SHOP MANUAL

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TRX420TM1/TE1/FM1/FM2/

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FE1/FA1/FA2/FA5/FA6

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TRX420TM1/TE1/FM1/FM2/FE1/FA1/FA2E
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TRX420TM1/TE1/FM1/FM2/FE1/FA1/FA2/FA5/FA6F
TRX420TM1/FM1/FE1/FA2/FA5/FA6H
TRX420TM1/TE1/FM1/FM2/FE1/FA2/FA5/FA6L
TRX420TM1/TE1/FM1/FM2/FE1/FA2/FA5/FA6N
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HOW TO USE THIS MANUAL

A Few Words About Safety
HOW TO USE THIS MANUAL

Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting

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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.

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This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures

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require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service

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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 Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.

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For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while

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servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

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Improper service or repairs can create an unsafe
condition that can cause your customer to be

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seriously hurt or killed.

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Follow the procedures and precautions in this
manual and other service materials carefully.

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

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Failure to properly follow instructions and

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

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
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using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
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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
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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,
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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:
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• 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.
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• 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
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working around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

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HOW TO USE THIS MANUAL

How To Use This Manual
This manual describes the service procedures for the TRX420TM1/TE1/FM1/FM2/FE1/FA1/FA2/FA5/FA6.
Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removal/installation of components that may be

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required to perform service described in the following sections.
Section 4 through 25 describe parts of the vehicle, grouped according to location.

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Follow the Maintenance Schedule (section 3) recommendations to ensure that the vehicle is in peak operating condition and the

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emission levels are within the standards set by the U.S. Environmental Protection Agency (EPA), California Air Resources Board

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(CARB) and Environment and Climate Change Canada (ECCC).
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.

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Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent
pages give detailed procedure.

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Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI
section troubleshooting first.

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Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety

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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 judgment.

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You will find important safety information in a variety of forms including:

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• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
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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.

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

• Instructions – how to service this vehicle correctly and safely.
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As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
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BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
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WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
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© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: June, 2021
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HOW TO USE THIS MANUAL

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.

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

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Use the recommended engine oil, unless otherwise specified.

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Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

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Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

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Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example:

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• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or

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equivalent).
Example:

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• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Pro Honda M-77 Assembly Paste (Moly)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Moly Paste 500 manufactured by Sumico Lubricant, Japan
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Use silicone grease.
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Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
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Apply sealant.
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Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
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Use fork or suspension fluid.

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CONTENTS
GENERAL INFORMATION 1

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FRAME/BODY PANELS/EXHAUST SYSTEM 2

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MAINTENANCE 3

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PGM-FI SYSTEM 4
IGNITION SYSTEM 5
ENGINE/DRIVE TRAIN AND ELECTRICAL

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ELECTRIC STARTER 6
FUEL SYSTEM

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7

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COOLING SYSTEM 8
LUBRICATION SYSTEM 9

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CYLINDER HEAD/VALVE 10

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CYLINDER/PISTON 11

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CLUTCH/GEARSHIFT LINKAGE (Except FA models) 12
DUAL CLUTCH TRANSMISSION (FA models) 13
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ALTERNATOR/STARTER CLUTCH 14
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CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
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ENGINE REMOVAL/INSTALLATION 16
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FRONT WHEEL/SUSPENSION/STEERING 17
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REAR WHEEL/SUSPENSION 18
CHASSIS

BRAKE SYSTEM 19
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FRONT DRIVING MECHANISM (Except TM1/TE1 models) 20

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REAR DRIVING MECHANISM 21

BATTERY/CHARGING SYSTEM
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22
ELECTRICAL

LIGHTS/METERS/SWITCHES
FRAME

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ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models) 24

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ELECTRIC POWER STEERING (EPS: FM2/FA2/FA6 models) 25

WIRING DIAGRAMS 26
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INDEX
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MEMO

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1. GENERAL INFORMATION

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SERVICE RULES··································· 1-2 LUBRICATION & SEAL POINTS ············ 1-26

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MODEL IDENTIFICATION ······················· 1-3 CABLE & HARNESS ROUTING ············· 1-30

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SPECIFICATIONS·································· 1-5 EMISSION CONTROL SYSTEMS ··········· 1-54

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TORQUE VALUES ······························· 1-17 EVAPORATIVE EMISSION CONTROL

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SYSTEM (After '19 AC type)·················· 1-56
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GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION

1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don’t meet Honda’s design
specifications may cause damage to the vehicle.

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2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners.

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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

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incremental steps unless a particular sequence is specified.

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6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable & Harness routing (page 1-30).
9. Do not bend or twist control cables. Damaged control cables will not operates smoothly and may stick or bind.

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10.Do not tow your ATV behind a car or other vehicle.

ABBREVIATION

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Throughout this manual, the following abbreviation are used to identify the respective parts or systems.

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Abbrev. term Full term
CKP sensor Crankshaft Position sensor
DLC Data Link Connector

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DTC Diagnostic Trouble Code
ECM (TM1/FM1/FM2 models) Engine Control Module

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ECT sensor Engine Coolant Temperature sensor
EEPROM Electrically Erasable Programmable Read Only Memory

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EOT sensor (FA models) Engine Oil Temperature sensor
EPS Electric Power Steering
ESP Electric Shift Program
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FP Fuel Pump
IACV Idle Air Control Valve
IAT sensor Intake Air Temperature sensor
LCD Liquid Crystal Display
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MAP sensor Manifold Absolute Pressure sensor

MCS Motorcycle Communication System
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MIL Malfunction Indicator Lamp

O2 sensor Oxygen sensor
PCM (TE/FE/FA models) Powertrain Control Module
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PGM-FI Programmed Fuel Injection

SCS Service Check Signal
TP sensor Throttle Position sensor
TR sensor Transmission Range sensor
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VS sensor Vehicle Speed sensor

2WD 2 Wheel Drive
4WD 4 Wheel Drive
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DESTINATION CODE
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Throughout this manual, the following codes are used to identify individual models for each region.
A 49 state
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AC 50 state (meets California)

CM Canada
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GENERAL INFORMATION
MODEL IDENTIFICATION
This manual covers 9 types of TRX420 models:
Model name TM1 TE1 FM1 FM2 FE1 FA1 FA2 FA5 FA6

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Manual transmission O O O O O – – – –

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Dual clutch transmission – – – – – O O O O
2WD O O – – – – – – –

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4WD – – O O O O O O O

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Left foot operated gearshift O – O O – – – – –
ESP – O – – O – – – –
EPS – – – O – – O – O
Recoil starter ’14 CM type – – O O O – – – –

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After ’14 CM type – – O O O O O – O
Independent rear suspension – – – – – – – O O
Rear hydraulic disc brake – – – – – – – O O

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Be sure to refer to the procedure that pertains to the appropriate version of the TRX420.

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FA2 model shown:

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SERIAL NUMBERS/LABELS
The Vehicle Identification Number (VIN) [1] is stamped on the The engine serial number [1] is stamped on the left side of the
front side of the frame under the front fender. rear crankcase.
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[1]
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[1]
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GENERAL INFORMATION
The throttle body identification number is stamped on the The safety certification label [1] is attached on the left front
lower side of the throttle body. frame down pipe.
[1]

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[1]

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The color label [1] is attached on the left front frame down The vehicle emission control information label is attached on

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pipe. When ordering color-coded parts, always specify the the left front frame pipe.
designated color code. – ALL types [1]
– CM type only [2]

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[1] [2]
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GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS (’14 – ’19)

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ITEM SPECIFICATIONS
DIMENSIONS Overall length Except FA5/FA6 2,103 mm (82.8 in)

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FA5/FA6 2,148 mm (84.6 in)
Overall width 1,205 mm (47.4 in)

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Overall height Except FA5/FA6 1,174 mm (46.2 in)

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FA5/FA6 1,189 mm (46.8 in)
Wheelbase Except FA5/FA6 1,268 mm (49.9 in)
FA5/FA6 1,294 mm (50.9 in)

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Front tread Except FA5/FA6 860 mm (33.9 in)
FA5/FA6 904 mm (35.6 in)
Rear tread Except FA5/FA6 890 mm (35.0 in)

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FA5/FA6 933 mm (36.7 in)
Seat height Except FA5/FA6 856 mm (33.7 in)

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FA5/FA6 887 mm (34.9 in)
Footpeg height Except FA5/FA6 344 mm (13.5 in)
FA5/FA6 366 mm (14.4 in)
Ground clearance Except FA5/FA6 183 mm (7.2 in)

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FA5/FA6 233 mm (9.2 in)
Curb weight A, AC TM1 260 kg (573 lbs)

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TE1 261 kg (575 lbs)
FM1 ’14 – ’16 276 kg (608 lbs)

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After ’16 277 kg (611 lbs)
FM2 282 kg (622 lbs)
FE1 277 kg (611 lbs)
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FA1 284 kg (626 lbs)
FA2 ’14 – ’16 290 kg (639 lbs)
After ’16 291 kg (642 lbs)
FA5 300 kg (661 lbs)
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FA6 307 kg (676 lbs)

CM FM1 ’14 – ’16 277 kg (611 lbs)
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After ’16 278 kg (613 lbs)

FM2 283 kg (624 lbs)
FE1 278 kg (613 lbs)
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FA2 ’14 291 kg (642 lbs)

After ’14 292 kg (644 lbs)
FA6 308 kg (678 lbs)
Maximum weight capacity 220 kg (485 lbs)
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GENERAL INFORMATION
ITEM SPECIFICATIONS
FRAME Frame type Double cradle
Front suspension Double wishbone
Front wheel travel Except FA5/FA6 170 mm (6.7 in)

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FA5/FA6 185 mm (7.3 in)
Front damper Double tube

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Rear suspension Except FA5/FA6 Swingarm (trailing type)

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FA5/FA6 Double wishbone
Rear wheel travel Except FA5/FA6 170 mm (6.7 in)

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FA5/FA6 215 mm (8.5 in)
Rear damper Double tube
Front tire size AT24 x 8-12

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Rear tire size AT24 x 10-11
Front rim size 12 x 6.0 AT
Rear rim size 11 x 7.5 AT

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Front tire brand M977 (Maxxis)
Rear tire brand M978 (Maxxis)

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Front brake Hydraulic disc brake
Rear brake Except FA5/FA6 Mechanical drum brake
FA5/FA6 Hydraulic disc brake

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Caster angle 2°
Trail length Except FA5/FA6 5 mm (3/16 in)

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FA5/FA6 4 mm (3/16 in)
Camber angle Except FA5/FA6 0°

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FA5/FA6 0.2°
Fuel tank capacity 14.7 liters (3.88 US gal, 3.23 Imp gal)
Fuel tank reserve capacity 4.9 liters (1.29 US gal, 1.08 Imp gal)
ENGINE Cylinder arrangement Single cylinder, longitudinally installed
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Bore and stroke 86.5 x 71.5 mm (3.41 x 2.81 in)
Displacement 420 cm3 (25.6 cu-in)
Compression ratio 9.9 : 1
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Valve train OHV

Except FA models Intake opens 9° BTDC at 1 mm lift
valve closes 44° ABDC at 1 mm lift
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Exhaust opens 36° BBDC at 1 mm lift

valve closes 7° ATDC at 1 mm lift
FA models Intake opens 9° BTDC at 1 mm lift
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valve closes 46° ABDC at 1 mm lift

Exhaust opens 46° BBDC at 1 mm lift
valve closes 4° ATDC at 1 mm lift
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Lubrication system Forced pressure and wet sump

Oil pump type Trochoid
Cooling system Liquid cooled
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Air filtration Oiled double urethane foam

Engine dry weight TM1 49.3 kg (108.7 lbs)
TE1 50.3 kg (110.9 lbs)
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FM1/FM2 49.7 kg (109.6 lbs)

FE1 50.7 kg (111.8 lbs)
’14 model 56.2 kg (123.9 lbs)
FA1/FA2
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After ’14 A, AC 56.2 kg (123.9 lbs)

FA2 After ’14 CM 57.3 kg (126.3 lbs)
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FA5/FA6 57.3 kg (126.3 lbs)

FUEL Type PGM-FI
DELIVERY Throttle bore 34 mm (1.3 in)
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GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVE TRAIN Clutch system Centrifugal and multi-plate wet clutches
(Except FA Clutch operation system Automatic
models) Transmission Constant mesh, 5-speeds with reverse

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Primary reduction 2.103 (61/29)
Secondary reduction 1.818 (40/22)

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Final reduction TM1/TE1 Rear 3.153 (41/13)

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Except Front 3.230 (42/13)
TM1/TE1 Rear 3.153 (41/13)

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Gear ratio 1st 3.857 (54/14)
2nd 2.235 (38/17)
3rd 1.571 (33/21)

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4th 1.178 (33/28)
5th 0.848 (28/33)
Reverse 4.831 (46/14 x 25/17)

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Gearshift pattern TM1/FM1/FM2 R–N–1–2–3–4–5
Left foot operated return system

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TE1/FE1 R–N–1–2–3–4–5
Electric shift (left hand operated) return
system
DRIVE TRAIN Clutch system Centrifugal and 2 multi-plate wet

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(FA models) clutches
Clutch operation system Automatic

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Transmission Automatic, 5-speeds with reverse

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Primary reduction 2.680 (67/25)
Secondary reduction 1.480 (37/25)
Final reduction Front 3.230 (42/13)
Rear 3.153 (41/13)
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Gear ratio 1st 3.058 (52/17)
2nd 2.157 (41/19)
3rd 1.541 (37/24)
4th 1.178 (33/28)
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5th 0.848 (28/33)

Reverse 3.996 (45/16 x 27/19)
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Gearshift pattern R–N–1–2–3–4–5

Automatic and Electric shift (left hand
operated) return system
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ELECTRICAL Ignition system Full transistorized ignition

Starting system Electric starter motor and/or emergency
recoil starter
Charging system Triple phase output alternator
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Regulator/rectifier FET shorted, triple phase full-wave

rectification
Lighting system Battery
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GENERAL INFORMATION
GENERAL SPECIFICATIONS (After ’19)
ITEM SPECIFICATIONS
DIMENSIONS Overall length Except FA5/FA6 2,104 mm (82.8 in)

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FA5/FA6 2,147 mm (84.5 in)
Overall width 1,205 mm (47.4 in)

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Overall height Except FA5/FA6 1,174 mm (46.2 in)
FA5/FA6 1,200 mm (47.2 in)

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Wheelbase Except FA5/FA6 1,269 mm (50.0 in)

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FA5/FA6 1,294 mm (50.9 in)
Front tread TM1/TE1 860 mm (33.9 in)
FM1/FM2/FE1/FA2 859 mm (33.8 in)

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FA5/FA6 903 mm (35.6 in)
Rear tread Except FA5/FA6 890 mm (35.0 in)
FA5/FA6 918 mm (36.1 in)

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Seat height TM1/TE1 855 mm (33.7 in)
FM1/FM2/FE1/FA2 854 mm (33.6 in)

