenly, binds, or has ver-
tical movement, inspect the steering head bearings
(page 14-22).
4. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM .............4-2 TROUBLESHOOTlNG ..................................... 4-3
SERVICE INFORMATION .............................. 4-3 OIL PUMP........................................................ 4-4
4- 1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
CRANKSHAFT
7-
OIL STRAINER
OILPUMP
4-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is
unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.
0 The oil pump can be serviced with the engine installed in the frame.
When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as a n assembly.
Refer to page 3-8 for engine oil level check and oil change information.

Engine oil capacity After draining 0.9 liter (1.0 US qt, 0.8 Imp qt) -
After disassembly 1.0 liter (1.1 US qt, 0.9 Imp qt) -
Recommended engine oil Honda 4-stroke oil or equivalent motor -
oil
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 - 0.20 (0.006 - 0.008) 0.25 (0.010)
Side clearance 0.04 - 0.09 (0.002- 0.004) 0.12 (0.005)
TORQUE VALUES
Oil pump cover screw 2 N.m (0.2 kgf.m, 1.5 Ibf.ft)
TROUBLESHOOTING
Engine oil level too low, high oil consumption
Normal oil consumption
External oil leak
Worn piston rings or incorrect piston ring installation (page 9-6)
Worn cylinder (page 9-6)
Worn valve guide or stem seal (page 8-13)
Oil contamination
Oil not changed often enough
Faulty cylinder head gasket
0 Worn piston rings or incorrect piston ring installation (page 9-6)
Worn valve guide or stem seal (page 8-13)
Oil emulsification
Blown cylinder head gasket
Worn or damaged water pump mechanical seal
Water entry
4-3
LUBRlCATlON SYSTEM
OIL PUMP
REMOVAL
Remove the flywheel (page 12-10).
- bolt
- sprocket cover
- snapring
- driven sprocket and drive chain
- two bolts
- sprocket housing
- oil pump
DISASSEMBLY
Remove the following from the oil pump body:
- pumpshaft
- screw
- pumpcover
4-4
LUBRICATION SYSTEM
- dowel pin
- inner rotor
- outer rotor
Wash all parts with a high flash point or non-flam-
mable solvent.
INSPECTION
NOTE:
Measure at several points and use the largest
reading to compare the service limit.
If any portion of the oil pump is worn beyond the
specified service limits, replace the oil pump as
an assembly.
Temporarily install the outer, inner rotors and oil
pump shaft into the oil pump body.
Measure the tip clearance between the outer rotor
and the inner rotors.
SERVICE LIMIT: 0.20 mm (0.008 in)
Measure the body clearance between the oil pump

body and the outer rotor.
SERVICE LIMIT:0.25 mm (0.010 in)
4-5
LUBRICATION SYSTEM
Measure the side clearance using a straight edge
and feeler gauge.
ASSEMBLY
Apply engine oil to the inner and outer rotors and
install them into the oil pump body.
Install the dowel pin into the oil pump body.
Aligntheflatsof Apply engine oil to the pump shaft and insert it

the pump shaft and through the pump body and inner rotor.
rotor. Install the pump cover by aligning the hole with the
dowel pin.
Install the cover screw and tighten it.
TORQUE: 2 N-m (0.2 kgf,m, 1.5 Ibf-ft)
Check that the oil pump shaft turns smoothly.
INSTALLATION
Position the oil Install the oil pump onto the crankcase by aligning
pump so the screw the bolt holes.
side is facing down
Install the sprocket housing with the two mounting
bolts and tighten them.
4-6
LUBRICATION SYSTEM
Make sure the Apply engine oil to the drive chain and the drive
pump shaft is sprocket of the crankshaft.
installed in the rotor
Set the drive chain over the driven sprocket, and
properly.
install them onto the drive sprocket and pump shaft.
Install the snap ring into the pump shaft groove
with the chamfered side facing the sprocket.
Install the sprocket cover by aligning the tab with

the slit in the housing and tighten the bolt.
Install the flywheel (page 12-13).
4-7
5. FUEL SYSTEM (Programmed Fuel Injection)
SYSTEM COMPONENTS .............................. 5-2 AIR CLEANER HOUSING ............................. 5-36
THROTTLE BODY ......................................... 5-37
TROUBLESHOOTlNG .................................... 5-4 INJECTOR ..................................................... 5-41
SYSTEM LOCATION...................................... 5-5 FUEL PUMP RELAY ...................................... 5-43
SYSTEM DIAGRAM....................................... 5-6 ENGINE STOP REMY .................................. 5-44
PGM-FI SELF-DIAGNOSIS BANK ANGLE SENSOR ............................... 5-45

INFORMATION .............................................. 5-7
MIL CODE INDEX......................................... 5-10

ENGINE COOLANT TEMPERATURE (ECT)
SENSOR ........................................................ 5-48
DTC INDEX ................................................... 5-19 ENGINE CONTROL MODULE (ECM)........... 5-48
ENGINE IDLE SPEED.................................... 5-49
SECONDARY AIR SUPPLY SYSTEM * * * . . - - * * * 5-49
FUEL PUMP.................................................. 5-35 FUEL TANK ................................................... 5-52
5-1
FUEL SYSTEM (Programmed Fuel Injection)
SYSTEM COMPONENTS
12 N.m (1.2 kgf.m, 9 Ibf.ft)

@
-
5-2
SERVICE INFORMATION
GENERAL
Before disconnecting fuel feed hose, relieve pressure from the system (page 5-31).
Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bend, resulting
in loss of vehicle control.
Work i n a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire o r explosion.
Do not apply commercially available carburetor cleaner t o the inside of the throttle bore, which is coated wit h molybde-
num.
Do not snap the throttle d ru m fro m full open to full close after the throttle cable has been removed. It may cause incor-
rect idle operation.
Seal the intake manifold with tape or a clean cloth to keep dirt and debris from entering the intake port after the throttle
body has been removed.
Prevent dirt and debris fro m entering the throttle bore and fuel feed hose, clean them using compressed air.
The engine control module (ECM) is mounted o n the throttle body (the throttle body with the built-in ECM). Do not dis-
assemble the throttle body/ECM assembly. Replace the throttle body/ECM as an assembly when the it is faulty.
The throttle body/ECM assembly may be damaged if dropped. Also if a connector is disconnected when current is flow-
ing, the excessive voltage may damage the ECM. Always turn off the ignition switch before servicing.
The throttle body/ECM assembly is factory pre-set. Do not disassemble i n a way other than shown in this manual. Loos-
ening the white painted fasteners can cause throttle body/ECM malfunction.
The programmed fuel injection (PGM-FI) system is equipped with the Self-Diagnostic System described o n page 5-7. If
the malfunction indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures to remedy the problem.
When checking the PGM-FI, always follow the steps in the troubleshooting fl ow chart (page 5-1 1 or 5-22).
The PGM-FI system is provided with fail-safe function to secure a mi ni mum running capability even when there is any
trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured b y
making use of the numerical values of a situation preset i n advance i n the simulated program map. It must be remem-
bered, however, that when any abnormality is detected i n injector the fail safe function stops the engine from the stand-
point of protecting it.
A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
The vehicle speed sensor sends digital pulse signal to the ECM (PGM-FI unit) and computation. Refer t o procedures for
vehicle speed sensor inspection (MIL trouble shooting:page 5-10 or DTC trouble shooting:page 5-19).
Use a digital tester for PGM-FI system inspection.
Refer t o page page 20-10 for fuel gauge/fuel level sensor inspection.
Refer t o page page 20-1 1 for coolant temperature gauge/ECT sensor inspection.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identifica- SH125 GQMIA
tion number SH150 GQM2A
Idle speed 1,500 f 100 min-' (rpm)
Throttle grip free play 2 - 6 mm (0.08 - 0.24 in)
ECT sensor resistance (at 2OoC/68"F) 2.3 - 2.6 kC1
Fuel injector resistance (at 20C /68"F) 11.1 - 12.3 R
Fuel pressure 294 kPa (3.0 kgf/cm2, 43 psi)
Fuel p u m p f low (at 12 V) 22 cm3 (0.7 US 02.0.8 ImD 02) minimum/lO seconds
TORQUE VALUES
Fuel pump retaining plate nut 12 N.m (1.2 kgf.m, 9 I b f W
Throttle body insulator band bolt See page 5-40
Engine coolant temperature (ECT) sensor 23 N.m (2.3 kgf.m, 17 Ibf.ft)
02 sensor 44 N.m (4.5 kgf.m, 32 Ibf.ft)
Bank angle sensor screw 1.2 N.m (0.12 kgf.m, 0.9 Ibf.ft)
5-3
FUEL SYSTEM (Proarammed Fuel Iniection)
TOOLS
DLC short connector ECM test harness, 32P Fuel pressure gauge
070Pz-zY30100 070MZ-0010201 07406-0040003
Pressure gauge manifold Pressure gauge hose

07ZAJ-S5A0110 07ZAJ-S5A0120
TROUBLESHOOTING
Engine cranks but will not start
Intake air leak
Fuel contaminated/deteriorated
Pinched or clogged fuel feed hose
Faulty fuel pu mp
Clogged fuel injector
Sticking injector needle
Faulty fuel pump operating system
Faulty idle air control (IAC) valve in the engine control module (ECM)
Engine stall, hard to start, rough idling
Intake air leak
Fuel contaminated/deteriorated
Faulty IAC valve in the ECM
Afterburn when engine braking is used
Faulty secondary air supply system
- Faulty pulse secondary air injection (PAIR) solenoid valve
- Faulty PAIR check valve
- Clogged hose o f the secondary air supply system
Faulty ignition system (page 18-4)
Backfiring or misfiring during acceleration
Poor performance (driveability) and poor fuel economy
5-4
SYSTEM LOCATION
ENGINE STOP RELAY

I
i' li\J
The following components are incorporated in the throttle body/ECM assembly.

Manifold absolute pressure (MAP) sensor
Intake air temperature (IAT) sensor
Throttle position (TP) sensor
Idle air control (IAC) valve
5-5
SYSTEM DIAGRAM
Fuel Pump
-
-
Ir
IFLR
BliW
CKP SENSOR
ECM [lGP
-
19R 12 R
@C WIY
1- 1INJ PIBU
I
EI;p 102 HTCNL
GI0 I
OSG
IDLE AIR
CONTROI
(IAC)VAL\
29
E CT
SENSOR
TO Coolant
Temprature----- 7
GIBu
Gauge
@<
-
-
lFANC
IIGPLS
WIBU mMIL
w BVBr
L r-iFl
9 PGll
IEX-AI: P
PAIR SOLENOID
1
VALVE
Blrw
ECM connector r e a r view:
I t U U i t
5-6
PGM-FI SELF-DIAGNOSIS
INFORMATION
SELF-DIAGNOSTIC PROCEDURE
Place the scooter on its center stand.
Turn the ignition switch to ON.
The malfunction indicator lamp (MIL) comes on for
a few seconds, then goes off.
Start the engine and let it idle.
NOTE:
If the engine control module (ECM) detects any
problem at the moment, the MIL will be follow-
ing status depending on the engine speed:
- under 2,000 min-' (rpm), idle speed; the MIL
brinks as detection item
- over 2,000 min~'(rpm), during riding; the MIL
turns on (stays lit)
If the MIL does not blink, the ECM has no problem
data.
If the MIL blinks, the PGM-FI system has a problem.
Confirm the problem either way as follows:
Read how many times the MIL blink. Determine
the cause of the problem (page 5-10).
Read the diagnosis trouble code (DTC) with the
Honda Diagnosis System (HDS) Pocket Tester.
Determine the cause of the problem (page 5-19).
To read the ECM memory of the MIL code or DTC,
perform the following:
MIL CODE
Turn the ignition switch to OFF.
Remove the dummy connector from the data link
connector (DLC).
Short the DLC terminals using the special tool.
TOOL:
DLC short connector 07OPZ-ZY30100
Connection: Brown - Green
Turn the ignition switch to ON and check the MIL.

If the ECM has no problem data, the MIL will come
on and stay on.
If the ECM has problem data in its memory, the MIL
will start blinking.
Read and record how many times the MIL blinks,
and determine the cause of the problem (page 5-10).
5-7
DTC (with the HDS pocket tester)
Remove the dummy connector from the data link
connector ( DLC 1.
Connect the HDS Pocket Tester to the DLC.
Read the DTC and determine the cause of the prob-
lem (page 5-19). Also, check the freeze data.
NOTE:
Refer to the user's manual of the HDS Pocket
Tester for tester operation.
The freeze data indicates the engine condition
where the first malfunction was detected.
SELF-DIAGNOSTIC MEMORY RESET

PROCEDURE
Procedure with DLC short connector
1. Remove the maintenance lid (page 2-4).
2. Short the data link connector (DLC) terminals
using a special tool with the ignition switch
turned to OFF.
TOOL:
DLC short connector 070Pz-zY30100
Connection: Brown - Green

3. Turn the ignition switch to ON.
4. Remove the special tool from the DLC.
5. The MIL lights about 5 seconds.
While the MIL lights, connect the DLC terminals
again with the special tool.
The self-diagnostic memory is erased, if the MIL
goes off and starts blinking.
I
NOTE:
The DLC must be jumped while the MIL lights. If
not, the MIL not start blinking.
Note that the self-diagnostic memory cannot be
erased if you turn off the ignition switch before
the MIL starts blinking.
If the MIL blinks 20 times, the diagnostic memory
has not been erased.
Procedure with HDS pocket tester

Reset the diagnostic memory in the ECM using the
HDS Pocket Tester.
NOTE:
Refer to the user's manual of the HDS Pocket
Tester for tester operation.
5-8
FUEL SYSTEM (Pronrammed Fuel Injection)
TEST HARNESS CONNECTION
Disconnect the ECM 32P connector from the ECM by
releasing the lock lever.
Connect the ECM test harness between the ECM

and ECM connector.
TOOL:
ECM test harness, 32P 070MZ-0010201
TEST HARNESS TERMINAL LAYOUT

The ECM test harness connector terminals are num-
bered o n the connector and the same layout as for TEST HARNESS CONNECTOR:
ECM as shown.
t T 7 - $ - 4 r F r r F @5 - lm
I _
I? 18 a"!@21 22 23 24 25-2K 27 28 29 30 31 31 1
ECM:
" 1" 6"
5-9
MIL CODE INDEX
The PGM-FI malfunction indicator lamp (MIL) denotes the failure codes (the number of blinks from 0 to 29). The MIL has
two type of blinks, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.5 second.
When two long blinks occur, and three short blinks, that failure code is 23 (two long blinks = 20 blinks, three short blinks
= 3 blinks). Then, go to the flow chart and see failure code 23.
When the engine control module (ECM) stores some failure codes, the MIL shows the failure codes in the order from the
lowest number to highest number. For example, when the MIL blinks once, then seven times, two failures have
occurred. Follow the flow chart for failure codes 1 and 7.
1 MIL Function Failure Causes Symptoms

Refer
to
Page
I
No blinks ECM power1 Open circuit in the power input Engine does not start 5-48
ground circuits wire of the ECM
ma Ifunctio n Open circuit in the engine stop
relay related wires
Faulty engine stop relay
Open circuit in the bank angle
sensor related wires
Faulty bank angle sensor
Blown sub-fuse 10 A (IGN, At,
- START, FUEL PUMP)
MIL circuit Open or short circuit in the MIL Engine operates nor- -
malfunction wire mally
Data link circuit Short circuit in the data link con- Engine operates nor- -
malfunction nector terminals mally
Short circuit in the data link con-
nector wire
Faulty ECM
MAP sensor Faulty MAP sensor (in the ECM) Engine operates nor- 5-11
circuit mally
malfunction
ECT sensor Loose or poorly connected ECT Hard start at a low tem- 5-11
circuit sensor connector perature (ECM controls
malfunction Open or short circuit in the ECT using preset value; cool-
sensor wire ant temperature: 90 C/
r
Faulty ECT sensor 194 O F )
8 blinks TP sensor circuit Faulty TP sensor (in the ECM) Poor engine response 5-13
malfunction when operating the
throttle quickly (ECM
controls using preset
value; throttle opening:
0)
IAT sensor circuit Faulty IAT sensor (in the ECM) Engine operates nor- 5-13
malfunction mally (ECM controls
using preset value;
intake air temperature:
25 CI77 OF)
Fuel injector Loose or poorly connected injec- Engine does not start 5-13
circuit tor connector
malfunction Open or short circuit in the injec-
tor wire
r- 21 blinks sensor circuit

0 2
malfunction
~
Faulty injector
Loose or poorly connected 0 2
sensor connector
Open or short circuit in the 0 2
sensor wire
Engine operates nor-
mally
5-15
r-
Faulty 0 2 sensor
23 Blinks sensor heater
0 2 Loose or poorly connected 0 2 Engine operates nor- 5-17
malfunction sensor connector mally
Open or short circuit in the 0 2
sensor heater wire
Faulty 0 2 sensor
IAC valve circuit Faulty IAC valve (in the ECM) Engine operates nor- 5-18
malfunction mally
MIL TROUBLESHOOTING
MIL 1 BLINK (MAP SENSOR)
1. Recheck MIL
Erase the self-diagnostic memory to reset the
ECM (page 5-81,
Start the engine and let it idle. Check that the
7 MIL
MIL blinks.
Is the MIL blinking?
NO - Temporarily failure; the system is nor-
mal.
YES - Replace the throttle body/ECM assem-
bly with a new one, and inspect again.
MIL 7 BLINKS (ECT SENSOR)

NOTE:
Before starting the troubleshooting, check the
ECT sensor 3P connector for loose contacts or
corroded terminals and recheck the MIL.
1. ECT Sensor Output Voltage inspection
Connect the test harness between the ECM con-
nectors (page 5-9).
Measure the voltage between the test harness
terminals with the ignition switch turned to ON.
-
Connection: #I3 (+) #31 (-)
Standard: 2.7 - 3.1 V (2OoC/68"F)
Is the voltage within 2.7 - 3.1 V?
YES - Loose or poorly connected ECM con-
nector.
Temporarily failure; the system is
r-7
normal.
NO - GO TO STEP 2.
I
2. ECT Sensor Input Voltage Inspection
Disconnect the ECT sensor 3P (gray) connector.
Measure the voltage between the terminals of
the wire harness side 3P connector with the igni-
tion switch turned to ON.
-
Connection: Pink/white (+) Greedorange I-)
Standard: 4.75 - 5.25 V
Is the voltage within 4.75 - 5.25 V?
NO - GO TO STEP 3.
YES - GO TO STEP 4.
3. ECT Sensor Open Circuit Inspection
Check for continuity between each test harness
terminal and wire harness side 3P connector ter-
minal.
Connection: # I 3 - Pink/white
#31- Greenlorange
II
Is there continuity?
NO - Open circuit in Pinuwhite or Green/
orange wire.
YES - GO TO STEP 5.
ECT SENSOR 3P CONNECTOR

4. ECT Sensor Short Circuit Inspection
Disconnect the test harness.
Check for continuity between the wire harness
side 3P connector terminal and ground.
Connection: Pinklwhite - Ground
YES - Short circuit in the Pinuwhite wire.
NO - GO TO STEP 5.
Measure the resistance between the ECT sensor

terminals. I Green/
I ECTSENSOR
MIL 8 BLINKS (TP SENSOR)
1. Recheck MIL
ECM (page 5-8).
MIL blinks.
mal.
MIL 9 BLINKS (IAT SENSOR)

1. Recheck MIL
ECM (page 5-8).
MIL blinks.
mal.
MIL 12 BLINKS (FUEL INJECTOR)
.
NOTE:
injector 2P connector for loose contacts or cor-
roded terminals, and recheck the MIL.
1. Injector Resistance Inspection
Disconnect the injector 2P connector.
Measure the resistance between the injector ter-
minals.
Standard: 11.1 - 12.3 2
! (20C/68"F)
Is the resistance within 11.1 - 12.3 R /20"c/
68 OF)?
NO - Faulty injector.
YES - GO TO STEP 2.
5-13
2. Injector Power Input Line Inspection
Measure the voltage between the wire harness
side 2P connector terminal and ground with the
ignition switch turned to ON.
-
Connection: Black/white (+) Ground (-1
Does the battery voltage exit?
NO - Open circuit in BlacWwhite wire.
YES - GO TO STEP 3.
3. Injector Signal Line Open Circuit Inspection

nectors (page 5-9).
Check for continuity between the test harness
minal.
Connection: #20 - Pinklblue
Is there continuity? h
NO - Open circuit in PinMblue wire.
YES - GO TO STEP 4.
INJECTOR 2P
CONNECTOR
I PinMblue
4. Injector Signal Line Short Circuit Inspection

Connection: Pink/blue - Ground
YES - Short circuit in PinWBlue wire.
NO - Replace the throttle body/ECM assem-
MIL 21 BLINKS ( 0 2 SENSOR)
NOTE:
Before starting the troubleshooting, check the 0 2
sensor 4P connector for loose contacts or cor-
1. 0 2 Sensor Output Voltage Inspection
nectors (page 5-9).
Start the engine and warm it u p until the cooling
fan comes on.
Check the voltage between the test harness ter-
minals.
Connection: #29 (+) - #31 (4
Standard: 0.1 - 0.3 V
Is the voltage within the standard value?
YES - Check the fuel supply system (page
5-33).
If the system is normal, GO TO STEP
4.
NO - GO TO STEP 2.
2. 0 2 Sensor Open Circuit Inspection
Turn the ignition switch t o OFF.
Disconnect the 0 2 sensor 4P (black) connector
(page 5-47).
Check for continuity between each test harness orange
minal. Black/
orange
Connection: #29 - Black/orange
OR
#31- Greedorange
NO - Open circuit in the BlacWorange or
Greedorange wire. 4P
YES - GO TO STEP 3. CONNECTOR
3. 0 2 Sensor Short Circuit Inspection

Connection: Black/orange - Ground
YES - Short circuit in the BlacWorange wire.
NO - GO TO STEP 4.
4. 0
2 Sensor Output Voltage Inspection
Replace the 02 sensor with a known-good one
(page 5-47).
Connect the test harness.
ECM (page 5-8).
Start the engine and warm it up until the cooling
fan comes on.
Check the voltage between the test harness ter-
minals.
Connection:#29 (+) - #31 (-1
YES - Faulty original 0 2 sensor.
5-16
MIL 23 BLINKS ( 0 2 SENSOR HEATER)
NOTE:
Before starting the troubleshooting, check the 02
1. 0 2 Sensor Heater Resistance Inspection
(page 5-47).
Measure the resistance between the sensor side
4P connector terminals.
Connection: White - White
Is the resistance below 13 L2 [2OoC/68"F)?
NO - Faulty 0 2 sensor.
YES - GO TO STEP 2.
2. 0
2 Sensor Heater Power Input Line inspection
Connection: Black/white (+) - Ground (-1
NO - Open circuit in the BlacWwhite wire.
YES - GO TO STEP 3.
3. 0
2 Sensor Heater Open circuit inspection
nectors (page 5-9). .___-
5 R i 8 9 ' ( i l l 1 2 1 3 4l5W
Check for continuity between the test harness I I
terminal and wire harness side 4P connector ter- 0600000000060000
J-_I1-C
minal. 0 b 0 Q 0 0 0: 0'0 0 0 0 0
Connection:#23 - White
NO - Open circuit in White wire.
YES - GO TO STEP 4.
0 2 SENSOR 4P CONNECTOR
(Harness side)
5-17
4. 0 2 Sensor Heater Short Circuit Inspection
Check for continuity between the 4P connector
terminal and ground.
Connection: White - Ground
YES - Short circuit i n the White wire.
NO - Replace the throttle body/ECM assern-
bly with a n e w one, and inspect again.
MIL 29 BLINKS (IAC VALVE)

1. Recheck MIL
ECM (page 5-8).
MIL blinks.
mal.
bly with a n e w one, and inspect again.
5-18
DTC INDEX
The Diagnostic Trouble Codes (DTC) are based upon Malfunction Indicator Lamp (MIL) codes and are displayed as
hyphenated numbers. The digits in front of the hyphen are equal to an MIL code and indicate the Function Failure. The
digit behind the hyphen details the symptom. For example, in the case of the TP sensor, the ECM stores two levels of
information, a function failure and a detail of the symptom:
(08 - 1) = TP sensor voltage - lowerthan the specified value
or
(08 - 2) = TP sensor voltage - higher than the specified value.
The MAP, ECT, TP and IAT sensor can be mean diagnosis according to the sensor output voltage value.
If the failure occurs, the ECM determines the failure function, the output voltage is high or low compared to the stan-
dard voltage, then read out the DTC to the HDS pocket tester.
For example:
- If the input voltage line (A) on the MAP sensor is opened, the ECM detects the output voltage is about 5 V, then the
DTC 1-2 (MAP sensor circuit high voltage) will be read out.
- If the input voltage line (B)on the TP sensor is opened, the ECM detects the output voltage is 0 V, then the DTC 8-1 (TP
sensor circuit low voltage) will be read out.
-
5v
MAP SENSOR -t 5 v TP SENSOR
5v
1
I,
OUTPUT VOLTAGE
- OUTPUT VOLTAGE
ECT SENSOR
n e OUTPUT VOLTAGE
IAT SENSOR
b
t5v
OUTPUT VOLTAGE
Refer
DTC Function Failure Causes Symptoms to
Page
ECM power/ Open circuit at the power input Engine does not start 5-48
ground circuits wire of the ECM MIL does not blink
malfunction Open circuit in engine stop relay
related wires
Faulty engine stop relay
Open circuit in bank angle sensor
related circuit
Faulty bank angle sensor
Blown sub-fuse 10 A (IGN, Al,
START, FUEL PUMP)
MIL circuit Faulty ECM Engine operates nor- -
malfunction Open or short circuit in the MIL ma Ily
wire MIL does not blink
Data link circuit Short circuit in the data link con- Engine operates nor- -
malfunction nector terminals mally
Short circuit in the data link con- MIL stays lit
nector wire
~.
Faulty ECM
_circuit
~____ l o_w_voltage
_- mally
circuit high mally
~
voltage
7- 1 ECT sensor circuit Short circuit i n the ECT sensor Hard start at a l o w tem- 5-23
l o w voltage wire perature (ECM controls
Faulty ECT sensor using preset value; cool-
ant temperature: 90 "C/
______
194 OF)
7-2 ECT sensor circuit Loose or poorly connected ECT Hard start at a l o w tem- 5-24
high voltage sensor connector perature (ECM controls
Open circuit i n the ECT sensor wire using preset value; cool-
Faulty ECT sensor ant temperature: 90 "C/
194 OF)
8- 1 TP sensor circuit Faulty TP sensor (in the ECM) Poor engine response 5-25
l o w voltage when operating the
~
0")
8-2 TP sensor circuit Faulty TP sensor (in the ECM) Poor engine response 5-25
high voltage when operating the
0)
9-1 IAT sensor circuit Faulty IAT sensor (in the ECM) Engine operates nor- 5-25
l o w voltage mally (ECM controls
using preset value;
25 "GI77 OF)
9-2 IAT sensor circuit Faulty IAT sensor (in the ECM) Engine operates nor- 5-25
high voltage mally (ECM controls
using preset value;
25 "CI77 OF)
12-1 Fuel injector Loose or poorly connected injector Engine does not start 5-26
circuit connector
malfunction Open or short circuit i n the injector
wire
Faulty injector
21-1 sensor circuit
0 2 Loose or poorly connected 0 2 sen- Engine operates nor- 5-28
malfunction sor connector mally
Open or short circuit in the 02 sen-
sor wire
Faulty 0 2 sensor
5-20
Refer
DTC Function Failure Causes Symptoms to
Page
____
23-1 sensor heater
0 2 Loose or poorly connected 0 2 sen- Engine operates nor- 5-29
malfunction sor connector mally
Open or short circuit in the 0 2 sen-
sor heater wire
Faulty 0 2 sensor
________ ~ -___
29-1 IAC valve circuit Faulty IAC valve (in the ECM) Engine operates nor- 5-30
malfunction mallv
33-2 ECM E2-PROM Faulty ECM Engine operates nor- 5-30
malfunction mally
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW
VOLTAGE)
1. Recheck DTC
ECM (page 5-8).
Stop the engine.
Turn the ignition switch to ON and check the
MAP sensor with the HDS.
Is the DTC I - I indicated?
mal.
YES - Replace the throttle body/ECM assern-
DTC 1-2 (MAP SENSOR HIGH

VOLTAGE)
1. MAP Sensor (Inside of ECM) Open Circuit
Inspection
ECM (page 5-8).
Stop the engine.
Turn the ignition switch t o ON and check the
MAP sensor w i th the HDS.
Is the DTC 1-2indicated?
mal.
5-22
DTC 7-1 (ECT SENSOR LOW
VOLTAGE)
1. ECT Sensor System Inspection
Check the ECT sensor with the HDS.
Is about 0 Vindicated?
mal.
YES - GO TO STEP 2.
2. ECT Sensor Inspection
Is about 0 V indicated7
NO - GO TO STEP 3.
YES - GO TO STEP 4.
Remove the ECT sensor (page 5-48).

Measure the resistance between the ECT sensor
terminals. Green/
-
Connection: Pinklwhite Greenlorange orange Pinuwhite
Standard: 2.3 - 2.6 kQ (2O0Cl68"F)
Is the resistance within 2.3 - 2.6 kO?
NO - Faulty ECT sensor.
ECT SENSOR I
4. ECT Sensor Short Circuit Inspection
Disconnect the ECM 32P connector by releasing
the lock lever.
side ECT sensor connector terminal and ground.
Connection: Pinklwhite - Ground
YES - Short circuit in P i n W h i t e wire.
5-23
FUEL SYSTEM IProarammed Fuel Iniection)
DTC 7-2 (ECT SENSOR HIGH
VOLTAGE)
NOTE:
ECT sensor 3P connector for loose contacts or
corroded terminals, and recheck the DTC.
1. ECT Sensor System Inspection
NO - Loose or poorly connected ECT sen-
sor 3P connector.
normal.
YES - GO TO STEP 2.
2. ECT Sensor Inspection
Connect the wire harness side connector termi-
nals with a jumper wire.
Connection: Pinklwhite - Greenlorange
YES - Faulty ECT sensor.
NO - GO TO STEP 3.
3. ECT Sensor Open Circuit Inspection

Disconnect the jumper wire.
Disconnect the ECM 32P connector by releasing Pinuwhite ECM 32P CONNECTOR
the lock lever.
Check each wire for continuity between the wire
harness side ECM connector and ECT sensor
connector.
Connection: Pink/white - Pink/white
Greenlorange - Greenlorange
ECTSENSOR 3P
NO - Open circuit in PinWwhite or Green/ CONNECTOR
Orange wire.
YES - Replace the throttle body/ECM assem- I
DTC 8-1 (TP SENSOR LOW VOLTAGE)
1. Recheck DTC
ECM (page 5-8).
Stop the engine.
Turn the ignition switch to ON and check the TP
sensor with the HDS.
Is the DTC 8-1 indicated?
mal.
DTC 8-2 (TP SENSOR HIGH VOLTAGE)

1. Recheck DTC
ECM (page 5-8).
Stop the engine.
Turn the ignition switch to ON and check the TP
Is the DlC 8-2 indicated?
mal.
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
1. Recheck DTC
ECM (page 5-8).
Stop the engine.
Turn the ignition switch to ON and check the IAT
Is the DTC 9-1 indicated7
mal.
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)

1. Recheck DTC
ECM (page 5-8).
Stop the engine.
Turn the ignition switch to ON and check the IAT
Is the D l C 9-2 indicated?
mal.
5-25
DTC 12-1 (FUEL INJECTOR)
NOTE:
injector 2P connector for loose contacts or cor-
roded terminals, and recheck the DTC.
1. Injector System Inspection
ECM (page 5-8).
Start the engine and check the injector with the
HDS.
YES - Loose or poorly connected injector
2P connector.
normal.
NO - GO TO STEP 2.
2. Injector Resistance Inspection
Disconnect the injector 2P connector.
Measure the resistance between the injector ter-
minals.
Standard: 11.1 - 12.3 R (2OoC/68"F)
Is the resistance within 11.1 - 12.3 0 (20C/
68 O F ) ?
NO - Faulty injector.
YES - GO TO STEP 3.
3. Injector Power Input Line Inspection

Connection: Black/white (+) - Ground (-)
NO - Open circuit in BlacWwhite wire.
YES - GO TO STEP 4.
5-26
4. Injector Signal Line Open Circuit Inspection
Disconnect the ECM 32P connector by releasing ECM 32P CONNECTOR
the lock lever.
Check for continuity between the PinWblue wire
terminals of the injector 2P connector and ECM
32P connector.
NO - Open circuit in Pink/blue wire.
YES - GO TO STEP 5.
INJECTOR 2P CONNECTOR
5-27
DTC 21-1 ( 0 2 SENSOR)
NOTE:
1. 0 2 Sensor System Inspection
fan comes on.
Check the 0 2 sensor with the HDS.
YES - Check the fuel supply system (page
5-33).
If the system is normal, GO TO STEP
4.
NO - GO TO STEP 2.
2. 0 2 Sensor Open Circuit Inspection
Disconnect the ECM 32P connector by releasing Green/ ECM 32P CONNECTOR
the lock lever, and the 0 2 sensor 4P (black) con-
nector (page 5-47).
Check each wire for continuity between the ECM
connector and 0 2 sensor connector.
Connection: Black/orange - Black/orange
Greenlorange - Greedorange
NO - Open circuit in the Blacklorange or
Greenlorange wire. 0 2 SENSOR 4P
CON NECTO R
YES - GO TO STEP 3.
3. 0 2 Sensor Short Circuit Inspection

Connection: Blacklorange - Ground
YES - Short circuit in the Blacklorange wire.
NO - GO TO STEP 4.
5-28
4. Recheck DTC
Replace the 0 2 sensor with a known-good one
(page 5-47).
Connect the ECM 32P connector.
ECM (page 5-8).
fan comes on.
Check the 0 2 sensor with the HDS.
NO - Faulty original 0 2 sensor.
DTC 23-1 ( 0 2 SENSOR HEATER)

NOTE:
1. 0
2 Sensor Heater Resistance Inspection
(page 5-47).
Measure the resistance between the sensor side
4P connector terminals.
Connection: White - White
Is the resistance below 73 f2 (2OoC/68*F)7
NO - Faulty 0 2 sensor.
YES - GO TO STEP 2.
2. 0 2 Sensor Heater Power Input Line Inspection

Connection: Blacklwhite (+) - Ground (-1
NO - Open circuit in the BlacWwhite wire.
YES - GO TO STEP 3.
5-29
3. 0 2 Sensor Heater Open circuit Inspection
Disconnect the ECM 32P connector by releasing
the lock lever. ECM 32P CONNECTOR
Check for continuity between the White termi-
nals of the 0 2 sensor 4P connector and ECM 32P
connector.
NO - Open circuit in White wire.
YES - GO TO STEP 4. White
0 2 SENSOR 4P CONNECTOR
(Harness side)
2 Sensor Heater Short Circuit Inspection

4. 0
Check for continuity between the 4P connector
terminal and ground.
Connection: White - Ground
YES - Short circuit in the White wire.
DTC 29-1 (IAC VALVE)

1. Recheck DTC
ECM (page 5-81.
Start the engine and check the IAC valve with the
HDS.
mal.
DTC 33-2 ( E2-PROM)

1. Recheck DTC
ECM (page 5-8).
Turn the ignition switch to ON and recheck the
ECM E2-PROMwith the HDS.
mal.
FUEL LINE INSPECTION
QUICK-CONNECT FlTTlN G
PRESSURE RELIEVING/REMOVAL
NOTE:
To disconnect the fuel feed hose, relieve pres-
sure from the system as follows.
FUEL FILL CAP
1. Disconnect the fuel pump 5P (white) connector
with the ignition switch turned to OFF.
2. Start the engine and let it idle until the engine is
stall.
3. Remove the fuel fill cap t o relieve fuel pressure
from the fuel tank.
Install the fuel fill cap.
Cleanaroundthe 4. Release the feed hose from the clip on the fuel
quick-connect fit-
ting before discon-
necting the hose,
pump retaining plate.
Take the rubber seal off of the hose joint. I RUBBER
SEAL HOSE JOINT
and be sure that no

dirt IS allowed to
enter into the fuel
system
Prevent the remain- 5. Place a shop towel over the quick-connect fitting.
ing fuelin the hose Hold the connector with one hand and press CONNECTOR
from flowing out down the retainer tabs with the other hand, then
with a shop towel. pull the connector off.
NOTE:
Be careful not t o damage the joint retainer or
other parts. Do not use tools.
If the connector does not move, keep the retainer
tabs pressed down, and alternately pull and push
the connector until it comes off easily.
R ETA1N E R
TABS
5-31
6. To prevent damage and keep foreign material
out, cover the hose and joint ends with plastic
bags.
INSTALLATION
NOTE:
Always replace the retainer with a new one when
the feed hose is disconnected.
Check the hose joint contact area for dirt, and clean
if necessary. CONNECTOR
Make sure the rubber seal is i n good condition and
replace it if necessary.
Install the rubber seal onto the hose joint properly
as shown.
Insert a new retainer into the connector by aligning
the retainer pawls with the connector grooves.
Do not twist the Press the connector onto the hose joint until both
feedhose retainer pawls lock w i th a clicking sound.
NOTE:
If it is hard t o connect, put a small amount of
engine oil o n the hose joint end.
Make sure the connection is secure and the pawls
are firmly locked into place.
Secure the fuel feed hose w i th the clip.

5P CONNECTOR
Connect the fuel pump 4P connector.
Do not start the Turn the ignition switch to ON.
engine. The fuel p u m p will run for about 2 seconds t o rise
the fuel pressure.
Repeat above procedure about 2 - 3 times.
Check that there is no leakage.
Install the luggage box (page 2-5).
5-32
FUEL PRESSURE INSPECTION
Remove the hose clamp bolt.
Disconnect the fuel feed hose from the fuel pump
after relieving the fuel pressure (page 5-31).
Connect the pressure gauge, gauge manifold and

gauge hose between the fuel pump and feed hose. PRESSURE GAUGE
TOOLS:
Fuel pressure gauge 07406-0040003
Pressure gauge manifold 07ZAJ-S5A0110
Pressuregauge hose 07ZAJ-S5A0120
Start the engine and let it idle, and read the fuel
pressure.
STANDARD: 294 kPa (3.0 kgf/cm2, 43 psi)
If the fuel pressure is higher than the specified pres-
sure, replace the fuel pump.
If the fuel pressure is lower than the specified pres-
sure, inspect the following:
- fuel line leaking
- fuel p u mp (page 5-33)
Remove the pressure gauge, manifold and hose.
Install the feed hose clamp and tighten the bolt.
Connect the fuel feed hose (page 5-32).
FUEL FLOW INSPECTION

after relieving the fuel pressure (page 5-311.
BlacWwhite
Remove the fuel pump relay.
Short the Black/white and Brown wire terminals of
the relay connector with a jumper wire.
Br own
f-
)R Front +
5-33
FUEL SYSTEM (Proqrammed Fuel Injection)
Connect an appropriate fuel hose t o the hose joint
of the fuel pump.
Place the hose end into the an approved gasoline
container.
Turn the ignition switch to ON, let the fuel flow into
the container for 10 seconds and turn the ignition
switch t o OFF.
Measure the amount of fuel flow.
FUEL PUMP FLOW CAPACITY
22 cm3 (0.7 US oz,0.8 Imp o z ) minimum/
10 seconds
If the fuel flow is less than the specified capacity,
replace the fuel pump (page 5-35).
If the fuel flow is normal, inspect the fuel pump sys-
tem (page 5-35).
install the removed parts in the reverse order of
removal.
5-34
FUEL PUMP
SYSTEM INSPECTION
Turn the ignition switch to ON and confirm that the
fuel pump operates for a few seconds.
If the fuel pump does not operate, inspect as fol-
lows:
Disconnect the fuel pump 5P (white) connector.
Measure the voltage between the Brown wire termi-
nal (+) and Green wire terminal (-1 of the 5P connec-
tor.
There should be battery voltage for few seconds
with the ignition switch turned to ON.
If there is voltage, check the fuel flow (page 5-33).
If there is no voltage, check the related wires as
follows.
Check for continuity between the Green wire termi-
nal of the 5P connector and ground.
There should be continuity.
Remove the frame body cover (page 2-51.
Check for continuity between the Brown wire termi-
nals of the 5P connector and relay connector.
If the wires are normal, check the fuel pump relay
and its circuits (page 5-43).
REMOVAL
Disconnect the fuel feed hose from the fuel pump Y
after relieving the fuel pressure (page 5-31).
- seven nuts
- retaining plate
- fuel pump assembly
- rubberseal
INSTALLATION
Check the mating surfaces (seal contact areas) for
dirt, and clean if necessary.
Apply 1 g o f engine oil t o the inner surface of a new
rubber seal and install it o n to the fuel pump.
Install the fuel p u mp assembly into the fuel tank,
being careful not to damage the float arm.
Install the retaining plate in the direction as shown

(triangular marks a Iigned 1.
Place the fuel p u m p so the locating pins are aligned
w i th the grooves in the plate.
Make sure the retaining plate is touched o n the fuel
p u m p and tank evenly.
Install the nuts and tighten them in the sequence i n
several steps as shown.
TORQUE: 12 N m (1.2 kgfm, 9 1bf.h)
PLATE --
AIR CLEANER HOUSING

REMOVALA NSTALLATION
Remove the crankcase breather tube from the
clamp.
Remove the each washer-screws.

Loosen the connecting tube band screw.
5-36
FUEL SYSTEM (Programmed Fuel Iniection)
Remove the two mounting bolts and washers, and
release the air cleaner housing from the air cham-
ber.
Release the starter motor cable from the cable guide

on the housing
Sea/ the opening in Disconnect the crankcase breather hose to remove
the air chamber the air cleaner housing.
with a tape or a
clean cloth to keep
dirt and debris from
entering the
engine.

NOTE:
Before tightening the fasteners, be sure to align UP
the tab on the housing with the slit in the mud
guard.
6mm f
Position the tube band in the direction as shown
and tighten the band screw until the band end
clearance is 6 mm.
BAND
THROTTLE BODY
REMOVAL
- air cleaner housing (page 5-36)
Release the fuel feed hose from the clamp on the air
chamber.
Disconnect the air supply hose.
5-37
Remove the mounting bolt.
Loosen the connecting tube band screw (chamber
side) and remove the air chamber.
Loosen the throttle cable lock nut fully.
Becarefidnot to Remove the throttle cable from the cable holder by

damage the cable aligning the flat surface and disconnect it from the
threads. throttle d rum.
Do not snap the throttle drum from full open to

full close after the throttle cable has been
removed. It may damage the throttle bore and
cause incorrect idle operation.
Disconnect the engine control module (ECM) 32P
connector by releasing the lock lever.
Loosen the insulator band bolts.

Sea/ the intake Remove the throttle body/ECM assembly from the
manifold with a intake manifold.
tape or a clean cloth
NOTE:
to keep d r t and
debris from enter. Handle the throttle body/ECM assembly with
,ng the care. The assembly may be damaged if dropped.
Loosen the band screw and remove the connecting

tube. TUBE
Do not spread the Remove the following from the insulator:
msulator band more - insulator band bolts
than necessary - plate nuts
- collars
- insulator band
Remove the throttle body insulator.
The throttle body/ECM assembly is factory pre-

set. Do not disassemble it. Loosening the white
painted fasteners can cause throttle body/ECM
malfunction.
INSTALLATION
NOTE:
Route the hoses and cable properly (page 1-17).
The insulator is Install the insulator onto the throttle body by align-
installed with the ing the groove with the lug.
"THROT BODY"
side facing the
throttle body.
Install the insulator band over the insulator by align-

ing the hole with the locating pin of the insulator. I TUBE
Install the band bolts and collars (between the band
ends). Install the plate nuts and tighten the bolts
loosely.
Install the connecting tube and tighten the band
screw in the direction as shown.
5-39
Install the throttle body/ECM assembly onto the
intake manifold by aligning the insulator groove
with the lug.
Tighten the band bolts alternately until the band
ends are contacted to the collars.
Connect the ECM 32P connector.
Becarefulnotto Connect throttle cable to the throttle drum and

damage the cable install it into the cable holder by aligning the flat
threads. surface.
Temporarily tighten the cable lock nut.
If the chamber inner duct was removed, install it by

aligning the lug with the groove in the chamber.
Install the air chamber into the connecting tube.

Install the mounting bolt.
Be sure that the chamber is fully seated in the con-
necting tube and tighten the band screw in the
direction as shown.
Tighten the mounting bolt.
5-40
Connect the air supply hose to the chamber.
Secure the fuel feed hose with the clamp.
Adjust the throttle grip free play (page 3-41.
INJECTOR
Clean around the injector with compressed air

before removing it and be sure that no dirt is
allowed.
Handle the injector with care to prevent any dirt
from entering in it. Clogged injector may cause
engine malfunction.
REMOVAL
after relieving the fuel pressure (page 5-311.
Disconnect the following:
- ECM 32P connector (by releasing the lock lever)
- injector 2P connector
Remove the hose clamp bolt.

Remove the two bolts securing the stay and injec-
tor.
5-41
Carefully pull up the injector out of the intake mani-
fold to remove it with the feed hose.
Remove the setting plate.
Remove the injector from the hose joint.
Remove the O-rings.
INSTALLATION
Coat a new O-rings with engine oil.
Install the O-rings into the injector grooves in posi-
tion as shown, being careful not to damage them.
Install the injector into the hose joint by aligning the
tab with the hole.
Install the setting plate by aligning the groove with

the tab of the injector, then install the injectodhose
assembly into the manifold until it is fully seated.
Install the stay and two bolts onto the hose joint,
and tighten them securely.
Install the hose clamp and tighten the bolt.
5-42 -~
Connect the injector 2P connector and ECM 32P
connector.
FUEL PUMP RELAY

INSPECTION
Check the connector for loose contacts or corroded
terminals.
SIGNAL LINE
Check for continuity between the Brown/black wire
terminal of the relay connector and ground. Brownlblack
\
There should be no continuity with the ignition
switch turned to OFF.
If there is continuity, check for a short circuit in
the Brown/black wire between the relay connec-
tor and engine control module (ECM).
There should be continuity for a few seconds.
If there is no continuity, check for an open circuit
i n the Brownlblack wire between the relay con-
nector and ECM.
RELAY COIL POWER INPUT LINE

Measure the voltage between each BlacWwhite wire
terminal (+) of the relay connector and ground (-) BIa ck/w hite
with the ignition switch turned to ON.
There should be battery voltage.
If there is no voltage, check the following:
- open circuit in the BlacWwhite wire between the
fuel pump relay and engine stop relay (front side
of the pump relay)
- engine stop relay and its circuit (page 5-44)
5-43
FUNCTION TEST
Connect an ohmmeter to the switching side relay
terminals. BATTERY
I I I T
CONNECTION: Black/white #2 - Brown
Connect a 12-V battery to the signal line side relay
terminals.
CONNECTION: Black/white #I (+) - Brownlblack (-)
There should be continuity while the battery is con-
nected to the relay terminals and there should be no
continuity when the battery is disconnected.
ENGINE STOP RELAY

INSPECTION
Remove the frame body cover (page 2-51.
Remove the engine stop relay.
terminals.
SIGNAL LINE
Check for continuity between the Redlorange wire
terminal of the relay connector and ground.
There should be no continuity with the ignition
switch turned to OFF.
If there is continuity, check for a short circuit in
the Red/orange wire between the relay connector
and bank angle sensor.
9
There should be continuity for a few seconds. Redlorange
in the Redlorange wire between the relay con-
nector and bank angle sensor.
-
&r

Measure the voltage between each Black wire termi-
nal (+) of the relay connector and ground (-) with
the ignition switch turned to ON.
- open circuit in the Black wire between the engine
stop relay and fuse box
- sub-fuse 10 A (IGN, Al, START, FUEL PUMP)
- open circuit in the Redlblack wire between the
fuse box and ignition switch
- bank angle sensor and its circuit (page 5-45) Black
- -
FUNCTION TEST
Connect an ohmmeter to the switching side relay
BATTERY
terminals. I
I1
I I -I
CONNECTION: Black #2 - Black/white
terminals. I
' I
--
I k
CONNECTION: Black #I(+) - Red/orange (-1 Black #
' (+) orange (-1
nected to the relay terminals and there should be no
continuity when the battery is disconnected. 1 Black#2
k
\
BlacWwhite
BANK ANGLE SENSOR

I NSPECTlON
Disconnect the bank angle sensor 3P connector.
Check the connectors for loose contacts or corroded
terminals.
1. Check for continuity between the Green wire ter-

minal of the wire harness side 3P connector and Green
ground.
There should be continuity at all times.
In/ J
in the Green wire.

If there is continuity, GO TO STEP 2.
(Viewed from the harness side)
2. Measure the voltage between the Black wire ter-

minal (+) of the wire harness side connector and Black
ground (-) with the ignition switch turned to ON.
If there is no voltage, check for open circuit in the
Black wire between the angle sensor and fuse
box.
If there is battery voltage, GO TO STEP 3.
0 -
-
5-45
3. Turn the ignition switch to OFF.
Remove the bank angle sensor (page 5-46).
Green Redlorange
Connect the 3P connector.
4. Measure the voltage between the Redlorange
wire terminal (+) and Green wire terminal (-) of
the 3P connector.
Place the bank angle sensor horizontal and turn
the ignition switch to ON.
There should be 0 - 1 V.
Angle the sensor approximately 60 degrees to
the left or right with the ignition switch to ON.
NOTE:
If you repeat this test, first turn the ignition
switch to OFF, then back to ON before you try the
test again.
Horizontal 60" f..

position
REMOVAL/INSTALLATION
Remove the three bolts and frame bracket.
Remove the two screws.

Disconnect the 3P connector to remove the bank
angle sensor.
TORQUE: Screw: 1.2 N.m (0.12 kgfam, 0.9 Ibf.ft)
0 2 SENSOR
NOTE:
Do not service the 0 2 sensor while it is hot.
Handle the 0 2 sensor with care. Do not get
grease, oil or other materials o n the 0 2 sensor
head.
Be careful not to damage the sensor wire.
Remove the t w o washer-bolts securing the sensor
cover.
Take care not to Release the connectors and wires from guides t o
damage the sensor remove the sensor cover.
wire.
Disconnect the 0 2 sensor 4P connector.
Remove the 0 2 sensor and sealing washer.

Always replace the Installation is in the reverse order of removal.
sealing washer with
a new one.
TORQUE: 44 N.m (4.5 kgf-m, 32 Ibf4t)
Route the wires in
the sensor cover
properly
(page 1-17).
5-47
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
REMOVAL/ INSTALLATION
Drain the coolant (page 6-8).
Remove the ECT sensor and sealing washer.
Alwaysreplace the Install the ECT sensor in the reverse order of
seahng washer with removal.
a new one.
TORQUE: 23 N - m (2.3 kgf.m, 17 Ibf.ft)
Fill and bleed the cooling system (page 6-7).
ENGINE CONTROL MODULE (ECM)

NOTE:
The ECM is mounted on the throttle body (the
throttle body with the built-in ECM). Do not dis-
assemble the throttle body/ECM assembly.
POWER/GROUND LINE INSPECTION
GROUND LINE
Check for continuity between each ground wire ter-
minal and ground.
There should be continuity at all times. ECM 32P CONNECTOR
If there is no continuity, check for an open circuit in
the Green or Greedpink wire.
POWER INPUT LINE

Measure the voltage between the BlacUwhite wire
terminal (+) and ground (-).
There should be battery voltage. ECM 32P CONNECTOR
- open circuit in the BlacWwhite wire between the
ECM and engine stop relay
- engine stop relay and its circuits (page 5-44)
5-48
FUEL SYSTEM (Programmed Fuel Iniection)
ENGINE IDLE SPEED
INSPECTlON
NOTE:
Make sure the malfunction indicator lamp (MIL)
does not indicate any failure codes before
inspecting the engine idle speed.
Use a tachometer with graduations of 100 min-
(rpm) or smaller that will accurately indicate a
100 min (rpm) change.
Start the engine and w a rm it u p t o normal operating
temperature.
Stop the engine and connect a tachometer accord-
ing t o the tachometer manufacturers instructions.
Start the engine and let it idle. Check the idle speed.
ENGINE IDLE SPEED: 1,500 k 100 min (rpm)
If the engine hard to start or the idle speed is out of
specification, refer to the Troubleshooting (page 5-
4).
IDLE AIR CONTROL (IAC) VALVE
The IAC valve is incorporated i n the throttle body/
ECM assembly which it operating by the step motor.
When the ignition switch is turned t o ON, the IAC
valve operates for a few seconds.
Check the step motor operating (beep) sound with
the ignition switch turned t o ON.

SYSTEM INSPECTION
Start the engine and w a rm it u p t o normal operating
temperature.
Disconnect the air supply hose from the air cham-
ber.
Check that the hose joint (secondary air intake port)
o f the air chamber is clean and free of carbon
deposits.
Check the pulse secondary air injection (PAIR) check
valve if the port is carbon fouled (page 5-51).
5-49
Start the engine and open the throttle slightly to be
certain that air is sucked in through the air supply PAIR SOLENOID AIR SUPPLY
hose. VALVE HOSE
If the air is not drawn in, check the air supply hoses
for clogs and the PAIR solenoid valve (page 5-511.
PAIR SOLENOID VALVE INSPECTION

- maintenance lid (page 2-4) I HOSE (Input)
- 02 sensor cover (page 5-47)
Disconnect the air supply hoses from the cylinder
head cover and air chamber.
Disconnect the PAIR solenoid valve 2P connector.
I VALVE (Output)
Check air fl o w fro m input side hose to output side

hose. Air should fl o w out.
Connect a 12-V battery t o the solenoid valve side 2P
connector terminals.
CONNECTION: Black/white (+) - Pink (-)
Air should not fl o w when the battery is connected.
5-50
-
PAIR CHECK VALVE INSPECTION
- t w o bolts
- check valve cover
- PAIR check valve
Check the reed for damage o r fatigue. Replace if

necessary.
Replace the PAIR check valve if the rubber seat is
cracked, deteriorated or damaged, or if there is
clearance between the reed and seat.
PAIR SOLENOID VALVE REMOVAL/

INSTALLATION
- 0 2 sensor cover (page 5-47)
Disconnect the air supply hoses from the cylinder
head cover and air chamber.
Disconnect the solenoid valve 2P connector.
Remove the tw o bolts and washer.

Remove the PAIR solenoid valve assembly out of
the frame.
5-51
Remove the following fro m the PAIR solenoid valve:
- solenoid valve stay
- air supply hoses
FUEL TANK
R EMOVAL/ INSTALLATION
after relieving the fuel pressure (page 5-31 1.
Remove th e following:
- wire clip (securing the fuel drain hose)
- wire band (securing the fuel pump wire)
- t w o 8 -m m bolts and frame cross-bracket
- four 6-mm bolts
- fuel tank
5-52
6. COOLING SYSTEM
SYSTEM FLOW PATTERN ............................ 6-2 THERMOSTAT ................................................ 6-9
SERVICE INFORMATION .............................. 6-3 WATER PUMP .............................................. 6-10
TROUBLESHOOTlNG .................................... 6-5 COOLING FAN MOTOR ............................... 6-13
SYSTEM TESTING ......................................... 6-6 RADIATOR RESERVE TANK ........................ 6-16
COOLANT REPLACEMENT ........................... 6-7 RADIATOR .................................................... 6-17
6-I
COOLING SYSTEM
SYSTEM FLOW PATTERN
SIPHON HOSE
TANK
WATER PUMP
6-2
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap. I
I NOTICE I
Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages.
Using tap water may cause engine damage.
Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system services can be done with the engine in the frame.
Avoid spilling coolant on painted surfaces.
After servicing the system, check for leaks with a cooling system tester.
For coolant temperature gaugelECT sensor information, see page 20-11.
SPEC1FlCATlONS
ITEM SPECIFICAT~ONS
Coolant capacity Radiator and engine 0.95 liter (1.00US qt, 0.84 Imp qt)
Reserve tank 0.4 liter (0.42US qt, 0.35 Imp qt)
Thermostat Begin to open 80 - 84 "C (176- 183 O F )

Fully open 95 "C (203 O F )
Vnlvn lift I
.. - mm
4.5 I - . . - in)
. . .. . . 10.18 .. ., minimum
. . ... ... . .-. . .
1:l mixture with distilled water
TORQUE VALUES
Water pump impeller 12 N.m (1.2kgf.m, 9 Ibf.ft) Left-hand threads
Cooling fan motor mounting bolt 8.4 N.m (0.86kgf.m, 6.2Ibf.ft)
6-3
COOLING SYSTEM
TOOLS
Bearing remover head, 14 mm Bearing remover shaft Remover weight
07WMC-KFG0100 07936-KC10100 07741-0010201
Driver Attachment, 22 x 24 mm Pilot, 14 mm

07749-0010000 07746-0010800 07746-0041200
Mechanical seal driver

07PMD-KBP0100
6-4
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
Insufficient coolant
Air i n system
Faulty radiator cap
Thermostat stuck closed
Passage blocked in radiator, hoses or water jacket
Faulty water pump
Faulty cooling fan motor or fan motor circuit
Faulty coolant temperature gauge circuit or ECT sensor (page 20-11)
Engine temperature too low
Thermostat stuck open
Faulty cooling fan motor or fan motor circuit
Faulty coolant temperature gauge circuit or ECT sensor (page 20-11)
Coolant leaks
Faulty water pump mechanical seal
Deteriorated O-rings
Damaged or deteriorated seals and gaskets
Faulty radiator cap
Loose hose connection or clamp
Damaged or deteriorated hoses
6-5
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
The engine must be Remove the front upper cover (page 2-81,
cool before remov- Remove the radiator cap.
ing the radiator cap.
Test the coolant gravity using a hydrometer.
STANDARD COOLANT CONCENTRATION:

1 : l (distilled water and t h e recommended
antifreeze)
Look for contamination and replace the coolant if
necessary.
COOLANT GRAVITY CHART
6-6
COOLING SYSTEM
RADIATOR CAPISYSTEM PRESSURE
INSPECTION
Remove the radiator cap (page 6-6).
Wet the sealing surfaces of the cap, then install the
cap onto tester.
Pressurize the radiator cap using the tester.
Replace the radiator cap if it does not hold pressure,
or if relief pressure is too high or too low. It must
hold the specified pressure for a t least 6 seconds.
RADIATOR CAP RELIEF PRESSURE:
-
108 - 137 kPa (1.1 1.4 kgf/cm2, 16 - 20 psi)
Pressure test the radiator, engine and hoses, and

check for leaks.
C I
Excessive pressure can damage the cooling system

components. Do not exceed 137 kPa (7.4 kgf/cm2, 20
psi).
Repair or replace components if the system will not
hold the specified pressure for a t least 6 seconds.
Remove the tester and install the radiator cap.
Install the front upper cover (page 2-8).
COOLANT REPLACEMENT
PREPARATION
I NOTICE I
Using coolant with silicate corrosion inhibitors may
cause premature wear of water pump seals or
blockage of radiator passages. Using tap water may
cause engine damage.
NOTE:
The effectiveness of coolant decreases with the
accumulation of rust or if there is a change in the
mixing proportion during usage. Therefore, for
best performance change the coolant regularly
as specified i n the maintenance schedule.
Mix only distilled, low mineral water with the rec-
ommended antifreeze.
RECOMMENDED ANTIFREEZE: SOLUTION) OR DISTILLED
High quality ethylene glycol antifreeze containing
corrosion protection inhibitors
RECOMMENDED MIXTURE:
1:l (distilled water and the recommended
antifreeze)
6-7
COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
The engme must be Place the scooter o n its center stand o n a level sur-
cool before serwc- face.
Ing the coolng -Remove the front upper cover (page 2-8).
tern.
Drain the coolant from the system by removing the
drain bolt and sealing washer, and the radiator cap.
Reinstall the drain bolt with a new sealing washer
securely.
Remove the reserve tank cap.