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FA5/FA6 900 mm (35.4 in)
Footpeg height Except FA5/FA6 343 mm (13.5 in)
FA5/FA6 379 mm (14.9 in)
Ground clearance Except FA5/FA6 181 mm (7.1 in)

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FA5/FA6 244 mm (9.6 in)
Curb weight A TM1 262 kg (577 lbs)

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TE1 263 kg (580 lbs)

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FM1 278 kg (612 lbs)
FM2 284 kg (626 lbs)
FE1 ’19 - ’21 280 kg (617 lbs)
After ’21 279 kg (615 lbs)
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FA2 ’19 - ’21 292 kg (644 lbs)
After ’21 293 kg (645 lbs)
FA5 302 kg (665 lbs)
FA6 310 kg (683 lbs)
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AC TM1 264 kg (582 lbs)

TE1 ’19 - ’21 265 kg (584 lbs)
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After ’21 264 kg (582 lbs)

FM1 ’19 - ’21 281 kg (619 lbs)
After ’21 280 kg (617 lbs)
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FM2 ’19 - ’21 287 kg (633 lbs)

After ’21 286 kg (631 lbs)
FE1 280 kg (617 lbs)
FA2 294 kg (648 lbs)
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FA5 304 kg (670 lbs)

FA6 311 kg (686 lbs)
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CM FM1 ’19 - ’21 280 kg (617 lbs)

After ’21 278 kg (612 lbs)
FA6 310 kg (683 lbs)
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Maximum weight capacity 220 kg (485 lbs)

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GENERAL INFORMATION
ITEM SPECIFICATIONS
FRAME Frame type Double cradle
Front suspension Double wishbone
Front wheel travel Except FA5/FA6 170 mm (6.7 in)

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FA5/FA6 185 mm (7.3 in)
Front damper Double tube

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Rear suspension Except FA5/FA6 Swingarm (trailing type)

R.
FA5/FA6 Double wishbone
Rear wheel travel Except FA5/FA6 170 mm (6.7 in)

OR RIZ
FA5/FA6 215 mm (8.5 in)
Rear damper Double tube
Front tire size AT24 x 8-12

OT TO
Rear tire size AT24 x 10-11
Front rim size 12 x 6.0 AT
Rear rim size 11 x 7.5 AT

LM U
Front tire brand M977 (Maxxis)
Rear tire brand M978 (Maxxis)

RA O A
Front brake Hydraulic disc brake
Rear brake Except FA5/FA6 Mechanical drum brake
FA5/FA6 Hydraulic disc brake

AB N
Caster angle Except FA5/FA6 2°
FA5/FA6 1°

-C O
Trail length Except FA5/FA6 4 mm (3/16 in)
FA5/FA6 -3 mm (-1/8 in)

L. US
Camber angle Except FA5/FA6 0.1°
FA5/ Front 0.1°
FA6 Rear -0.4°
Fuel tank capacity 14.7 liters (3.88 US gal, 3.23 Imp gal)
S. N O
Fuel tank reserve capacity 4.9 liters (1.29 US gal, 1.08 Imp gal)
ENGINE Cylinder arrangement Single cylinder, longitudinally installed
Bore and stroke 86.5 x 71.5 mm (3.41 x 2.81 in)
R.
420 cm3 (25.6 cu-in)
RS IÓ

Displacement
Compression ratio 9.9 : 1
Valve train OHV
TO UC

Except FA Intake opens 9° BTDC at 1 mm lift

valve closes 44° ABDC at 1 mm lift
Exhaust opens 36° BBDC at 1 mm lift
MO RIB

valve closes 7° ATDC at 1 mm lift

FA Intake opens 9° BTDC at 1 mm lift
valve closes 46° ABDC at 1 mm lift
AL ST

Exhaust opens 46° BBDC at 1 mm lift

valve closes 4° ATDC at 1 mm lift
Lubrication system Forced pressure and wet sump
BR DI

Oil pump type Trochoid

Cooling system Liquid cooled
Air filtration Oiled double urethane foam
CA SU

Engine dry weight TM1 49.3 kg (108.7 lbs)

TE1 50.3 kg (110.9 lbs)
FM1/FM2 49.7 kg (109.6 lbs)
24 O

FE1 50.7 kg (111.8 lbs)

FA2 56.2 kg (123.9 lbs)
-20 BID

FA5/FA6 57.3 kg (126.3 lbs)

FUEL Type PGM-FI
DELIVERY Throttle bore 34 mm (1.3 in)
SYSTEM
-07 HI
28 O
PR

1-9
 dummyhead

GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVE TRAIN Clutch system Centrifugal and multi-plate wet clutches
(Except FA) Clutch operation system Automatic
Transmission Constant mesh, 5-speeds with reverse

S. O
Primary reduction 2.103 (61/29)
Secondary reduction 1.818 (40/22)

L.
S AD
Final reduction TM1/
Rear 3.153 (41/13)

R.
TE1
Except Front 3.230 (42/13)

OR RIZ
TM1/
Rear 3.153 (41/13)
TE1
Gear ratio 1st 3.857 (54/14)

OT TO
2nd 2.235 (38/17)
3rd 1.571 (33/21)
4th 1.178 (33/28)

LM U
5th 0.848 (28/33)
Reverse 4.832 (46/14 x 25/17)

RA O A
Gearshift pattern TM1/FM1/ R–N–1–2–3–4–5
FM2 Left foot operated return system
TE1/FE1 R–N–1–2–3–4–5
Electric shift (left hand operated) return

AB N
system
DRIVE TRAIN Clutch system Centrifugal and 2 multi-plate wet clutches

-C O
(FA) Clutch operation system Automatic
Transmission Automatic, 5-speeds with reverse

L. US
Primary reduction 2.680 (67/25)
Secondary reduction 1.480 (37/25)
Final reduction Front 3.230 (42/13)
S. N O
Rear 3.153 (41/13)
Gear ratio 1st 3.058 (52/17)
2nd 2.158 (41/19)
3rd 1.542 (37/24)
R.
RS IÓ

4th 1.178 (33/28)

5th 0.848 (28/33)
TO UC

Reverse 3.997 (46/16 x 27/19)

Gearshift pattern R–N–1–2–3–4–5
Automatic and Electric shift (left hand
operated) return system
MO RIB

ELECTRICAL Ignition system Full transistorized ignition

Starting system A, AC Electric starter motor
CM Electric starter motor and emergency
AL ST

recoil starter
Charging system Triple phase output alternator
Regulator/rectifier FET shorted, triple phase full-wave
BR DI

rectification
Lighting system Battery
CA SU

PGM-FI SPECIFICATIONS
ITEM SPECIFICATIONS
24 O

IAT sensor resistance (20°C/68°F) 2.2 – 2.7 kΩ

-20 BID

ECT sensor resistance (40°C/104°F) 1.0 – 1.3 kΩ

Fuel injector resistance (20°C/68°F) 11.1 – 12.3 Ω
O2 sensor heater resistance (20°C/68°F) 6.7 – 9.5 Ω
-07 HI
28 O
PR

1-10
dummyhead

GENERAL INFORMATION
IGNITION SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug BKR5E-11 (NGK), K16PR-U11 (DENSO)

S. O
Spark plug gap 1.0 – 1.1 mm (0.039 – 0.043 in)
Ignition coil primary peak voltage 100 V minimum

L.
S AD
CKP sensor peak voltage 0.7 V minimum
Ignition timing ("F" mark) 10° BTDC at idle

R.
OR RIZ
FUEL SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS

OT TO
Throttle body ’14 – ’19 GQBKA
identification number ’20 - ’21 (Except AC) GQBBA
’20 - ’21 (AC) GQBZA

LM U
After ’21 (Except AC) GQBPB

RA O A
After ’21 (AC) GQBPA
Idle speed 1,400 ± 100 rpm
Throttle lever freeplay 3 – 8 mm (1/8 – 5/16 in)
Fuel pressure at idle 333 – 363 kPa (3.4 – 3.7 kgf/cm2, 48 – 53 psi)

AB N
Fuel pump flow (at 12 V) 356 cm3 (12.0 US oz, 12.5 Imp oz) minimum/10 seconds
EVAP purge control solenoid valve resistance (20°C/68°F) 30 - 34 Ω

-C O
(After ’19 AC type)

L. US
COOLING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
S. N O
Coolant capacity Replacement 1.5 liters (1.6 US qt, 1.3 Imp qt)
After disassembly 1.6 liters (1.7 US qt, 1.4 Imp qt)
Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm2, 16 – 20 psi)
R.
RS IÓ

Thermostat Begin to open 80 – 84°C (176 – 183°F)

Fully open 95°C (203°F)
Valve lift 8 mm (0.3 in) minimum at 95°C (203°F)
TO UC

Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene

glycol antifreeze containing corrosion protection inhibitors
Standard coolant concentration 1:1 mixture with distilled water
MO RIB

LUBRICATION SYSTEM SPECIFICATIONS

AL ST

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil Except After draining 2.6 liters (2.7 US qt, 2.3 Imp qt) –
BR DI

capacity FA After draining/filter change 2.7 liters (2.9 US qt, 2.4 Imp qt) –
After disassembly 3.3 liters (3.5 US qt, 2.9 Imp qt) –
FA After draining 3.4 liters (3.6 US qt, 3.0 Imp qt) –
CA SU

After draining/filter change 3.6 liters (3.8 US qt, 3.2 Imp qt) –
After disassembly 4.0 liters (4.2 US qt, 3.5 Imp qt) –
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.A. &
24 O

Canada) or equivalent motor oil

API service classification: SG or higher –
-20 BID

JASO T903 standard: MA

Viscosity: SAE 10W-30
Oil pressure at 5,000 rpm (80°C/176°F) 510 kPa (5.2 kgf/cm2, 74 psi) –
Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)
-07 HI
28 O
PR

1-11
 dummyhead

GENERAL INFORMATION
CYLINDER HEAD/VALVE SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 400 rpm 500 kPa (5.1 kgf/cm3, 73 psi) –

S. O
Valve clearance IN 0.15 ± 0.02 (0.006 ± 0.001) –

L.
S AD
EX 0.23 ± 0.02 (0.009 ± 0.001) –
Valve, valve Valve stem O.D. IN 5.975 – 5.990 (0.2352 – 0.2358) 5.95 (0.234)

R.
guide EX 5.955 – 5.970 (0.2344 – 0.2350) 5.93 (0.233)

OR RIZ
Valve guide I.D. IN/EX 6.000 – 6.012 (0.2362 – 0.2366) 6.02 (0.237)
Valve guide projection above
IN/EX 14.8 – 15.0 (0.58 – 0.59) –
cylinder head
Valve seat width IN/EX 1.2 (0.05) 1.5 (0.06)

OT TO
Valve spring Free length Inner 42.94 (1.691) 42.08 (1.657)
Outer 43.63 (1.718) 42.76 (1.683)
Rocker arm Arm I.D. IN/EX 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)

LM U
Shaft O.D. IN/EX 11.966 – 11.984 (0.4711 – 0.4718) –

RA O A
Camshaft Cam lobe Except IN 35.9400 – 36.1800 (1.41496 – 1.42441) 35.74 (1.407)
and cam height FA EX 35.6811 – 35.9211 (1.40476 – 1.41421) 35.48 (1.397)
follower FA IN 35.1861 – 35.4261 (1.38528 – 1.39473) 34.98 (1.377)
EX 35.3009 – 35.5409 (1.38980 – 1.39925) 35.10 (1.382)

AB N
Cam follower O.D. IN/EX 22.467 – 22.482 (0.8845 – 0.8851) 22.46 (0.884)
Follower bore I.D. IN/EX 22.510 – 22.526 (0.8862 – 0.8868) 22.54 (0.887)

-C O
Cylinder head warpage – 0.10 (0.004)

L. US
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
S. N O
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 86.500 – 86.510 (3.4055 – 3.4059) 86.60 (3.409)
Out-of-round – 0.10 (0.004)
Piston, Piston O.D. at 15 (0.6) from bottom 86.470 – 86.490 (3.4043 – 3.4051) 86.42 (3.402)
R.
RS IÓ

piston pin, Piston pin hole I.D. 19.002 – 19.008 (0.7481 – 0.7483) 19.04 (0.750)
piston ring Piston pin O.D. 18.994 – 19.000 (0.7478 – 0.7480) 18.96 (0.746)
TO UC

Piston ring end gap Top 0.15 – 0.30 (0.006 – 0.012) 0.5 (0.02)
Second 0.30 – 0.45 (0.012 – 0.018) 0.6 (0.02)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.9 (0.04)
MO RIB

Piston ring-to-ring Top 0.030 – 0.060 (0.0012 – 0.0024) –

groove clearance Second 0.030 – 0.060 (0.0012 – 0.0024) –
Connecting rod small end I.D. 19.020 – 19.041 (0.7488 – 0.7496) 19.07 (0.751)
AL ST

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (Except FA models)

BR DI

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Centrifugal Drum I.D. 140.0 – 140.2 (5.512 – 5.520) 140.4 (5.53)
CA SU

clutch Weight lining thickness 2.0 (0.08) 1.3 (0.05)

Clutch spring height 3.8 (0.15) 3.68 (0.145)
Clutch weight spring free length 24.65 (0.970) 25.6 (1.01)
Change clutch Spring free length TM1/FM1/FM2 47.3 (1.86) 45.8 (1.80)
24 O

TE1/FE1 48.7 (1.92) 47.2 (1.86)

-20 BID

Disc thickness 2.62 – 2.78 (0.103 – 0.109) 2.3 (0.09)

Plate warpage – 0.20 (0.008)
Outer I.D. 29.000 – 29.021 (1.1417 – 1.1426) –
Outer guide I.D. 22.000 – 22.021 (0.8661 – 0.8670) –
-07 HI

O.D. 28.959 – 28.980 (1.1401 – 1.1409) –

Mainshaft O.D. at clutch outer guide 21.967 – 21.980 (0.8648 – 0.8654) –
28 O

Primary drive Gear I.D. 29.000 – 29.021 (1.1417 – 1.1426) –

gear Crankshaft O.D. at drive gear 28.959 – 28.980 (1.1401 – 1.1409) –
PR

1-12
dummyhead

GENERAL INFORMATION
DUAL CLUTCH TRANSMISSION (FA models)
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Centrifugal Drum I.D. 140.0 – 140.2 (5.512 – 5.520) 140.4 (5.53)

S. O
clutch Weight lining thickness 2.0 (0.08) 1.3 (0.05)

L.
S AD
Clutch spring height 3.8 (0.15) 3.68 (0.145)
Clutch weight spring free length 24.65 (0.970) 25.6 (1.01)

R.
Oil pressure at 5,000 rpm (80°C/176°F) Line 510 kPa (5.2 kgf/cm2, 74 psi) –

OR RIZ
Shift clutch 510 kPa (5.2 kgf/cm2, 74 psi) –
Shift clutch Initial clearance 1st 0.70 – 0.90 (0.028 – 0.035) –
2nd 0.65 – 0.95 (0.026 – 0.037) –
Disc thickness 1.88 – 2.00 (0.074 – 0.079) worn out lining