Pump out the coolant with a fluid evacuator to drain
the reservoir tank.
Fill the system with the recommended coolant

through the filler opening u p to the filler neck.
6-8
COOLING SYSTEM
Fill the reserve tank to the upper level line and
install the tank cap.
Bleed air from the system as follows:
1. Start the engine and let it idle for 2 - 3 minutes.
2. Snap the throttle 3 - 4 times t o bleed air from the
system.
3. Stop the engine and add coolant u p t o the filler
neck.
4. Install the radiator cap.
Install the front upper cover (page 2-8).
THERMOSTAT
REMOVALANSTALLATION
Drain the coolant f r o m the system (page 6-8).
- spark plug cap
- wire band (from the stay)
Place a shop towel - t w o bolts

under the thermo- - wire retaining stay
stat housing. - thermostat cover
- thermostat
NOTE:
The thermostat is installed with the bleed hole
facing up.
6-9
COOLING SYSTEM
INSPECTION
Visually inspect the thermostat for damage and the
rubber seal for deterioration.
Replace the thermostat if the valve stays open at
room temperature.
Do not let the ther- Heat a container of water with an electric heating
mostat or ther- element for 5 minutes.
mometer touch the Suspend the thermostat in heated water to check its
pan, or you will get operation.
a false reading.
THERMOSTAT BEGINS TO OPEN:
80 - 84 "C (176 - 183 OF)
VALVE LIFT:
4.5 mm (0.18 in) minimum at 95 "C (203 OF)
Replace the thermostat if the valve opens at a tem-
perature other than those specified.
WATER PUMP
MECHANICAL SEAL INSPECTION
Inspect the telltale hole for signs of coolant leakage.
If there is leakage, the water p u m p mechanical seal I WATER PUMP
is defective and the mechanical should be replaced.
MECHANICAL SEAL REPLACEMENT

Remove the stator/CKP sensor assembly (page 12-
9).
- three bolts
- water p u m p cover
- O-ring
- tw o dowel pins
Turn the water pump impeller with your finger. The
pump shaft should turn smoothly and quietly.
Replace the faulty part if the shaft do not turn
smoothly or quietly.
The impeller has Hold the pump shaft groove securely and remove
/eft-hand threads. the impeller.
Take care not to
damage the mating
surface of the
crankcase cover.
Remove the snap rings.

Remove the pump shaft and bearing by tapping the
shaft lightly with a plastic hammer.
Remove the mechanical seal using the special tools.
TOOLS:
Bearing remover head, 14 m m 07WMC-KFG0100
Remover shaft, 15 mm 07936-KC10100
Remover weight 07741-0010201
Remove the oil seal.

Blow the telltale hole in the crankcase cover with
compressed air to clean it.
Apply engine oil to the seal lips and outer surface of
a new oil seal.
Install the oil seal with the marking facing up until it
is fully seated.
TOOLS:
Driver 07749-0010000
Attachment, 22 X 24 mm 07746-0010800
Pilot, 14 mm 07746-0041200
6-11
Drive a new mechanical seal.
TOOL:
Mechanical seal driver 07PMD-KBP0100
Install each snap Install the bearing onto the pump shaft and secure it
ring with the cham- with the snap ring.
fered
edge Degrease the pump shaft thoroughly and apply
facing the bearing.
molybdenum oil solution to the shaft journal.
I NOTICE I
Do not apply molybdenum oil solution to the
mechanical seal sliding area.
Install the pump shaft into the crankcase cover and

secure it with the snap ring.
Make sure the snap rings are fully seated i n the
grooves.
Apply engine oil to the bearing.
Theimpellerhas Install the impeller. Hold the shaft groove and

/eft-hand threads. tighten the impeller.
Take care not to
damage the ,,,atjng TORQUE: I 2 N.m (1.2 kgf.m, 9 Ibf.ft)
surface of the
Check the pump shaft for smooth rotation.
crankcase cover.
COOLING SYSTEM
Install the following t o avoid damaging the impeller:
- t w o dowel pins
- water pump cover
- three bolts
Install the stator/CKP sensor assembly (page 12-10).
COOLING FAN MOTOR

RELAY INSPECTION
Remove the glove box inner cover (page 2-13).
FAN MOTOR RELAY
Remove the fan motor relay from the connector.
I
Connect a 12-V battery positive (+) terminal to the
relay Blue # I wire terminal and negative (-) terminal BATTERY
to the Black/blue wire terminal.
There should be continuity between the Blue #2 and
Black wire terminals while the battery is connected,
and n o continuity when the battery is disconnected.
Black/
blue (-1
I I IJ
-+Blue #2
-\
Black
6-13
COOLING SYSTEM
SYSTEM INSPECTION
Fan motor does not stop
Check the fan motor relay (page 6-13)
If the relay is faulty, replace the fan motor relay.
If the relay function is normal, check as follows.
Install the fan motor relay.
connector.
Turn the ignition switch to O N and check the fan
motor.
If the fan motor does not stop, check for a short
circuit in the BlacUblue wire between the fan
motor relay and ECM.
If the fan motor stops, replace the throttle body/
ECM assembly.
Fan motor does not start

Before testing, check for a blown fan motor fuse.
1. Check the fan motor relay (page 6-13).
If the relay is faulty, replace the fan motor relay.
If the relay function is normal, check as follows.
2. Measure the voltage between each Blue (+) wire
terminal of the relay connector and ground (-). FAN MOTOR RELAY CONNECTOR:
There should be battery voltage with the ignition
switch turned to ON. RIiin I i I
If there is no voltage, check for an open circuit in
the Blue wires.
If there is battery voltage, check as follows.
3. Remove the front upper cover (page 2-8).

Remove the front lower cover right side fasten-
ers (page 2-9).
Disconnect the fan motor 2P (white) connector.
COOLING SYSTEM
Short the Blue and Black wire terminals of the
relay connector with a jumper wire. RE LAY CONNECTOR : MOTOR CONNECTOR:
Measure the voltage between the Black (+) and
i
Green (-) wire terminals of the wire harness side Black
motor 2P connector.
switch turned to ON.
the Black and Green wires.
If there is battery voltage, check as follows.
Black (+) Green (-1
4. Install the fan motor relay.

connector.
Measure the voltage between the BlacWblue (+)
wire terminal of the wire harness side 32P con-
nector and ground (-).
the BlacWblue wire between the relay and ECM.
If there is battery voltage, check the fan motor as
follows.
5. Connect a 12-V battery positive (+) terminal to
the Black wire terminal and negative (-1 terminal
to the Green wire terminal of the motor side fan
motor 2P connector.
If the fan motor does not start, replace the fan
motor.
If the motor starts, check the related connector
terminals. If they are OK, replace the throttle
body/ECM assembly.
REMOVALANSTALLATION
- front lower cover right side fasteners (page 2-9) 2P CONNECTOR
Release the fan motor wire from the three wire
guides located on the body covers and air guide
plate.
Disconnect the fan motor 2P (white) connector.
GUIDES
6-15
COOLING SYSTEM
Disconnect the siphon hose from the radiator and
release it from the clamp.
Be careful not to Remove the two mounting bolts and clamp, and the
damage the radiator fan motor assembly.
fins.
Route the motor Installation is in the reverse order of removal.
wire properly
TORQUE: 8.4 N.m (0.86 kgf.m, 6.2 IbfW
(page 1-17),
RADIATOR RESERVE TANK

Remove the front lower cover (wheel removal is not
required) (page 2-9).
Disconnect the siphon hose from the radiator and
release it from the clamp.
Remove the mounting bolt, then release the boss

from the stay to remove the reserve tank.
Fill the reserve tank to the upper level line, if it was
drained (page 3-10).
6-16
COOLING SYSTEM
RADIATOR
R E MOVA LANSTALLATION
- reserve tank (page 6-16)
- fan motor (page 6-15)
Drain the coolant from the system (page 6-8).
- four screws
- front air guide plate
Be careful not to - water hoses

damage the radiator - three mounting bolts
fins. - radiator
6-17
7. ENGINE REMOVALANSTALLATION
SYSTEM COMPONENTS .............................. 7-2 ENGINE REMOVAL,....................................... 7-4
SERVICE INFORMATION .............................. 7-3 ENGINE INSTALLATION ................................7-7
7- 1
ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS
49 N.m (5.0kgf.m, 36 Ibf.ft)
7-2
SERVICE INFORMATION
GENERAL
When removing/installing the engine, tape the frame around the engine beforehand for frame orotection.
A hoist or equivalent is required to support the frame when removing and installing
-
the engine. Support the engine
using a jack or other adjustable support to ease engine mounting bolt removal.
The crankcase and crankshaft require engine removal for service. Other components can be serviced with the engine
installed in the frame.
ITEM SPECIFICATIONS
Engine oil capacity After draining 0.9 liter (1.0 US qt, 0.8 Imp qt)
After disassembly 1.0 liter (1.1 US qt, 0.9 Imp qt)
Coolant capacity (radiator and engine) 0.95 liter (1.00 US qt, 0.84 Imp qt)
TORQUE VALUES
Engine hanger bracket bolt (frame side) 49 N.m (5.0 kgf.m, 36 Ibf.ft)
Engine mounting nut (engine side) 49 N - m (5.0 kgf.m, 36 IbfW U-nut.
7-3
ENGINE REMOVAL
Drain the engine oil (page 3-9).
- rear fender A (page 2-7)
- mud guard (page 2-14)
- exhaust system (page 2-15)
- throttle body/ECM assembly (page 5-37)
- fuel injector (page 5-41)
- bolt and fuel feed hose
- wire band (from the engine hanger bracket)
- wire band (from the wire retaining stay)

- spark plug cap
- water hose (from the thermostat housing)
- water hose (from the water pump)

- terminal bolt (to disconnect the ground wire and
cable)
- alternator 3P (white) connector (remove from the

frame and disconnect it)
- alternator wire (release from the clamp)
7-4
- crankshaft position (CKP) sensor 3P (white) con-
nector
- engine coolant temperature (ECT) sensor 3P
(gray) connector
- wire bands (from the wire retaining stay)
- wires (main harness, alternator and CKP sensor;
fro m the wire guide)
- pulse secondary air injection (PAIR) solenoid

valve 2P (black) connector (remove the wire har-
nesses out o f the frame)
- seat release cable (from the clamp)

- crankcase breather hose (from the clamp and
remove fro m the hose guide)
- motor mounting bolt (to disconnect the battery

negative (-1 cable)
- terminal nut and starter motor cable
7-5
- brake cable clamp bolt
- adjusting nut
- joint pin
- brake arm spring
- brake cable (from the cable holder)
Place a floor jack or other adjustable support under

the engine and support it securely.
Remove the shock absorbers (page 15-8).
Support the frame securely with a hoist or equiva-

lent.
Thejackheight Remove the hanger bracket bolts o n both sides of
must be adjusted to the frame.
relieve stress for
Make sure the wires and cables do not interfere with
Of
the engine components, and separate the frame
removal.
f r o m the engine.
7-6
Remove the engine mounting nuts, bolt and engine
hanger bracket.
Check the bushings in the engine and hanger

bracket for wear, deterioration or damage.
Check the rubber stoppers on the hanger bracket for
wear, cracks or deterioration.
ENGINE INSTALLATION
NOTE:
Route the wires, hoses and cables properly (page
1-17).
Install the hanger bracket onto the engine with the
rubber stoppers facing to the right by inserting the
mounting bolt from the left side.
Install the mounting nut. Set the angle of the
bracket as shown and temporarily tighten the nut.
7-7
ENGINE REMOVALANSTALLATION
Thelack he/ght Carefully place the frame over the hanger bracket
must beadlusted to on the engine. Align the bracket bolt holes in the
reheve stress for bracket and frame, using a jack or other adjustable
ease of bolt support.
insta//at/on. Install the bracket bolts.
Install the shock absorbers (page 15-8).

Tighten the bracket bolts.
TORQUE: 49 N-m (5.0 kgf-m, 36 Ibf.ft)
Tighten the mounting nut.
TORQUE: 49 N.m (5.0 kgf.m, 36 Ibf4t)
Install the removed parts from the engine removal
procedure (page 7-4 to 7-6) in the reverse order of
removal.
- fuel injector (page 5-42)
- throttle body/ECM assembly (page 5-39)
After installing the engine, adjust the rear brake
lever free play (page 3-16).
Fill the crankcase with engine oil (page 3-9).
Check the engine oil level (page 3-8).
- rear fender A (page 2-7)
8. CYLINDER HEADIVALVES
SYSTEM COMPONENTS .............................. 8-2 CYLINDER HEAD DISASSEMBLY -*--.----..-.-.

8-13
SERVICE INFORMATION .............................. 8-3 VALVE GUIDE REPLACEMENT ...................8-15
TROUBLESHOOTlNG .................................... 8-6 VALVE SEAT INSPECTION/REFACING ......8-16
CYLINDER COMPRESSION TEST................. 8-7 CYLINDER HEAD ASSEMBLY ..................... 8-19
CYLINDER HEAD COVER REMOVAL--*----*.--

8-7 CYLINDER HEAD INSTALLATION............... 8-2 1
CAMSHAFT/ROCKER ARM REMOVAL ....... 8-8 CAMSHAfT/ROCKER ARM

INSTALLATION............................................. 8-24
CYLINDER HEAD REMOVAL ...................... 8-1 1
CYLINDER HEAD COVER
INSTALLATION............................................. 8-27
CYLINDER HEADNALVES
SYSTEM COMPONENTS
27
1 2 N.m (1.2 kgf.m, 9 Ibf.ft)
8-2
CYLINDER HEADNALVES
SERVICE INFORMATION
GENERAL
This section covers service of the rocker arms, camshaft, valves and cylinder head. These parts can be serviced with the
engine installed in the frame.
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca-
tions.
Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
The rocker arm and camshaft lubricating oil is fed through the oil passages in the cylinder head and head cover. Clean
the oil passages before assembling.
Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
SPECIFICATIONS
Unit: mm (in)
ance I 0.030 - 0.057 (0.0012 - 0.0022) j 0.10 io.oo4j

Valve guide projection I IN/EX I 11.35 - 11.65 (0.447 - 0.459) -
I abovecvlinder head I I I I
Valve spring free length 1 IN/EX 36.2 (1.43) 34.4 (1.35)
Cylinder head warpage - 0.05 (0.002)
TORQUE VALUES
Camshaft holder nut 27 N.m (2.8 kgf.m, 20 1bf.ft) Apply engine oil to the threads.
Cam sprocket bolt 9 N.m (0.9 kgf.m, 6.6 Ibf.ft)
Timing hole cap 6 N.m (0.6 kgf.m, 4.4 Ibf.ft)
Cylinder head cover bolt 12 N - m (1.2 kgfem, 9 1bf.e)
8-3
CYLINDER HEADNALVES
TOOLS
~
Cam chain tensioner holder Valve spring compressor Valve guide reamer, 5.0 mm
070M G-0010100 07757-0010000 07984-MA60001
Valve guide driver, 5.0 mm Cutter holder 5.0 m m

07942-MA60000 07781-0010400
For the SH125:

Seat cutter, 27.5 mm (45" IN) Seat cutter, 24 m m (45" EX) Flat cutter, 30 mm (32" IN)
07780-0010200 07780-0010600 07780-0012200
Flat cutter, 25 m m (32" EX) Interior cutter, 26 mm (60" IN) Interior cutter, 22 m m (60" EX)
07780-0012000 07780-0014500 07780-0014202
8-4
CYLINDER HEADNALVES
For the SH150:
Seat cutter, 33 mm (45"IN) Seat cutter, 24 mm (45"EX) Flat cutter, 33 mm (32"IN)
07780-0010800 07780-0010600 07780-0012900
Flat cutter, 27 mm (32"EX) Interior cutter, 30 mm (60"IN) Interior cutter, 26 mm (60"EX)

07780-0013300 07780-0014000 07780-0014500
8-5
TROUBLESHOOTING
0 Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test,
or by tracing top-end noise with a sounding rod or stethoscope.
If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky,
check for a seized piston ring (page 9-21.
Compression too low, hard starting or poor performance at low speed
Valves:
- Incorrect valve adjustment
- Burned or bent valve
- Incorrect valve timing
- Broken valve spring
- Uneven valve seating
- Valve stuck open
Cylinder head:
- Leaking or damaged head gasket
- Warped or cracked cylinder head
- Loose spark plug
Cylinder/piston problem (page 9-41.
Compression too high, overheating or knocking
Excessive carbon build-up on piston head or on combustion chamber
Excessive smoke
Worn valve stem or valve guide
Damaged stem seal
Cylinder/piston problem (page 9-4)
Excessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring
Excessive worn valve seat
Worn or damaged camshaft
Worn cam chain
Worn cam sprocket teeth
Worn rocker arm and/or shaft
Worn or damaged cam chain tensioner
Cylinder/piston problem (page 9-41.
Rough idle
Low cylinder compression
8-6
CYLINDER COMPRESSION TEST
Warm up the engine to normal operating tempera-
ture.
Stop the engine and remove the spark plug cap and
spark plug (page 3-6).
Install a compression gauge into the spark plug
hole.
To avoid discharging Open the throttle all the way and crank the engine
the battery, do not with the starter motor until the gauge reading stops
operate the starter rising. The maximum reading is usually reached
motor for more within 4 - 7 seconds.
than 7 seconds.
COMPRESSION PRESSURE:
1,373 kPa (14.0 kg/cm2, 199 psi) at 600 min- (rpm)
Low compression can be caused by:
- blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston ring or cylinder
High compression can be caused by:
- carbon deposits in the combustion chamber or
o n the piston head
CYLINDER HEAD COVER REMOVAL

- pulse secondary air injection (PAIR) check valve
(page 5-51)
Disconnect the crankcase breather hose.
Remove the two bolts and cylinder head cover.
Remove the rubber seal.

Remove the O-ring and joint collar.
8-7
CYLINDER HEADNALVES
CAMSHAFT/ROCKER ARM REMOVAL
CAMSHAFT HOLDER REMOVAL
Release the crankcase breather hose and the throt-
tle cable out of each clamp.
Remove the timing hole cap and O-ring from the

right crankcase cover.
Rotate the drive pulley (crankshaft) counterclock-

wise and align the T mark on the flywheel with the
index notch in the crankcase cover.
The index line on the cam sprocket must be flush
with the cylinder head surface, and the timing mark
"1" is facing up and "2" is facing down (TDC; Top
Dead Center on the compression stroke).
If the timing marks are not above position, rotate
the crankshaft one full turn and align the T mark
again.
Remove the tensioner lifter sealing screw and 0-

ring located on the upper side of the cylinder.
Turn the cam chain tensioner lifter shaft clockwise
fully and secure it with the special tool to loosen the
tensioner lifter.
TOOL:
Cam chain tensioner holder 070MG-0010100
CYLINDER HEADNALVES
Place a shop towel into the cylinder head opening to
prevent fasteners from falling into the crankcase.
Remove the two bolts while holding the drive pulley
(crankshaft), and the cam sprocket off of the cam-
shaft.
Attach a piece of Remove the cam sprocket from the cam chain.
wire to the cam Attach a piece of wire to the cam chain to prevent it
chain to prevent it from falling into the crankcase.
from falling into the
crankcase.

- four nuts and washers
- camshaft holder assembly
- two dowel pins
CAMSHAFT HOLDER DISASSEMBLY

- snaprings
- rocker arm shafts (by screwing a 5-mm bolt and
pull it out)
- rocker arms
8-9
- snap ring
- camshaft
INSPECTION
NOTE:
For cam chain tensioner lifter inspection, see
page 8-15.
ROCKET ARMISHAFT
Inspect the sliding surfaces of the rocker arms and
shafts for wear or damage.
Check the oil holes for clogs.
Measure the O.D. of each shaft at the rocker arm
sliding areas.
Measure the I.D. of each rocker arm.
Calculate the rocker arm-to-shaft clearance.
CAMSHAFT
Check each bearing t o turn the outer race. The bear-
ing should turn smoothly and quietly.
Check the cam lobes for scoring, scratches or evi-
dence of insufficient lubrication.
Check the cam sprocket for wear or damage.
8-10
CYLINDER HEAD/VALVES
_____ ~ ~ _ _ _ ~
Measure each cam lobe height using a micrometer.

SERVICE LIMITS: IN: 29.637 mm (1.1668 in)
EX: 29.395 mm (1.1573 in)
CYLINDER HEAD REMOVAL

valve (page 5-51)
- injector (page 5-411
- throttle body (page 5-37)
- camshaft holder (page 8-8)
Remove the following if the cylinder will be
removed:
- water hose (disconnect from the cylinder, being
careful not to damage it)
- two bolts and clamp stay

- cam chain tensioner lifer
- gasket

- crankshaft position (CKP) sensor 3P (white) con-
nector
- plug wire band (from the wire retaining stay)
- plug cap
- spark plug
8-1I
CYLINDER HEADNALVES
- two bolts and PAIR solenoid valve stay
- thermostat housing assembly (from the cylinder
head)
- O-ring
- two bolts and clamp stay

- intake manifold
- manifold insulator
- O-rings (from the manifold and insulator)
Do not strike the - two bolts

cylinder head too - cylinder head
hard and do not
damage the mating
surface with a
screwdriver.
- gasket
- cam chain guide
- two dowel pins
CYLINDER HEADNALVES
CYLINDER HEAD DISASSEMBLY
Remove the cylinder head (page 8-11).
Toprevent loss of Remove the valve spring cotters using the spring
tension, do not compressor.
compress the valve
springs more than
TOOL:
necessary, Valve spring compressor 07757-0010000
Mark a// the parts Remove the following:

so they can be - spring retainer
placed back in their - Valve spring
original locations. - valve
- stem seal
- spring seat
INSPECTION
CYLINDER HEAD
Be careful not to Remove the carbon deposits from the combustion
damage the valve chamber.
seat and gasket
Check the spark plug hole and valve areas for
surfaces.
cracks.
Check the cylinder head for warpage with a straight

edge and feeler gauge across the stud holes.
CYLINDER HEADNALVES
VALVE SPRING
Check the valve springs for fatigue or damage.
Measure the valve spring free length.
SERVICE LIMIT: IN/EX: 34.4 mm (1.35 in)
VALVENALVE GUIDE
Check that the valve moves smoothly in the guide.
Check the valves for bending, burning or abnormal
wear.
Measure each valve stem O.D. and record it.
Ream the guides to remove any carbon build-up

before measuring the guide.
Insert the reamer from the combustion chamber
side of the head and always rotate the reamer clock-
wise.
TOOL:
Valve guide reamer, 5.0 mm 07984-MA60001
Measure each valve guide I.D. and record it.

Subtract each valve stem O.D. from the correspond-
ing guide I.D. to obtain the stem-to-guide clearance.
SERVICE LIMITS: IN: 0.08 mm (0.003 in)
EX: 0.10 mm (0.004 in)
lnspect and reface If the stem-to-guide clearance exceeds the service
the valveseats limit, determine if a new guide with standard
whenever the valve dimensions would bring the clearance within toler-
guidesarereplaced ance. If so, replace any guides as necessary and
(page 8-76). ream to fit.
If the stem-to-guide clearance exceeds the service
limit with a new guide, also replace the valve.
CYLINDER HEADNALVES
CAM CHAIN TENSIONER LIFTER
Check the lifter operation as follows.
The tensioner shaft should not go into the body
when it is pushed.
When it is turned clockwise with the stopper tool or
a screwdriver, the tensioner shaft should be pulled
into the body. The shaft spring out of the body as
soon as the stopper tool is released.
CAM CHAIN GUIDE AND TENSIONER

Check the cam chain guide and the tensioner in the
crankcase for excessive wear or damage.
VALVE GUIDE REPLACEMENT

Mark new valve guides at the specified height indi-
cated below, using a marker.
Chill new valve guides in a freezer for about 1 hour.
Be sure to wear Heat the cylinder head to 130 - 140C (275 - 290F)
heavygloves to with a hot plate or oven. Use temperature indicator
avoid burns when sticks, available from welding supply stores, to be
handling the heated sure the cylinder head is heated to the proper tem-
cylinder head. perature
Using a torch to heat the cylinder head may cause

warpage.
Support the cylinder head and drive the valve
guides out of the cylinder head from the combus-
tion chamber side.
TOOL:
Valve guide driver, 5.0 mm 07942-MA60000
CYLINDER HEADNALVES ~~ - ~~
Remove the guides from the freezer.

While the cylinder head is still heated, drive new
valve guides into the cylinder head from the cam-
shaft side until the exposed height is at the specified
value (at the mark).
TOOL:
Valve guide driver, 5.0 mm 07942-MA60000
VALVE GUIDE PROJECTION:

IN/EX: 11.35 - 11.65 mm (0.447 - 0.459 in)
Let the cylinder head cool to room temperature.
Use cutting oil on Ream the new valve guides.

the reamer during Insert the reamer from the combustion chamber
this operation. Take side of the cylinder head and always rotate the
care not to tilt or reamer clockwise.
learn the reamer in
the guide while TOOL:
Valve guide reamer, 5.0 mm 07984-MA60001
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve
seats (page 8-17).
VALVE SEAT INSPECTION/REFACING

Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coat of Prussian Blue to each valve
seat.
Tap the valve against the valve seat several times
without rotating the valve, to check for proper valve
seat contact.
The valve cannot be Remove the valve and inspect the valve seat face.
ground. / f the valve The valve seat contact should be within the speci-
face Is burned or fied width and even all around the circumference. I
badly worn or rf it
contacts the seat
STANDARD: 0.90 - 1.10 mm (0.035 - 0.043 in)
unevenly, replace
the valve.
SERVICE LIMIT: 1.8 mm (0.07 in) .c
If the seat width is not within specification, reface
the valve seat. f
SEAT WIDTH
Inspect the valve seat face for:
Damaged face:
- Replace the valve and reface the valve seat.
Uneven seat width:
- Replace the valve and reface the valve seat.
DAMAGED FACE UNEVEN SEAT WIDTH
Contact area (too high or too low)

- Reface the valve seat.
TOO LOW TOO HIGH
REFAClNG
Follow the refacing Valve seat cutterdgrinders or equivalent valve seat
manufacturer's refacing equipment are recommended t o correct
operating instruc- worn valve seats.
tions
If the contact area is too high o n the valve, the seat

must be lowered using a 32" flat cutter. I CONTACT TOO HIGH OLDSEAT
If the contact area is too l o w on the valve, the seat
must be raised using a 60"interior cutter.
1 I
CONTACT TOO LOW
L
32"
OLD SEAT
I I
CYLINDER HEADNALVES
Reface the seat Use a 45" seat cutter to remove any roughness or
with a 45"cutter irregularities from the seat.
whenever a valve
g u d e I S replaced. TOOLS:
ROUGHNESS
SH125:
Seat cutter, 27.5 mm (45" IN) 07780-0010200
Seat cutter, 24 mm (45" EX) 07780-0010600
Cutter holder, 5.0 mm 07781-0010400
SH150:
Seat cutter, 33 mm (45" IN) 07780-0010800
Seat cutter, 24 mm (45" EX) 07780-0010600
I
I ~~ ~
Using a 32" flat cutter, remove 1/4 of the existing

valve seat material.
TOOLS:
SH125: OLD SEAT WIDTH
Flat cutter, 30 mm (32" IN) 07780-0012200
Flat cutter, 25 mm (32" EX) 07780-0012000
SH150:
Flat cutter, 33 mm (32" IN) 07780-0012900
Flat cutter, 27 mm (32" EX) 07780-0013300
Using a 60" interior cutter, remove 1/4 of the exist-

ing valve seat material. I
TOOLS:
SH125:
Interior cutter, 26 mm (SO" IN) 07780-0014500
Interior cutter, 22 mm (60" EX) 07780-0014202
SH150:
Interior cutter, 30 mm (60" IN) 07780-0014000
Interior cutter, 26 mm (60" EX) 07780-0014500
Using a 45" seat cutter, cut the seat to the proper

width.
VALVE SEAT WIDTH: 0.90 - 1.10 mm (0.035 - 0.043 in)
8-18
Lubricate the valve stem sliding surface with engine
oil.
Insert the valve into the guide while turning it
slowly to avoid damaging to the stem seal.
Install the valve spring with the tightly wound coils

facing the combustion chamber.
Install the spring retainer.
Toprevent loss of Install the valve spring cotters using the valve
tension, do not spring compressor.
compress the valve
springs more than
necessary. Valve spring compressor 07757-0010000
Supportthecyh- Tap the valve stems gently with two plastic ham-
der head so the mers to seat the cotters firmly.
valve heads wilnot Install the cylinder head (page 8-21).
contact anything
that cause damage.
CYLINDER HEADNALVES
CYLINDER HEAD INSTALLATION
Be carefulnot to Clean the mating surfaces of the cylinder head and
damage the mating cylinder thoroughly.
surfaces. Blow out the oil passages in the cylinder head with
compressed air.
Install the cam chain guide by aligning the bosses
with the grooves in the cylinder.
Install the two dowel pins and a new gasket.
Route the cam chain through the cylinder head and

install the cylinder head.
Install the two cylinder head bolts.
Temporarily install the camshaft holder (page 8-24).
Clean the mating surfaces of the intake manifold

and cylinder head thoroughly.
Coat new O-rings with engine oil and install them
into each groove in the manifold and insulator.
Place the insulator and manifold onto the cylinder
head with the cutout facing forward.
8-21
CYLINDER HEADNALVES
Install the two bolts and clamp stay in the direction
as shown, and tighten them.
Install a new O-ring onto the thermostat housing

joint.
Install the thermostat housing assembly into the
cylinder head until it is fully seated.
Install the two bolts with the solenoid valve stay,

and tighten them to secure the thermostat housing.
Install the spark plug (page 3-7).

Install the wire band into the stay.
Connect the CKP sensor 3P (white) connector
through the stay.
8-22
CYLINDER HEADNALVES
Install the following if the cylinder was removed:
- newgasket
- tensioner lifter
- clamp stay
- two bolts
- water hose (connect to the cylinder, being careful

not to damage it)
- camshaft holder (page 8-24)
- injector (page 5-42)
- throttle body (page 5-39)
valve (page 5-511
CYLINDER HEADNALVES
CAMSHAFJIROCKER ARM
INSTALLATI0N
CAMSHAFT HOLDER ASSEMBLY
Clean the rocker arm shaft holes and camshaft bear-
ing mating areas.
Blow out the oil passage (stud bolt hole) in the cam-
shaft holder with compressed air.
Install the camshaft and the snap ring with the
chamfered (rolled) edge facing the bearing side.
Apply engine oil to the bearings.
Do not exchange Apply engine oil to the sliding surface of the rocker
the intake and arm and shaft. Place the rocker arms into the head
exhaustrockerarm cover in the direction as shown, and install the
shafts. rocker arm shafts with the thread ends facing the
sprocket side.
Install each snap ring into the camshaft holder
groove with the chamfered (rolled) edge facing the
rocker arm side.
CAMSHAFT HOLDER INSTALLATION

Be careful not to Clean the mating surfaces of the camshaft holdeF
damage the mating and cylinder head thoroughly.
surfaces.
Install the two dowel pins.
8-24
CYLINDER HEADNALVES
~ ~ ~~
Apply engine oil to the slipper surface of the rocker

arms.
Apply molybdenum oil solution to the cam lobes.
Install the camshaft holder assembly with the cam

lobes facing the cylinder head side (the punch mark
facing the front side).
Apply engine oil to the holder nut threads.
Install the four washers and nuts, and tighten them
in a crisscross pattern in several steps.
TORQUE: 27 N-m (2.8 kgf-m, 20 Ibf-ft)
Tighten the cylinder head bolts securely.
Be carefulnot to Rotate the drive pulley (crankshaft) counterclock-

jam the cam chain wise and align the T mark on the flywheel with the
and timing sprocket index notch in the crankcase cover.
on the crankshaft
when rotating the
crankshaft.
Install the tensioner holder (stopper tool; page 8-8)

if it was removed.
Apply engine oil to the cam chain and sprocket
teeth.
Install the cam sprocket onto the cam chain so that
the index line on the cam sprocket is flush with the
cylinder head surface while the "1" mark is facing up
("2" is facing down).
Install the cam sprocket onto the camshaft.
8-25
CYLINDER HEADNALVES
Cover the cylinder head with a shop towel to pre-
vent sprocket bolt from falling into the crankcase.
Align the bolt holes in the sprocket and camshaft.
Install the sprocket bolts and tighten them while
holding the drive pulley (crankshaft).
TORQUE: 9 N-m (0.9 kgf-m, 6.6 Ibf.ft)
Remove the tensioner holder from the tensioner

lifter.
Make sure the index line on the cam sprocket is
flush with the cylinder head surface when the T
mark on the flywheel is aligned with the index notch
in the crankcase cover.
Coat a new O-ring with engine oil and install it into
the tensioner lifter groove.
Install the sealing screw and tighten it.
Adjust the valve clearance (page 3-7).
Coat a new O-ring with engine oil and install it onto

Install the cap and tighten it.
TORQUE: 6 N-m(0.6 kgf-m,4.4 Ibf-ft)
Install the crankcase breather hose and the throttle

cable into each clamp.
CYLINDER HEAD COVER INSTALLATION
Be careful not to Clean the mating surfaces of the cylinder cover and
damage the mating cylinder head thoroughly.
surfaces. Blow out the oil passage in the head cover with
compressed air.
Install the joint collar into the cylinder head.

the joint collar.
Install the rubber seal.
The "UP"markof install the head cover, and the cover bolts with the
the washeris facing special washers by aligning each bolt tip with the
the bolt head. bolt hole in the cylinder head.
Tighten the cover bolts alternately i n several steps.

TORQUE: 12 Nam (1.2 kgf-m, 9 Ibf-ft)
Connect the crankcase breather hose.
- pulse secondary air injection (PAIR) check valve
(page 5-51)
9. CYLINDER/PISTON
SYSTEM COMPONENTS .............................. 9-2 CYLINDER/PISTON REMOVAL ..................... 9-5
SERVICE INFORMATION .............................. 9-3 CYLINDER/PISTON INSPECTION -.-.-..*----.----

9-6
TROUBLESHOOTlNG .................................... 9-4 PISTON/CYLINDER INSTALLATION............. 9-9
9-1
CYLINDER/PISTON
SYSTEM COMPONENTS
i
\
\
\
\,
9-2
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
This section covers maintenance of the cylinder and piston.
The cylinder and piston can be serviced with the engine installed in the frame.
Be careful not to damage the mating surfaces when removing the cylinder.
Take care not to damage the cylinder wall and piston.
The rocker arm and camshaft lubricating oil is fed through the oil passage (stud bolt hole) in the cylinder. Clean the oil
passage before installing the cylinder.
SPECIFICATIONS
SH125: Unit: mm (in)
ITEM STANDARD ] SERVICE LIMIT
Cylinder I.D. 1 52.400- 52.410(2.0630- 2.0634) I 52.44 (2.065)
Out-of-round - 0.05(0.002)
Taper - 0.05 (0.002)
Warpage - 0.05(0.002)
Piston O.D. at 10 (0.4)
from bottom 52.37- 52.39(2.062- 2.0634) 52.30(2.059)
piston pin, Piston oin hole I.D. 14.002- 14.008(0.5513- 0.5515) 14.02(0.552)
piston ring
Piston ring end gap Top 0.15 - 0.30(0.006- 0.012) 0.50(0.019)

Second 0.30- 0.45(0.012- 0.018) 0.65(0.026)
Oil (side rail) 0.20- 0.70(0.008- 0.028) 0.90(0.035)
Y -
Piston rina-to-rinq
I TOD 0.030- 0.065(0.0012- 0.0026) 0.105(0.0041)
groove clearance Se'cond 0.015 - 0.050(0.0006- 0.0020) 0.095(0.0038)
Cylinder-to-pistc I clearance 0.010- 0.040(0.0004- 0.0016) 0.10(0.004)
Connecting rod nall end I.D. 14.016- 14.034(0.5518- 0.5525) 14.06(0.554)
Connecting rod-to-piston pin clearance 0.016- 0.040(0.0006- 0.0016) 0.06(0.002)
SH150: Unit: m m (in)
Cvlinder-to-Diston clearance I 0.010- 0.040(0.0004- 0.0016) I 0.10 (0.004)

Connecting rod small end I.D. 14.016- 14.034(0.5518- 0.5525) 14.06'(
0.554)
Connecting rod-to-piston pin clearance 0.016- 0.040 (0.0006- 0.0016) 0.06(0.002)
TORQUE VALUES
Cylinder stud bolt 9 N.m (0.9kgf.m, 6.6Ibf-ft)
9-3
CY LINDER/PISTON
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
Worn, stuck or broken piston ring
Worn or damaged cylinder and piston
Cylinder headhalve problem (page 8-6)
Compression too high, overheating or knocking
Excessive carbon build-up on piston head or on combustion chamber
Excessive smoke
Worn cylinder, piston or piston ring
Improper installation of piston rings
Scored or scratched piston or cylinder wall
Cylinder headhalve problem (page 8-6)
Abnormal noise
Worn piston pin or piston pin hole
Worn connecting rod small end
Worn cylinder, piston or piston rings
Piston ring stickinglscuffing, bearing damage
Clogged oil gallery or oil strainer screen
Internal oil leak
Use of poor quality engine oil
9-4
CYLlNDER/PISTO N
CYLlNDER/PISTON REMOVAL
CYLINDER REMOVAL
Remove the cylinder head (page 8-8).
Remove the cylinder being careful not to damage
the piston with the stud bolts.
Remove the gasket and dowel pins.

Clean off any gasket material from the cylinder mat-
ing surface.
PISTON REMOVAL
Place a clean shop towel over the crankcase to pre-
vent the piston pin clip from falling into the crank-
case.
Remove the piston pin clips with pliers.
Push the piston pin out of the piston and connecting
rod, and remove the piston.
Do not damage the Spread each piston ring and remove it by lifting up
piston ring by at a point opposite the gap.
spreading the ends
too far.
9-5
CYLINDER/PISTON
- ~~ ~~~
Never use a wire Clean carbon deposits from the ring grooves with a
brush, it w / / /scratch ring that will be discarded.
the groove.
CYLINDER STUD BOLT

REPLACEMENT
Thread two nuts onto the stud and tighten them
together, and use the wrench on them to turn the
stud bolt out.
Install new stud bolts.
TORQUE: 9 N-m(0.9 kgf-m, 6.6 I b f W
Be sure to verify the stud height from the crankcase
surface.
Adjust the height if necessary.
SPECIFIED LENGTH:
Left (drive pulley) side: 181.5 mm (7.15 in)
Right (flywheel side) side: 175.5 mm (6.91 in)
CYLINDER/PISTON INSPECTION
CYLINDER
Inspect the cylinder wail for scratches or wear.
Measure the cylinder I.D. a t three levels i n the X and
Y axis. Take the maximum reading to determine the
cylinder wear.
SERVICE LIMITS:
SH125: 52.44 mm (2.065 in)
SH150: 58.04 mm (2.285 in)
Calculate the taper and out-of-round at three levels
in the X and Y axes. Take the maximum reading to
determine both measurements.
SERVICE LIMITS:
Taper: 0.05 mm (0.002 in)
Out-of-round: 0.05 mm (0.002 in)
The cylinder must be rebored and an oversize pis- Y
ton/piston rings fitted if the service limits are
exceeded.
The following oversize pistons/piston rings are
available:
0.25 mm (0.010 in)
0.50 mm (0.020 in)
The piston-to-cylinder clearance for the oversize pis-
ton must be 0.010 - 0.040 mm (0.0004 - 0.0016 in).
9-6
~~
CYLINDER/PISTON
Check the cylinder for warpage with a straight edge
and feeler gauge in the directions shown.
PISTON/ PISTON RING

Inspect the piston rings for movement by rotating
the rings. The rings should be able to move in their
grooves without catching.
Push the ring until the outer surface of the piston
ring is nearly flush with the piston and measure the
ring-to-groove clearance.
SERVICE LIMITS: Top: 0.105 mm (0.0041 in)
Second: 0.095 mm (0.0038 in)
Insert each piston ring into the bottom of the cylin-

der squarely using the piston.
Measure the ring end gap.
SERVICE LIMITS:
SH125: Top: 0.50 mm (0.019 in)
Second: 0.65 mm (0.026 in)
Oil (side rail): 0.90 mm (0.035 in)
SH150 Top: 0.45 mm (0.018 in)
Second: 0.70 mm (0.028 in)
Oil (side rail): 0.90 mm (0.035 in)
Measure the piston pin hole I.D. Take the maximum

reading to determine I.D.
Measure the piston pin O.D. at piston and connect-
ing rod sliding areas.
Calculate the piston-to-piston pin clearance.
~ ~ ~~~
Measure the piston O.D. at the point 10 mm (0.39 in)

from the bottom and 90" to the piston pin hole.
SERVICE LIMITS:
FES125: 52.30 mm (2.059 in)
FESIBO: 57.90 mm (2.280 in)
Calculate the cylinder-to-piston clearance (cylinder
I.D.: page 9-6).
Measure the connecting rod small end I.D.

Calculate the connecting rod-to-piston pin clear-
ance.
9-8
CYLINDER/PISTON
PISTONKYLINDER INSTALLATION
PISTON INSTALLATION
Apply engine oil to the ring grooves.
Be careful not to Carefully install the piston rings into the piston ring
damage the piston grooves with the marks facing up. MARK "R"
and rings. Do not confuse the top and second rings.
To install the oil ring, install the spacer first, then
I MARK "R N
I'
install the side rails.

Stagger the piston ring end gaps 120 degrees apart
from each other.
Stagger the side rail end gaps as shown.
20 mm or more
Placeashop towel Apply engine oil to the piston pin and piston pin
at the opening of hole.
the crankcase to
Install the piston with the "IN" mark facing the intake
prevent the piston
side.
Din c l i ~ sfrom fallina
' into the crankcase. Install the piston pin and new pin clips.
Make sure the piston pin clips are seated
securely.
Do not align the piston pin clip end gap with the
piston cut-out.
CYLINDER INSTALLATION
Be careful not to Clean the mating surfaces of the cylinder and crank-
damage the mating case thoroughly.
surfaces. Blow out the oil passage (stud bolt hole) in the cylin-
der with compressed air.
Install the dowel pins and a new gasket.
9-9
CYLINDER/ PISTON ~~~~ ~
Apply engine oil to the cylinder wall, piston outer

surface and piston rings.
Route the cam chain through the cylinder and install
the cylinder over the piston while compressing the
piston rings with your fingers.
Install the cylinder head (page 8-21 1.
9-10
10. DRIVE AND DRIVEN PULLEYWCLUTCH
SYSTEM COMPONENTS ............................ 10-2 DRIVE BELT .................................................. 10-8
SERVICE INFORMATION ............................ 10-3 DRIVE PULLEY............................................... 0-9
TROUBLESHOOTlNG .................................. 10-5 CLUTCH/DRIVEN PULLEY.........................
LEFT CRANKCASE COVER ......................... 10-6

DRIVE AND DRIVEN PULLEYSKLUTCH
SYSTEM COMPONENTS
36 Ibf.ft)
, 7 I bf.ft)
10-2
SERVICE INFORMATION
GENERAL
This section covers maintenance of the drive pulley, driven pulley and clutch.
These services can be done with the engine installed in the frame.
Avoid getting grease and oil on the drive belt and driveldriven pulley faces in order to prevent belt slippage.
Do not apply grease to the weight rollers.
SPECIFICATIONS
Drive belt width 22.5 (0.89) 21.5 (0.85)
Weight roller O.D. 19.92 - 20.08 (0.784 - 0.791) 19.5 (0.77)
Driven Dullev . " free lenath
Face smina " 143.3 (5.64) 123.0 (4.84)

Drive belt width 22.5 (0.89) 21.5 (0.85)
Weight roller O.D. 19.92 - 20.08 (0.784 - 0.791) 19.5 (0.77)
- thickness
Lininn 4.0 (0.16) 2.0 (0.08)
Driven pulley Face spring free length 143.3 (5.64) 123.0 (4.84)
TORQUE VALUES
Clutch lock nut 54 N.m (5.5 kgf.m, 40 let.ft)
Clutch outer nut 49 N.m (5.0 kgfm, 36 let31
Drive pulley face nut 59 N.m (6.0 kgf.m, 44 Ibf.ft) Apply engine oil to the threads and seating surface.
Left crankcase cover bolt 10 N.m (1.0 kgfm, 7 Ibf.ft)
Belt case air cleaner housing bolt See page 10-8.
10-3
TOOLS
Universal holder Flywheel holder Clutch spring compressor
07725-0030000 07725-0040000 07LME-GZ40200
Socket wrench, 39 x 41 m m Bearing remover, 20 m m Fork seal driver attachment, 37.2 mm

07GMA-KS40100 07931- MA70 00 0 07747-0010600
Driver Attachment, 28 x 30 m m Pilot, 22 m m

07749-0010000 07946-1870100 07746-0041000
10-4
DRIVE AND DRIVEN PULLEYWCLUTCH
TROUBLESHOOTING
Engine starts but scooter won't move
Worn drive belt
Damaged ramp plate
Worn or damaged clutch shoe
Broken driven face spring
Engine stalls or scooter creeps
Broken clutch shoe spring
Poor performance at high speed or lack of power
Worn drive belt
Weak driven face spring
Worn weight rollers
Contaminated pulley faces
10-5
DRIVE AND DRIVEN PULLEYSICLUTCH
LEFT CRANKCASE COVER
REMOVAL
- two bolts and belt case air cleaner
- O-ring
- nut and cable guide

- bolt and cable clamp
- tapping screw
- two bolts and left passenger footrest
BOLTS
- five bolts
- left crankcase cover
- rubberseal
- two dowel pins
INSTALLATION
Check the rubber seal and replace it if necessary.
Clean the rubber seal groove i n the left crankcase
cover.
Install the rubber seal onto the left crankcase cover.
Install the two dowel pins into the left crankcase.
Be careful not to Install the left crankcase cover onto the left crank-
damage the rubber case by aligning the holes with the dowel pins.
seal.
Install the left crankcase cover bolts and tighten
them in a crisscross pattern in two or three steps to
the specified torque.
Route the rear Install the left passenger footrest and tighten the
brake cable and fuel two bolts.
drain hose properly
(page 1-77).
10-7
DRIVE AND DRIVEN PULLEYSKLUTCH ~ ~~ ~~
Install the tapping screw.

Install the cable clamp and tighten the bolt.
Install the cable guide and tighten the nut.
Install a new O-ring onto the left crankcase cover.
Install the belt case air cleaner and tighten the two
bolts.
Take care not to ruin TORQUE: 10 N-m (1.0 kgf-m, 7 Ibf-ft)
the female threads
that were made If the left crankcase cover was replaced, tighten the
when the bolt (CT bolt with the following torque value.
bolt) was tightened TORQUE: 14 N-m (1.4 kgf-m, 10 Ibf.ft)
first time.
DRIVE BELT
REMOVAL
- left crankcase cover (page 10-6)
- drive pulley face (page 10-9)
- clutch outer (page 10-12)
Remove the clutch/driven pulley assembly with the
drive belt from the drive shaft.
Remove the drive belt from the driven pulley.
Check the drive belt for cracks, separation or abnor-
mal or excessive wear.
DRIVE BELT
Measure the drive belt width. \
INSTALLATION
Clean any oil and grease from the driven faces.
Spread the driven pulley width by compressing the
driven face spring while turning the movable driven
face clockwise, and install the drive belt into the
driven pulley.
Jake care not to get Install the clutch/driven pulley assembly onto the
grease of the driven drive shaft, and the drive belt onto the drive face
face inner surface boss.
to the splines and
Of
drive - clutch outer (page 10-20)
shaft. - drive pulley face (page 10-11)
- left crankcase cover (page 10-7)
DRIVE PULLEY
REMOVAL
Remove the left crankcase cover (page 10-6).
Hold the drive pulley face with special tool and
loosen the drive pulley face nut.
TOOL:
Universal holder 07725-0030000
Remove the nut, washer and drive pulley face.
10-9
Remove the drive belt from the crankshaft.
Remove the movable drive face assembly while

holding the back of the ramp plate.
Remove the drive face boss from the movable drive
face assembly.
Remove the ramp plate, slide pieces and weight