OT TO
Plate thickness 1.55 – 1.65 (0.061 – 0.065) discoloration
Primary drive Gear I.D. 29.000 – 29.021 (1.1417 – 1.1426) –
gear Crankshaft O.D. at drive gear 28.959 – 28.980 (1.1401 – 1.1409) –

LM U
RA O A
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT

AB N
Starter driven gear boss O.D. 51.705 – 51.718 (2.0356 – 2.0361) –
I.D. 31.946 – 31.962 (1.2577 – 1.2583) –

-C O
Crankshaft O.D. at starter driven gear 31.884 – 31.900 (1.2553 – 1.2559) –

L. US
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER SPECIFICATIONS
Except FA models
S. N O
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Reverse selector lever freeplay (Except after ’19 TE/FE) 2 – 4 (3/32 – 5/32) –
R.
RS IÓ

Shift fork I.D. Front, rear 13.000 – 13.021 (0.5118 – 0.5126) –

Center 13.000 – 13.018 (0.5118 – 0.5125) –
Claw thickness 4.93 – 5.00 (0.194 – 0.197) –
TO UC

Shaft O.D. 12.966 – 12.984 (0.5105 – 0.5112) –

Transmission Gear I.D. M3 25.000 – 25.021 (0.9843 – 0.9851) –
M5 20.000 – 20.021 (0.7874 – 0.7882) –
MO RIB

C1, C2, C4, CR 28.020 – 28.041 (1.1031 – 1.1040) –

Reverse idle 13.000 – 13.021 (0.5118 – 0.5126) –
Gear bushing M3 24.959 – 24.980 (0.9826 – 0.9835) –
AL ST

O.D. M5 19.966 – 19.984 (0.7861 – 0.7868) –

C2 27.984 – 28.005 (1.1017 – 1.1026) –
C1, C4, CR 27.979 – 28.000 (1.1015 – 1.1024) –
BR DI

Gear bushing I.D. M3 22.000 – 22.021 (0.8661 – 0.8670) –

M5 17.016 – 17.034 (0.6699 – 0.6706) –
C4 25.000 – 25.021 (0.9843 – 0.9851) –
CA SU

Mainshaft O.D. at M3 21.959 – 21.980 (0.8645 – 0.8654) –

at M5 16.976 – 16.987 (0.6683 – 0.6688) –
Countershaft O.D. at C4 24.959 – 24.980 (0.9826 – 0.9835) –
24 O

Reverse idle shaft O.D. 12.966 – 12.984 (0.5105 – 0.5112) –

Crankshaft Runout – 0.15 (0.006)
-20 BID

Big end side clearance 0.05 – 0.65 (0.002 – 0.026) 0.8 (0.03)
Big end radial clearance 0.006 – 0.018 (0.0002 – 0.0007) 0.05 (0.002)
-07 HI
28 O
PR

1-13
 dummyhead

GENERAL INFORMATION
FA models
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Reverse selector lever freeplay (Except after ’19) 2 – 4 (3/32 – 5/32) –

S. O
Shift fork I.D. 13.000 – 13.018 (0.5118 – 0.5125) –
Claw thickness 5.93 – 6.00 (0.233 – 0.236) –

L.
S AD
Shaft O.D. 12.966 – 12.984 (0.5105 – 0.5112) –

R.
Transmission Gear I.D. M1 20.000 – 20.021 (0.7874 – 0.7882) –
M3 25.000 – 25.021 (0.9843 – 0.9851) –

OR RIZ
C2, C4, CR 28.020 – 28.041 (1.1031 – 1.1040) –
C5 31.000 – 31.025 (1.2205 – 1.2215) –
Reverse idle 13.000 – 13.018 (0.5118 – 0.5125) –

OT TO
Gear bushing M1 19.966 – 19.984 (0.7861 – 0.7868) –
O.D. M3 24.959 – 24.980 (0.9826 – 0.9835) –
C2/CR 27.979 – 28.000 (1.1015 – 1.1024) –

LM U
C4 27.984 – 28.005 (1.1017 – 1.1026) –
C5 30.950 – 30.975 (1.2185 – 1.2195) –

RA O A
Gear bushing I.D. M1 17.000 – 17.018 (0.6692 – 0.6700) –
M3 22.000 – 22.021 (0.8661 – 0.8670) –
C2/CR 25.000 – 25.013 (0.9843 – 0.9848) –

AB N
C5 28.000 – 28.021 (1.1024 – 1.1032) –
Mainshaft O.D. at M1 16.976 – 16.987 (0.6683 – 0.6688) –

-C O
at M3 21.959 – 21.980 (0.8645 – 0.8654) –
Countershaft O.D. at C2/CR 24.959 – 24.980 (0.9826 – 0.9835) –

L. US
at C5 27.960 – 27.980 (1.1008 – 1.1016) –
Reverse idle shaft O.D. 12.966 – 12.984 (0.5105 – 0.5112) –
Crankshaft Runout – 0.15 (0.006)
Big end side clearance 0.05 – 0.65 (0.002 – 0.026) 0.8 (0.03)
S. N O
Big end radial clearance 0.006 – 0.018 (0.0002 – 0.0007) 0.05 (0.002)

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

R.
RS IÓ

Unit: mm (in)
TO UC

ITEM STANDARD SERVICE LIMIT

Cold tire pressure Standard 30 kPa (0.30 kgf/cm2, 4.4 psi) –
With cargo 30 kPa (0.30 kgf/cm2, 4.4 psi) –
MO RIB

Tie-rod distance between the ball Except FA5/FA6 362.5 (14.27) –

joints FA5/FA6 388.6 (15.30) –
Toe ’14 – ’19 Except FA5/FA6 Toe-out: 15 ± 15 (9/16 ± 9/16) –
FA5/FA6 Toe-out: 13 ± 15 (1/2 ± 9/16) –
AL ST

After ’19 TM1/TE1 Toe-out: 9 ± 15 (3/8 ± 9/16) –

FM1/FM2/FE1/
Toe-out: 7 ± 15 (1/4 ± 9/16) –
FA2
BR DI

FA5/FA6 Toe-in: 1 ± 15 (1/16 ± 9/16) –

CA SU

REAR WHEEL/SUSPENSION SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT
24 O

Cold tire pressure Standard 30 kPa (0.30 kgf/cm2, 4.4 psi) –

With cargo 30 kPa (0.30 kgf/cm2, 4.4 psi) –
-20 BID

Toe After ’19 FA5/FA6 Toe-in: 0 ± 15 (0 ± 9/16) –

-07 HI
28 O
PR

1-14
dummyhead

GENERAL INFORMATION
BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Front brake Recommended brake fluid Honda DOT 4 brake fluid –

S. O
Disc thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)

L.
S AD
Disc runout – 0.30 (0.012)
Master cylinder I.D. 14.000 – 14.043 (0.5512 – 0.5529) –

R.
Master piston O.D. 13.957 – 13.984 (0.5495 – 0.5506) –

OR RIZ
Caliper cylinder I.D. 32.030 – 32.080 (1.2610 – 1.2630) –
Caliper piston O.D. 31.984 – 31.998 (1.2592 – 1.2598) –
Rear brake Rear (parking) brake lever freeplay 15 – 20 (19/32 – 25/32) –
(Except FA5/ Rear brake pedal freeplay 15 – 20 (19/32 – 25/32) –

OT TO
FA6) Rear brake drum I.D. 160.0 – 160.2 (6.30 – 6.31) 161.0 (6.34)
Rear brake Rear (parking) brake lever freeplay 25 – 30 (1 – 1 3/16) –
(FA5/FA6) Recommended brake fluid Honda DOT 4 brake fluid –

LM U
Disc thickness 7.3 – 7.7 (0.29 – 0.30) 6.0 (0.24)

RA O A
Disc runout – 0.30 (0.012)
Master cylinder I.D. 15.870 – 15.913 (0.6248 – 0.6265) –
Master piston O.D. 15.827 – 15.854 (0.6231 – 0.6242) –
Caliper cylinder I.D. 30.230 – 30.280 (1.1902 – 1.1921) –

AB N
Caliper piston O.D. 30.165 – 30.198 (1.1876 – 1.1889) –

-C O
FRONT DRIVING MECHANISM SPECIFICATIONS (Except TM1/TE1 models)

L. US
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Front final Oil capacity After draining 210 cm3 (7.1 US oz, 7.4 Imp oz) –
S. N O
drive After disassembly 250 cm3 (8.5 US oz, 8.8 Imp oz) –
Recommended oil Hypoid gear oil SAE #80W-90 –
Gear backlash 0.05 – 0.25 (0.002 – 0.010) 0.4 (0.02)
Backlash difference – 0.2 (0.01)
R.
RS IÓ

Slip torque 14 – 17 N·m (1.45 – 1.75 kgf·m, 12 N·m (1.2

10 – 13 lbf·ft) kgf·m, 9 lbf·ft)
TO UC

Face cam-to-housing distance 3.3 – 3.7 (0.13 – 0.15) 3.3 (0.13)

Differential ring gear depth 6.55 – 6.65 (0.258 – 0.262) 6.55 (0.258)
Cone spring free height 2.8 (0.11) 2.6 (0.10)
MO RIB

REAR DRIVING MECHANISM SPECIFICATIONS

AL ST

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Axle runout (Except FA5/FA6) – 3.0 (0.12)
BR DI

Rear final drive Oil capacity After draining 85 cm3 (2.9 US oz, 3.0 Imp oz) –
(Except FA5/
After disassembly 100 cm3 (3.4 US oz, 3.5 Imp oz) –
FA6)
CA SU

3
Oil capacity After draining 125 cm (4.2 US oz, 4.4 Imp oz) –
(FA5/FA6) After disassembly 145 cm3 (4.9 US oz, 5.5 Imp oz) –
Recommended oil Hypoid gear oil SAE #80W-90 –
Gear backlash 0.05 – 0.25 (0.002 – 0.010) 0.4 (0.02)
24 O

Backlash difference – 0.2 (0.01)

-20 BID

Ring gear-to-stop pin clearance 0.3 – 0.6 (0.01 – 0.02) –

-07 HI
28 O
PR

1-15
 dummyhead

GENERAL INFORMATION
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Battery A, TM/TE/ Type YTX14-BS

S. O
AC FM/FE Capacity 12 V – 12 Ah (10 HR)
Charging Normal 1.4 A/5 – 10 h

L.
S AD
current Quick 6.0 A/1 h
FA Type GYZ16H

R.
Capacity 12 V – 16 Ah (10 HR)

OR RIZ
Charging Normal 1.6 A/5 – 10 h
current Quick 8.0 A/1 h
CM All Type GYZ16H
models Capacity 12 V – 16 Ah (10 HR)

OT TO
Charging Normal 1.6 A/5 – 10 h
current Quick 8.0 A/1 h

LM U
Current leakage TM1 0.012 mA max.
FM1/FM2/FE1 0.27 mA max.

RA O A
TE1 0.31 mA max.
FA 0.3 mA max.
Voltage Fully charged 13.0 – 13.2 V
(20°C/68°F) Needs charging Below 12.3 V

AB N
Alternator Capacity Except FA 0.416 kW/5,000 rpm
FA 0.450 kW/5,000 rpm

-C O
Charging coil resistance (20°C/68°F) 0.1 – 1.0 Ω

L. US
LIGHTS/METERS/SWITCHES SPECIFICATIONS
TM1 model
S. N O
ITEM SPECIFICATIONS
Bulbs Headlight (high/low beam) 12 V - 35/35 W x 2
Brake/taillight LED
R.
RS IÓ

Neutral indicator 12 V-1.7 W

Reverse indicator 12 V-1.7 W
TO UC

Coolant temperature indicator 12 V-1.7 W

MIL 12 V-1.7 W
Low fuel indicator 12 V-1.7 W
MO RIB

Fuel level sensor Full 19.0 – 21.0 Ω

resistance Empty 772.0 – 788.0 Ω
Fuse Main fuse 30 A
Sub-fuse 10 A x 2, 20 A x 3
AL ST

Except TM1 model

BR DI

ITEM SPECIFICATIONS
Bulbs Headlight (high/low beam) 12 V - 35/35 W x 2
CA SU

Brake/taillight LED
Neutral indicator LED
Reverse indicator LED
24 O

Coolant temperature indicator LED

MIL LED
-20 BID

Meter light LED

EPS indicator (FM2/FA2/FA6
LED
only)
Fuel level sensor Full 19.0 – 21.0 Ω
-07 HI

resistance Empty 772.0 – 788.0 Ω

Fuse Main fuse 30 A
28 O

Sub-fuse FM1/FM2 10 A x 2, 20 A x 3
PR

Except FM1/FM2 10 A x 2, 20 A x 2, 30 A
EPS fuse (FM2/FA2/FA6 only) 40 A

1-16
dummyhead

GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES

S. O
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)

L.
S AD
5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
6 mm bolt and nut 6 mm screw 9 (0.9, 6.6)

R.
10 (1.0, 7)
(Include SH flange bolt) 6 mm flange bolt and nut (Include
12 (1.2, 9)

OR RIZ
8 mm bolt and nut 22 (2.2, 16) 8 mm head, large flange bolt)
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)

OT TO
ENGINE & FRAME TORQUE VALUES

LM U
• Torque specifications listed below are for important fasteners.
• Others should be tightened to standard torque values listed above.

RA O A
FRAME/BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)

AB N
Step bracket mounting nut 4 8 32 (3.3, 24)
Step bracket mounting bolt 4 8 32 (3.3, 24)

-C O
Muffler cover bolt 2 6 12 (1.2, 9)
Muffler cover band bolt (front side) 1 – 2 (0.2, 1.5)

L. US
(Except FA5/FA6)
Muffler cover band bolt (rear side) 1 – 3.2 (0.3, 2.4)
(Except FA5/FA6)
S. N O
Front muffler cover band bolt 1 – 2 (0.2, 1.5)
(Except FA5/FA6)
Exhaust pipe cover band bolt 3 – 2 (0.2, 1.5)
(Except FA5/FA6)
R.
RS IÓ

Muffler cover band bolt (FA5/FA6) 2 – 3.2 (0.3, 2.4)

Front muffler cover band bolt 1 – 3.2 (0.3, 2.4)
(FA5/FA6)
TO UC

Exhaust pipe cover rear band bolt 1 – 3.2 (0.3, 2.4)

(FA5/FA6)
Exhaust pipe cover band bolt 2 – 2.0 (0.2, 1.5)
MO RIB

(FA5/FA6)
Exhaust pipe stud bolt 2 8 6 (0.6, 4.4) See page 2-15

MAINTENANCE
AL ST

THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Spark plug 1 14 22 (2.2, 16)
BR DI

Valve adjusting lock nut 2 6 17 (1.7, 13)

Valve adjusting hole cap 2 36 12 (1.2, 9)
CA SU

Timing hole cap 1 14 10 (1.0, 7)

Engine oil drain bolt 1 12 25 (2.5, 18)
Front final gear case oil filler cap 1 30 12 (1.2, 9)
(Except TM1/TE1)
24 O

Front final gear case oil drain bolt 1 8 12 (1.2, 9)

(Except TM1/TE1)
-20 BID

Rear final gear case oil check bolt 1 8 12 (1.2, 9)

(Except FA5/FA6)
Rear final gear case oil filler cap 1 30 12 (1.2, 9)
-07 HI

Rear final gear case oil drain bolt 1 8 12 (1.2, 9)

Final clutch arm cover bolt 1 6 10 (1.0, 7)
Front master cylinder reservoir 2 4 2 (0.2, 1.5)
28 O

cap screw
PR

Rear brake master cylinder push 1 8 17 (1.7, 13)

rod joint lock nut (FA5/FA6)
Tie-rod lock nut (knuckle side) 2 12 54 (5.5, 40)
Tie-rod lock nut (steering arm 2 12 54 (5.5, 40) Left hand threads.
side)

1-17
 dummyhead

GENERAL INFORMATION
PGM-FI SYSTEM
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Sensor unit torx screw (T25) 3 5 3.4 (0.3, 2.5)

S. O
ECT sensor 1 10 12 (1.2, 9)
Bank angle sensor mounting bolt 2 6 10 (1.0, 7.4)

L.
S AD
O2 sensor 1 12 24.5 (2.5, 18)

R.
IGNITION SYSTEM

OR RIZ
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Timing hole cap 1 14 10 (1.0, 7)

OT TO
ELECTRIC STARTER
THREAD TORQUE
ITEM Q’TY REMARKS

LM U
DIA. (mm) N·m (kgf·m, lbf·ft)
Starter motor case bolt 2 5 4.9 (0.5, 3.6)

RA O A
Negative brush set screw 1 5 3.7 (0.4, 2.7)

FUEL SYSTEM

AB N
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Throttle body insulator band screw 1 5 – See page 7-20

-C O
Throttle drum cover screw 1 4 1.8 (0.2, 1.3)

L. US
Wire harness clamp stay screw 1 5 3.4 (0.3, 2.5)
Fuel feed hose clamp stay screw 1 5 3.4 (0.3, 2.5)
Fuel injector mounting bolt 2 5 5.1 (0.5, 3.8)
IACV torx screw (T20) 2 4 2.1 (0.2, 1.5)
S. N O
COOLING SYSTEM
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
R.
RS IÓ

Cooling fan nut 1 5 2.7 (0.3, 2.0) Apply locking agent to the threads.
Fan motor bolt 3 5 5.2 (0.5, 3.8)
TO UC

Fan motor stay bolt 3 6 8.4 (0.9, 6.2)

CYLINDER HEAD/VALVE
MO RIB

THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder head nut 4 10 39 (4.0, 29) Apply engine oil to the threads and
seating surface.
AL ST

Spark plug 1 14 22 (2.2, 16)

ECT sensor 1 10 12 (1.2, 9)
Upper engine hanger nut 1 10 63 (6.4, 46)
BR DI

Upper engine hanger bracket bolt 2 8 32 (3.3, 24)

Camshaft bearing setting plate 1 8 27 (2.8, 20) Apply locking agent to the threads.
CA SU

bolt Coating width: 5.0 – 8.0 mm

(0.20 – 0.31 in) except 2.0 – 5.0 mm
(0.08 – 0.20 in) from tip
Cam chain tensioner pivot bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
24 O

Coating width: 6.5 ± 1.0 mm

(0.26 ± 0.04 in) except 1.0 – 2.0 mm
-20 BID

(0.04 – 0.08 in) from tip

Cam chain tensioner lifter bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 – 4.0 mm
-07 HI

(0.12 – 0.16 in) from tip

CYLINDER/PISTON
28 O

THREAD TORQUE
PR

ITEM Q’TY REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)
Crankcase stud bolt 4 10 12 (1.2, 9) See page 11-5

1-18
dummyhead

GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE (Except FA models)
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Centrifugal clutch lock nut 1 20 118 (12.0, 87) Lock nut: replace with a new one.

S. O
Apply engine oil to the threads and
seating surface.

L.
S AD
Stake.
Change clutch center lock nut 1 18 108 (11.0, 80) Lock nut: replace with a new one.

R.
Apply engine oil to the threads and

OR RIZ
seating surface.
Stake.
Clutch spring bolt 4 6 12 (1.2, 9)
Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.

OT TO
Coating width: 8.0 ± 1.0 mm
(0.31 ± 0.04 in) except 1.0 – 2.0 mm
(0.04 – 0.08 in) from tip

LM U
Gearshift cam bolt 1 6 16 (1.6, 12) Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm

RA O A
(0.26 ± 0.04 in) except 3.0 – 4.0 mm
(0.12 – 0.16 in) from tip
Gearshift spindle A stopper bolt 1 8 27 (2.8, 20) Apply locking agent to the threads.
(TM1/FM1/FM2 only) Coating width: 6.5 ± 1.0 mm

AB N
(0.26 ± 0.04 in) except 6.0 – 8.0 mm
(0.24 – 0.31 in) from tip

-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-19
 dummyhead

GENERAL INFORMATION
DUAL CLUTCH TRANSMISSION (FA models)
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Centrifugal clutch lock nut 1 20 118 (12.0, 87) Lock nut: replace with a new one.

S. O
Apply engine oil to the threads.
Stake.

L.
S AD
Oil feed pipe setting cap 1 24 21 (2.1, 15)

R.
Orifice relief valve socket bolt 1 10 34 (3.5, 25) Do not remove unless necessary.
Sealing bolt 1 8 16 (1.6, 12) Do not remove unless necessary.

OR RIZ
Shift clutch lock nut 1 18 108 (11.0, 80) Lock nut: replace with a new one.
Apply engine oil to the threads and
seating surface.
Stake.

OT TO
Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
Coating width: 8.0 ± 1.0 mm
(0.31 ± 0.04 in) except 1.0 – 2.0 mm

LM U
(0.04 – 0.08 in) from tip

RA O A
Shift drum center bolt (’14 – ’19) 1 8 23 (2.3, 17) Apply locking agent to the threads.
Shift drum center bolt (After ’19) 31 (3.2, 23) Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 – 4.0 mm
(0.12 – 0.16 in) from tip

AB N
Shift drum guide plate bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 – 4.0 mm

-C O
(0.12 – 0.16 in) from tip

L. US
Shift spindle angle sensor socket 2 5 6 (0.6, 4.4) Apply locking agent to the threads.
bolt Coating width: 5.0 ± 1.0 mm
(0.2 ± 0.04 in) except 1.0 – 2.0 mm
(0.04 – 0.08 in) from tip
S. N O
Shift drum position switch wire 2 6 12 (1.2, 9) Apply locking agent to the threads.
clamp bolt (’14 – ’19) Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 – 4.0 mm
(0.12 – 0.16 in) from tip
R.
RS IÓ

Shift drum position switch 1 6 12 (1.2, 9) Apply locking agent to the threads.
retaining bolt (’14 – ’19) Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 – 4.0 mm
TO UC

(0.12 – 0.16 in) from tip

EOT sensor 1 10 14.5 (1.5, 11)
Reverse switch 1 10 13 (1.3, 10)
MO RIB

TR sensor bolt (After ’19) 1 6 12 (1.2, 9)

Neutral switch (After ’19) 1 10 13 (1.3, 10)
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-20
dummyhead

GENERAL INFORMATION
ALTERNATOR/STARTER CLUTCH
ITEM Q’TY THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear sub-frame lower mounting 2 12 130 (13.3, 96) Lock nut: replace with a new one.

S. O
nut (’15 – ’19 FA5/FA6)
Rear sub-frame lower mounting 2 12 120 (12.2, 89)

L.
S AD
bolt (After ’19 FA5/FA6)

R.
Rear sub-frame rear mounting nut 1 12 130 (13.3, 96) Lock nut: replace with a new one.
(’15 – ’19 FA5/FA6)

OR RIZ
Rear sub-frame rear mounting nut 75 (7.6, 55)
(After ’19 FA5/FA6)
CKP sensor bolt 2 5 6 (0.6, 4.4) Apply locking agent to the threads.
Coating width: 6.0 ± 1.0 mm

OT TO
(0.24 ± 0.04 in) except 1.0 – 3.0 mm
(0.04 – 0.12 in) from tip
Stator bolt 3 6 10 (1.0, 7) Apply locking agent to the threads.

LM U
Flywheel bolt (A, AC types) 1 12 108 (11.0, 80) Apply engine oil to the threads and

RA O A
seating surface.
Flywheel/driven pulley bolt 1 12 108 (11.0, 80) Apply engine oil to the threads and
(CM type) seating surface.
Starter clutch bolt (’14 – ’21) 6 8 37 (3.8, 27) Apply locking agent to the threads.

AB N
Starter clutch bolt (After ’21) 6 8 23 (2.3, 17) Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 3.0 – 4.0 mm
(0.12 – 0.16 in) from tip

-C O
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER

L. US
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Mainshaft bearing setting bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
S. N O
(Except FA models) Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) except 1.0 – 2.0 mm
(0.04 – 0.08 in) from tip
Shift drum bearing setting bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
R.
RS IÓ

(FA models only) Coating width: 5.0 ± 1.0 mm

(0.20 ± 0.04 in) except 1.0 – 3.0 mm
(0.04 – 0.12 in) from tip
TO UC

ENGINE REMOVAL/INSTALLATION
THREAD TORQUE
MO RIB

ITEM Q’TY REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)
Lower engine hanger nut 2 10 63 (6.4, 46)
Upper engine hanger nut 1 10 63 (6.4, 46)
AL ST

Upper engine hanger bracket bolt 2 8 32 (3.3, 24)

Front final gear case mounting nut 2 10 44 (4.5, 32) Lock nut: replace with a new one.
(Except TM1/TE1)
BR DI

Gearshift pedal pinch bolt 1 6 20 (2.0, 15)

(TM1/FM1/FM2 only)
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-21
 dummyhead

GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Front master cylinder holder bolt 2 6 12 (1.2, 9)

S. O
Throttle housing cover screw 3 4 1.5 (0.2, 1.1)
Front wheel nut 8 10 64 (6.5, 47)

L.
S AD
Front brake disc bolt 8 8 42 (4.3, 31) ALOC bolt: replace with a new one.

R.
Upper and lower arm ball joint nut 4 12 29 (3.0, 21) Castle nut: tighten to the specified
torque and further tighten until its

OR RIZ
grooves align with the cotter pin
hole.
Tie-rod joint nut 4 12 54 (5.5, 40) Lock nut: replace with a new one.

OT TO
Splash guard bolt 6 6 11 (1.1, 8) ALOC bolt: replace with a new one.
Front wheel hub nut 2 20 137 (14.0, 101) Castle nut: tighten to the specified
torque and further tighten until its
grooves align with the cotter pin

LM U
hole.

RA O A
Apply sealant to the threads.
Coating width: 5 mm (0.2 in)
Front brake caliper mounting bolt 4 8 30 (3.1, 22) ALOC bolt: replace with a new one.
Outboard guard bolt 4 6 11 (1.1, 8)

AB N
Brake hose clamp bolt 7 6 12 (1.2, 9) ALOC bolt: replace with a new one.
Steering shaft end nut 1 14 108 (11.0, 80) Lock nut: replace with a new one.

-C O
(Except FM2/FA2/FA6)
Lower steering bearing holder nut 3 10 33.5 (3.4, 25) Lock nut: replace with a new one.

L. US
(Except FM2/FA2/FA6)
Steering shaft holder bolt 2 8 32 (3.3, 24)
EPS unit mounting nut 3 10 33.5 (3.4, 25) Lock nut: replace with a new one.
(FM2/FA2/FA6 only)
S. N O
EPS unit output shaft end nut 1 14 108 (11.0, 80) Lock nut: replace with a new one.
(FM2/FA2/FA6 only)
Steering shaft pinch bolt 1 10 60 (6.1, 44) ALOC bolt: replace with a new one.
(FM2/FA2/FA6 only)
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-22
dummyhead

GENERAL INFORMATION
REAR WHEEL/SUSPENSION
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear wheel nut 8 10 64 (6.5, 47)

S. O
Rear wheel hub nut (FA5/FA6) 2 20 137 (14.0, 101) Castle nut: tighten to the specified
torque and further tighten until its

L.
S AD
grooves align with the cotter pin
hole.

R.
Apply sealant to the threads.

OR RIZ
Coating width: 5 mm (0.2 in)
minimum
Shock absorber lower mounting 1 12 113 (11.5, 83) Lock nut: replace with a new one.
bolt (Except FA5/FA6)

OT TO
Shock absorber upper mounting 2 10 44 (4.5, 32) Lock nut: replace with a new one.
nut (FA5/FA6)
Shock absorber lower mounting 2 14 88 (9.0, 65) Lock nut: replace with a new one.

LM U
nut (FA5/FA6)

RA O A
Universal joint guard bolt (Except 2 6 10 (1.0, 7) ALOC bolt: replace with a new one.
FA5/FA6)
Swingarm pivot nut (’14 – ’19 TM1/ 2 12 130 (13.3, 96) U-nut: replace with a new one.
TE1/FM1/FM2/FE1/FA1/FA2)

AB N
Swingarm pivot bolt (After ’19 2 12 120 (12.2, 89)
TM1/TE1/FM1/FM2/FE1/FA2)
Trailer hitch mounting nut (Except 2 10 34 (3.5, 25) Lock nut: replace with a new one.

-C O
FA5/FA6)

L. US
Upper arm pivot nut (frame side) 2 10 44 (4.5, 32) Lock nut: replace with a new one.
(FA5/FA6)
Lower arm pivot nut (frame side) 4 10 34 (3.5, 25) Lock nut: replace with a new one.
(FA5/FA6)
S. N O
Upper and lower arm pivot nut 4 10 44 (4.5, 32) Lock nut: replace with a new one.
(knuckle side) (FA5/FA6)
Stabilizer arm holder bolt (FA5/ 4 8 26.5 (2.7, 20)
FA6)
R.
RS IÓ

Stabilizer link nut (FA5/FA6) 4 10 39 (4.0, 29) Lock nut: replace with a new one.
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-23
 dummyhead

GENERAL INFORMATION
BRAKE SYSTEM
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Front brake caliper bleed valve 2 8 5.4 (0.6, 4.0)

S. O
Front master cylinder reservoir 2 4 2 (0.2, 1.5)
cap screw

L.
S AD
Front brake caliper mounting bolt 4 8 30 (3.1, 22) ALOC bolt: replace with a new one.

R.
Front brake pad pin 2 10 17.2 (1.8, 13)
Front brake pad pin plug 2 10 2.4 (0.2, 1.8)

OR RIZ
Front brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
Front brake lever pivot nut 1 6 5.9 (0.6, 4.4)
Front brake switch screw 1 4 1.2 (0.1, 0.9)

OT TO
Front master cylinder holder bolt 2 6 12 (1.2, 9)
Front brake hose oil bolt 3 10 34 (3.5, 25)
Front brake caliper slide pin 2 8 22 (2.2, 16) Apply locking agent to the threads.