rollers.
INSPECTlON
WEIGHT ROLLER
Check each roller for wear or damage.
Measure the weight roller O.D.
MOVABLE DRIVE FACE
Check the drive face boss for wear or damage.
Measure the face bushing I.D.
SERVICE LIMIT: SH125: 24.09 mm (9.484 in)
SH150: 24.064 mm (9.4740 in)
Measure the boss O.D.
SERVICE LIMIT: SH125: 23.93 mm (0.942 in)
SH150: 23.956 mm (0.9431 in)
INSTALLATI0N
Clean any oil and grease from the weight rollers.
Install the weight rollers on the movable drive face.
Install the slide piece and ramp plate.
Clean any oil and grease from the drive face and the
drive belt.
Install the drive face boss into the movable drive
face assembly.
Install the movable drive face assembly onto the
crankshaft while holding the ramp plate.
Install the drive belt onto the drive face boss.
Clean any oil and grease from the drive pulley face.
Install the drive pulley face and washer.
Apply engine oil to the threads and seating surface
of the drive pulley face nut, and install the nut.
~~~
10-11
Hold the drive pulley face with the special tool and
tighten the nut to the specified torque.
TOOL:
Universal holder 07725-0030000
TORQUE: 59 N-m (6.0 kgf-m, 44 Ibf4-t)

Install the left crankcase case cover (page 10-7).
CLUTCHIDRIVEN PULLEY
REMOVAL
Remove the drive pulley face (page 10-9).
Hold the clutch outer with the special tool and
loosen the clutch outer nut.
TOOL:
Flywheel holder 07725-0040000
Remove the nut, washer and clutch outer.
Remove the clutch/driven pulley assembly with the

drive belt from the drive shaft.
Remove the drive belt from the driven pulley.
CLUTCH OUTERISHOE LINING INSPECTION

Check the clutch outer for wear or damage.
Measure the clutch outer I.D.
SERVICE LIMIT 125.5 mm (4.94 in)
Check the clutch shoes for wear or damage.
Measure the thickness of each lining.
SERVICE LIMIT 2.0 mm (0.08 in)
DISASSEMBLY
CLUTCH/DRWEN PULLEY
Set the clutch spring compressor onto the clutch/
driven pulley by aligning the bosses with the holes
in the clutch.
TOOL:
Clutch spring compressor 07LME-GZ40200
To prevent loss of Hold the clutch spring compressor in a vise and
tension, do not compress the clutch/driven pulley and remove the
compress the clutch/driven pulley nut using the special tool.
clutch spring more
than necessary to
TOOL:
the Socket wrench, 39 X 41 mm 07GMA-KS40100
driven pulley nut
Loosen the clutch spring compressor gradually and

remove the following:
- clutch assembly
- spring collar
- driven face spring
- spring cap
- spring seat
- driven pulley assembly
CLUTCH
Remove the E-clips and clutch side plate.
Remove the shoe springs and clutch shoes from the

drive plate.
10-13
Remove the rubber dampers f r o m the drive plate.
DRIVEN PULLEY
Remove the seal collar f r o m the driven pulley.
Remove the guide pins and rollers from the driven

pulley.
Remove the movable driven face f r o m the driven
face.
Remove the O-rings f r o m the movable driven face.

Remove the oil seals f r o m the movable driven face.
10-14
DRIVEN FACE BEARING
REPLACEMENT
Set the special tools to the driven face.
TOOLS:
Fork seal driver
attachment, 37.2 mm 07747-0010600
Bearing remover, 20 mm 07931-MA70000
Remove the driven face needle bearing using the
special tools.
Remove the snap ring and remove the ball bearing.
Pack new ball bearing cavities with grease.

Press the ball bearing into the driven face with the
sealed side facing down until it is fully seated using
the special tool.
TOOL:
Driver 07749-0010000
Install the snap ring to the groove in the driven face

securely.
Apply 7 - 8 g of grease to the driven face inner sur-
face.
Apply grease to a new needle nearing rollers.
Press the needle bearing into the driven face with
the marked side facing up until it is flush with the
driven face using the special tools.
TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 22 mm 07746-0041000
INSPECTlON
DRIVEN FACE SPRING
Measure the driven face spring free length.
DRIVEN FACE
Check the driven face for scratches, scoring or dam-
age.
Measure the driven face boss O.D.
MOVABLE DRIVEN FACE

Check the movable driven face for scratches, scar-
ing or damage.
Check the guide grooves for stepped wear or dam-
age.
Measure the movable driven face I.D.
10-16
ASSEMBLY
MOVABLE DRIVEN FACE
BALL BEARING SNAP RING
\ GUIDEPINS
/
\ \ ROLLERS
\
?/ /
\
NEEDLE 'BEARING
,.'\ OIL SEAL

,
,
DRIVEN FACE
9
,
- 'CLUTCH SIDE PLATE
CLUTCH/DRIVEN PULLEY NUT
/ \ SHOE SPRINGS
DRIVE PLATE RUBBER DAMPERS
I NOTICE I
Apply specified quantity of grease to the inside
of the driven face and the guide grooves in the
movable driven face.
Avoid getting grease or oil on the clutch shoe lin-
ings and driven faces. Discard contaminated
shoes and clean contaminated faces with a high
quality degreasing agent.
7-89
6
DRIVEN PULLEY
Apply engine oil to new oil seal lips and outer sur-
faces, and install them into the movable driven face.
Coat new O-rings with engine oil and install them
into grooves in the movable driven face.
Clean any oil and grease from the pulley face.
Install the movable driven face onto the driven face.
Install the rollers and guide pins.
Apply 2 - 2.5 g of grease to the guide grooves.
Install the seal collar onto the driven pulley.

Clean any oil and grease from the pulley face.
CLUTCH
Install the rubber dampers onto the drive plate.
Install the clutch shoes and shoe springs onto the

drive plate.
10-18
~ _ _
Install the clutch side plate and secure it with the E-
clips
CLUTCHIDRIVEN PULLEY
Assemble the fo Ilowing:
- clutch assembly
- spring collar SPRING SEAT
- driven face spring
- spring cap
- spring seat
- driven pulley assembly
DRIVEN
PULLEY
I SPRING COLLAR I
Set the clutch spring compressor over the clutch/
driven pulley assembly by aligning the bosses with
the holes in the clutch.
TOOL:
Clutch spring compressor 07LME-GZ40200
Toprevent loss of Compress the driven face spring while aligning the
tension, do not flat surfaces of the driven pulley and clutch.
compress the Install the clutch/driven pulley nut.
spring Hold the spring compressor in a vice and tighten the
than necessary to
clutch/driven pulley nut using the special tool to the
install the clutch/ specified torque.
driven pulley nut.
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100
TORQUE: 54 N-m (5.5 kgf-m, 40 Ibf-ftl

Remove the clutch/driven pulley assembly from the
spring compressor.
~~
INSTALLATlON
Install the drive belt onto the clutch/driven pulley
assembly and drive face boss (page 10-9).
Clean any oil and grease from the clutch outer.
Install the clutch outer, washer and clutch outer nut.
Hold the clutch outer with the special tool and
tighten the clutch outer nut to the specified torque.
TOOL:
TORQUE: 49 N.m (5.0 kgf-m,36 Ibf-ft)

Install the drive pulley face (page 10-11).
FINAL REDUCTION
Ilm
SYSTEM COMPONENTS ............................ 11-2 FINAL REDUCTION DISASSEMBLY/

lNSPECTlON ................................................. 11-6
SERVICE INFORMATION ............................ 11-3
BEARING REPLACEMENT ........................... 11-8
TROUBLESHOOTlNG .................................. 11-5
FINAL REDUCTION ASSEMBLY ..................11-9
FINAL REDUCTION
SYSTEM COMPONENTS
11-2
FINAL REDUCTION
SERVICE INFORMATION
GENERAL
The final reduction can be serviced with the engine installed in the frame.
Refer to page 3-13 for final reduction oil level check and change.
When installing the drive shaft, be sure to use the special tools; position the special tools against the bearing inner race
and pull the drive shaft into the bearing until it is fully seated.
ITEM SPECIFICATIONS
Final drive oil capacity After draining 190 cm3 (6.4 US oz, 6.9 Imp oz)
After disassembly 220 cm3 (7.4 US 02.7.7 Imp oz)
Viscositv: SAE IOW-30
TOOLS
Case puller Bearing remover set, 12 mm Bearing remover head, 12 mm
07SMC-0010001 07936-1660101 07936-1660110
Bearing remover shaft Bearing remover, 20 mm Bearing remover handle

07936-1660120 07936-3710600 07936-3710100
Remover weight Driver Attachment, 32 x 35 mm

07741-0010201 07749-0010000 07746-0010100
11-3
FINAL REDUCTION
Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 44 x 49.5 mm
07746-0010200 07746-0010300 07945-3330300
Attachment, 41 x 52 mm Pilot, 12mm Pilot, 20 mm

07948-8830000 07746-0040200 07746-0040500
Pilot, 22 mm Pilot, 25 mm Assembly shaft

07746-0041000 07746-0040600 07965-VM00200
Assembly collar
07LMF-KAB0110
FINAL REDUCTION
TROUBLESHOOTING
Engine does start but scooter wont move
Damaged final reduction
Seized final reduction
Faulty drive pulley and driven pulley/clutch (page 10-5)
Abnormal noise
Worn, seized or chipped gears
Worn or damaged final reduction bearing
Oil leak
Oil level too high
Worn or damaged oil seal
Cracked crankcase and/or final reduction case
FINAL REDUCTION
FINAL REDUCTION DISASSEMBLY/
INSPECTION
- clutch/driven pulley (page 10-12)
- rear brake shoes and arm (page 16-18)
Drain the final drive oil (page 3-13)
Remove the brake cable from the reduction case.
Remove the seven bolts, sealing washer and clamp.
Remove the final reduction case.
Remove the gasket and dowel pins.

Clean any gasket materials from the final reduction
case mating surfaces.
Remove the thrust washer, counter gear,

countershaft and final gear shaft.
Check the bearings in the crankcase.

Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly i n
the crankcase.
Check the drive shaft oil seal for wear, damage or
deterioration.
11-6
~
Remove the final gear shaft oil seal.

Check the bearings in the final reduction case.
Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly i n
the crankcase.
Use two 10 m m nuts to the case puller.

TOOL:
Case puller 07SMC-0010001
Remove the drive shaft using the case puller.

Remove the oil seal from the crankcase.
If the bearing comes out with the drive shaft,

remove it with the commercially available bearing
puller.
11-7
FINAL REDUCTION
Check the countershaft, counter gear, final gear
shaft and drive shaft for wear or damage.
BEARING REPLACEMENT
Disassemble the final reduction (page 11-6).
LEFT CRANKCASE
Becarefulnot to Remove the drive shaft bearing if it is left in the
damage the final crankcase.
reduction case Remove the countershaft and final gear shaft bear-
mating surface. ings using the special tools.
TOOLS:
Countershaft bearing:
Bearing remover set, 12 mm 07936-1660101
- Bearing remover head, 12 mm 07936-1660110
- Bearing remover shaft 07936-1660120
Final gear shaft bearing:
Bearing remover, 20 mm 07936-3710600
Bearing remover handle 07936-3710100
Apply engine oil to new bearing cavities.
Drive the bearings into the left crankcase with the
marked side facing the attachment until it is fully
seated, using the special tools.
TOOLS:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Drive shaft bearing:
Driver 07749-0010000
Attachment, 44 x 49.5 mm 07945-3330300
Pilot, 22 mm 07746-0041000
11-8
FINAL REDUCTION CASE
Be careful not to Drive the final gear shaft bearing out of the reduc-
damage the final tion case.
reduction case mat-
Remove the drive shaft and countershaft bearings
ing surface.
using the special tools.
TOOLS:
Bearing remover set, 12 mm 07936-1660101
- Bearing remover head, 12 mm 07936-1660110
- Bearing remover shaft 07936-1660120
Apply engine oil to new bearing cavities.

Drive the bearings into the final reduction case with
the marked side facing up until it is fully seated, using
the special tools.
TOOLS:
Drive shaft bearing:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
Driver 07749-0010000
Attachment, 41 x 52 mm 07948-8830000
Pilot, 25 mm 07746-0040600
FINAL REDUCTION ASSEMBLY

Clean the mating surfaces of the reduction case and
crankcase.
Apply engine oil to lips and outer surface of a new
final gear shaft oil seal.
Install the oil seal with the flat side facing down
(bearing side) until it is flush with the final redaction
case.
Install the drive shaft into the bearing.
Position the assembly collar against the drive shaft
bearing inner race and pull the drive shaft into the
bearing until it is fully seated.
TOOLS:
Assembly shaft 07965-VM00200
Assembly collar 07LMF-KAB0110
Apply engine oil t o the lips and outer surface of a

new drive shaft oil seal.
Install the oil seal until it is flush with the crankcase
using the same tools.
TOOLS:
Assembly collar 07LMF-KAB0110
Apply engine oil t o the gear and shaft sliding sur-

faces.
Mesh the final gear and counter gear, and install the
final gear shaft, countershaft and counter gear into
the left crankcase.
Install the thrust washer onto the countershaft

Install the t w o dowel pins and a new gasket.
Install the final reduction case.
Install the seven bolts with the clamp and a new
sealing washer (indicated by the triangular mark),
and tighten them in a crisscross pattern in 2 or 3
steps.
Install the brake cable into the cable holder on the
reduction case.
Fill the final reduction case with the recommended
oil (page 3-13).
- rear brake arm and shoes (page 16-20)
11-11
12. ALTERNATORISTARTER CLUTCH
SYSTEM COMPONENTS ............................ 12-2 RIGHT CRANKCASE COVER ....................... 12-5
SERVICE INFORMATION ............................ 12-3 STATOR/CRANKSHAFT POSITION (CKP)

SENSOR ........................................................ 12-9
FLYWHEEL/STARTER CLUTCH................. 12-10
SYSTEM COMPONENTS
86 Ibf.ft)
12-2
ALTERNATOWSTARTER CLUTCH
SERVICE INFORMATION
GENERAL
This section covers the removal and installation of the flywheel, starter clutch and alternatorkrankshaft position (CKP)
sensor.
These service can be done with the engine installed in the frame.
Refer to page 17-8 for alternator inspection.
Refer to page 18-6 for CKP sensor inspection.
SPECIFICATIONS
Starter driven gear Boss O.D. 39.622 - 39.635 (1.5599 - 1.5604) 39.58 (1.558)
Bushing I.D. 22.026 - 22.045 (0.8672 - 0.8679) 22.10 (0.870)
Starter clutch outer I.D. 56.279 - 56.309 (2.2157 - 2.2169) 56.36 (2.219)
TORQUE VALUES
Stator bolt 12 N.m (1.2 kgf.m, 9 Ibf.ft)
Crankshaft position (CKP) sensor bolt 5 N.m (0.5 kgf.m, 3.7 1bf.R)
Starter clutch outer bolt 30 N.m (3.1 kgfm, 22 Ibf.ft) Apply locking agent to the threads.
Flywheel nut 116 N.m (11.8 kgfm, 86 Ibf.ft) Apply engine oil to the threads and seating sur-
face.
12-3
TOOLS
~ ~~~
Flywheel holder Flywheel puller Driver

07725-0040000 07KMC-HE00100 07749-0010000
Attachment, 22 x 24 m m Pilot, 14 m m Bearing remover set, 15 mm

07746-0010800 07746-0041200 07936-KC10500
Bearing remover shaft Bearing remover head, 15 mm Remover weight

07936-KC10100 07936-KC10200 07741-0010201
TROUBLESHOOTING
Engine does not turn
Faulty starter one-way clutch
Damage starter reduction gear
12-4
ALTERNATORISTARTER CLUTCH
RIGHT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-91,
- luggage box (page 2-51,
- floor under cover (page 2-8).
- exhaust pipe/muffler (page 2-15).
Remove the alternator 3P (white) connector from
the frame and disconnect it.
Remove the alternator wire from the clamp.
Disconnect the crankshaft position (CKP) sensor 3P

(white) connector.
Remove the two wire bands from the stay.
Release the CKP sensor and alternator wires from
the wire guide and remove them out of the engine.
Remove the tapping screw and two bolts.

Spread the rear end of the floor panel and remove
the right passenger footrest.
Disconnect the lower radiator hose and bypass hose

from the water pump cover.
12-5
~~ ~
Disconnect the water hose from the right crankcase

cover.
Loosen the three water pump cover bolts.
Support the scooter using a safety stand or hoist.

Retract the center stand.
Unhook the center stand return spring from the
spring pin of the right crankcase cover.
Support the scooter on its center stand.
Remove the air chamber bolt.

The right crankcase Loosen the ten bolts in a crisscross pattern in 2 or 3
cover (stator) is steps, and remove the bolts, ground wire terminal
magnetically and right crankcase cover.
attracted to the fly-
wheel, be careful
during removal.
Remove the dowel pins and gasket.
12-6
INSTALLATION
Take care not to Remove the snap ring.
damage the stator. Remove the oil seal using the special tools.
TOOLS:
Bearing remover set, 15 mm 07936-KC10500
- Bearing remover head, 15 mm 07936-KC10200
- Bearing remover shaft 07936-KC10100
Apply engine oil to a new oil seal lip.
Install the oil seal into the right crankcase cover with
the marked side facing up until it is fully seated
using the special tools.
TOOLS:
Driver 07749-0010000
Attachment, 22 x 24 mm 07746-0010800
Pilot, 14 mm 07746-0041200
Install the snap ring into the right crankcase cover
groove securely.
Install the dowel pins and a new gasket.
Remove the three bolts and water pump cover from

the right crankcase cover.
Remove the dowel pins and O-ring.
The right crankcase Install the right crankcase cover by aligning the oil
cover (stator) is pump shaft tab with the water pump shaft groove.
magnetically
attracted to the fly-
wheel, be careful
during ins tallation.
Install the ground wire terminal and ten bolts, and

tighten the bolts in a crisscross pattern in 2 or 3
steps.
Install the air chamber bolts and tighten it.
12-7
Install the dowel pins into the right crankcase cover.
Install a new O-ring into the water pump cover
groove.
Install the water pump cover.
Tighten the water pump cover bolts.

Connect the water hose to the right crankcase cover.
Connect the lower radiator hose and bypass hose to

the water pump cover.
Support the scooter using a safety stand or hoist.

Retract the center stand.
Hook the center stand return spring to the spring
pin of the right crankcase cover.
Support the scooter on its center stand.
ALTERNATORSTARTER CLUTCH
Spread the rear end of the floor panel and install the
right passenger footrest.
Install the two bolts and tapping screw, and tighten
them.
Route the wires Install the CKP sensor and alternator wires into the
properly (page 1- wire guide and install the two wire bands onto the
171. stay.
Connect the CKP sensor 3P (white) connector
through the stay.
Secure the alternator wire with the clamp.

Connect the alternator 3P white connector and
install it onto the frame.
- exhaust pipe/muffler (page 2-15).
- floor under cover (page 2-8).
- luggage box (page 2-5).
Fill the crankcase with the recommended engine oil
(page 3-9).
Fill the system with the recommended coolant and
bleed any air (page 6-7).
STATORKRANKSHAFT POSITION
(CKP) SENSOR
REMOVAL
Remove the right crankcase cover (page 12-51,
Remove the following from the right crankcase
cover:
- two flange bolts and CKP sensor
- three socket bolts and stator
- wire grommet
12-9
INSTALLATI0N
Install the stator and tighten the three socket bolts.
TORQUE: 12 Nmm
(1.2 kgf-m, 9 Ibf-ft)
Install the CKP sensor and tighten the two flange

bolts.
TORQUE: 5 N.m (0.5 kgf-m, 3.7 Ibf.ft1

Apply sealant to the grommet seating surface and
install it into the right crankcase cover groove prop-
erly.
Install the right crankcase cover (page 12-7).
FLYWHEELBTARTER CLUTCH
REMOVAL
Remove the right crankcase cover (page 12-51,
Remove the starter reduction gear shaft and reduc-
tion gear.
Hold the flywheel with the special tool and loosen

the flywheel nut.
TOOL:
Remove the flywheel nut and washer.
12-10
ALTERNATORSTARTER CLUTCH
Remove the flywheel using the special tool.
TOOL:
Flywheel puller 07KMC-HE00100
Remove the woodruff key from the crankshaft.
DISASSEMBLY
Remove the starter driven gear from the starter
clutch on the flywheel while turning it clockwise.
Hold the flywheel with the special tool and remove

the starter clutch outer bolts.
TOOL:
Remove the starter clutch assembly from the fly-
wheel.
Remove the sprag clutch from the clutch outer.
INSPECTION
Check the starter driven gear and reduction gear
teeth for wear or damage.
Measure the starter driven gear bushing I.D.
Measure the starter driven gear boss O.D.
Check the starter clutch outer and sprag clutch for

abnormal wear or damage.
Measure the starter clutch outer I.D.
ASSEMBLY
Apply engine oil to the sprag clutch.
Install the sprag clutch into the clutch outer with the
marked side facing to the flywheel side.
Install the clutch outer onto the flywheel with the
marked side facing to the starter driven gear side.
12-12
Apply locking agent to the starter clutch outer bolt
threads and install them.
Hold the flywheel with the special tool and tighten
the bolts.
TOOL:
TORQUE: 30 N.m (3.1 kgf.m, 22 Ibf-ft)
Apply engine oil to the starter driven gear teeth and

sprag clutch contacting area.
Install the starter driven gear into the starter clutch
on the flywheel while turning it clockwise.
Check that the starter driven gear turns clockwise
smoothly and does not turn counterclockwise.
INSTALLATION
Install the woodruff key in the crankshaft key
groove.
Apply molybdenum oil solution to the starter driven
gear sliding surface of the crankshaft.
Clean any oil from the tapered portions of the crank-

shaft and flywheel.
Install the flywheel onto the crankshaft, aligning the
groove with the woodruff key.
ALTERNATORETARTER CLUTCH
Apply engine oil to the flywheel nut threads and
seating surface.
Install the washer and nut.
Hold the flywheel with the special tool and tighten
the nut.
TOOL:
TORQUE: 116 N.m (11.8 kgf-m, 86 ibf4-t)
Apply engine oil to the starter reduction gear and

shaft.
Install the starter reduction gear and insert the shaft.
Install the right crankcase cover (page 12-7).
12-14
13. CRANKCASEKRANKSHAFT
SYSTEM COMPONENTS ............................ 13-2 CRANKCASE SEPARATION......................... 13-5
SERVICE INFORMATION ............................ 13-3 CRANKSHAFT lNSPECTlON ........................ 13-7
TROUBLESHOOTlNG .................................. 13-4 CRANKCASE ASSEMB Ly ............................ 13-7

SYSTEM COMPONENTS
10 N.m (1.0 kgf.m, 7 Ibf.ft)
I
CRANKCASEICRANKSHAFT
SERVICE INFORMATION
GENERAL
This section covers the crankcase separation to service the crankshaft.
The following parts must be removed before separating the crankcase.
- engine (page 7-2)
- cylinder head (page 8-2)
- cylinder and piston (page 9-2)
- starter motor (page 19-2)
- flywheel (page 12-2)
- oil pump (page 4-3)
- drive pulley and clutch/driven pulley (page 10-2)
In addition t o the parts listed above, remove the final reduction (page 11-2) when the left crankcase half must be
replaced.
Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves.
Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
When installing the crankshaft, be sure to use the special tools; position the special tools against the bearing inner race
and pull the crankshaft into the bearing until it is fully seated.
Prior t o assembling the crankcase halves, apply sealant to their mating surfaces, Wipe off excess sealant thoroughly.
SPECIFICATIONS
Crankshaft runout - 0.10 (0.004)
Connecting rod big end side clearance 0.10 - 0.35 (0.004 - 0.014) 0.60 (0.024)
Connecting rod big end radial clearance 0 - 0.008 (0- 0.0003) 0.05 (0.002)
TORQUE VALUES
Cam chain tensioner pivot bolt 10 N.m (1.0 kgf.m, 7 Ibf.ft)
13-3
CRANKCASEKRANKSHAFT
TOOLS
Attachment, 72 x 75 m m Pilot, 35 mm Driver
07746-0010600 07746-0040800 07749-0010000
Case puller Universal bearing puller Assembly shaft

07SMC-0010001 07631-0010000 07965-VM00200
~~
Assembly collar Assembly shaft adaptor

07965-VM00100 07YM F-KFG0300
TROUBLESHOOTING
Abnormal noise
Worn crankshaft bearing
Worn connecting rod big end bearing
Worn connecting rod small end
13-4
CRANKCASEKRANKSHAFT
CRANKCASE SEPARATION
Be carefulnot to Remove the following:
damage the crank- -
engine (page 7-4)
case mating sur- -
cylinder head (page 8-8)
-
faces. cylinder and piston (page 9-5)
- drive pulley (page 10-9)
- two bolts
- oil seal stopper plate
- pivot bolt and O-ring

- cam chain tensioner slider
Loosen the three crankcase bolts in a crisscross pat-

tern in two or three steps and remove them.
Place the crankcase with the left crankcase down

and separate the right crankcase from the left crank-
case using the special tool.
TOOL:
CRANKCASEKRANKSHAFT
Remove the dowel pins f r o m the right crankcase.
Clean any sealant f r o m the crankcase mating sur-
face.
Slide the cam chain off the timing sprocket o n the

crankshaft.
Remove the crankshaft f r o m the left crankcase
using the special tool.
TOOL:
Remove the cam chain.
Remove the oil seal f r o m the left crankcase.
If the bearings come out with the crankshaft,

remove it with the special tool.
TOOL:
Universal bearing puller 07631-0010000
CRANKCASEXRANKSHAFT
CRANKSHAFT INSPECTION
Separate the crankcase (page 13-5).
Measure the connecting rod big end side clearance
with a feeler gauge.
Measure t he connecting rod big end radial clear-

ance a t two points in the directions indicated by the
arrows.
Set the crankshaft o n a stand or V-blocks and mea-

sure the runout a t points as shown using a dial indi-
cator.
CRANKCASE ASSEMBLY
Be careful not to Remove the crankshaft bearings if they are left in
damage the crank- the crankcases.
case mating sur-
faces.
13-7
Apply 2 cc minimum of engine oil to each new
crankshaft bearing.
Drive in each new crankshaft bearing into the crank-
case with the marked side facing up until it is fully
seated.
TOOLS:
Driver 07749-0010000
Attachment, 72 x 75 mm 07746-0010600
Pilot, 35 mm 07746-0040800
After installation, check that the height from the
crankcase mating surface to the bearing surface is
within specification.
SPECIFIED HEIGHT:
Right side: 24.54 - 24.62 mm (0.966 - 0.969 in)
Left side: 21.55 - 21.63 mm (0.848 - 0.852 in)
Clean the insides and mating surface of the crank-
cases.
Check for cracks or other damage.
Dress any roughness or irregularities with an oil
stone.
Apply 3 cc minimum of engine oil to the connecting

rod big end bearing.
Install the special tools onto the left crankshaft bear-
ing inner race and crankshaft.
TOOLS:
Assembly collar 07965-VM00100
Be careful not to Draw the crankshaft into the crankshaft bearing
bend the connect- inner race.
ing rod by letting it
press against the
crankcase mating
surface.
Apply sealant to the right crankcase mating surface.
CRANKCASEKRANKSHAFT
Install the two dowel pins into the left crankcase.
Install the right crankcase over the left crankcase.

Install the assembly shaft adaptor to the right crank-
shaft.
TOOLS:
Assembly shaft adaptor 07YMF-KFG0300
Install the special tools onto the left crankshaft bear-

ing inner race and crankshaft.
TOOLS:
Assembly collar 07965-VM00100
Draw the crankshaft into the crankshaft bearing
inner race.
Install the three crankcase bolts and tighten them in

a crisscross pattern in t w o or three steps.
Apply engine oil to the timing sprocket and cam
chain.
Install the cam chain onto the timing sprocket.
Apply engine oil to a new oil seal lip and outer sur-
face.
Install a new oil seal squarely until it is flush with
the left crankcase.

the cam chain tensioner pivot bolt.
Install the cam chain tensioner slider and pivot bolt,
and tighten the bolt.
TORQUE: 10 N.m (1.0 kgf-m, 7 Ibf-ftl
Install the oil seal stopper plate onto the left crank-
case and tighten the bolts.
- drive pulley (page 10-11)
- cylinder and piston (page 9-91
- cylinder head (page 8-21 1
- engine (page 7-7)
14. FRONT WHEEL/SUSPENSION/STEERlNG
SYSTEM COMPONENTS ............................ 14-2 FORK ........................................................... 14-12
SERVICE INFORMATION ............................ 14-3 HANDLEBAR ............................................... 14-19
TROUBLESHOOTlNG .................................. 14-6 STEERING STEM ........................................ 14-22
FRONT WHEEL ............................................ 14-7

SYSTEM COMPONENTS
12 Nem (1.2 kgf.m, 9 Ibf.ft)
39 N
i
i
+
Ad-1,
-...-
/
30 N.m (3.1 kgf.m,
22 Ibf.ft)
68 N.m (6.9 kgf.-rn, 50 Ibf.ft)
14-2
SERVICE INFORMATION
GENERAL
Raise the front wheel off the ground by supporting the frame securely when servicing the front wheel, suspension and
steering stem. A hoist or equivalent is required to support the scooter.
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
After installing the front wheel, check the brake operation by applying the front brake lever.
Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE".
Refer to page 16-2 for brake system service.
Refer to page 20-14 for handlebar switch inspection.
SPECIFICATIONS
pressure Driver and passenger 175 kPa (1.75 kgf/cm2, 25 psi) -
Axle runout - 0.2 (0.01 1
Wheel rim Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel balance weight - 70 g (2.50~)
max.
Fork Spring free length 257.2 (10.13) 252 (9.9)
Tube runout - 0.2 (0.01
Recommended fork fluid Honda Ultra Cushion Oil 1OW -
or equivalent
Fluid level 106 (4.2) -
Fluid capacity 100 f 1 cm3(3.4 f 0.03 US 02, 3.5 f 0.04 -
ImD 02)
TORQUE VALUES
Steering stem lock nut 68 N.m (6.9 kgf.m, 50 Ibf.ft)
Steering bearing upper inner race See page 14-26
Fork socket bolt 20 N.m (2.0 kgf.m, 15 Ibf.ft) Apply locking agent to the threads.
Handlebar post nut 39 N.m (4.0 kgf.m, 29 Ibf.f&)U-nut.
Master cylinder holder bolt 12 N.m (1.2 kgf.m, 9 Ibf.ft)
Brake disc bolt 42 N.m (4.3 kgf.m, 31 1bf.h) ALOC bolt: replace with a new one.
Front axle nut 68 N.m (6.9 kgfem, 50 Ibf.ft) U-nut.
Speedometer cable setting screw 2.2 N.m (0.22 kgf.m, 1.6 Ibf.ft)
Caliper mounting bolt 30 N.m (3.1 kgf.m, 22 Ibf.ft) ALOC bolt: replace with a new one.
TOOLS
Bearing remover shaft Bearing remover head, 12 m m Driver
07746-0050100 07746-0050300 07749-0010000
Attachment, 32 x 35 mm Attachment, 44 x 49.5 m m Pilot, 12 m m

07746-0010100 07945-3330300 07746-0040200
Fork seal driver weight Fork seal driver attachment, Socket wrench
07747-0010100 33 m m I.D. 07916-KM10000
07747-0010501
Lock nut wrench Adjustable bearing remover Bearing remover shaft

07SMA-GBCOl00 07JAC-PH80100 07JAC-PH80200
14-4
Bearing remover weight Ball race remover Oil seal driver
07741-0010201 07948-4630100 07947-SB00200
Attachment, 35 mm I.D.
07746-0030400
14-5
TROUBLESHOOTING
Hard steering
Insufficient tire pressure
Faulty tire
Steering top thread too tight
Worn or damaged steering head bearings
Worn or damaged steering head bearing races
Bent steering stem
Steers to one side or does not track straight
Bent front axle
Wheel installed incorrectly
Worn or damaged wheel bearings
Bent fork leg
Damaged or loose steering head bearings
Damaged frame
Worn or damaged engine mounting bushings (page 7-2)
Front wheel wobbles
Bent rim
Worn or damaged wheel bearings
Loose axle fasteners
Faulty tire
Wheel turns hard
Faulty wheel bearings
Bent front axle
Brake drag (page 16-5)
Soft suspension
Low tire pressure
Weak fork spring
Low fluid level i n fork
Incorrect fluid weight (low viscosity)
Stiff suspension
High tire pressure
Bent fork tube
Fork slider binds
High fluid level in fork
Incorrect fluid weight (high viscosity)
Clogged fork fluid passage
Suspension noise
Loose fork fasteners
Incorrect fluid weight (low viscosity)
Worn guide bushing
14-6
FRONT WHEEL/SUSPENSION/STEERr"
FRONT WHEEL
REMOVAL
Remove the screw and disconnect the speedometer
cable.
Loosen the axle nut.
Support the scooter securely using a hoist or equiv-
alent and raise the front wheel off the ground.
Do not operate the Remove the axle nut,

brake levers after Pull the axle out and remove the front wheel.
removing the
Remove the side collar and speedometer gear box.
wheel. To do so will
cause difficulty in
fitting the brake
disc between the
brake pads.
INSPECTlON
AXLE
Set the axle in V-blocks
Turn the axle and measure the r u n o u t using a dial
indicator.
Actual runout is 112 the total indicator reading.
14-7
WHEEL
Check the rim runout by placing the wheel in a tru-
ing stand.
Spin the wheel slowly and read the runout using a
dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
I
WHEEL BEARING
Turn the inner race of each bearing with your finger;
the bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the hub.
Replace the wheel Remove and discard the bearings if the races do not
bearings in pairs. turn smoothly, quietly, or if they fit loosely in the
hub.
DISASSEMBLY
Remove the four bolts and brake disc.
Remove the dust seal.
Remove the speedometer gear retainer.
14-8
~~ ~~
Replace the bear- Install the remover head into the bearing.
ings m pars Do not From the opposite side of the wheel, install the
reuse old beanng bearing remover shaft and drive the bearing out of
the wheel hub.
TOOLS:
Bearing remover shaft 07746-0050100
Bearing remover head, 12 mm 07746-0050300
Remove the distance collar and drive out the other
bearing.
ASSEMBLY
BEARING (6201U)
GEAR
BEARING (6201U)
BOLTS
BRAKE DISC
Pack the cavities in new bearings with grease.

Drive in the left side bearing (brake disc side)
squarely with the sealed side facing up until it is
fully seated.
Install the distance collar.
Drive in the right side bearing squarely with the
sealed side facing up until it is fully seated.
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
Donotgetgrease Install the brake disc on the wheel hub with the
on the brake disc or stamp facing out.
stopping power will Install the new disc bolts and tighten them in a criss-
be reduced. cross pattern in several steps.
TORQUE: 42 N-m (4.3 kgf.m, 31 Ibf.f't)
WHEEL BALANCE
NOTE:
Mount the tire with the arrow mark facing in the
direction of rotation.
For optimum balance, the tire balance mark (light
mass point: a paint dot on the side wall) must be
located next to the valve stem. Remount the tire
if necessary.
The wheel balance must be checked when the
front tire is remounted.
Mount the wheel, tire and brake disc assembly on

an inspection stand.
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) part of the wheel with 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.
I \ STAND
I
To balance the wheel, install a balance weight on

the lightest 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 70 g (2.5 02) to the front
wheel.
Apply grease to a new dust seal lips and install the
dust seal until it is flush with the hub.
Be carefulnot to Install a new gear retainer into the right side of the
damage the seallip. hub until it is fully seated.
INSTALLATION
Apply grease to the speedometer gear teeth and
sliding surface, and install the washers and gear.
Apply grease to the dust seal lip, and install the gear
box so the tabs o n the gear and retainer are not
interfered.
Install the side collar.
Be carefulnot to Place the wheel between the fork legs while insert-
damage the brake ing the brake disc between the pads in the caliper so
pads. the lug on the gear box is positioned against the
stopper as shown.
Carefully align the axle holes and insert the axle
from the right side.
14-1I
Install the axle nut and tighten it.
Coat a new O-ring with grease and install it into the

cable groove.
Connect the speedometer cable by aligning the
groove with the blade.
Install the setting screw and tighten it.
TORQUE: 2.2 N.m (0.22 kgf.m, 1.6 Ibf.ft)
With the front brake applied, pump the suspension
up and down several times and check brake opera-
tion.
FORK
REMOVAL
Support the brake Remove the following left fork:
caliper so it does - bolt and brake hose clamp
not hang from the - two bolts and brake caliper
brake hose.
Remove the front fender (page 2-8).
twist the brake
Remove the front wheel (page 14-7).
hose.
Remove the upper mounting bolt.

Loosen the lower mounting bolt and remove the
fork leg.
14-12
FRONT WHEEL/SUSPENSION/STEERI"
DISASSEMBLY
Hold the fork slider in a vise with soft jaws or shop
towels.
Remove the socket Loosen the fork socket bolt.
bolt after draining
the fork f l u d
Remove the fork tube cap.
Press the spring seat using a hydraulic press and

remove the stopper ring.
Do not compress the fork spring more than neces-
sa ry.
Take care not to allow the spring seat to pop out
when removing the fork leg from a hydraulic press.
Remove the spring seat and fork spring.

Pour out the fork fluid by pumping the fork tube up
and down several times.
14-13
~ ~~

- socket bolt and sealing washer
- fork piston
- rebound spring
- forktube
- oil lock piece
- dustseal
- stopper ring
- oil seal
- back-up ring
INSPECTION
Measure the fork spring free length.
SERVICE LIMIT: 257.2 rnrn (10.13 in)
14-14
Check the fork tube, slider and fork piston for score
marks, and excessive or abnormal wear.
Check the fork piston ring for wear or damage.
Check the rebound spring for fatigue or damage.
Replace any damaged component if necessary.
Visually inspect the guide bushing in the fork slider.

If it is excessive scoring or scratching, or if the teflon
is worn so the copper surface appears on more than
3/4 of the entire surface, replace the fork slider.
Set the fork tube in V-blocks and measure the fork

tube runout with a dial indicator.
SERVICE LIMIT: 0.2 mm (0.Olin)
ASSEMBLY
Before assembly, wash all parts with a high flash
point or non-flammable solvent and wipe them off
completely.
DUST SEAL FORK TUBE FORK TUBE CAP

PISTON
RING /
PER RING
SPRING SEAT
/
i
\ FORK SPRING
REBOUND
SPRING
SOCKET BOLT

- rebound spring (onto the fork piston)
- fork piston (into the fork tube)
- oil lock piece (onto the fork piston)
Install the fork tube into the fork slider.
Hold the fork slider in a vise with soft jaws or shop

towels.
If the forkpiston Apply locking agent to the fork socket bolt threads.
turns with the Install the socket bolt with a new sealing washer
socket bolt, hold and tighten it.
the fork piston with
the fork spring.
14-16
Install the back-up ring. 7
Wrap vinyl tape around the fork tube top end to I DUSTSEAL 11
avoid damaging the oil seal lip.
Apply fork fluid to a new oil seal lip. Install the oil
seal with the marking facing up.
Drive the oil seal until the stopper ring groove is vis-
ible.
TOOLS:
Fork seal driver weight 07747-0010100
Driver attachment, 33 mm I.D. 07747-0010501
Install the stopper ring into the groove in the fork

slider, being careful not to scratch the fork tube slid-
ing surface.
Coat the lips of a new dust seal with fork fluid and
install it.
Pour the specified amount of the recommended fork

fluid into the fork tube.
...
RECOMMENDED FORK FLUID:
Honda Ultra Cushion Oil 1OW or equivalent
FLUID CAPACITY 67mm

100 f 1 cm3 (3.4 f 0.03 US 0 ~ 3 . f
5 0.04 Imp 0 2 )
Slowly pump the fork tube several times to remove
any trapped air from the lower portion of the fork - .
tube.
Compress the fork tube fully. Measure the fluid level
from the top of the fork tube.
FLUID LEVEL: 106 mm (4.2 in)
Pull the fork tube up and install the fork spring with
the tightly wound coil side facing down.
Coat a new O-ring with fork fluid and install it into
the spring seat groove.
Install the spring seat, spacer and joint plate.
Make sure to pull Set the fork leg, spring seat and stopper ring onto a
the fork leg up into hydraulic press.
the spring seat. Press the spring seat until the stopper ring groove is
visible.
Do not compress the fork spring more than neces-
sary.
Install the fork tube cap.
INSTALLATION
Install the fork leg into the fork bridge and align the
fork tube groove with the bolt hole, then install the
upper mounting bolt.
Tighten the two mounting bolts securely.
- front wheel (page 14-11)
Left fork only: Install the brake caliper with new mounting bolts
and tighten the bolts.
TORQUE: 30 N-m (3.1 kgfam, 22 Ibf-ft)
Install the brake hose clamp and tighten the bolt.
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR
REMOVAL
Remove the combination meter (page 20-8).
Loosen the brake joint cable lock nut and screw the
adjuster fully.
Disconnect the joint cable from the cable joint on
the brake arm and remove the setting spring.
Keep the reservoir Remove the two bolts and master cylinder holder,
upright to prevent and the brake master cylinder off of the handlebar.
air from entering Remove the joint cable from the cable holder on the
the hydraulic sys-
master cylinder by turning the adjuster.
tem.

- two screws
- upper throttle housing
- throttle cable (disconnect by turning the throttle

grip)
- lower throttle housing
- throttle grip
- washer-bolt and bracket holder
- rear brake lever bracket
- left handlebar grip
Remove the following from the cable guides:

- brake joint cable
- throttle cable
- front brake hose
- speedometer cable
- rear brake cable
- nut and setting collar

- bolt
- handlebar
- setting collar
INSTALLATION
NOTE:
Route the cables and hose properly (page 1-17).
Align the round Install the handlebar over the steering stem with the
surface of each front setting collar.
collarproperly Align the bolt holes and insert the bolt.
Install the rear setting collar and nut, and tighten it.
TORQUE: 39 N-m (4.0 kgf.m, 29 Ibfdt)
Set the following into the cable guides:

- rear brake cable
- speedometer cable
- front brake hose
- throttle cable
- brake joint cable
Clean the inside surface of the left handlebar grip
and the outside surface of the handlebar.
Apply Honda Bond A or equivalent to the inside sur-
face of the handlebar grip and to the outside surface
of the handlebar.
~ l l o w t h e a d h e s i v e Wait 3 - 5 minutes and install the grip. Rotate the
to dry for I hour grip for even application of the adhesive.
before using.
Install the brake lever bracket by aligning the locat-

ing pin with the hole in the handlebar, and secure it
with the holder and washer-bolt. Tighten the bolt
securely.
Clean the sliding surfaces of the throttle grip pipe

and handlebar.
Install the throttle grip onto the handlebar.
Apply grease to the throttle grip flange groove.
Connect the throttle cable to the throttle grip flange
and set the lower throttle housing by aligning the
locating pin with the hole in the handlebar.
Install the upper throttle housing and tighten the

two screws securely.
14-21
Be careful not to Install the joint cable into the cable holder on the MASTER CYLINDER
cross-thread the master cylinder and screw the adjuster fully. MASTER
adjuster. CYLINDER
Align the edge of Install the brake master cylinder and holder with the
the master cylinder "UP"mark facing up.
with the punch Tighten the upper bolt first, then tighten the lower
mark on the handle- bolt.
bar.
TORQUE: 12 N.m (1.2 kgf-m, 9 Ibf.ft)
Install the setting spring into the cable holder and
connect the cable to the cable joint.
Adjust the rear brake lever and joint cable free play
(page 3-16).
Install the combination meter (page 20-8).
STEERING STEM
REMOVAL
NOTE:
Always replace the bearings and races as a set.
- handlebar (page 14-19)
- fork legs (page 14-12)
Remove the bolt and brake hose clamp.
Loosen the stem lock nut while holding the upper

inner race.
TOOLS:
Socket wrench 07916-KM10000
Lock nut wrench 07SMA-GBC0100
14-22
Remove the lock nut.
Loosen the upper inner race.
TOOLS:
Remove the upper inner race while supporting the

steering stem.
- steering stem
- upper steering bearing
- lower steering bearing
Remove the upper outer race using the special tool.
TOOLS:
Adjustable bearing remover 07JAC-PH80100
Remover shaft 07JAC-PH80200
14-23
Remove the lower outer race using the special tool
and a drift.
TOOL:
Ball race remover 07948-4630100
Install the stem nut onto the stem to prevent the

threads from being damaged when removing the
lower bearing inner race.
Remove the lower inner race with a chisel or equiv-
alent tool, being careful not to damage the stem.
Remove the dust seal.
INSTALLATION
LOWER OUTER RACE

LOCK NUT
ER INNER RACE
LOWER INNER
ER STEERING BEARING
LOWER DUST SEAL
UPPER OUTER RACE
STEERING STEM
CLAMP
14-24
~~ _ _ ~
NOTE:
Use urea based multi-purpose grease with
extreme pressure agent for the steering bearings
and dust seals:
- Excelite EP2 (Kyodo Yushi) or
- Alvania EP2 (Shell) or equivalent
Apply grease to a new lower dust seal lip and install
it onto the steering stem.
Press a new lower bearing inner race using the spe-
cial tool.
TOOL:
Attachment, 35 mm I.D. 07746-0030400
Drive in a new lower outer race into the steering

head pipe.
TOOL:
Oil seal driver 07947-SB00200
Drive in a new upper outer race into the steering

head pipe.
TOOLS:
Driver 07749-0010000
Attachment, 44 x 49.5 mm 07945-3330300
14-25
FRONT WHEEL/SUSPENSION/STEERI"
Apply 3 - 5 g of grease to each new steering bearing
and fill it up. Install the lower steering bearing onto
the stem.
Donotgetgrease Insert the steering stem into the steering head pipe
on the stern and install the following while holding the stem:
threads.- upper steering bearing
- upper inner race (and temporarily tighten it)
1. Tighten the upper inner race.

TOOLS:
TORQUE: 8 N.m (0.8 kgf.m, 5.9 Ibf-ft)
2. Turn the steering stem left and right, lock-to-lock

several times to seat the bearings.
14-26
3. Loosen the upper inner race fully and finger
tighten it all the way.
Turn the inner race counterclockwise 45" (1/8)
from above (finger tightened) position.
4. Install the lock nut.

Tighten the lock nut while holding the upper
inner race.
TOOLS:
Socket wrench 07916-KM10000
TORQUE: 68 N-m (6.9 kgfmm, 50 Ibf-ft)

Make sure the steering stem moves smoothly,
without play or binding.
Install the brake hose clamp and tighten the bolt.

- fork legs (page 14-18)
- handlebar (page 14-20)
14-27
15. REAR WHEEL/SUSPENSlON
SYSTEM COMPONENTS ............................ 15-2 REAR WHEEL ................................................ 15-5
SERVICE INFORMATION ............................ 15-3 REAR SHOCK ABSORBER ........................... 15-8

SYSTEM COMPONENTS
I
,,/" i
\
118 N.m (12.0 kgf.m, 87 Ibf.ft)
15-2
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated
drum with a high quality brake degreasing agent.
Use only tires marked "TUBELESS" and tubeless valve stems on rims marked "TUBELESS TIRE APPLICABLE".
Use genuine Honda replacement bolts for all suspension pivots and mounting points.
Refer to page 16-2 for brake system service.

pressure Driver and passenger 225 kPa (2.25 kgf/cm2, 33 psi) -
~ - _ _ _ _ _ _
Wheel rim -
Radial - 2.0 (0.08)
I runout ....- .
.Axial - 2.0
-. - (0
Shock absorber spring pre-load adjuster I Middle position -
TORQUE VALUES
Rear axle nut 118 N.m (12.0 kgf.m, 87 Ibf.ft) U-nut.
TOOLS
Driver Attachment, 42 x 47 mm Pilot, 17 rnm
07749-0010000 07746-0010300 07746-0040400
15-3
TROUBLESHOOTING
Rear wheel wobbles
Bent rim
0 Axle or swingarm fasteners not tightened properly
Loose or worn final shaft bearings
Faulty tire
Improperly tightened engine mount fasteners (page 7-2)
Wheel turns hard
Brake drag (page 16-5)
Soft suspension
Weak rear shock absorber spring
Oil leakage from damper unit
Stiff suspension
Tire pressure too high
Bent damper rod
Damaged shock absorber bushings
Damaged engine mount bushings (page 7-2)
Rear suspension noise
Loose shock absorber fasteners
Worn or damage shock absorber bushings
Faulty damper unit
15-4
REAR WHEEL
INSPECTION
Check the wheel rim runout.
Spin the wheel slowly and read the runout using a
dial indicator.
SERVICE LIMITS:Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Check the wheel rim for distortion or damage.
REMOVAL
- exhaust system (page 2-15).
Lock the rear brake.
Lower the rear wheel and ground it, then loosen the
axle nut.
Support the left crankcase and remove the follow-
ing:
- shock absorber lower mounting bolt (and secure
the shock absorber with a piece of rope)
- axle nut
- swingarm bolts and washers
- swingarm
- inside collar
- outside collar
- rearwheel
NOTE:
Refer to page 14-10 for note of the tire replace-
ment.
15-5
BEARING INSPECTION/
REPLACEMENT
Remove dust seals from the both sides of the swin-
garm.
Remove the snap ring.

Turn the inner race of the bearing with your finger;
the bearing should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
swing arm.
Replace the bearing if the inner race does not turn
smoothly and quietly, or if the outer race fits
loosely.
Drive the bearing out of the swingarm.
Drive in a new bearing squarely until it is fully

seated.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 17 mm 07746-0040400
Install the snap ring into the swingarm groove

securely with the chamfered side facing the bearing.
Apply grease to the lips of new dust seals. SNAP RING
Install each dust seal until it is flush with the swing-
arm.
15-6
INSTALLATI0N
Install the rear wheel onto the final shaft, aligning
the splines.
Apply grease to grease groove and bearing fitting
area of the final shaft.
Install the collars into the swingarm.
Install the swingarm onto the final shaft.

Install the swingarm bolts with the washers and
axle nut, and tighten them.
TORQUE: Axle nut: 118 N-m (12.0 kgf-m, 87 IbfW
Set the shock absorber onto the swingarm, and
install the lower mounting bolt and tighten it.
- exhaust system (page 2-15).
15-7
REAR SHOCK ABSORBER
For left side: Remove the air cleaner housing mounting fasteners
t o get the clearance for lower mounting bolt
removal (page 5-36).
For right sde: Remove the exhaust system (page 2-15).
Support the engine with a jack or adjustable support
to relieve stress from the shock absorber.
Remove the lower mounting bolt.
Remove the upper mounting bolt and the shock

absorber.
INSPECTlON
Check the pivot bushings in the shock absorber and
engine or swingarm for wear, deterioration or dam-
age.
Check the damper rod for bend or damage.
Check the damper unit for leaks or other damage.
15-8
16. BRAKE SYSTEM
SYSTEM COMPONENTS ............................ 16-2 BRAKE PAD/DISC ......................................... 16-9
TROUBLESHOOTlNG .................................. 16-5 FRONT BRAKE CALIPER ............................ 16-15
BRAKE FLUID REPLACEMENT/ REAR DRUM BRAKE .................................. 16-18

AIR BLEEDING ............................................. 16-7
COMBINED BRAKE EQUALIZER ...............16-21
16-1
BRAKE SYSTEM
SYSTEM COMPONENTS
FRONT:
1.5 N.m (0.15 kgf.m, 1.1 Ibf.ft)
kgf.m, 9 Ibf.ft)
k g f m , 25 Ibf.ft)
30 N.m (3.l'kgf.m, 22 IbfW
16-2
BRAKE SYSTEM
REAR:
10 N.m (1.0 kgf.m, 9 Ibf.ft)
16-3
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad and shoe dust, regardless of material composition, could be hazardous t o your
health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
I NOTICE I
Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be
careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
This scooter is equipped with combined brake system that is designed to engage both front and rear brakes when the
rear brake lever is used. This system is connecting the rear brake lever to the front master cylinder with the joint cable
via the mechanical equalizer.
A contaminated brake disclpad and brake drumlshoe reduces stopping power. Discard contaminated pads and shoes,
and clean a contaminated disc and drum with a high quality brake degreasing agent.
Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different
types of fluid as they may not be compatible.
Never allow contaminants (dirt, water, etc.) to enter an open reservoir.
Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
Always check brake operation before riding the scooter.
SPEC1FlCATlONS
Unit: mm (in)
TORQUE VALUES
Caliper bleed valve 5.5 N.m (0.56 kgf.m, 4.1 Ibf-ft)
Pad pin 18 N.m (1.8 kgfam, 13 Ibf.ft)
Pad pin plug 2.5 N.m (0.25 kgf.m, 1.8 Ibf.ft)
Master cylinder reservoir cap screw 1.5 N.m (0.15 kgf.m, 1.1 Ibf.ft)
Brake hose oil bolt 34 N.m (3.5 kgf.m, 25 Ibfdt)
Front brake lever pivot bolt 1 Nsm (0.1 kgf.m, 0.7 Ibf.ft)
Front brake lever pivot nut 6 Nsm (0.6 kgf.m, 4.4 Ibfaft)
Front brake light switch screw 1.2 N.m (0.12 kgf.m, 0.9 Ibf.ft)
Master cylinder holder bolt 12 N.m (1.2 kgf.m, 9 Ibf.ft)
Caliper mounting bolt 30 N.m (3.1 kgf.m, 22 Ibf.ft) ALOC bolt: replace with a new one.
Rear brake lever pivot screw 4.2 N.m (0.43 kgf.rn, 3.1 Ibf.ft)
Rear brake lever pivot nut 5.2 N.m (0.53 kgf.m, 3.8 Ibf.ft)
Rear brake lever equalizer joint screw 4.2 N.m (0.43 kgf.m, 3.1 IbfW ALOC screw: replace with a new one.
Rear brake arm bolt 10 N.m (1.0 kgf.m, 7 Ibf-ft)ALOC bolt: replace with a new one.
16-4 ~
BRAKE SYSTEM
TOOL
Snap ring pliers
07914-SA50001
TROUBLESHOOTING
FRONT BRAKE
Brake lever soft or spongy
Air i n hydraulic system
Leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master piston cups
Worn brake padldisc
Contaminated caliper
Contaminated master cylinder
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warped/deformed brake disc
Sticking/worn caliper piston
Sticking/worn master piston
Bent brake lever
Brake lever hard
Clogged/restricted fluid passage
Sticking/worn caliper piston
Worn caliper piston seal
Sticking/worn master piston
Bent brake lever
Brake drags
Incorrect adjustment of brake (page 3-16)
Contaminated brake pad/disc
Misaligned wheel
Badly worn brake pad/disc
Warped/deformed brake disc
Clogged/restricted fluid passage
Sticking caliper piston
16-5
BRAKE SYSTEM
REAR BRAKE
Poor brake performance
Worn brake shoe linings
Worn brake drum
Worn brake cam and shoes
Contaminated brake shoe linings and drum
Brake sliding areas needs lubrication
Brake lever hard
Bent brake lever
Improper actuation of equalizer linkage
Brake squeaks
Worn brake shoe linings
Worn brake drum
Contaminated brake shoe linings and drum
Brake drags
BRAKE SYSTEM
BRAKE FLUID REPLACEMENTIAIR
BLEEDING
I NOTICE I
Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE:
Do not mix different types of fluid, as they are
not compatible with each other.
Do not allow foreign material to enter the system
when filling the reservoir.
BRAKE FLUID DRAINING
Turn the handlebar so the reservoir is level before
removing the reservoir cap.
Remove the screws, reservoir cap, set plate and dia-
phragm.
Connect a bleed hose to the caliper bleed valve.

Loosen the bleed valve and pump the front brake
lever until no more fluid flows out of the bleed
valve.
16-7
BRAKE FLUID FILLING/AIR BLEEDING
Close the bleed valve.
Fill the front master cylinder reservoir with DOT 3 or
DOT 4 brake fluid from a sealed container.
Follow the manu- Connect a commercially available brake bleeder to
facturer's operating the bleed valve.
instructions.
Operate the brake bleeder and loosen the bleed
valve.
Check the fluid level If an automatic refill system is not used, add fluid
often while bleed- when the fluid level in the reservoir is low.
ing the brake to pre-
Perform the bleeding procedure until the system is
vent air from being
completely flushed/bled.
pumped into the
s ys tem. After bleeding air, operate the front brake lever. If it
If air enters the still feels spongy, bleed the system again.
bleeder from
Tighten the bleed valve.
around the bleed
valve threads, seal TORQUE: 5.5 N - m (0.56 kgf-m, 4.1 I b f W
the threads with
teflon tape.
If the brake bleeder is not available, perform the fol-

lowing procedure:
Pump up the system pressure with the front brake
lever until the lever resistance is felt.
Connect a bleed hose to the bleed valve and bleed
the system as follows:
~ o n o t r e l e a s ethe 1. Squeeze the brake lever all the way and loosen
brake lever until the the bleed valve 1/4 of a turn. Wait several sec-
bleed valve has onds then close the bleed valve.
been closed.
2. Release the brake lever slowly and wait several
seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding air, operate the front brake lever. If it
still feels spongy, bleed the system again.
Tighten the bleed valve.
TORQUE: 5.5 N-m (0.56 kgf-m, 4.1 Ibf-ft)
Fill the master cylinder reservoir to the casting
ledge with brake fluid.
Install the diaphragm, set plate and reservoir cap,
and tighten the screws.
TORQUE: 1.5 N.m (0.15 kgfmm, 1.1 Ibf-ft)
16-8
BRAKE SYSTEM
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
Remove the pad pin plugs and loosen the pad pins.
Remove the two bolts and brake caliper.
Check the fluid Push the caliper pistons all the way to allow installa-
level in the master tion of new brake pads.
cylinder reservoir as
Pull the pad pins out of the caliper while pushing in
this operation
the pads against the pad spring.
causes the fluid
level to rise.
Make sure the pad Install new pads and insert the pad pins by pushing
spring is installed in the pads against the pad spring to align the pad
correctly. pin holes.
Always replace the Temporarily tighten the pad pins.
brake pads in pairs
to ensure even disc
pressure.
Becarefulnot to Install the brake caliper so the disc is positioned

damage the pads. between the pads.
Install new mounting bolts and tighten them.
TORQUE: 30 N-m (3.1 kgf-m,22 Ibf.ft)
Tighten the pad pins.
TORQUE: 18 N-m (1.8 kgf-m, 13 Ibf4t)
Install the pad pin plugs and tighten them.
Squeeze the brake lever to seat the caliper piston
against the pad.
16-9
BRAKE SYSTEM
BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness at several points.
Measure the brake disc warpage with a dial indica-

tor.
Check the wheel bearings for excessive play, if the
warpage exceeds the service limit.
Replace the brake disc if the wheel bearings are nor-
mal.
16-10
BRAKE SYSTEM
FRONT MASTER CYLINDER
DISASSEMBLY
Remove the rear handlebar cover (page 2-12).
Drain the brake fluid from the hydraulic system
(page 16-71.
Remove the brake light switch connectors.
I CONNECTORS /
1
i
I
Loosen the brake joint cable lock nut and screw the
adjuster fully.
When removing the Remove the following:

oil bolt, cover the - joint cable (from the cable joint on the brake arm)
endof the hose to - setting spring
prevent contamina- - oil bolt and sealing washers
tion. - brake hose
- two bolts
- master cylinder holder
- joint cable (from the cable holder on the master
cylinder by turning the adjuster)
- master cylinder
- pivot nut
- pivot bolt and return spring
- brake lever
- brake arm
BRAKE SYSTEM
~ ~~ ~~~
- screw and brake light switch

- piston boot
- snapring
TOOL:
Snap ring pliers 07914-SA50001
- master piston
- spring
Clean the master cylinder, reservoir and master pis-
ton in clean brake fluid.
INSPECTlON
Check the piston cups and boot for wear, deteriora-
tion or damage.
Check the spring for damage.
Check the master cylinder and piston for scoring,
scratches or damage.
Measure the master cylinder I.D.

Measure the master piston O.D.
16-12
BRAKE SYSTEM
ASSEMBLY
SNAP RING
rivu i
I
DULI
\ MASTER PISTON /
PISTON SPRING
SWITCH
SCREW
Coat the master piston and piston cups with clean

brake fluid.
Install the spring onto the master piston.
DO not allow the Install the master piston/spring into the master cyl-
piston cup /ips to inder.
turn inside out.
Make sure the snap Install the snap ring into the groove in the master
ring is firmlyseated cylinder with the chamfered side facing the piston.
in the groove.
TOOL:
Snap ring pliers 07914-SA50001
BRAKE SYSTEM
Install the boot into the master cylinder and piston
groove.
Apply silicone grease to the brake lever contacting
surface of the piston.
Apply silicone grease to the brake lever and arm

pivots.
Hook the spring Set the brake lever and arm into the master cylinder
long end into the and install the pivot bolt with the spring.
hole in the leverand Tighten the pivot bolt.
the short end
against the master
TORQUE: 1.0 N-m (0.1 kgf-m, 0.7 Ibf.ft)
cylinder body.
Install the pivot nut and tighten it.

TORQUE: 6 N.m (0.6 kgf-m, 4.4 Ibf-ft)
Install the brake light switch, aligning the locating
pin with the hole, and tighten the screw.
BRAKE SYSTEM
Be careful not to Install the joint cable into the cable holder on the
cross-thread the master cylinder and screw the adjuster fully.
adjuster.
Align the edge of Install the master cylinder and holder with the "UP"
the master cylinder mark facing up.
with the punch Tighten the upper bolt first, then tighten the lower
mark on the handle- bolt.
bar.
TORQUE: 12 N-m (1.2 kgf-m,9 Ibf.ft)
Rest the hose joint Connect the brake hose to the master cylinder with
pin against the the oil bolt and new sealing washers.
stopper. Tighten the oil bolt.
Install the setting spring into the cable holder and
connect the cable to the cable joint.
Adjust the rear brake lever and joint cable free play
(page 3-16).
Connect the brake light switch connectors.

Fill and bleed the hydraulic system (page 16-8).
Install the rear handlebar cover (page 2-1 2).
I
i
CONNECTORS
i
FRONT BRAKE CALIPER
DISASSEMBLY
Drain the brake fluid from the hydraulic system
(page 16-7).
When removing the Disconnect the brake hose from the brake caliper by
oil bolt, cover the removing the oil bolt and sealing washer.
the hose to Remove the brake pads (page 16-9).
prevent contamina-
tion.
BRAKE SYSTEM ~-
- caliper bracket
- padspring
- boots
Place a shop towel over the piston.

~ o n o t u s e h i g h Position the caliper body with the piston facing
pressureairorbring down and apply small amounts of air pressure to
the nozzle too close the fluid inlet t o remove the piston.
to the inlet.
Be careful not to Push the dust and Diston seals in and lift them out.
damage the piston
Clean the seal grooves, caliper cylinder and piston
sliding surface.
with clean brake fluid.
INSPECTION
Check the caliper cylinder and piston for scoring,
scratches or damage.
Measure the caliper cylinder I.D.
Measure the caliper piston O.D.
SERVICE LIMIT: 26.91 mm (1.059in)
16-16
BRAKE SYSTEM
ASSEMBLY
CALIPER BRACKET
\ PIN BOOT B
PIN
PAD SPRING
BRAKE PADS
Coat n e w piston and dust seals with clean brake

fluid and install them into the seal grooves in the
caliper.
Coat the caliper pistons with clean brake fluid and
install them into the caliper cylinder with the open
side toward the pads.
Check the pin boots and replace them if they are

hard, deteriorated or damaged.
Apply silicone grease to the insides of the boots.
Install the boot into the caliper body.
Install the pad spring in the direction as shown.
Install the pad retainer with adhesive Honda Bond A
or equivalent if it was removed.
Install the caliper bracket over the caliper body.
Make sure the boot ribs are seated into the boot
grooves in the bracket pins properly.
BRAKE SYSTEM
install the brake pads (page 16-91.
Resrrhe hosejoint Connect the brake hose to the caliper with the oil
against the caliper bolt and new sealing washers.
body. Tighten the oil bolt.
TORQUE: 34 N-m (3.5 kgf-m, 25 IbfW
Fill and bleed the hydraulic system (page 16-8).
REAR D R U M BRAKE
Remove the rear wheel (page 15-5).
INSPECTION
NOTE:
For brake shoe inspection, see page 3-15
(inspected at the wear indicator).
Measure the rear brake drum I.D.
SERVICE LIMIT: 131 mm (5.2 in)
DISASSEMBLY
Always replace the Expand the brake shoes and remove them.
brake shoes in
Remove the shoe springs from the brake shoes.
pairs.
BRAKE SYSTEM
~~ ~

- adjusting nut
- brake cable
- joint pin
- spring
- bolt
- brake arm
- brake cam
- lockwasher
- dust seals
BRAKE SYSTEM
ASSEMBLY
BRAKE CAM
Apply grease to the grease groove in the bushing.

Apply grease to the lips of new dust seal and install
them into the cam pivot with the flat surface facing
the wheel.
0 2 mm
Wheel side
Install the brake cam with the lock washer, aligning

washer tabs with the lug on the brake panel.
BRAKE SYSTEM
Install the brake arm by aligning the wide groove
with the wide tooth (indicated at the punch marks).
Install a new brake arm bolt and tighten it.
Install the spring between the hollow in the engine

and tab of the brake arm.
Install the joint pin into the brake arm and connect
the brake cable with the adjusting nut.
Apply grease to the anchor pin and shoe sliding sur-

faces of the brake cam.
Install the shoe springs onto the brake shoes in the
same direction.
Install the brake shoes onto the anchor pin and
brake cam with the spring ends facing the wheel
while spreading them.
Install the rear wheel (page 15-7).
Adjust the rear brake lever free play (page 3-16).
COMBINED BRAKE EQUALIZER

DISASSEMBLY
Remove the front handlebar cover (page 2-1 1).
- flange screw
- guide seal
- twoscrews
- equalizer cover
16-21
BRAKE SYSTEM
- locklever
- return spring
- equalizer joint screw

- lever pivot nut
- pivot screw
- rear brake lever
Loosen the adjusting nut and disconnect the rear

brake cable (page 3-16).
Disconnect the joint cable from the master cylinder
(page 16-11).
Be careful not to Remove the following:
damage the cable - link rod boot
endboots. - rear brake cable
- jointcable
- equalizer link
For lever bracket removal and installation, refer to
page 14-19 "Handlebar".
INSPECTlON
Check the link arm and rod for wear, deformation or
damage.
Check the boot for wear, deterioration or damage.
ASSEMBLY
NOTE:
Do not exchange the rear brake cable and joint
cable.
Route the cables properly (page 1-17).
Apply grease to the link sliding area.
Place the equalizer link into the equalizer housing of
the lever bracket through the link rod hole in the
direction as shown.
Install the joint Connect the cables to the link arm and install them
cable first, then the into the housing.
cable.
Install the boot onto the link rod, and set the boot
ribs into the groove in the rod and into the groove in
the housing.
BRAKE SYSTEM
Apply grease t o the brake lever and link rod pivots.
Install the brake lever and pivot screw, and tighten
it.
TORQUE: 4.2 N.m (0.43 kgf-m, 3.1 Ibf-ft)
Install the pivot nut and tighten it.
TORQUE: 5.2 N-m (0.53 kgf-m, 3.8 IbfW
Connect the lever to the link rod with a new joint
screw, and tighten the screw.
Set the spring ends Install the lock lever and return spring.
against the lever
plate inner surface
(long end) and
housing wall (short
end).
Install the equalizer cover through the lock lever, be

careful not to come o f fthe spring.
Be sure to align the cover tabs with each cable joint.
Install the two front side screws and temporarily
tighten them.
Install the guide seal and the flange screw.