LM U
Outboard guard bolt 4 6 11 (1.1, 8)
Rear brake arm nut (Except FA5/ 1 8 20 (2.0, 15)

RA O A
FA6)
Rear brake panel drain bolt 1 8 12 (1.2, 9)
(Except FA5/FA6)
Rear wheel hub nut (Except FA5/ 2 20 137 (14.0, 101) Castle nut: tighten to the specified

AB N
FA6) torque and further tighten until its
grooves align with the cotter pin

-C O
hole.
Apply sealant to the threads.

L. US
Rear brake caliper bleed valve 1 8 5.4 (0.6, 4.0)
(FA5/FA6)
Rear brake hose oil bolt (FA5/FA6) 2 10 34 (3.5, 25)
S. N O
Rear brake caliper mounting bolt 2 8 30 (3.1, 22) ALOC bolt: replace with a new one.
(FA5/FA6)
Rear brake caliper bracket pin bolt 1 8 32 (3.3, 24)
(FA5/FA6)
R.
RS IÓ

Rear brake caliper slide pin 1 8 22 (2.2, 16)

retaining bolt (FA5/FA6)
Rear brake caliper parking brake 1 10 27 (2.8, 20) Apply locking agent.
TO UC

arm nut (FA5/FA6)

Rear brake master cylinder 1 4 1.5 (0.2, 1.1) Apply locking agent.
reservoir hose joint screw (FA5/
MO RIB

FA6)
Rear brake lever pivot bolt 1 6 9.8 (1.0, 7.2)
Rear brake lever pivot nut 1 6 9.8 (1.0, 7.2)
AL ST

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
BR DI

Front final clutch shift fork bolt 1 6 10 (1.0, 7) ALOC bolt: replace with a new one.
Front final clutch housing bolt 3 8 25 (2.5, 18)
CA SU

4WD select switch 1 10 12 (1.2, 9)

Front final gear case cover bolt 2 10 46.5 (4.7, 34) Apply locking agent to the threads.
4 8 25 (2.5, 18)
Front final gear pinion bearing lock 1 60 98 (10.0, 72) Lock nut: replace with a new one.
24 O

nut Stake.
Differential ring gear bolt 10 8 49 (5.0, 36) ALOC bolt: replace with a new one.
-20 BID

Front final gear case mounting nut 2 10 44 (4.5, 32) Lock nut: replace with a new one.
Final clutch arm cover base bolt 2 6 10 (1.0, 7)
-07 HI
28 O
PR

1-24
dummyhead

GENERAL INFORMATION
REAR DRIVING MECHANISM
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear final gear pinion bearing lock 1 64 98 (10.0, 72) Lock nut: replace with a new one.

S. O
nut (Except FA5/FA6) Stake.
Rear final gear pinion bearing lock 1 72 98 (10.0, 72) Lock nut: replace with a new one.

L.
S AD
nut (FA5/FA6) Stake.

R.
Rear final gear case cover bolt 2 10 46.5 (4.7, 34) Apply locking agent to the threads.
6 8 25 (2.5, 18)

OR RIZ
Rear final gear case mounting bolt 8 10 74 (7.5, 55)
(Except FA5/FA6)
Rear final gear case mounting nut 2 10 44 (4.5, 32) Lock nut: replace with a new one.
(FA5/FA6)

OT TO
Rear final gear pinion joint lock nut 1 16 108 (11.0, 80) Apply locking agent to the threads.
(FA5/FA6)
Rear brake panel mounting nut 4 10 46.5 (4.7, 34) Lock nut: replace with a new one.

LM U
(Except FA5/FA6)

RA O A
Rear wheel hub nut (Except FA5/ 2 20 137 (14.0, 101) Castle nut: tighten to the specified
FA6) torque and further tighten until its
grooves align with the cotter pin
hole.

AB N
Apply sealant to the threads.
Rear brake disc bolt (FA5/FA6) 5 6 20 (2.0, 15) ALOC bolt: replace with a new one.

-C O
LIGHTS/METERS/SWITCHES

L. US
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Combination meter mounting 3 5 0.8 (0.1, 0.6)
screw
S. N O
Front brake switch screw 1 4 1.2 (0.1, 0.9)
Rear brake switch screw (rear 1 4 1.2 (0.1, 0.9)
brake lever side)
Gear position switch wire clamp 2 6 12 (1.2, 9) Apply locking agent to the threads.
R.
RS IÓ

bolt (Except ’14 – ’19 FA models Coating width: 6.5 ± 1.0 mm

and after ’19 TM/FM models) (0.2 ± 0.04 in) except 1.0 – 2.0 mm
TO UC

(0.04 – 0.08 in) from tip

4WD select switch (Except TM1/ 1 10 12 (1.2, 9)
TE1)
MO RIB

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
AL ST

Shift spindle angle sensor socket 2 5 6 (0.6, 4.4) Apply locking agent to the threads.
bolt Coating width: 5.0 ± 1.0 mm
(0.2 ± 0.04 in) except 1.0 – 2.0 mm
BR DI

(0.04 – 0.08 in) from tip

TR sensor bolt (After ’19) 1 6 12 (1.2, 9)
Neutral switch (After ’19) 1 10 13 (1.3, 10)
CA SU

OTHERS
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
24 O

Gearshift spindle return spring pin 1 8 22 (2.2, 16) Apply locking agent to the threads.
-20 BID

(’14 – ’19) Coating width: 6.5 ± 1.0 mm

Gearshift spindle return spring pin 26 (2.7, 19) (0.26 ± 0.04 in) except 3.0 – 4.0 mm
(After ’19) (0.12 – 0.16 in) from tip
Brake pipe joint bolt 2 10 14 (1.4, 10)
-07 HI

Rear brake lever pivot bolt 1 6 9.8 (1.0, 7.2)

Rear brake lever pivot nut 1 6 9.8 (1.0, 7.2)
28 O

Parking brake lock lever pivot 1 6 6.9 (0.70, 5.1)

screw
PR

1-25
 dummyhead

GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE

S. O
MATERIAL LOCATION REMARKS
Engine oil Inside of oil filter cover

L.
S AD
Rocker arm followers and adjusting screw
Cam chain whole surfaces

R.
Cam follower whole surfaces

OR RIZ
Connecting rod small end inner surface
Piston outer surface and piston pin hole
Piston ring whole surfaces

OT TO
Cylinder bore
Clutch adjusting plate boss outer surface Except FA models
Change clutch disc lining whole surfaces Except FA models

LM U
Primary drive gear sliding surface of crankshaft FA models
Shift clutch assembly rolling surface of mainshaft FA models

RA O A
Shift clutch disc whole surface FA models
Centrifugal clutch drum sprag clutch contacting surface
Centrifugal clutch drive plate sprag clutch contacting
surface

AB N
Starter reduction gear teeth
Reverse stopper shaft journal surface

-C O
Starter sprag clutch whole surface
Mainshaft and countershaft journal surfaces

L. US
Shift fork shaft whole surface
Shift drum grooves
Collar and bushing journal surfaces Except FA models
S. N O
Each bearing rotating area
Each O-ring whole surface
Each oil seal lip
Molybdenum oil Camshaft cam lobes
R.
RS IÓ

solution (a mixture of Rocker arm shaft sliding surface

1/2 engine oil and 1/2 Valve stem (valve guide sliding surface)
molybdenum disulfide
TO UC

Change clutch outer guide inner and outer surfaces Except FA models
grease) Crankshaft starter driven gear sliding surfaces
Piston pin outer surface
MO RIB

Starter reduction gear shaft whole surface

Water pump shaft journal
Mainshaft gear and bushing sliding surfaces
Countershaft gear and bushing sliding surfaces
AL ST

Starter motor shaft splines

Locking agent Gear position switch retaining bolt threads TE1/FE1 only
Coating width: 6.5 ± 1.0 mm
BR DI

(0.26 ± 0.04 in) except 3.0 – 4.0 mm

(0.12 – 0.16 in) from tip
Recoil starter assembly mounting bolt threads CM type only
CA SU

Coating width: 6.5 ± 1.0 mm

(0.26 ± 0.04 in) except 3.0 – 4.0 mm
(0.12 – 0.16 in) from tip
Mobilith SHC 100 Recoil starter driven pulley oil seal lips CM type only
24 O

(EXXON)
-20 BID

UNIREX N3 grease Electric shift reduction gear teeth and journals (front TE1/FE1/FA1/FA2/FA5/FA6 only
(EXXON) crankcase cover) 2 – 4 g (0.07 – 0.14 oz)
TE1/FE1: See page 24-32
FA models: See page 13-70
-07 HI
28 O
PR

1-26
dummyhead

GENERAL INFORMATION
MATERIAL LOCATION REMARKS
Liquid sealant Front crankcase cover mating surface Except FA models: See page 12-7
FA models: See page 13-60
Alternator/CKP sensor wire grommet seating surface

S. O
Gear position switch wire grommet seating surface TE1/FE1 only
Shift drum position switch wire grommet seating surface FA models only

L.
S AD
Rear crankcase cover mating surface See page 14-11

R.
Crankcase mating surface See page 15-19
Reduction gear cover mating surface TE1/FE1/FA1/FA2/FA5/FA6 only

OR RIZ
TE1/FE1: See page 24-33
FA models: See page 13-70

OT TO
FRAME
MATERIAL LOCATION REMARKS

LM U
Multi-purpose grease Throttle cable end

RA O A
Throttle cable outer threads
Throttle lever dust seal lips
Rear (parking) brake lever pivot
Parking arm pin

AB N
Steering shaft bushing sliding surface 2 – 3 g (0.07 – 0.11 oz)
Stabilizer arm and bushing contacting surfaces FA5/FA6

-C O
Rear brake cam dust seal lips Except FA5/FA6
Rear brake cam spindle Except FA5/FA6

L. US
0.2 – 0.3 g (0.007 – 0.011 oz)
Rear brake shoe cam contacting surfaces Except FA5/FA6
0.2 – 0.3 g (0.007 – 0.011 oz)
S. N O
Rear brake shoe anchor pin contacting surfaces Except FA5/FA6
0.2 – 0.3 g (0.007 – 0.011 oz)
Rear brake drum cover dust seal lips Except FA5/FA6
Rear brake panel O-ring Except FA5/FA6
R.
RS IÓ

Rear brake panel dust seal lips Except FA5/FA6

Rear brake panel bearing Except FA5/FA6
4 – 5 g (0.14 – 0.18 oz)
TO UC

Rear brake pedal pivot

Rear brake pedal pivot dust seal lips
Rear brake cable ends (lever and pedal side) Except FA5/FA6
MO RIB

Rear brake cable ends (lever side) FA5/FA6

Front final gear case oil seal lips (for drive shafts) Except TM1/TE1
Front final gear case cover O-ring Except TM1/TE1
AL ST

Front final gear oil filler cap O-ring Except TM1/TE1

Front final clutch arm shaft oil seal Except TM1/TE1
Front final clutch arm shaft O-ring Except TM1/TE1
BR DI

Front final clutch arm shaft outer surface Except TM1/TE1

Front final clutch joint oil seal lips Except TM1/TE1
Front final clutch case O-ring Except TM1/TE1
CA SU

Front axle shaft splines (wheel side) TM1/TE1 only

Rear final gear pinion joint O-ring FA5/FA6
Rear final gear case oil seal lips (for propeller shaft)
24 O

Rear final gear case oil seal lips (for ring gear)
Rear final gear oil filler cap O-ring
-20 BID

Left axle housing O-ring Except FA5/FA6

Left axle housing dust seal lip Except FA5/FA6
Swingarm O-ring Except FA5/FA6
Pro Honda Foam Filter Air cleaner element inside 17 – 23 g (0.6 – 0.8 oz)
-07 HI

Oil or equivalent
Honda Bond A or Pro Handlebar grip rubber inside
28 O

Honda Handgrip Air cleaner housing-to-connecting tube mating area

Cement (U.S.A. only) Air cleaner housing-to-duct tube mating area
PR

or equivalent Air cleaner housing-to-IAT sensor grommet mating area

Air cleaner housing breather hose joint grommet mating
areas (inner and outer surfaces)

1-27
 dummyhead

GENERAL INFORMATION
MATERIAL LOCATION REMARKS
Molybdenum disulfide Rear knuckle pivot bushing FA5/FA6
grease Rear knuckle pivot seal lips FA5/FA6
Rear shock absorber lower pivot dust seal lip and FA5/FA6

S. O
bushing
Front drive shaft splines (wheel side) Except TM1/TE1

L.
S AD
Rear drive shaft splines (wheel/final gear side) FA5/FA6

R.
Steering shaft spline Except FM2/FA2/FA6
Steering shaft bearing Except FM2/FA2/FA6

OR RIZ
2 – 3 g (0.07 – 0.11 oz)
Lower steering bearing dust seal lips Except FM2/FA2/FA6
EPS unit output shaft spline FM2/FA2/FA6 only

OT TO
Front propeller shaft boot lip (gear case side) Except TM1/TE1
Front propeller shaft seal lips Except TM1/TE1
Front propeller shaft joint splines (engine side) Except TM1/TE1

LM U
Front propeller shaft joint splines (shaft side) Except TM1/TE1
5.0 – 8.0 g (0.18 – 0.28 oz)

RA O A
Front propeller shaft splines Except TM1/TE1
5.0 – 8.0 g (0.18 – 0.28 oz)
Front propeller shaft end (final clutch joint contacting Except TM1/TE1
area)

AB N
Front drive shaft splines (wheel side) Except TM1/TE1
Rear propeller shaft splines (gear case side) Except FA5/FA6

-C O
Rear propeller shaft boot contacting area FA5/FA6
Rear propeller shaft pinion joint spline FA5/FA6

L. US
5.0 – 8.0 g (0.18 – 0.28 oz)
Universal joint splines (both sides)
Output shaft O-ring
S. N O
Rear propeller shaft O-ring
Rear axle splines Except FA5/FA6
NKG814 (Kyodo Yushi) Front drive shaft outboard joint inside Except TM1/TE1 and except After
’16 FM1/FE1/FA2
R.
RS IÓ

35 – 55 g (1.2 – 1.9 oz)

Front drive shaft inboard joint inside Except TM1/TE1 and except After
’16 FM1/FE1/FA2
TO UC

50 – 70 g (1.8 – 2.5 oz)

G.A. Besmoly CE Front drive shaft outboard joint inside After ’16 FM1/FE1/FA2
(Brugarolas) 50 – 70 g (1.8 – 2.5 oz)
MO RIB

Front drive shaft inboard joint inside After ’16 FM1/FE1/FA2

65 – 85 g (2.3 – 3.0 oz)
NKG509 (Kyodo Yushi) Rear drive shaft outboard joint inside ’15 – ’19 FA5/FA6
40 – 60 g
AL ST