Tighten the three screws alternately in several
steps.
Install the front handlebar cover (page 2-1 1).
17. BATTERYKHARGING SYSTEM
SYSTEM LOCATION .................................... 17-2 BATTERY....................................................... 17-6
SYSTEM DIAGRAM ..................................... 17-2 CHARGING SYSTEM INSPECTION............. 17-7
SERVICE INFORMATION ............................ 17-3 ALTERNATOR CHARGING COIL ..-..-.*--..-..--

17-8
TROUBLESHOOTlNG .................................. 17-5 REGULATOR/RECTIFIER ............................. 17-8

BATTERYKHARGING SYSTEM
SYSTEM LOCATION
REG ULATOR/RECTIFlER
ALTERNATOR
SYSTEM DIAGRAM
BI -R/BI
IY Y
FUSE (10 A)
IGNITION
Y SWITCH
MAIN FUSE
BI: Black
G:Green
R: Red
W White
Y Ye II ow
+
-
I
REG U LATOR/RECTIFIER BATTERY -
-
SERVICE INFORMATION
GENERAL
The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective
clothing and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician
immediately.
Always turn OFF the ignition switch before disconnecting any electrical component.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is in the ON position and current is present,
For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service
life, charge the stored battery every two weeks.
For a battery remaining in a stored scooter, disconnect the negative battery cable from the battery terminal.
The maintenance free (MF) battery must be replaced when it reaches the end of its service life.
The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same condi-
tions contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery dete-
riorates after 2 - 3 years.
Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventu-
ally die out. For this reason, the charging system is often suspected as the problem. Battery overcharging often results
from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is
shorted and battery voltage does not increase, the regulatorhectifier supplies excess voltage to the battery. Under these
conditions, the electrolyte level goes down quickly.
Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery
is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the
scooter.
The battery will self-discharge when the scooter is not in use. For this reason, charge the battery every two weeks to
prevent sulfation from occurring.
Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance,
always charge the battery. Also, the battery life is lengthened when it is initially charged.
When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-5).
For alternator service, refer to page 12-9.
Battery charging
This model comes with a maintenance free (MF) battery. Remember the following about MF batteries
- Use only the electrolyte that comes with the battery.
- Use all of the electrolyte.
- Seal the battery properly.
- Never open the seals after installation.
For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or
extending the charging time may damage the battery.
Battery testing
Refer to the battery instruction of the Operation Manual for the recommended battery tester. The recommended battery
tester puts a "load" on the battery so the actual battery condition of the load can be measured.
Recommended battery tester: BM210 or BATTERY MATE or equivalent
ITEM SPECIFICATION
Battery Capacity 12V-6Ah
Current leakage 0.2 mA max.
Vo Ita g e Fully charged 13.0 - 13.2 V
(20C/68"F) Needs charging Below 12.3 V
Charging cur- Normal 0.6N 5 - 10 h
rent I
Quick 3.0 N1.0 h
Alternator Capacity 300 W/5,000 min-' (rpm)
Charging coil resistance (2OoC/68"F) 0.1 - 0.5 R
17-4
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove the battery (page 17-6).
Check the battery condition using the recommended battery tester.
RECOMMENDED BAlTERY TESTER: BM210 or BATTERY MATE or equivalent
Is the battery good condition?
YES - GO TO STEP 2.
NO - Faulty battery.
2. CURRENT LEAKAGE TEST
Install the battery (page 17-6).
Check the battery current leakage (Leak test; page 17-7).
Is the current leakage below 0.2 mA?
YES - GO TO STEP4.
NO - GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGURETOR/RECTIFIRE CONNECTOR
Disconnect the regulatorhectifier 3P black connector and recheck the battery current leakage.
Is the current leakage below 0.2 mA?
YES - Faulty regulatorlrectifier.
NO - Shorted wire harness.
Faulty ignition switch.
4. ALTERNATOR CHARGING COIL INSPECTION
Check the alternator charging coil (page 17-8).
Is the alternator charging coil resistance within 0.7 - 0.5 l2 (20C/68"F)?
YES - GO TO STEP 5.
NO - Faulty charging coil.
5. CHARGING VOLTAGE INSPECTION
Measure and record the battery voltage using a digital multimeter (page 17-6).
Start the engine.
Measure the charging voltage (page 17-71,
Compare the measurement to result of the following calculation.
STANDARD: Measured battery Voltage e Measured charging voltage e 15.5 V at 5,000 min-'(rpm)
Is the measured charging voltage within the standard voltage?
YES - Faulty battery.
NO - GO TO STEP 6.
6. REGULATOR/RECTIFIER WIRE HARNESS INSPECTION
Check the voltage and continuity a t the regulatorhectifier connector (page 17-8).
Are the results of checked voltage and continuity correct?
YES - Faulty regulator/rectifier.
NO - Open circuit in related wire.
Loose or poor contacts of related terminal.
Shorted wire harness.
BATTERY/CHARGING SYSTEM
BATTERY
REMOVAL/I NSTALLATION
Always turn the Remove the maintenance lid (page 2-4).
ignition switch OFF
Remove the two screws and battery setting plate.
before removing
the battery.
Remove screw and disconnect the negative (-1

cable.
Remove screw and disconnect the positive (+) cable
and remove the battery.
Connect the posi- Install the battery i n the reverse order of removal.
After installing the battery, coat the terminals with
(+) cab'e first
then connect the
clean grease.
negative (--) cable.
VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (2OoC/68"F):
Fully charged: 13.0 - 1 3 . N
Under charged: Below 12.3V
BATTERY CHARGING
Remove the battery (page 17-6).
BATTERY I
Turn power O N / O f f Connect the charger positive (+) cable to the battery
at the charger, not positive (+) terminal.
at the battery termi- Connect the charger negative (-) cable to the battery
na/. negative (-1 terminal.
CHARGING CURRENT/TIME:
Standard: 0.6 A15 - 10 h
Quick: 3 All h
Quick-charging should only be done i n an emer-
gency; slow charging is preferred.
For battery charging, do not exceed the charging
current and time specified on the battery. Using
excessive current or extending the charging time
may damage the battery.
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Remove the battery setting plate (page 17-6).
Turn the ignition switch to OFF and disconnect the
negative (-) cable from the battery.
Connect the ammeter (+) probe to the negative (-1
cable and the ammeter (-) probe to the battery (-1
terminal.
With the ignition switch turned to OFF, check for
current leakage.
When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the
range selected may blow out the fuse in the
tester.
While measuring current, do not turn the ignition
switch to ON. A sudden surge of current may
blow out the fuse in the tester.
STANDARD: 0.2 mA max.
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one
by one and measuring the current.
CHARGING VOLTAGE INSPECTION

Be sure that the battery is in good condition before
performing this test.
Start the engine and warm it up to the normal oper-
ating temperature.
Stop the engine, remove the battery setting plate
(page 17-6) and connect the multimeter as shown.
To prevent a short, make absolutely certain
which are the positive and negative terminals or
cable.
Restart the engine.
With the headlight on Hi beam, measure the voltage
on the multimeter when the engine runs at 5,000
min-' (rpm).
STANDARD: BV (page 17-6) c Measured CV < 15.5 V
B V Battery voltage
C V Charging voltage
BAlTERY/CHARGING SYSTEM
ALTERNATOR CHARGING COIL
INSPECTION
It is not necessary Remove the luggage box (page 2-5).
to remove the sta- Remove the regulatorhectifier 3P white connector
tor ' O i l t o make this
from the frame and disconnect it.
test.
Measure the resistance between the Yellow wire
terminals of the alternator side connector.
STANDARD: 0.1 - 0.5 0 (2OoC/68"F)
Check for continuity between each Yellow wire ter-
minals of the alternator side connector and ground.
There should be no continuity.
If readings are far beyond the standard, or if any
wire has continuity to ground, replace the alternator
stator (page 12-9).
REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Remove the regulatorhectifier 3P white connector
from the frame and disconnect it.
Check the following at the wire harness side con-
nector:
Measure the voltage between the Red/white wire
terminal (+) and ground (-1.
There should be battery voltage at all times.
Measure the voltage between the Black wire ter-
minal (+) and ground (-).
There should be battery voltage when the igni-
tion switch is turned to ON.
Check for continuity between the Green wire ter-
minal and ground.
There should be continuity a t all times.
Remove the regulatorhectifier 3P connectors from
the frame and disconnect them.
Remove the two mounting bolts and the regulator/
rectifier.
Apply locking agent to the mounting bolt threads.
Install the regulator/rectifier onto the frame and
tighten the two mounting bolts.
Connect the regulator/rectifier 3P connectors and
install them onto the frame.
Install the frame body cover (page 2-5).
18. IGNITION SYSTEM
SYSTEM LOCATION.................................... 18-2 IGNITION SYSTEM INSPECTION .---*.--*..-*-.. 18-5
SYSTEM DIAGRAM ..................................... 18-2 IGNITION COIL ............................................. 18-7
SERVICE INFORMATION ............................ 18-3 [GNlTlON TIMING ........................................ 18-8
18-1
IGNITION SYSTEM
SYSTEM LOCATION
BA~~ERY FUSE BOX
SYSTEM DIAGRAM
1-p-q
- -
aEzsE R~*R/BI-BI-
IGNITION
SWITCH
FUSE (10A)
BI: Black
~
Bu: Blue
BATTERY G: Green
0: Orange
P: Pink
R: Red
W. White
YYellow
-
ENGINE CONTROL ENGINE COOLANT CAMSHAFT ENGINE STOP BANK ANGLE -
MODULE (ECM) TEMPERATURE POSlTlON RELAY SENSOR
(ECT) SENSOR (CKP) SENSOR
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is turned to ON and current is present.
When servicing the ignition system, always follow the steps in the troubleshooting sequence o n page 18-4.
This scooter's Ignition Control Module (ICM) is built into the Engine Control Module (ECM).
The ignition timing cannot be adjusted since the ECM is factory preset.
The ECM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the ECM. Always turn the ignition switch to OFF before servicing.
A faulty ignition system is often related to poor connections. Check those connections before proceeding.
Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine
cranking speed as well as no spark at the spark plug.
Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
For ignition switch servicing, refer to page 20-12.
For crankshaft position (CKP) sensor removal/installation, refer to page 12-9.
SPECIFICATION
ITEM SPECIFICATIONS
%ark d u o aaD 0.8 - 0.9 mm (0.031 - 0.035 in1
Crankshaft position (CKP) sensor peak voltage 0.7 V minimum

Ignition timing ("F" mark) 10" BTDC at idle
TOOL
Peak voltage adaptor
07HGJ-0020100
With commercially available digital

multimeter (impedance 10 MWmin-
imum)
or lmrie diagnostic tester (model
625)
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Water got into the spark plug cap (leaking the ignition coil secondary voltage)
"Initial voltage" of the ignition primary coil is the battery voltage with the ignition switch turned to ON (The engine is not
cranked by the starter motor).
NO SPARK AT PLUG
Unusual condition Probable cause (Check in numerical order)
Ignition coil No initial voltage with ignition 1. An open circuit in BlacWwhite wire between the igni-
primary volt- switch turned to ON (Other electri- tion coil and engine stop relay.
age cal components are normal) 2. An open circuit or loose connection in engine stop
relay related circuit or faulty engine stop relay.
3. Loose or poor contact of the ignition coil primary wire
terminal, or an open circuit in primary coil. (Check at
the ECM connector.)
4. Faulty ECM (when the initial voltage is normal with the
ECM connector disconnected).
Initial voltage is normal, but it drops 1. Incorrect peak voltage adaptor connections.
down t o 2 - 4 V while cranking the 2. Undercharged battery.
engine. 3. No voltage between the BlacWwhite (+) and body
ground (-1 at the ECM connector or loosen ECM con-
nect0r.
4. An open circuit or loose connection in Greedpink wire
of the ECM.
5. An open circuit or loose connection in Yellowlblue
wire between the ignition coil and ECM.
6. Short circuit in the ignition primary coil.
Z Faulty CKP sensor (measure the peak voltage).
8. Faulty ECM (when above No.1 - 7 are normal).
Initial voltage is normal, but no peak 1. Incorrect peak voltage adaptor connections.
voltage while cranking the engine. 2. Faulty peak voltage adaptor.
3. Faulty ECM (when above No.1 and 2 are normal).
Initial voltage is normal, but peak 1. The multimeter impedance is too low; below 10 MR/
voltage is lower than standard DCV.
value. 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sample timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
4. Faulty ignition coil.
5. Faulty ECM (when above No.1 - 4 are normal).
Initial and peak voltage are normal, 1. Faulty spark plug or leaking ignition coil secondary
but no spark jumps at plug. current amDere.
2. Faulty ignit'ion coil.
Crankshaft Peak voltage low 1. The multimeter impedance is too low; below 10 M W
position DCV.
(CKP) sensor 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
4. Faulty CKP sensor (when above No. 1 - 3 are normal).
No peak voltage. 1. Faulty peak voltage adaptor.
2. Faultv CKP sensor.
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
If there is no spark present at the plug, check all
connections for loose or poor contact before
measuring the peak voltage.
Use a commercially available digital multimeter
(impedance 10 MWDCV minimum).
The display value differs depending upon the
internal impedance of the multimeter.
If the lmrie diagnostic tester (model 625) is used,
follow the manufacturer's instruction.
Connect the peak voltage adapter to the digital mul-
timeter, or use the peak voltage tester. DIGITAL MULTIMETER
TOOLS:
lmrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MWDCV minimum)
PEAK VOLTAGE ADAPTOR

IGNITION COIL PRIMARY PEAK
VOLTAGE
Check all system connections before this inspec-
tion. Poor connected connectors can cause incor-
rect readings.
Remove the maintenance lid (page 2-41,
Disconnect the spark plug cap from the spark plug.
Connect a known-good spark plug to the spark plug

cap and ground it to the cylinder as done in a spark
test.
IGNITION SYSTEM
With the ignition coil primary wire connected, con-
nect the lmrie diagnostic tester or peak voltage
adaptor probes to the ignition coil primary terminal
and ground.
TOOLS:
lmrie diagnostic tester (model 625) or
(impedance 10 MCUDCV minimum)
CONNECTION: Yellow/blue (+) - Ground (-1

Turn the ignition switch to ON and measure the ini-
tial voltage a t this time.
STANDARD: Battery voltage
If the initial voltage cannot be measured, check each
item in the troubleshooting chart (page 18-4).
Turn the ignition switch to ON and squeeze brake
lever fully.
Crank the engine with the starter switch and mea-
sure the ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
If the peak voltage is abnormal, check each item in
the troubleshooting chart (page 18-4).
CRANKSHAFT POSITION (CKP)

SENSOR PEAK VOLTAGE
Check all system connections before this inspec-
tion. Poor connected connectors can cause incor-
rect readings.
connector by releasing the lock lever.
Connect the lmrie diagnostic tester or peak voltage
adaptor probes to the ECM connector terminals.
TOOLS:
lmrie diagnostic tester (model 6251 or
(impedance 10 MQ/DCV minimum)
CONNECTION: Yellow (+) - White/yellow (-1

Turn the ignition switch to ON and squeeze brake
lever fully.
Crank the engine with the starter switch and mea-
sure the CKP sensor peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured a t the ECM connector
is abnormal, measure the peak voltage at the CKP
sensor connector.
18-6
Disconnect the CKP sensor 3P white connector.
Connect the lmrie diagnostic tester or peak voltage
adaptor probes to the CKP sensor side connector
terminals.
In the same manner as at the ECM connector, mea-
sure the peak voltage and compare it to the voltage
measured at the ECM connector.
If the peak voltage measured at the ECM is
abnormal and the one measured at the CKP sen-
sor is normal, the wire harness has an open or
short circuit, or loose connection.
If both peak voltages are abnormal, check each
item in the troubleshooting chart (page 18-4).
See page 12-9 for CKP sensor replacement.
Install the removed parts in the reverse order of
removal.
IGNITION COIL
Disconnect the spark plug cap.
Remove the wire band from the stay.
Remove the spark plug wire from the engine.

Remove the two wire bands from the frame.
Disconnect the ignition coil wire connectors.
Remove the bolts, set plates and ignition coil.
IGNITION SYSTEM
IGNITION TIMING
Start the engine and warm it up operating
temperature.
Stop the engine and remove the timing hole cap
from the right crankcase cover.
Read the instruc- Connect the timing light to the spark plug wire.
tions for timing light
Start the engine, let it idle and check the ignition
operation.
timing.
The ignition timing is correct if the "F" mark on the

flywheel aligns with the index mark on the rear
crankcase cover at idle.
Increase the engine speed and make sure the "F"
mark begins to move.

Install the timing hole cap and tighten it.
TORQUE: 6 N m (0.6 kgf-m, 4.4 Ibf-ft)
19. ELECTRIC STARTER
SYSTEM LOCATION.................................... 19-2 TROUBLESHOOTlNG ................................... 19-4
SYSTEM DIAGRAM ..................................... 19-2 STARTER MOTOR ........................................ 19-6
S ERVlCE INFORMATION ............................ 19-3 STARTER RELAY SWITCH ......................... 19-11

ELECTRIC STARTER
SYSTEM LOCATION
SYSTEM DIAGRAM
1- I MAINFUSE
I
R
IGNITION
SWITCH
I
BAlTERY -ISTARTER
RELAY
SWITCH
STARTER
MOTOR (M)
Y
1
BI: Black
Br: Brown
I I '7
REAR BRAKE
G: Green LIGHT SWITCH
R: Red
YYellow I -
- -
MAIN RELAY
19-2
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
Always turn the ignition switch to OFF before servicing the starter motor. The motor could suddenly start, causing seri-
ous injury.
A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
The starter motor can be serviced with the engine in the frame.
When checking the starter system, always follow the steps in the troubleshooting (page 19-4).
If the current is kept flowing through the starter motor to turn i t while the engine is not cranking over, the starter motor
may be damaged.
Refer to page 12-10 for starter clutch servicing.
Refer to page 20-12 for ignition switch inspection servicing.
Refer to page 20-14 for starter switch inspection.
Refer to page 20-14 for brake light switch inspection.
ELECTRIC STARTER
TROUBLESHOOTING
Starter motor does not turn
1. Fuse Inspection
Check for b l o w n main fuse (30 A) or sub-fuse (15 A).
Is the fuse blow?
YES - Replace the fuse.
NO - GO TO STEP 2.
2. Battery Inspection
Check the battery is fully charged and i n good condition.
Is the battery in good condition7
YES - GO TO STEP 3.
NO - Charge or replace the battery (page 17-6).
3. Starter Relay Switch Operation Inspection
Squeeze the brake lever fully and push the starter switch.
You should hear the starter relay switch "CLICK" when the starter switch is pushed.
Is the "CLICK" hear7
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. Starter Motor Inspection
Apply battery voltage t o the starter motor directly and check the operation.
Dose the starter motor turn7
YES - Loose or poorly connected starter motor cable.
Faulty starter relay switch.
NO - Inspect the starter motor (page 19-6).
5. Starter Relay Coil Power Input Line Inspection
Check the relay coil power input line of the starter relay switch (page 19-12).
Is the power input line normal7
YES - GO TO STEP 6.
NO - Faulty ignition switch (page 20-12).
Faulty main relay (page 20-15).
Faulty brake light switch (page 20-14).
Faulty starter switch (page 20-14).
Loose or poor contact of the related connector terminal.
Open circuit in the wire harness between the ignition switch and starter relay switch.
6. Starter Relay Coil Ground Line Inspection
Check the ground line of the starter relay switch (page 19-12).
Is the ground line normal7
YES - Faulty starter relay.
NO - Loose or poor contact of the ground terminal
Open circuit in the wire harness between the starter relay switch and ground terminal.
ELECTRIC STARTER
Starter motor turns engine slowly
Low battery voltage
Poorly connected battery cable
Poorly connected starter motor cable
Faulty starter motor
Poor connected ground cable
Starter motor turns, but engine does not turn
Faulty starter clutch
Damaged or faulty starter drive gear
Starter relay "CLICK",but engine does not turn over
Crankshaft does not turn due to engine problems
19-5
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
Remove the air cleaner housing (page 5-36).
Slide the rubber cap off the starter motor terminal,
and remove the terminal nut and starter motor
cable.
Pull the starter motor cable out of the frame.
Remove the tw o mounting bolts, ground cable and
starter motor from the crankcase.
Remove the O-ring from the starter motor.
DISASSEMBLYANSPECTION
- starter motor case bolts and O-rings
Record the location - front cover

and number of - lock washer
shims. - insulated washer
- shims
- seal ring
- rear cover assembly

- shims
- seal ring
- armature
ELECTRIC STARTER
Check the dust seal and needle bearing in the front
cover for deterioration, wear or damage.
Check the bushing in the rear cover for wear or

damage.
Check for continuity between the cable terminal and

the insulated brush.
Check for continuity between the cable terminal and

rear cover.
19-7
ELECTRIC STARTER
Remove the following fro m the rear cover:
- nut
- washer
- insulators
- O-ring
- brush holder
Remove the brushes fro m the brush holder.

Inspect the brushes for damage and measure the
brush length.
Donotuseemery Inspect the commutator bars of the armature for

or sand paper on discoloration.
the commutator.
Check for continuity between pair of commutator

bars.
These should be continuity.
ELECTRIC STARTER
Check for continuity between each commutator bar
and the armature shaft.
ASSEMBLY
LOCK WASHER
O-RING
\ SEAL RING
w
/
/
BOLTS
HERS
INSULATOR PLATE
INsuLATED WASHER
BRUSH SPRINGS
ARMATURE /=-@ip
/
BRUSHHOLDER f &(
I
SEAL RING REAR COVER
Install the brushes in the brush holder.
19-9
Install the brush holder assembly into the rear cover
by aligning the tab with the groove in the rear cover.
- new O-ring
- insulators
- washer
- nut
Thecoilmaybe Install the armature into the motor case while hold-
damagedif the ing the armature tightly to keep the magnet of the
magnetpulls the case from pulling the armature against it.
armature against
the case.
Install a new seal ring onto the motor case.

Apply a thin coat of grease to the armature shaft
end.
Install the same number of shims in the same loca-
tions as noted during disassembly onto the arma-
ture shaft.
Install the rear cover assembly by aligning the brush
holder tab with the motor case groove, while push-
ing the brushes into the brush holder.
Install the same number of shims in the same loca-

tions as noted during disassembly.
Install the insulated washer onto the armature shaft.
Install a new seal ring onto the motor case.
Install the lock washer onto the front cover.
Apply grease to the oil seal lip and needle bearing
and install the front cover onto the motor case.
ELECTRIC STARTER
Align the index lines o n the front cover and motor
case.
Install new O-rings onto the motor case bolts.
Install the motor case bolts and tighten them
securely.
INSTALLATI0N
Coat a n e w O-ring with engine oil and install it into
the starter motor groove.
Install the starter motor into the crankcase.
Install the mounting bolts with the ground cable,

and tighten the bolts securely.
Route the starter motor cable as shown and install it
onto the motor terminal.
Install the terminal nut and tighten it securely.
Install the rubber cap over the motor terminal.
Install the air cleaner housing (page 5-36).
STARTER RELAY SWITCH

OPERATION INSPECTION
Turn the ignition switch t o ON.
Squeeze the brake lever fully and push the starter
switch.
The coil is normal if the starter relay switch clicks.
If you don't hear the relay "CLICK", inspect the
starter relay circuits (page 19-12).
ELECTRIC STARTER
CIRCUIT INSPECTION
Release the connector cover.
Measure the voltage between the starter relay 4P
red connector terminal and ground with the ignition
CONNECTION: Yellow/red (+) - Ground (-)
There should be battery voltage only when the
brake lever squeezed and the starter switch is
pushed.
GROUND LINE
Release the connector cover and disconnect the
starter relay 4P red connector.
Check for continuity between the wire harness side
connector terminal and ground.
CONNECTION: Green - Ground
CONTlNUITY INSPECTION
Yellow/red (+)
Disconnect the negative (-1 cable from the battery.
Disconnect the starter relay switch 4P red connec-
tor.
Remove the battery (+) cable and starter motor
cable from the starter relay switch.
Connect the fully charged 12 V battery positive ter-
minal to the Yellowhed wire terminal and negative
C
terminal to the Green wire terminal of the starter
relay switch. T
There should be continuity between the cable termi-

nals while the battery is connected, and no continu- Green (-1
ity when the battery is disconnected.
19-12
20. LIGHTS/METERS/SWITCHES
COMPONENT LOCATION........................... 20-2 FUEL GAUGE/FUEL LEVEL SENSOR ----.-.20-10
COOLANT TEMPERATURE GAUGE/

ECT SENSOR .............................................. 20-1 1
HEADLIGHT.................................................. 20-4
IGNITION SWITCH ..................................... 20-12
FRONT TURN SIGNAL/
POSlTlON LIGHT ......................................... 20-5 HANDLEBAR SWITCH................................ 20-14
REAR TURN SIGNAL/BRAKE/ BRAKE LIGHT SWITCH .............................. 20-14

TAILLIGHT.................................................... 20-6
MAIN RELAY............................................... 20-15
LICENSE LIGHT............................................ 20-7
TURN SIGNAL RELAY................................ 20-16
COMBlNATlON METER............................... 20-7
HORN .......................................................... 20-16
20- 1
LIGHTS/METERS/SWITCHES
COMPONENT LOCATION
COMBINATION METER REAR BRAKE

LIGHT SWITCH
FRONT BRAKE \
20-2
SERVICE INFORMATION
GENERAL
m
Note the following when replacing the halogen headlight bulb.
- Wear clean gloves while replacing the headlight bulb. Do not put fingerprints on the headlight bulb, as they may create
hot spots on the bulb and cause it to fail.
- If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.
A halogen headlight bulb becomes very hot while the headlight is on, and remains hot for a while after it is turned off.
Be sure t o let it cool down before servicing.
Be sure to install the dust cover after replacing the bulb.
Use an electric heating element to heat the water/coolant mixture for the ECT sensor inspection. Keep all flammable
materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection.
Check the battery condition before performing any inspection that requires proper battery voltage.
A continuity test can be made with the switches installed on the scooter.
The following color codes used are indicated through out this section.
Bu: Blue G: Green Lg: Light Green W: White
El: Black Gr: Gray 0: Orange Y Yellow
Br: Brown Lb: Light Blue R: Red
ITEM SPECIFICATIONS
Bulb Headlight (high/low beam) 12 V - 60155 W
Brakehailliaht 12 V - 2115 W
Turn signal light 12v-21w x 4

Position light 12v-5wx2
Instrument light 12 v - 1.7 w x 3
Hiah beam indicator
Y
12 V - 1.7 W
Turn signal indicator 12 V - 1.7 W x 2
PGM-FI malfunction indicator LED
Engine oil maintenance indicator LED
Fuse Main fuse 30 A
Sub-fuse 15Ax 1,10Ax4
TORQUE VALUES
License light screw 1.5 N.m (0.15 kgf.m, 1.1 Ibf.fi)
Speedometer cable joint nut 3.4 N.m (0.35 kgf.m, 2.5 Ibfeft)
20-3
HEADLIGHT
BULB REPLACEMENT
Be careful not to Release the dust cover and disconnect the bulb con-
scratch the nector.
headlight lens
during servicing. I NOTICE I
Avoid touching a new halogen bulb. Finger prints
can create hot spots that cause a bulb to break.
Remove the bulb retainer by turning it counterclock-
wise.
Remove the headlight bulb and replace it with a
new one.
NOTE:
Align the bulb tab with the grooves properly.
When installing the dust cover, align the wires
with the cutout in the headlight housing and set
the dust cover tightly against the housing.
BULB
Remove the three screws and the headlight assem-
bly while spreading the handlebar cover upward.
FRONT TURN SIGNAL/POSITION
LIGHT
BULB REPLACEMENT
TURN SIGNAL BULB
Remove the bulb socket by turning it counterclock-
wise.
Remove the socket/bulb out of the front lower
cover, being careful not to damage the its wire.
While pushing the bulb in, turn it counterclockwise
t o remove it, and replace it with a new one.
Check the rubber seal is in good condition and
replace it with a new one if necessary.
POSITION LIGHT BULB

Pull the bulb socket out of the light housing.
Remove the socket/bulb out of the front lower
cover, being careful not t o damage the its wire.
Pull the bulb out of the socket and replace it with a
new one.
REMOVAL/ INSTA LLATlON

Remove the front lower cover (page 2-9).
Release the wires from the wire guide.
Remove the three screws and turn signal/position
light assembly.
Route the wires Installation is i n the reverse order of removal.
properly
(page 1-17).
REAR TURN SIGNAL/BRAKE/
TAILLIGHT
BULB REPLACEMENT
- two screws
- brakehaillight lens
- screw(s)
- turn signal light lens(es)
While pushing the bulb in, turn it counterclockwise
to remove it, and replace it with a new one.
Make sure the lens gasket is installed in position
and is in good condition, and replace it with a new
one if necessary.
REMOVAL/I NSTALLATION
Be careful not to Remove the eight screws and rear combination light
damage the cover assembly.
tab
Release the tab and separate the left and right body
covers.
LIGHT ASSEMBLY
LICENSE LIGHT
BULB REPLACEMENT
Remove the screw and washer, and license light
housing from the rear fender.
Pull the bulb socket out of the light housing.
new one.
TORQUE: 1.5 N-m (0.15 kgf.m. 1.1 Ibf4-t)
COMBINATION METER
POWERIGROUND LINE INSPECTION
Remove the front lower cover (page 2-8).
Disconnect the meter 9P (white) and 6P (white) con-
nectors.
Check the following at each wire harness side con-
nector.
POWER INPUT LINE
Measure the voltage between the Black/brown wire
terminal (+) of the 6P connector and ground (-).
If there is no voltage, check for open circuit in Black/
brown wire.
GROUND LINE
Check for continuity between the Green wire termi-
nal of the 9P connector and ground.
If there is no continuity, check for an open circuit i n
the Green wire.
BACK-UP VOLTAGE LINE
Measure the voltage between the Light greedblack
wire terminal (+) of the 9P connector and ground (-).
- open circuit in the Light greedblack wire
- blown "CLOCK" fuse (10 A)
- open circuit in the Red wire in the fuse box
20-7
BULB REPLACEMENT
Pull the bulb socket out of the meter housing.
new one.
If the lower side instrument bulb will be replaced,
remove the rear handlebar cover off of the handle-
bar without disconnecting the switch connectors
(page 2-12).
REMOVAL/INSTALLATlON
- front handlebar cover (page 2-11)
Remove the handlebar post lid by sliding it rear-
ward.
Loosen the speedometer cable joint nut (but do not
disconnect it yet).
Disconnect each brake light switch connectors.
Release the wire band from the rear air guide plate.
Disconnect the 6P (white) and 9P (white) connec-
tors.
Support the meter Disconnect the speedometer cable.

so it does not hang
Release the following from the cable guide on the
from the wire
handlebar post:
harness.
- throttle cable
- brake hose
- speedometer cable
Release the speedometer out of the frame and
guide to remove the combination meter.
Route the cables, Installation is in the reverse order of removal.
hose and wires
properly
TORQUE:
(page 1-1 7). Cable joint nut: 3.4 N-m(0.35 kgf-m, 2.5 Ibf-ft)
DISASSEMBLY/ASSEMBLY
Remove the combination meter (page 20-8).
- three connectors (3P, 2P and single lead)
- tapping screw and wire clamp
- two plugs
- two washer-screws (4 x 10 m m ) and terminal
(green)
- washer-screw (3 x 10 mm) and terminal (light
greedred)
- six washer-screws (3 x 22 m m ) and terminals
(attaching the coolant temperature gauge and
fuel gauge)
- bulb socketdwire harness
- five screws (3 x 14 mm) and meter lens
- cover plate
- meter assembly
- two screws (3 x 14 mm), connector and LED indi-
cator printed circuit board
- three screws (3 x 14 mm), and clock/switch
printed circuit board
Assembly is in the reverse order of disassembly.
TS
Install the bulb sockets and wire terminals in posi-

tion as shown.
20-9
FUEL GAUGEIFUEL LEVEL SENSOR
NOTE:
The fuel level sensor is mounted on the fuel
pump (the fuel pump with the built-in level sen-
sor). Do not disassemble the fuel pump. Replace
the fuel pump as an assembly when the it is
fa uIty .
SYSTEM INSPECTION
Make sure that the coolant temperature gauge and
indicator function properly.
Disconnect the fuel pump 5P connector.
Check for continuity between the Greenlblack
(ground) wire terminal of the wire harness side 5P
connector and ground.
Check the Greenlblack and the Yellowlwhite wires
for continuity between the fuel gauge and level sen-
so r
If the above checks are abnormal, check for open
circuit or loose connection in the related wires.
If the wires are normal, check the fuel level sen-
sor (page 20-10). If it is OK, replace the combina-
tion meter.
FUEL LEVEL SENSOR INSPECTION

Remove the fuel pump assembly (page 5-35).
Measure the resistance between the connector ter-
I Ye IIowlw hite
minals. Greei
STANDARD (20C/68"F):
Float Position
Terminals
Yellow/white
I Yellow/white
Gravlblack
- 450 - 750 R
If it is out of the specification, replace the fuel pump

assembly.
20-10
COOLANT TEMPERATURE GAUGE/
ECT SENSOR
SYSTEM INSPECTION
Make sure that the fuel gauge and indicator function
properly.
Disconnect the engine coolant temperature (ECT)
sensor 3P (gray) connector.
Ground the Greedblue wire terminal of the 3P con-
nector with a jumper wire.
Turn the ignition switch to ON and check the tem-
perature gauge.
The gauge needle should move to "H".
If the needle moves, check the ECT sensor (page
20-12).
If the needle does not move, check as follows.

Check the Greedblue wire for continuity between
the temperature gauge and ECT sensor 3P connec-
tor.
Disconnect the Greedblack wire terminal of the

temperature gauge by removing the terminal screw.
Check for continuity between the Greedblack
(ground) wire terminal and ground.
If the above checks are abnormal, check for open
circuit or loose connection in the related wires.
If the wires are normal, replace the combination
meter.
20-1I
The coolant temperature is low, but the gauge
remains "H"
- front handlebar cover (page 2-11)
Disconnect the Greedblue wire terminal of the tem-
perature gauge by removing the terminal screw.
Check for continuity between the Greedblue termi-
nal and ground.
If there is continuity, check for short circuit in the
Greerdblue wire.
If there is no continuity, check the ECT sensor
(page 20-12). If the sensor is normal, replace the
combination meter.
ECT SENSOR INSPECTION

Remove the ECT sensor (page 5-48).
THERMOMETER
Suspend the ECT sensor in a pan of coolant (1:l
mixture) o n an electric heating element and mea-
sure the resistance between the temperature signal
terminal and body as the coolant heats up.
Soak the sensor in coolant up to its threads with
at least 40 mm (1.57 in) from the bottom of the
pan to the bottom of the sensor.
Keep the temperature constant for 3 minutes
before testing. A sudden change of temperature
will result i n incorrect reading. Do not let the TERMINAL
thermometer or ECT sensor touch the pan. (Greedblue)
ECT SENSOR
Temperature I 80C (176F) 1 120C (248F)
Resistance I 47-57R I 14-18R
If the resistance is out of above range by 10% a t any
temperature listed, replace the ECT sensor.
Install the ECT sensor (page 5-48).
IGNITION SWITCH
INSPECTION
- front lower cover right side fasteners (page 2-9)
Disconnect the ignition switch 2P (white) connector.
Check for continuity between the switch side con-
nector terminals in each switch position.
Continuity should exist between the color coded
wire terminals as follows:
COLOR
LOCK
OFF
ON
20-12
Remove the radiator (page 6-17).
Release the following and remove the rear air guide
plate.
- ignition switch wire (from the wire guide)
- two wire bands
Remove the switch cap by turning it counterclock-

wise.
Disconnect the ignition switch 2P (white) connector.
Remove the rubber sheet from the ignition switch,
being careful not to damage it.
Loosen the cable joint nut and disconnect the seat

lock cable from the ignition switch.
Remove the two bolts and ignition switch.
Install the ignition switch with new switch bolts and
tighten them securely.
Route the wires Install the removed parts in the reverse order of
and cable properly removal.
lpage 7-77). Install the radiator (page 6-17)
HANDLEBAR SWITCH
INSPECTION
DIMM E R I
Check for continuity between the switch terminals
PASSING
in each switch position.
Continuity should exist between the terminals of the
corresponding color coded wire as follows:
STARTER
STARTER
TURN SIGNAL
BRAKE LIGHT SWITCH

INSPECTION
Disconnect the brake light switch connectors.
Check for continuity between the switch terminals.
There should be continuity with the brake lever
squeezed, and there should be no continuity when
the brake lever is released.
20- 14
MAIN RELAY
INSPECTION
MAIN RELAY
Remove the main relay.
terminals.
RELAY COIL LINE

Measure the voltage between the Redlblack (+) and
Green (-) wire terminals of the relay connector.
- open circuit in the Green wire
- open circuit in the Redlblack wire between the
main relay and ignition switch
- ignition switch (page 20-12)
RELAY SWITCH LINE

Measure the voltage between the Red wire terminal
(+) of the relay connector and ground I-).
If there is no voltage, check for open circuit in Red
wire.
If the Red wire is normal, check for open circuit in
the Red/yellow wire between the main relay and
fuse box.
FUNCTION TEST
Connect an ohmmeter to the switching side relay I
terminals. BATTERY
CONNECTION: Red - Red/yellow

terminals.
CONNECTION: Red/black (+) - Green (-1 Red/black (+) Green (-1

nected to the relay terminals and there should be no I I
continuity when the battery is disconnected. I -- Red
-\
Red/yelI ow
TURN SIGNAL RELAY
INSPECTION
All turn signal lights does not blink
I RELAY
Disconnect the 3P connector to remove the turn sig-
nal relay.
terminals.
Connect the BlacVbrown and Gray wire terminals of
the 3P connector with a jumper wire.
Turn the ignition switch to ON and check the turn
signal lights by operating the turn signal switch.
If the light does not come on, check for an open
circuit i n the BlacVbrown and Gray wires.
If the light comes on, check for open circuit in the
Green wire. If it is OK, replace the relay.
HORN
INSPECTION
Disconnect the horn connectors.
Connect a 12-V battery to the horn terminals.
The horn is normal if it sounds when the 12-V bat-
tery is connected across the horn terminals.
Remove the radiator without disconnecting the
water hoses (page 2-8).
Disconnect the horn connectors.
Be careful not to Move the rear air guide plate and radiator forward
damage the radiator to get the clearance for mounting bolt removal.
fm. Remove the bolt and horn.
20-16
22.TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT LOW AND

TO START .................................................... 22-2 IDLE SPEED................................................... 22-5
ENGINE LACKS POWER ............................. 22-3 POOR PERFORMANCE AT HIGH SPEED .---22-6
POOR HANDLING ......................................... 22-7
22- 1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1. Spark Plug Inspection
Remove and inspect spark plug.
Is there spark plug in good condition?
NO - Incorrect spark plug heat range
Incorrect spark plug gap
Dirty air cleaner element
YES - GO TO STEP 2.
2. SparkTest
Perform spark test.
Is the spark good?
NO - Faultysparkplug
Fouled spark plug
YES - GO TO STEP 3.
3. Fuel Injection System Inspection
Check the fuel injection system (page 5-7).
Is the fuel injection system normal?
NO - Faulty fuel injection system.
YES - GO TO STEP 4.
4. Fuel Line Inspection
Check the fuel line (page 5-31).
Is the fuel line normal?
NO - Faulty fuel line or fuel pump system.
YES - GO TO STEP 5.
5. Cylinder Compression Inspection
Test cylinder compression.
Is the compression within specification?
NO - Valvestuckopen
W o r n cylinder and piston rings
Seized valve
Incorrect valve seat contact
improper valve timing
YES - GO TO STEP 6.
6. Engine Starting Condition
Start the engine by following the normal procedure.
Does the engine start but then stops?
YES - lntakeair leak
Faulty idle air control (IAC) valve in engine control module (ECM)
Improper ignition timing (faulty ECM or CKP sensor)
Contaminated fuel
22-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Brake Drag Inspection
Raise the wheel off the ground and spin it by hand.
Does the wheel spin freely?
NO - Brake dragging
YES - GO TO STEP 2.
2. Tire Pressure Inspection
Check the tire pressure.
Is the pressure correct?
NO - Faulty tire valve
Punctured tire
YES - GO TO STEP 3.
3. Clutch Inspection
Accelerate rapidly.
Does the engine speed change accordingly?
NO - Clutch slipping
Worn clutch shoes or outer
0 Weak driven face spring
Additive in engine oil
Weight roller stuck
YES - GO TO STEP 4.
4. Engine Performance Inspection
Accelerate lightly.
Does the engine speed increase?
NO - 0 Faulty idle air control (IAC) valve in ECM
Clogged air cleaner
Clogged muffler
Faulty fuel pump
YES - GO TO STEP 5.
Remove and inspect the spark plug.
Is the spark plug in good condition?
NO - Plug not serviced frequently enough
Incorrect spark plug heat range
YES - GO TO STEP 6.
6. Engine Oil Inspection
Check the oil level and condition.
Is the engine oil in good condition?
NO - Oil level too high
Oil level too low
0 Contaminated oil
YES - GO TO STEP 7.
22-3
TROUBLESHOOTING
7. Ignition Timing Inspection
Check the ignition timing.
Is the ignition timing correct?
NO - Faulty ECM
Faulty crankshaft position (CKP) sensor
Improper valve timing
YES - GO TO STEP 8.
8. Cylinder compression Inspection
Test the cylinder compression.
Is the compression within specification?
NO - Valvestuckopen
Worn cylinder and piston rings
Seized valve
Incorrect valve seat contact
YES - GO TO STEP 9.
Check the fuel injection system (page 5-7).
YES - GO TO STEP 10.
10. lubrication Inspection
Remove the cylinder head cover and inspect for sings of proper lubrication
Is the valve train lubricated properly?
NO - Clogged oil passage.
YES - GO TO STEP 11.
11. Overheating Inspection
Check for engine overheating.
Is the engine overheating?
YES - Coolant level too low
Faulty radiator fan
Thermostat stuck closed
Excessive carbon build-up in combustion chamber
Use of poor quality fuel
Clutch slipping
Lean fuel mixture
NO - GO TO STEP 12.
12. Engine Knocking Inspection
Accelerate or run a t high speed.
Is the engine knocking?
YES - Worn piston and cylinder
Wrong type of fuel
Excessive carbon build-up in combustion chamber
Ignition timing too advanced (faulty ECM)
Lean fuel mixture
NO - Engine does not knock
22-4
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
YES - GO TO STEP 2.
2. ignition Timing inspection
NO - Faulty ECM
YES - GO TO STEP 3.
3. Intake Air Leaking Inspection
Check for leaks around the intake manifold.
Does it leak?
YES - Loose manifold mounting bolt
Damaged insulator
Damaged O-ring
NO - GO TO STEP 4.
4. SparkTest
Perform spark test.
Is the spark good?
NO - Faultysparkplug
Fouled spark plug
YES - Faulty idle air control (IAC) valve
Improperly adjusted valve clearance
22-5
TROUBLESHOOTING
~~
POOR PERFORMANCE AT HIGH SPEED

1. Ignition Timing Inspection
NO - Faulty engine control module (ECM)
YES - GO TO STEP 2.
Check the fuel injection system (page 5-71,
YES - GO TO STEP 3.
3. Fuel Line Inspection
Check the fuel line (page 5-31).
Is the fuel line normal?
NO - Faulty fuel line or fuel p u m p system.
YES - GO TO STEP 4.
YES - GO TO STEP 2.
5. Air Cleaner Inspection
Check the air cleaner.
Is the air cleaner element clean?
NO - Dirty air cleaner
YES - GO TO STEP 6.
6. Valve Timing Inspection
Check the valve timing.
Is the valve timing correct?
NO - Cam sprocket not installed properly
YES - GO TO STEP 7.
7. Camshaft Inspection
Remove and inspect the camshaft.
Is the cam lobe height within specification?
NO - Faultycamshaft
YES - GO TO STEP 8.
8. Valve Spring Inspection
Check the valve springs.
Are the valve springs normal?
NO - Faulty valve springs
TROUBLESHOOTING
POOR HANDLING
Steering is heavy
Steering upper inner race too tight
Damaged steering head bearings
Either wheel is wobbles
Excessive wheel bearing play
Bent rim
Excessively worn engine mount bushings
Bent frame
The scooter pulls to one side
Front and rear wheel not aligned
Faulty shock absorber
Bentfork
Bent axle
Bentframe
22-7
23.INDEX
AIR CLEANER .................................................................. 3-5 FRONT BRAKE CALIPER ............................................. 16-15
AIR CLEANER HOUSING .............................................. 5-36 FRONT FENDER............................................................... 2-8
ALTERNATOR CHARGING COIL .................................. 17-8 FRONT HANDLEBAR COVER ....................................... 2-1 1
BANK ANGLE SENSOR ................................................ 5-45 FRONT INNER COVER .................................................. 2-1 0
B A n E R Y ....................................................................... 17-6 FRONT LOWER COVER ................................................... 2-9
BEARING REPLACEMENT ............................................ 11-8 FRONT MASTER CYLINDER ....................................... 16-1 1
BELT CASE AIR CLEANER ............................................ 3-12 FRONT UPPER COVER .................................................... 2-8
BODY PANEL LOCATlONS ............................................. 2-3 FRONT WHEEL .............................................................. 14-7
BODY PANEL REMOVAL CHART ................................... 2-3 FUEL GAUGE/FUEL LEVEL SENSOR ......................... 20-10
BRAKE FLUID ................................................................ 3-14 FUEL LINE ........................................................................ 3-4
BRAKE FLUID REPLACEMENT/AIR BLEEDING........... 16-7 FUEL LINE lNSPECTlON ............................................... 5-31
BRAKE LIGHT SWITCH FUEL PUMP ................................................................... 5-35
LIGHTS/METERS/SWITCHES................................. 20-14 FUEL PUMP RELAY ....................................................... 5-43
MAINTENANCE ........................................................ 3-17 FUEL TANK .................................................................... 5-52
BRAKE LOCK OPERATION ........................................... 3-17 GLOVE BOX INNER COVER .......................................... 2-13
BRAKE PAD/DISC .......................................................... 16-9 HANDLEBAR ................................................................ 14-19
BRAKE SHOES/PADS WEAR ........................................ 3-15 HANDLEBAR SWITCH ................................................. 20-14
BRAKE SYSTEM ............................................................ 3-15 HEADLIGHT ................................................................... 20-4
CABLE & HARNESS ROUTING .................................... 1-17 HEADLIGHT AIM ........................................................... 3-17
CAMSHAFT/ROCKER ARM INSTALLATION ...............8-24 HORN ........................................................................... 20-1 6
CAMSHAFT/ROCKER ARM REMOVAL .......................... 8-8 IGNITION COIL .............................................................. 18-7
CENTER STAND ............................................................ 2-14 IGNITION SWITCH ...................................................... 20-1 2
CHARGING SYSTEM lNSPECTlON .............................. 17-7 IGNITION SYSTEM lNSPECTlON ................................. 18-5
CLUTCH/DRIVEN PULLEY .......................................... 10-12 lGNlTlON TIMING ......................................................... 18-8
COMBlNATlON METER ................................................ 20-7 INJECTOR ...................................................................... 5-41
COMBINED BRAKE EQUALIZER ................................ 16-21 LEFT CRANKCASE COVER ........................................... 10-6
COOLANT REPLACEMENT............................................. 6-7 LICENSE LIGHT ............................................................. 20-7
COOLANT TEMPERATURE GAUGE/ECT LIGHTS/METERS/SWITCHES COMPONENT
SENSOR ....................................................................... 20-1 1 LOCATION ..................................................................... 20-2
COOLING FAN MOTOR ................................................ 6-13 LUBRICATION & SEAL POINTS ................................... 1-15
COOLING SYSTEM ....................................................... 3-1 1 LUBRlCATlON SYSTEM DIAGRAM ............................... 4-2
COOLING SYSTEM FLOW PATTERN ............................ 6-2 LUGGAGE BOX ............................................................... 2-5
COOLING SYSTEM TESTING ......................................... 6-6 MAIN RELAY................................................................ 20-1 5
CRANKCASE ASSEMBLY ............................................. 13-7 MAINTENANCE LID ........................................................ 2-4
CRANKCASE BREATHER ................................................ 3-6 MAINTENANCE SCHEDULE ........................................... 3-3
CRANKCASE SEPARATION ......................................... 13-5 MIL CODE INDEX .......................................................... 5-10
CRANKSHAFT lNSPECTlON ......................................... 13-7 MIL TROU BLESHOOTlNG ............................................ 5-1 1
CYLINDER COMPRESSlON TEST .................................. 8-7 MODEL lDENTlFlCATlON ............................................... 1-2
CYLINDER HEAD ASSEMBLY ...................................... 8-19 MUD GUARD ................................................................. 2-14
CYLINDER HEAD COVER INSTALLATION ..................8-27 NUTS, BOLTS, FASTENERS......................................... 3-18
CYLINDER HEAD COVER REMOVAL ............................. 8-7 0 2 SENSOR ................................................................... 5-47
CYLINDER HEAD DISASSEMBLY ................................ 8-13 OIL PUMP......................................................................... 4-4
CYLINDER HEAD INSTALLATION ................................ 8-21 PGM-FI SELF-DIAGNOSIS INFORMATION ...................5-7
CYLINDER HEAD REMOVAL ........................................ 8-1 1 PISTON/CYLINDER INSTALLATION .............................. 9-9
CYLINDER/PISTON lNSPECTlON ................................... 9-6 RADIATOR ..................................................................... 6-17
CYLINDER/PISTON REMOVAL ....................................... 9-5 RADIATOR COOLANT ................................................... 3-10
DRIVE BELT ................................................................... 10-8 RADIATOR RESERVE TANK ......................................... 6-16
DRIVE PULLEY............................................................... 10-9 REAR DRUM BRAKE ................................................... 16-18
DTC INDEX .................................................................... 5-19 REAR FENDER ................................................................. 2-7
DTC TROUBLESHOOTlNG ........................................... 5-22 REAR HANDLEBAR COVER .......................................... 2-12
EMISSION CONTROL SYSTEMS ................................. 1-32 REAR SHOCK ABSORBER ............................................ 15-8
ENGINE CONTROL MODULE (ECM) ........................... 5-48 REAR TURN SlGNAUBRAKE/TAlLLlGHT .................... 20-6
ENGINE COOLANT TEMPERATURE (ECT) REAR WHEEL .................................................................
SENSOR ......................................................................... 5-48 REGULATOR/RECTIFIER............................................... :I;:
ENGINE IDLE SPEED..................................................... 5-49 RIGHT CRANKCASE COVER ......................................... 12-5
ENGINE INSTALLATION ................................................. 7-7 SEAT.. ............................................................................... 2-4
ENGINE OIL ..................................................................... 3-8 SECONDARY AIR SUPPLY SYSTEM
ENGINE OIL STRAINER SCREEN ................................... 3-9 FUEL SYSTEM .......................................................... 5-49
ENGINE REMOVAL ......................................................... 7-4 MAINTENANCE ........................................................ 3-12
ENGINE STOP RELAY ................................................... 5-44 SERVICE INFORMATION
EXHAUST SYSTEM ...................................................... 2-15 ALTERNATOR/STARTER CLUTCH........................... 12-3
FINAL DRIVE OIL ........................................................... 3-13 BATTERY/CHARGING SYSTEM ............................... 17-3
FINAL REDUCTION ASSEMBLY .................................. 11-9 BRAKE SYSTEM ....................................................... 16-4
FINAL REDUCTION DlSASSEMBLY/INSPECTlON...... 11-6 COOLING SYSTEM ..................................................... 6-3
FLOOR LOWER COVER ................................................... 2-8 CRANKCASE/CRANKSHAFT .................................... 13-3
FLOOR PANEL ............................................................... 2-1 1 CYLINDER HEAD/VALVES .......................................... 8-3
FLYWHEEUSTARTER CLUTCH .................................. 12-10 CYLINDER/PISTON ..................................................... 9-3
FORK ............................................................................ 14-12 DRIVE AND DRIVEN PULLEYS/CLUTCH .................10-3
FRAME BODY COVER ..................................................... 2-5 ELECTRIC STARTER ................................................. 19-3
~
23-1
SERVICE INFORMATION SYSTEM DIAGRAM
ENGINE REMOVALANSTALLATION ......................... 7-3 6ATl-ERY/CHARGI NG SYSTEM ............................... 17-2
FINAL REDUCTION ................................................... 11-3 ELECTRIC STARTER .................................................. 19-2
FRAME/BODY PANELS/EXHAUST SYSTEM ............2-2 FUEL SYSTEM (Programmed Fuel Injection) ...........5-6
FRONT WHEEUSUSPENSION/STEERI" .............. 14-3 IGNITION SYSTEM ................................................... 18-2
FUEL SYSTEM (Programmed Fuel Injection)........... 5-3 SYSTEM LOCATION
IGNITION SYSTEM ................................................... 18-3 BATTERY/CHARGING SYSTEM ............................... 17-2
LIGHTS/METERS/SWITCHES ................................... 20-3 ELECTRIC STARTER .................................................. 19-2
LUBRlCATlON SYSTEM ............................................. 4-3 FUEL SYSTEM (Programmed Fuel Injection) ...........5-5
MAINTENANCE .......................................................... 3-2 IGNITION SYSTEM ................................................... 18-2
REAR WHEEUSUSPENSlON ................................... 15-3 THERMOSTAT ................................................................. 6-9
SERVICE RULES .............................................................. 1-2 THROTTLE BODY ........................................................... 5-37
SPARK PLUG ................................................................... 3-6 THROTTLE OPERATION .................................................. 3-4
SPECIFICATIONS TORQUE VALUES
ALTERNATORISTARTER CLUTCH ............................ 1-8 ENGINE & FRAME ..................................................... 1-11
BATTERY/CHARGING SYSTEM ................................. 1-9 STANDARD ................................................................ 1-11
BRAKE SYSTEM ......................................................... 1-9 TROUBLESHOOTING
COOLING SYSTEM ..................................................... 1-6 ALTERNATOR/STARTER CLUTCH ........................... 12-4
CRANKCASEJCRANKSHAFT...................................... 1-8 BATTERY/CHARGING SYSTEM ............................... 17-5
CYLINDER HEAD/VALVES .......................................... 1-6 BRAKE SYSTEM ........................................................ 16-5
CYLINDER/PISTON ..................................................... 1-7 COOLING SYSTEM ..................................................... 6-5
DRIVE AND DRIVEN PULLEYS/CLUTCH ...................1-8 CRAN KCASE/CRANKSHAFT .................................... 13-4
ELECTRIC STARTER ................................................. 1-10 CyLl N DER HEADNALVES .......................................... 8-6
FINAL REDUCTION ..................................................... 1-8 CyLl N DER/P[STON...................................................... 9-4
FRONT WHEEUSUSPENSION/STEERlNG ................1-9 DRIVE AND DRIVEN PULLEYS/CLUTCH..................10-5
FUEL SYSTEM (Programmed Fuel Injection) ...........1-6 ELECTRIC STARTER.................................................. 19-4
GENERAL .................................................................... 1-4 ENGINE DOES NOT START OR IS HARD TO
IGNITION SYSTEM ................................................... 1-10 START ........................................................................ 22-2
LIGHTS/METERS/SWITCHES ................................... 1-10 ENGINE LACKS POWER ........................................... 22-3
LUBRICATION SYSTEM ............................................. 1-6 FINAL REDUCTION ................................................... 11-5
REAR WHEEuSUSPENSlON ..................................... 1-9 FRAMEBODY PANELS/EXHAUST SYSTEM....... ......2-2
STARTER MOTOR ......................................................... 19-6 FRONT WHEEUSUSPENSION/STEERlNG ..............14-6
STARTER RELAY SWITCH .......................................... 19-11 FUEL SYSTEM (Programmed Fuel Injection) ...........5-4
STATOR/CRANKSHAFT POSITION (CKP) SENSOR ... 12-9 IGNITION SYSTEM ................................................... 18-4
STEERING HEAD BEARINGS ....................................... 3-19 LUBRICATION SYSTEM ............................................. 4-3
STEERING STEM ......................................................... 14-22 POOR HANDLING ..................................................... 22-7
SUSPENSlON ................................................................ 3-17 POOR PERFORMANCE AT HIGH SPEED .................22-6
SYSTEM COMPONENTS POOR PERFORMANCE AT LOW AND IDLE
ALTERNATOR/STARTER CLUTCH .......................... 12-2 SPEED ........................................................................ 22-5
BRAKE SYSTEM ....................................................... 16-2 REAR WHEEuSUSPENSlON .................................... 15-4
CRANKCASEICRANKSHAFT .................................... 13-2 TURN SIGNAL LIGHT .................................................... 20-5
CYLINDER HEAD/VALVES .......................................... 8-2 TURN SIGNAL RELAY ................................................. 20-16
CYLlN DER/PISTON ..................................................... 9-2 VALVE CLEARANCE ........................................................ 3-7
DRIVE AND DRIVEN PULLEYSKLUTCH .................10-2 VALVE GUIDE REPLACEMENT ..................................... 8-15
ENGINE REMOVALANSTALLATION ......................... 7-2 VALVE SEAT INSPECTION/REFACING ........................ 8-16
FINAL REDUCTION ................................................... 11-2 WATER PUMP ................................................................ 6-10
FRONT WHEEUSUSPENSION/STEERlNG..............14-2 WHEELS/TIRES .............................................................. 3-18
FUEL SYSTEM (Programmed Fuel Injection)........... 5-2 WIRING DIAGRAM ........................................................ 21-3
REAR WH E E US U S PEN SION ................................... 15-2
23-2
To print chapters, click on the printer icon and fill
in the page range.
1. General Information 5 - 38
2. Frame/Body panels/Exhaust system 39 - 53
3. Maintenance 54 - 72
4. Lubrication system 73 - 79
5. Fuel system
(Programmed Fuel Injection) 80 - 131
6. Cooling system 132 - 148
7. Engine removal/Installation 149 - 156
8. Cylinder head/Valves 157 - 183
9. Cylinder/Piston 184 - 193
10. Drive pulley/Driven pulley/Clutch 194 - 213
11. Final Reduction 214 - 224
12. Alternator/Starter clutch 225 - 238
13. Crankcase/Crankshaft 239 - 248
14. Front wheel/Suspension/Steering 249 - 275
15. Rear wheel/Suspension 276 - 283
16. Brake System 284 - 306
17. Battery/Charging system 307 - 314
18. Ignition system 315 - 322
19. Electric Starter 323 - 334
20. Lights/Meters/Switches 335 - 350
21. Wiring diagram 351
22. Troubleshooting 352 - 358
23. Index 359 - 360
Note: Make sure to select Shrink to fit in the
printer dialog box when printing wiring diagrams.

SH125 Service Manual Parts Guide

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Paper Book Part No.

HOW TO USE THIS MANUAL CONTENTS

Follow the Maintenance Schedule (Section 3) recommendations to

Performing the first scheduled maintenance is very important. It

Sections 1 and 3 apply to the whole scooter. Section 2 illustrates

Most sections start with an assembly or system illustration, service

If you don't know the source of the trouble, go to section 22

You CAN be KILLED or SERIOUSLY HURT

You CAN be HURT if you don't follow

Instructions - how to service this vehicle correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIREC-

Honda Motor Co., Ltd.

Date of Issue: February, 2005

Use only a nonflammable solvent, not gasoline, to clean parts.

Never drain or store gasoline in an open container.

Replace the part@)with new one(s) before assembly.

Use recommended engine oil, unless otherwise specified.

Use multi-purposegrease (Lithium based multi-purposegrease NLGl #2 or equivalent).

Use silicone grease.

Use Fork or Suspension Fluid.

CODE AREA TYPE

ED EUROPEAN DIRECT SALES

I1 ED EUROPEAN DIRECT SALES: Type I1

I EUROPEAN DIRECT SALES I

SERVICE RULES ............................................ 1-2 FRONJ WHEEL/SUSPENSION/STEERlNG

LUBRICATION SYSTEM BRAKE SYSTEM SPECIFICATIONS............... 1-9

ALTERNATOR/STARTER CLUTCH CABLE & HARNESS ROUTING ...................1-17

FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

CYLINDER HEADNALVES SPECIFICATIONS

Oil (side rail) 0.20 - 0.70 (0.008 - 0.028) ~ 0.90 (0.035)

ITEM STANDARD SERVICE LIMIT

ITEM STANDARD SERVICE LIMIT

ITEM STANDARD SERVICE LIMIT

I Final drive oil capacity

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

REAR WHEEL/SUSPENSION SPECIFICATIONS

1 Wheel rim I Radial I - I 2.0 (0.08) I

BRAKE SYSTEM SPECIFICATIONS

3.8 - 4.2 (0.15 0.17)

ELECTRIC STARTER SPECIFlCAT10NS

ENGINE & FRAME TORQUE VALUES

Exhaust pipe stud bolt 2 7 9 (0.9, 6.6)

ITEM THREAD TORQUE

Fuel pum p rubber seal inner surface Engine oil

BRAKE JOINT COMBINED BRAKE

LEFT FRONT TURN

. RELAYIFUSE BOX 6P (Black) AND 4P (White) CONNECTORS:

TURN SIGNAL SWITCH

HORN SWITCH 2P (Black)

REAR BRAKE LIGHT SWITCH

STARTER SWITCH 4P (White)

ENGINE COOLANT CRANKSHAFT POSITION

SPARK PLUG WIRE

REAR TURN SIGNAUBRAKE/

FUEL TANK TRAY

REAR BRAKE CABLE

LICENSE LIGHT WIRE

CRANKCASE BREATHER HOSE

PAIR SOLENOID VALVE

PAIR 1Exhaust Gas

THREE-WAY CATALYTIC CONVERTER