Rear drive shaft inboard joint inside ’15 – ’19 FA5/FA6

60 – 80 g
BR DI

OLISTAMOLY Rear drive shaft inboard joint and boot inside After ’19 FA5/FA6
2LN584LO (Castrol) 70 – 90 g (2.5 – 3.2 oz)
Rear drive shaft outboard joint and boot inside After ’19 FA5/FA6
CA SU

70 – 90 g (2.5 – 3.2 oz)

Engine oil Rear brake cam felt seal Except FA5/FA6
24 O
-20 BID
-07 HI
28 O
PR

1-28
dummyhead

GENERAL INFORMATION
MATERIAL LOCATION REMARKS
Silicone grease Front brake lever-to-master piston contacting area
Front brake lever pivot
Front brake caliper piston boot inside 0.2 g (0.007 oz) minimum

S. O
Front brake caliper slide pin groove 0.4 g (0.014 oz) minimum
Front brake caliper bracket pin boot inside 0.4 g (0.014 oz) minimum

L.
S AD
Rear brake caliper piston boot FA5/FA6

R.
Seal area: Apply 0.2 g
Inside: Fill up 0.5 – 0.7 g

OR RIZ
Rear brake caliper slide pin/bracket pin collar inner FA5/FA6
surface 0.4 g minimum
Rear brake caliper parking brake cam groove FA5/FA6

OT TO
Apply 0.35 g minimum
Rear brake caliper parking brake dust cover lips FA5/FA6
Apply 0.35 g minimum

LM U
Rear brake caliper parking brake sleeve piston FA5/FA6
Apply 0.8 g minimum

RA O A
Rear brake caliper parking brake rod ends FA5/FA6
Apply 0.35 g minimum
Rear brake caliper cup FA5/FA6
Apply 0.1 g minimum

AB N
Rear brake master cylinder push rod-to master piston FA5/FA6
contacting area Apply 0.1 g

-C O
Rear brake master cylinder push rod boot FA5/FA6
DOT 4 brake fluid Brake master cylinder piston and cups

L. US
Brake caliper piston and piston seal
Liquid sealant Rear final gear case cover mating surface
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-29
 dummyhead

GENERAL INFORMATION
CABLE & HARNESS ROUTING
’14 – ’19

S. O
L.
S AD
Inside of front fender:

R.
OR RIZ
OT TO
LM U
HEADLIGHT SUB-WIRE
HARNESS

RA O A
AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC

’14 model shown: REAR (PARKING) BRAKE CABLE

THROTTLE CABLE
MO RIB
AL ST

FRONT BRAKE HOSE A

BR DI

IGNITION SWITCH WIRE

DRIVE MODE SELECT SWITCH
CA SU

WIRE (FA models only)

REVERSE FRONT SUB-WIRE HARNESS

24 O

SELECTOR CABLE
-20 BID

HANDLEBAR SWITCH WIRE

-07 HI

After ’14:
28 O
PR

BANK ANGLE SENSOR

(Clip type) 3P (Black) CONNECTOR

1-30
dummyhead

GENERAL INFORMATION

TM1: INDICATOR SOCKET 10P (Gray)

CONNECTOR
BANK ANGLE SENSOR
Except TM1: FRONT SUB-WIRE
3P (Black) CONNECTOR
HARNESS 12P (Gray) CONNECTOR

S. O
’14 model: After ’14: HANDLEBAR SWITCH

L.
S AD
CONNECTOR
1 4 TM1/FM1/FM2: 8P (Green)

R.
3 2
2 TE1/FE1/FA1/FA2/FA5/FA6:

OR RIZ
4 1 3
14P (Green)

1: IGNITION SWITCH WIRE

OT TO
2: DRIVE MODE SELECT SWITCH WIRE
(FA models only)
3: FRONT SUB-WIRE HARNESS

LM U
4: HANDLEBAR SWITCH WIRE

RA O A
IGNITION SWITCH
4P CONNECTOR

AB N
-C O
L. US
HEADLIGHT SUB-
WIRE HARNESS
DRIVE MODE SELECT SWITCH 2P 3P CONNECTOR
S. N O
(Black) CONNECTOR (FA models only)
DLC 4P (Red) SIPHON HOSE

FRONT FINAL GEAR CASE

R.
RS IÓ

BREATHER HOSE
TO UC

FRONT BRAKE PIPE

MO RIB
AL ST
BR DI
CA SU
24 O

FRONT BRAKE HOSE B

-20 BID

FRONT BRAKE HOSE B

FRONT VS SENSOR 3P (Black)

CONNECTOR (FA models only)
-07 HI
28 O
PR

1-31
 dummyhead

GENERAL INFORMATION

DRIVE MODE SELECT SWITCH

WIRE (FA models only)

S. O
L.
S AD
R.
OR RIZ
Front
Front

OT TO
LM U
RA O A
HANDLEBAR
HANDLEBAR

AB N
-C O
L. US
HANDLEBAR
SWITCH WIRE
HANDLEBAR SWITCH WIRE
(To front brake switch)
S. N O

FRONT FINAL GEAR CASE

R.
HEADLIGHT SUB-WIRE
RS IÓ

HARNESS 3P CONNECTOR BREATHER HOSE (Except TM1/TE1)

TO UC
MO RIB
AL ST

MAIN WIRE HARNESS

BR DI

(To bank angle sensor)

CA SU
24 O

OVERFLOW HOSE
-20 BID
-07 HI
28 O
PR

SIPHON HOSE WATER HOSE

(Thermostat-to-radiator)

1-32
dummyhead

GENERAL INFORMATION

Inside
EPS ECU 2P (Brown) CONNECTOR
(FM2/FA2/FA6 only)
MAIN WIRE

S. O
HARNESS
EPS ECU 2P (Gray) CONNECTOR

L.
S AD
(FM2/FA2/FA6 only)

R.
FAN MOTOR
BREATHER HOSE

OR RIZ
OT TO
LM U
RA O A
EPS ECU 21P (Gray)
CONNECTOR
(FM2/FA2/FA6 only)

AB N
-C O
FUEL PUMP

L. US
BREATHER HOSE
S. N O
R.
RS IÓ

MAIN WIRE HARNESS

(To front VS sensor) WATER HOSE
(FA models only) (Radiator-to-water pump)
TO UC

Reverse side of radiator:

MO RIB

Left
AL ST
BR DI

FAN MOTOR 2P
(Natural) CONNECTOR
CA SU
24 O

FAN MOTOR
-20 BID

SIPHON HOSE BREATHER HOSE

-07 HI
28 O

Right
PR

FRONT FINAL GEAR

CASE BREATHER HOSE

1-33
 dummyhead

GENERAL INFORMATION

TORQUE SENSOR 3P (Gray) CONNECTOR (FM2/FA2/FA6 only)

EPS MOTOR 3P (Gray)

S. O
CONNECTOR (FM2/FA2/FA6 only)

L.
S AD
R.
OR RIZ
OT TO
FRONT BRAKE HOSE B

LM U
RA O A
AB N
-C O
L. US
S. N O
2WD/4WD SELECTOR MAIN WIRE HARNESS
CABLE (Except TM1/TE1) (To solenoid valves) (FA models only)
R.
RS IÓ

DUAL CLUTCH PC SOLENOID VALVE 2P WATER PIPE/HOSES

TO UC

(Black) CONNECTOR (FA models only) (Thermostat-to-water pump)

MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

SHIFT CONTROL MOTOR (TE1/ SHIFT SOLENOID VALVE 2P (Brown)

FE1/FA1/FA2/FA5/FA6 only) CONNECTOR (FA models only)

1-34
dummyhead

GENERAL INFORMATION

WATER HOSE
(Radiator-to-water pump)

S. O
Left

L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
L. US
SHIFT CONTROL MOTOR 2P (Black)
CONNECTOR (TE1/FE1/FA1/FA2/FA5/ 2WD/4WD SELECT SWITCH
FA6 only) CONNECTOR (Except TM1/TE1)
S. N O
EOT SENSOR 2P (Black)
CONNECTOR (FA models only)
R.
RS IÓ

MAIN POWER RELAY

TO UC

FUEL PUMP RELAY

STARTER INHIBITOR RELAY

MO RIB

Except FA5/FA6:
REAR FINAL GEAR CASE
AL ST

BREATHER HOSE
BR DI

O2 SENSOR 4P (Black)
CA SU

CONNECTOR
24 O
-20 BID
-07 HI
28 O

FUEL FEED HOSE

PR

SPARK PLUG WIRE

ECT SENSOR 2P CONNECTOR

1-35
 dummyhead

GENERAL INFORMATION

REVERSE SELECTOR CABLE PCM/ECM FUEL PUMP

BREATHER HOSE
THROTTLE CABLE

S. O
L.
S AD
R.
UP

OR RIZ
FRAME

OT TO
LM U
MAIN WIRE
HARNESS

RA O A
AB N
-C O
L. US
S. N O
MAIN WIRE HARNESS
REAR (PARKING) (To front VS sensor)
Except FA5/FA6:
ALTERNATOR WIRE BRAKE CABLE (FA models only)
REAR BRAKE BREATHER HOSE
R.
RS IÓ

FA5/FA6:
REAR FINAL GEAR CASE BREATHER HOSE
TO UC

FUEL PUMP FUEL PUMP UNIT 4P

BREATHER HOSE (Gray) CONNECTOR
MO RIB

FUEL FEED HOSE

AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

MAIN WIRE HARNESS

JOINT CONNECTOR

1-36
dummyhead

GENERAL INFORMATION

IGNITION COIL PRIMARY WIRE

CONNECTOR (Black/red)

S. O
L.
S AD
R.
OR RIZ
OT TO
SPARK PLUG WIRE

LM U
RA O A
AB N
-C O
L. US
MAIN WIRE HARNESS
IGNITION COIL PRIMARY WIRE
(To ECT sensor)
CONNECTOR (Green/yellow)
S. N O
R.
RS IÓ

INJECTOR 2P (Gray)
TO UC

FUEL FEED HOSE CONNECTOR THROTTLE CABLE

MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID

IACV 4P (Black)
CONNECTOR
O2 SENSOR 4P
-07 HI

(Black) CONNECTOR IAT SENSOR 2P

ALTERNATOR WIRE
(Gray) CONNECTOR
SENSOR UNIT 5P
28 O

(Black) CONNECTOR
PR

1-37
 dummyhead

GENERAL INFORMATION

Except FA5/FA6 shown: CRANKCASE

BREATHER HOSE O2 SENSOR 4P (Black)
CONNECTOR

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
L. US
S. N O
REAR FINAL GEAR
VS SENSOR 3P (Black) CASE BREATHER HOSE
CONNECTOR (Except TM1) (Except FA5/FA6)
R.
RS IÓ

Except FA5/FA6:

GROUND CABLE REAR BRAKE SWITCH

TO UC

ALTERNATOR WIRE CKP SENSOR 2P (Gray)

(Engine-to-frame) 2P (Black) CONNECTOR
CONNECTOR
MO RIB

REAR BRAKE
BREATHER HOSE
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

BATTERY NEGATIVE
(–) CABLE
STARTER MOTOR CABLE FRAME GROUND POINT

1-38
dummyhead

GENERAL INFORMATION
FA5/FA6:
ALTERNATOR BATTERY NEGATIVE REAR BRAKE SWITCH (Pedal side)
WIRE (–) CABLE 2P (Black) CONNECTOR

S. O
GROUND CABLE CKP SENSOR 2P
(Engine-to-frame) (Gray) CONNECTOR

L.
S AD
R.
OR RIZ
OT TO
LM U
REAR FINAL GEAR CASE

RA O A
BREATHER HOSE

AB N
-C O
L. US
REAR BRAKE SWITCH WIRE
S. N O
SHIFT DRUM ANGLE SENSOR WIRE ENGINE SUB-WIRE HARNESS

STARTER MOTOR CABLE

R.
RS IÓ

Except FA models: GEAR POSITION SWITCH WIRE REAR BRAKE

BREATHER HOSE
TO UC

FA models: SHIFT DRUM POSITION SWITCH WIRE

(Except FA5/FA6)

ENGINE SUB-WIRE
MO RIB

HARNESS (Except TM1)

AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O

VS SENSOR 3P (Black) REVERSE SWITCH

PR

CONNECTOR (Except TM1) CONNECTOR (FA models only)

SHIFT SPINDLE ANGLE SENSOR 3P (Black) REVERSE
CONNECTOR (Except TM1/FM1/FM2) SELECTOR CABLE

1-39
 dummyhead

GENERAL INFORMATION
Except FA5/FA6:
’14 - ’21 Except FA1/FA2: GEAR ENGINE SUB-WIRE HARNESS
POSITION SWITCH 8P (Gray) CONNECTOR (FA1/FA2 only)
CONNECTOR

S. O
FA1/FA2: SHIFT DRUM POSITION
SWITCH 10P (Gray) CONNECTOR

L.
S AD
After ’21 FM/TM: GEAR POSITION
REVERSE

R.
SWITCH 8P (Black) CONNECTOR
SELECTOR CABLE

OR RIZ
FRAME GROUND POINT

OT TO
LM U
REAR BRAKE

RA O A
SWITCH ENGINE SUB-WIRE HARNESS
CONNECTOR
TE1/FE1/FA1/FA2: 6P (Black)

AB N
FM1/FM2: 3P (Black)

-C O
L. US GROUND CABLE
S. N O
(Engine-to-frame)
LEVER REAR (PARKING)
BRAKE CABLE PEDAL REAR
BRAKE CABLE
R.
RS IÓ

FA5/FA6:
TO UC

’14 - ’21 shown: REAR BRAKE SWITCH (Pedal side)

2P (Black) CONNECTOR
ENGINE SUB-WIRE HARNESS CONNECTOR
CKP SENSOR 2P
MO RIB

(Gray) CONNECTOR
AL ST
BR DI

DRUM POSITION
SWITCH 10P (Gray)
CONNECTOR
LEVER REAR (PARKING)
CA SU

BRAKE CABLE

GROUND POINT
REVERSE SELECTOR CABLE
24 O
-20 BID

ENGINE SUB
HARNESS 6P (Black)
REAR BRAKE SWITCH
-07 HI

CONNECTOR
WIRE (Pedal side)
28 O
PR

REAR BRAKE HOSE

1-40
dummyhead

GENERAL INFORMATION
Except FA5/FA6:
LEVER REAR (PARKING)
BRAKE CABLE

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
L. US
S. N O
PEDAL REAR REAR BRAKE
BRAKE CABLE BREATHER HOSE

FA5/FA6:
R.
RS IÓ

REAR FINAL GEAR

TO UC

CASE BREATHER HOSE

MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID

LEVER REAR
(PARKING)
BRAKE CABLE
-07 HI
28 O
PR

REAR BRAKE HOSE

1-41
 dummyhead

GENERAL INFORMATION
’14 model:

BATTERY NEGATIVE (–) CABLE

BRAKE/TAILLIGHT 3P
REGULATOR/RECTIFIER (Black) CONNECTOR

S. O
3P (Black) CONNECTOR

L.
S AD
R.
ALTERNATOR

OR RIZ
3P (Gray) CONNECTOR

OT TO
CONDENSER
(CM type only) BATTERY POSITIVE

LM U
(+) CABLE

RA O A
CONDENSER
2P CONNECTOR

STARTER RELAY

AB N
SWITCH 2P (Green)
CONNECTOR

-C O
STARTER

L. US
MOTOR CABLE
S. N O
EPS FUSE (FM2/FA2
FUSE BOX only)
R.
RS IÓ

After ’14:
TO UC

BATTERY NEGATIVE (–) CABLE

BRAKE/TAILLIGHT 3P
REGULATOR/RECTIFIER (Black) CONNECTOR
3P (Black) CONNECTOR
MO RIB

ALTERNATOR
AL ST

3P (Gray) CONNECTOR
BR DI

CONDENSER
(CM type only)
CA SU

BATTERY POSITIVE
(+) CABLE
CONDENSER
24 O

2P CONNECTOR
(Black)
-20 BID

STARTER RELAY
SWITCH 2P (Green)
-07 HI

CONNECTOR STARTER
MOTOR CABLE
28 O
PR

EPS FUSE (FM2/

FUSE BOX FA2/FA6 only)

1-42
dummyhead

GENERAL INFORMATION
Except FA5/FA6:

MAIN WIRE HARNESS

(To brake/taillight)

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
CLIP
Up

AB N
Right

-C O
L. US
S. N O WIRE GUIDE

TOOL BOX LID MAIN WIRE HARNESS

FA5/FA6:
R.
RS IÓ
TO UC

BRAKE/TAILLIGHT WIRE
MO RIB
AL ST
BR DI
CA SU
24 O

Up
-20 BID

CLIP

Inboard
-07 HI
28 O
PR

BRAKE/TAILLIGHT WIRE
TOOL BOX LID

1-43
 dummyhead

GENERAL INFORMATION
After ’19
HEADLIGHT SUB-WIRE HARNESS

S. O
L.
S AD
R.
OR RIZ
HEADLIGHT SUB-WIRE HARNESS
3P CONNECTOR

OT TO
LM U
RA O A
AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB

LEFT HEADLIGHT CONNECTOR RIGHT HEADLIGHT CONNECTOR

AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-44
dummyhead

GENERAL INFORMATION

AC type shown: FUEL PUMP UNIT 4P

(Gray) CONNECTOR
FUEL PUMP

S. O
BREATHER HOSE

L.
S AD
R.
OR RIZ
OT TO
FUEL FEED HOSE

LM U
RA O A
AB N
-C O
L. US
S. N O
MAIN WIRE HARNESS
R.
RS IÓ

JUNCTION 1 24P (White) CONNECTOR

TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-45
 dummyhead

GENERAL INFORMATION
AC type only:

EVAP PURGE CONTROL

S. O
SOLENOID VALVE

L.
S AD
EVAP PURGE CONTROL SOLENOID

R.
VALVE 2P (Black) CONNECTOR

OR RIZ
EVAP CANISTER-to-PURGE CONTROL
EVAP PURGE CONTROL SOLENOID
SOLENOID VALVE HOSE
VALVE-to-THROTTLE BODY HOSE

OT TO
LM U
RA O A
AB N
-C O
L. US
FUEL PUMP BREATHER HOSE

CANISTER JOINT HOSE

S. N O
R.
RS IÓ
TO UC
MO RIB

AIR VENT HOSE

CANISTER CONNECT HOSE
EVAP CANISTER A
AL ST

EVAP CANISTER B
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-46
dummyhead

GENERAL INFORMATION
AC type only:

WHITE PAINT:
Clamp the hose on the paint mark.

S. O
L.
S AD
R.
WHITE PAINT:
Clamp the hose on

OR RIZ
the paint mark.

OT TO
LM U
WHITE PAINT:

RA O A
Clamp the hose
on the paint mark.

AB N
-C O
L. US
S. N O
WHITE PAINT:
Clamp the hose
R.
RS IÓ

on the paint mark.

TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O

Set the paint mark

downward.
PR

1-47
 dummyhead

GENERAL INFORMATION
AC type only:

S. O
AIR VENT HOSE

L.
S AD
R.
OR RIZ
OT TO
LM U
10 mm (0.4 in)

RA O A
AB N
-C O
L. US
S. N O
Set the paint mark
downward.
Front
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI

Clump the hose

between the hose
protector.
CA SU

AIR VENT HOSE Right

24 O
-20 BID
-07 HI
28 O
PR

FUEL PUMP BREATHER HOSE AIR VENT HOSE

1-48
dummyhead

GENERAL INFORMATION
AC type only:

S. O
EVAP PURGE CONTROL SOLENOID

L.
S AD
VALVE-to-THROTTLE BODY HOSE
WHITE PAINT:

R.
Clamp the hose on

OR RIZ
the paint mark.

OT TO
LM U
RA O A
AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB

THROTTLE CABLE
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-49
 dummyhead

GENERAL INFORMATION
TM/FM models:

GEAR POSITION

S. O
SWITCH WIRE

ALTERNATOR WIRE

L.
S AD
R.
OR RIZ
STARTER MOTOR CABLE

OT TO
VS SENSOR SUB-HARNESS
(FM model only)
GROUND CABLE

LM U
(Engine-to-frame)

RA O A
VS SENSOR 3P (Black) CONNECTOR
(FM model only)
BATTERY NEGATIVE (–) CABLE

AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU

REAR BRAKE
VS SENSOR SUB-HARNESS BREATHER HOSE
24 O

(FM model only)

-20 BID

REVERSE SELECTOR CABLE

-07 HI
28 O
PR

1-50
dummyhead

GENERAL INFORMATION
TE/FE/FA models:

BATTERY NEGATIVE (–) CABLE

S. O
SENSOR HARNESS

L.
S AD
REAR BRAKE

R.
SWITCH WIRE

OR RIZ
ALTERNATOR WIRE REAR VS SENSOR
SUB-HARNESS

OT TO
STARTER MOTOR CABLE

LM U
Except FA: VS SENSOR SUB-HARNESS GROUND CABLE
FA: REAR VS SENSOR SUB-HARNESS (Engine-to-frame)

RA O A
Except FA: VS SENSOR 3P (Black) CONNECTOR LEVER REAR (PARKING)

AB N
FA: REAR VS SENSOR 3P (Black) CONNECTOR BRAKE CABLE

-C O
L. US
S. N O
SENSOR HARNESS
R.
RS IÓ
TO UC

NEUTRAL SWITCH
CONNECTOR
(SWITCH SIDE)
MO RIB
AL ST
BR DI
CA SU
24 O

TR SENSOR SHIFT SPINDLE ANGLE

SENSOR CONNECTOR
-20 BID
-07 HI
28 O
PR

1-51
 dummyhead

GENERAL INFORMATION
Except FA5/FA6:
TM1/FM1/FM2: GEAR POSITION TE1/FE1/FA1/FA2: NEUTRAL
SWITCH 8P (Gray) CONNECTOR SWITCH 1P CONNECTOR
TE1/FE1/FA2: SENSOR HARNESS

S. O
8P (Black) CONNECTOR

L.
S AD
TM1/FM1/FM2:

R.
FRAME GROUND POINT REVERSE

OR RIZ
SELECTOR CABLE

OT TO
LM U
REAR BRAKE

RA O A
FM1/FM2/TE1/FE1:
SWITCH VS SENSOR SUB-HARNESS
3P (Black) CONNECTOR
FA2:

AB N
REAR VS SENSOR SUB-HARNESS
3P (Black) CONNECTOR

-C O
L. US GROUND CABLE
S. N O
(Engine-to-frame)
LEVER REAR (PARKING)
BRAKE CABLE PEDAL REAR
BRAKE CABLE
R.
RS IÓ

FA5/FA6:
TO UC

REAR BRAKE SWITCH (Pedal side)

2P (Black) CONNECTOR
NEUTRAL SWITCH 1P CONNECTOR
CKP SENSOR 2P
MO RIB

(Gray) CONNECTOR
AL ST
BR DI

SENSOR HARNESS
8P (Black) CONNECTOR
CA SU

LEVER REAR (PARKING)

BRAKE CABLE

GROUND POINT
24 O
-20 BID

REAR VS SENSOR
SUB-HARNESS 3P
(Black) CONNECTOR
-07 HI

REAR BRAKE SWITCH

WIRE (Pedal side)
28 O
PR

REAR BRAKE HOSE

1-52
dummyhead

GENERAL INFORMATION
TM/TE/FM/FE models:

CKP SENSOR WIRE

S. O
CKP SENSOR

L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
L. US
S. N O ALTERNATOR WIRE

FA models:
R.
RS IÓ

CKP SENSOR WIRE

TO UC

CKP SENSOR
MO RIB
AL ST
BR DI
CA SU
24 O

ALTERNATOR WIRE
-20 BID
-07 HI
28 O
PR

1-53
 dummyhead

GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Environment and Climate
Change Canada (ECCC) require that off-road ATVs comply with applicable exhaust emissions standards during their useful life,

S. O
when operated and maintained according to the instructions provided.
SOURCE OF EMISSIONS

L.
S AD
The combustion process produces oxides of nitrogen (NOx), carbon monoxide (CO) and hydrocarbons (HC). Controlling oxides of

R.
nitrogen and hydrocarbon emissions is very important because, under certain conditions, they react to form photochemical smog

OR RIZ
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.
EXHAUST EMISSION CONTROL SYSTEM

OT TO
The exhaust emission control system is composed of the PGM-FI system, and no adjustments should be made. The exhaust
emission control system is separate from the crankcase emission control system.

LM U
CRANKCASE EMISSION CONTROL SYSTEM

RA O A
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body.

AIR CLEANER

AB N
THROTTLE BODY

-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB

CRANKCASE
BREATHER HOSE
AL ST

Fresh air
BR DI

Blow-by gas
CA SU

SERVICING THE HONDA

24 O

U.S.A. Only
-20 BID

Maintenance, replacement or repair of the emission control devices and systems may be performed by any ATV repair
establishment or individual using parts that are "certified" to EPA standards.
PROHIBITED ACTIONS
-07 HI

The following prohibitions apply to everyone with respect to the engine’s emission control system.
28 O

You may not remove or disable any device or element of design that may affect an engine’s emission levels. This restriction applies
before and after the engine in placed in service.
PR

1-54
dummyhead

GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE EMISSION CONTROL SYSTEM IS PROHIBITED: U.S. Federal law prohibits, or Canadian
provincial law may prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other
than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any vehicle for the

S. O
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.

L.
S AD
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS:

R.
1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.

OR RIZ
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Removing or disabling any emissions compliance component, or replacing any compliance component with a non-compliant
component.

OT TO
FUEL PERMEATION EMISSION CONTROL SYSTEM
This ATV complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA), the

LM U
California Air Resource Board (CARB) and Environment and Climate Change Canada (ECCC). The fuel tank, fuel hoses, and fuel
vapor charge hoses used on this ATV incorporate fuel permeation control technologies. Tampering with the fuel tank, fuel hoses, or

RA O A
fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal
regulations.
REBUILT ENGINE

AB N
When you rebuild the engine including a major overhaul in which you replace the engine’s piston or power assemblies or make
other changes that significantly increase the service life of the engine, the vehicle will continue to comply with all emissions

-C O
regulations if you:
– Make sure you are technically qualified to rebuild the engine and have the proper tools

L. US
– Diagnose and respond to all Diagnostic Trouble Codes (DTC), and erase all DTCs after addressing their cause
– Use only Honda genuine parts or equivalents
– Make sure to maintain all specifications as described in this Service Manual
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

1-55
 dummyhead

GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM (After '19 AC type)
This model complies with California Air Resources Board (CARB) evaporative emission requirements. Fuel vapor from the fuel tank
is routed into the EVAP canisters where it is absorbed and stored while the engine is stopped. When the engine is running and the

S. O
EVAP purge control solenoid valve is open, fuel vapor in the EVAP canisters is drawn into the engine through throttle body.

L.
S AD
R.
OR RIZ
OT TO
FUEL TANK

LM U
RA O A
AB N
THROTTLE BODY

-C O
L. US
S. N O
EVAP PURGE CONTROL
R.
RS IÓ

SOLENOID VALVE
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O

EVAP CANISTER A
-20 BID

FRESH AIR

FUEL VAPOR
-07 HI

EVAP CANISTER B
28 O
PR

1-56
dummytext

2. FRAME/BODY PANELS/EXHAUST SYSTEM

S. O
2

L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION························ 2-2 ENGINE GUARD ··································· 2-8

RA O A
TROUBLESHOOTING ···························· 2-2 FRONT FENDER/CARRIER····················· 2-8

AB N
BODY PANEL LOCATIONS····················· 2-2 STEP BRACKET ································· 2-11

-C O
SEAT ··················································· 2-3 SKID PLATE ······································· 2-11

L. US
RADIATOR CAP LID ······························ 2-3
S. N O REAR FENDER COVER························ 2-12

OIL CHECK LID····································· 2-3 TOOL BOX LID ··································· 2-12

TANK COVER ASSEMBLY ····················· 2-4 REAR FENDER/CARRIER····················· 2-12

R.
RS IÓ

CENTER MUDGUARD ···························· 2-5 EXHAUST SYSTEM ····························· 2-14

TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

2-1
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM

GENERAL
• This section covers removal and installation of the body panels and exhaust system.

S. O
• Always replace the gaskets when removing the exhaust system.
• Always inspect the exhaust system for leaks after installation.

L.
S AD
R.
TROUBLESHOOTING

OR RIZ
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leaks

OT TO
Poor performance
• Deformed exhaust system

LM U
• Exhaust gas leaks
• Clogged muffler

RA O A
BODY PANEL LOCATIONS

AB N
’14 - ’21 FA2 type shown:
[2]

-C O
[1]

L. US
[6]
[7]
S. N O
[8]
R.
RS IÓ
TO UC
MO RIB

[3]
AL ST

[5] [4]
[9]
BR DI
CA SU

[13]
[12] [11] [10]
24 O

[1] RADIATOR CAP LID (page 2-3) [8] REAR FENDER COVER (page 2-12)
-20 BID

[2] HANDLEBAR COVER (page 23-6) [9] TOOL BOX LID (page 2-12)
[3] OIL CHECK LID (page 2-3) [10] SKID PLATE (page 2-11)
[4] FRONT FENDER/CARRIER (page 2-8) [11] REAR FENDER/CARRIER (page 2-12)
[5] ENGINE GUARD (page 2-8) [12] STEP BRACKET (page 2-11)
-07 HI

[6] TANK COVER ASSEMBLY (page 2-4) [13] CENTER MUDGUARD (page 2-5)
[7] SEAT (page 2-3)
28 O
PR

2-2
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

SEAT
Unlock the seat [1] by pulling the release lever [2] up. [3]
Raise the rear of the seat, slide it rearward and remove
[4] [5] [1]

S. O
it.
Install the seat by inserting the center prong [3] into the

L.
S AD
fuel tank cover [4] and hooking the front prongs [5] to
the seat retainers [6] of the frame.

R.
Push the seat forward and align the mounting bosses

OR RIZ
[7] with the rubber mounts [8], then press down to lock
it.

OT TO
LM U
RA O A
[6] [8] [7] [2]

RADIATOR CAP LID

AB N
Release the boss [1] from the grommet [2] and remove
[1] [4] [3]
the radiator cap lid [3].

-C O
Install the radiator cap lid by inserting the tabs [4] into
the slots [5] and aligning the boss with the grommet.

L. US
S. N O
R.
RS IÓ

[2] [5]
TO UC

OIL CHECK LID

MO RIB

Release the bosses [1] from the grommets [2] and

remove the oil check lid [3].
Install the oil check lid by inserting the tabs [4] into the
slots [5] and aligning the bosses with the grommets. [2] [5]
AL ST
BR DI
CA SU

[4]
[1]
24 O

[3]
-20 BID
-07 HI
28 O
PR

2-3
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

TANK COVER ASSEMBLY
REMOVAL/INSTALLATION
Remove the seat (page 2-3).

S. O
[1] [2]
Release the side Remove the tank cover assembly [1] by releasing the

L.
S AD
bosses first before eight bosses [2] from the grommets.
the two top bosses.

R.
Installation is in the reverse order of removal.

OR RIZ
• Align the tabs [3] with the slots.
• Be careful not to dislodge the grommets.

OT TO
LM U
RA O A
[3] [3]

AB N
DISASSEMBLY/ASSEMBLY

-C O
Remove the following:
[5]
– two (TM1/TE1: three) screws [1]

L. US
– six trim clips [2]
– TM1/TE1 only: side pocket [3]
– side covers [4] from the tank cover [5] [2]
S. N O
Assembly is in the reverse order of disassembly.
[3]
R.
RS IÓ

[1]
TO UC
MO RIB
AL ST
BR DI
CA SU

[4]
24 O
-20 BID
-07 HI
28 O
PR

2-4
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CENTER MUDGUARD
REMOVAL/INSTALLATION ('14 – '19)

S. O
• Take care not to scratch the front and rear fenders

L.
S AD
when removing and installing the center mudguard.
[7]
Remove the tank cover assembly (page 2-4).

R.
Remove the following:

OR RIZ
– two setting bolts [1] and step [2]
– bolts [3] and nuts [4] [4]
– nine trim clips [5]

OT TO
– center mudguard [6]
RIght side only: Release the water hose [7] and bleed hose [8] from the
center mudguard.

LM U
Installation is in the reverse order of removal. [8]

RA O A
[4]

AB N
[1]

-C O
L. US
S. N O
[5]
R.
[2]
RS IÓ

[6] [3] [3]

TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

2-5
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

REMOVAL/INSTALLATION (After '19)
LEFT SIDE

S. O
• Take care not to scratch the front and rear fenders
when removing and installing the center mudguard.

L.
S AD
Remove the tank cover assembly (page 2-4).

R.
Remove the following:

OR RIZ
– two setting bolts [1] and step [2]
– nine trim clips [3]
– two socket bolts [4] and two nuts [5]
– center mudguard [6]

OT TO
Installation is in the reverse order of removal.

LM U
RA O A
AB N
-C O
L. US
[5]
S. N O
[5] [1]
[4]
R.
RS IÓ
TO UC

[6]
MO RIB

[4]
AL ST

[2]
BR DI

[3]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

2-6
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

RIGHT SIDE

• Take care not to scratch the front and rear fenders

[1]
when removing and installing the center mudguard.

S. O
Remove the front fender/carrier (page 2-8).

L.
S AD
Remove the trim clip [1].

R.
Release the canister guard rubber slot [2] from the
center mudguard lug [3]. [2]/[3]

OR RIZ
OT TO
LM U
RA O A
Remove the following:
– two setting bolts [1] and step [2]
– five trim clips [3]
– socket bolt [4] and nut [5]

AB N
– center mudguard [6]
Release the water hose [7] from the center mudguard

-C O
guide [8].

L. US
Release the bleed hose [9] from the center mudguard
guide hole [10].
Installation is in the reverse order of removal.
S. N O
[9] [8]
R.
RS IÓ
TO UC

[10]
MO RIB

[7]
AL ST
BR DI
CA SU

[4]
24 O

[3] [5]
-20 BID
-07 HI

[1]
28 O
PR

[6]
[2]

2-7
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

ENGINE GUARD
Remove the two trim clips [1] and eight setting bolts [2].
Release the hooks [3] by sliding the engine guard [4]

S. O
rearward to remove it.

L.
S AD
Installation is in the reverse order of removal.

R.
OR RIZ
OT TO
[1]

LM U
RA O A
[3]

AB N
-C O
[4]

L. US
[2]
[3] [1]
S. N O

FRONT FENDER/CARRIER
R.
RS IÓ

REMOVAL/INSTALLATION
TO UC

Remove the tank cover assembly (page 2-4).

After ’19 model: Disconnect the air vent hose [1].
MO RIB

[1]
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

2-8
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Disconnect the headlight 3P connector [1].
’14 – ’19 shown:
Remove the following: [1]
– trim clips [2], socket bolts [3] and nuts [4] [7]

S. O
– setting bolts [5] [4]
– mounting bolts [6]

L.
S AD
– fuel tank cap [7]
– front fender/carrier assembly [8]

R.
Install the fuel tank cap.

OR RIZ
Installation is in the reverse order of removal.

OT TO
[8]
[6]

LM U
[2]
[3]

RA O A
[5]

AB N
-C O
L. US
S. N O
[5]

DISASSEMBLY/ASSEMBLY
R.
RS IÓ

After ’19 model: Remove the following:

[1]
– pocket lid [1]
TO UC

– rubber seal [2]

– grommets [3]
• Install the rubber seal to the pocket lid groove as
MO RIB

shown.
AL ST
BR DI

[2]
CA SU

[3]
24 O
-20 BID
-07 HI
28 O
PR

2-9
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Loosen the nuts [1]. '14 – '19 shown: [5]
Remove the following:
– setting bolts [2]

S. O
– bolts [3] and flange collars [4]
– front carrier [5] and front carry pipe [6] assembly [7]

L.
S AD
Remove the nuts and bolts [7] and separate the front
carrier and front carry pipe.

R.
• For headlight removal/installation, see "Lights/

OR RIZ
meters/Switches" section (page 23-4).
[6]

OT TO
[7] [1]

LM U
[3]/[4]

RA O A
AB N
-C O
[2]

L. US
S. N O
[3]/[4] [2]

Remove the fourteen trim clips [1] and separate the

'14 – '19 shown:
following:
R.
RS IÓ

[2]
– front center cover [2]
– right front fender [3]
TO UC

– left front fender [4]

– front grille [5]
MO RIB

[3]
AL ST

[4]
BR DI
CA SU
24 O
-20 BID

[5]
[1]
-07 HI
28 O
PR

2-10
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

After ’19 model: Remove the following from the front center cover [1]:
[3]
– air vent hose cover screws [2]
– air vent hose cover [3]
– screw [4]

S. O
– air vent hose [5]

L.
S AD
Assembly is in the reverse order of disassembly.

R.
OR RIZ
OT TO
[2] [4] [5] [1]

STEP BRACKET

LM U
Remove the center mudguard (page 2-5).

RA O A
[1] [2]/[3]
Remove the following:
– mounting bolts (short) [1]
– mounting nuts [2] and bolts (long) [3]

AB N
– step bracket [4]
Installation is in the reverse order of removal.

-C O
TORQUE:

L. US
Mounting bolts and nuts:
32 N·m (3.3 kgf·m, 24 lbf·ft)
S. N O
[4]

SKID PLATE
R.
RS IÓ

Except FA5/FA6:
TO UC

Remove the two bolts [1], setting bolt [2] and the skid
[2]
plate [3].
Install the skid plate with new bolts.
MO RIB
AL ST
BR DI
CA SU

[3] [1]

FA5/FA6:
24 O

Remove the setting bolts [1].

Release the hooks [2] from the frame and then remove
-20 BID

the skid plate [3].

Installation is in the reverse order of removal.
[3]
-07 HI

[2]
28 O
PR

[1]

2-11
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

REAR FENDER COVER
• Be careful not to scratch the cover with the carrier
[1] [5] [5] [4]
pipe.

S. O
Remove the seat (page 2-3).

L.
S AD
Unhook the retaining strap [1] from the tool box lid.
Release the bosses [2] from the grommets [3] and

R.
remove the rear fender cover [4] by sliding it forward.

OR RIZ
Be careful not to Installation is in the reverse order of removal.
dislodge the
• Align the tabs [5] with the slots.
grommets.

OT TO
LM U
[3] [2]

RA O A
TOOL BOX LID
Remove the brake/taillight (page 23-5).

AB N
Except FA5/FA6 shown:
Remove the following:
– brake/taillight wire [1]

-C O
– tool box lid [2] [1]

L. US
Installation is in the reverse order of removal.
S. N O
R.
RS IÓ

[2]

REAR FENDER/CARRIER
TO UC

REMOVAL/INSTALLATION
MO RIB

Remove the following:

’14 model: [4]
– tank cover assembly (page 2-4)
– rear fender cover (page 2-12)
[7]
AL ST

– battery [1] (page 22-5) [3] [1]

Disconnect the stator 3P (Gray) connector [2] and
regulator/rectifier 3P (Black) connector [3].
BR DI

Remove the following from the rear fender: [2]

– wire clips [4]
CA SU

– starter relay switch [5]

– fuse boxes [6]
– CM type only: condenser [7]
24 O

’14 model: Release the wire clamps [8] and remove the wires and
cables from the rear fender.
-20 BID

[5]
-07 HI
28 O
PR

[6]
[8] [6]

2-12
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

After ’14 model: Release the wire clamp [1], and remove the wire band
[2], wires, and cables. After ’14 model:
[2]

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
L. US
[1]

Remove the following:

’14 model shown:
S. N O
– eight trim clips [1] [4]
– two bolts [2] and nuts [3]
– two setting bolts [4] [5]
– six mounting bolts [5]
R.
RS IÓ

– rear fender/carrier assembly [6]

Installation is in the reverse order of removal.
TO UC
MO RIB
AL ST

[6]
[5]
BR DI
CA SU

[3]
24 O
-20 BID
-07 HI

[1]
[2]
28 O
PR

2-13
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY
Remove the bolts [1], flange collar [2] and separate the
’14 model shown:
rear carrier [3] from the rear fender [4].
[1]/[2]

S. O
Assembly is in the reverse order of removal.

L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
[4]

AB N
-C O
L. US
S. N O
[3]
R.
RS IÓ

EXHAUST SYSTEM
REMOVAL/INSTALLATION
TO UC

Remove the tank cover assembly (page 2-4).

[1] [4]
Disconnect the O2 sensor 4P (Black) connector [1].
MO RIB

Remove the following:

– joint nuts [2]
– muffler [3] (from the mounting grommets [4])
AL ST

– gasket [5]
Installation is in the reverse order of removal.
BR DI

• Always replace the gasket with a new one.

• Apply soapy water to the mounting grommets.
• After installation, inspect the exhaust system for
CA SU

leaks.
24 O
-20 BID

[2]
-07 HI
28 O
PR

[2]
[5] [3]

2-14
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

EXHAUST PIPE STUD BOLT
REPLACEMENT
Thread two nuts to the stud bolt [1] and tighten them
[1]
together, then use a wrench on them to turn the stud

S. O
bolt out.

L.
S AD
Install the stud bolts Install and tighten new stud bolts into the cylinder head
with their rounded to the specified torque.

R.
end facing out.
TORQUE: 6 N·m (0.6 kgf·m, 4.4 lbf·ft)

OR RIZ
After tightening the stud bolts, check that the length
from the bolt head to the cylinder head surface is within 22.5 – 23.5 mm
specification.

OT TO
(0.89 – 0.93 in)

50 mm (2.0 in)

LM U
RA O A
AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

2-15
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY
• For O2 sensor removal/installation, refer to "PGM-FI SYSTEM" section (page 4-44).

Except FA5/FA6:

S. O
12 N·m (1.2 kgf·m, 9 lbf·ft)

L.
S AD
FRONT MUFFLER COVER

R.
OR RIZ
2 N·m (0.2 kgf·m, 1.5 lbf·ft)

OT TO
MUFFLER COVER

LM U
RA O A
3.2 N·m (0.3 kgf·m,
2.4 lbf·ft)

AB N
-C O
O2 SENSOR

L. US
EXHAUST MUFFLER
PIPE COVER
S. N O

3.2 N·m (0.3 kgf·m, 2.4 lbf·ft)

R.
RS IÓ

MUFFLER LOWER COVER

TO UC

12 N·m (1.2 kgf·m, 9 lbf·ft)

FA5/FA6:
MO RIB

FRONT MUFFLER COVER

AL ST

2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)

BR DI

MUFFLER COVER
CA SU

MUFFLER LOWER COVER

O2 SENSOR
24 O
-20 BID

3.2 N·m (0.3 kgf·m, BAND

2.4 lbf·ft)

EXHAUST PIPE COVER

-07 HI
28 O
PR

MUFFLER 3.2 N·m (0.3 kgf·m, 2.4 lbf·ft)

2-16
dummytext

3. MAINTENANCE

S. O
L.
S AD
3

R.
OR RIZ
SERVICE INFORMATION························ 3-2 FRONT AND REAR FINAL GEAR OIL····· 3-25

MAINTENANCE MINDER INDICATOR ······ 3-2 2WD/4WD SELECT SYSTEM

OT TO
(Except TM1/TE1 models) ···················· 3-28
MAINTENANCE SCHEDULE ··················· 3-3
BRAKE FLUID ···································· 3-28

LM U
FUEL LINE ··········································· 3-8

RA O A
BRAKE SHOE WEAR (Except FA5/FA6)··· 3-29
THROTTLE OPERATION ························ 3-8
BRAKE PAD WEAR ····························· 3-30

AB N
AIR CLEANER ······································ 3-9

-C O
BRAKE LIGHT SWITCH························ 3-30
AIR CLEANER HOUSING DRAIN TUBE ··· 3-12

L. US
BRAKE SYSTEM ································· 3-31
SPARK PLUG ····································· 3-12
REVERSE INHIBITOR SYSTEM
S. N O
VALVE CLEARANCE ··························· 3-13 (’14 model) ········································· 3-33

REVERSE INHIBITOR SYSTEM

R.
RS IÓ

ENGINE OIL (Except FA models)··········· 3-17

(Except ’14 models and after ’19 TE/FE/FA
models) ············································· 3-34
TO UC

ENGINE OIL (FA models) ····················· 3-19

GUARDS············································ 3-34
ENGINE OIL FILTER
MO RIB

(Except FA models) ····························· 3-20

CLUTCH SYSTEM (Except FA models)···· 3-35
ENGINE OIL FILTER (FA models) ·········· 3-21
AL ST

SUSPENSION ····································· 3-35

ENGINE IDLE SPEED··························· 3-21
BR DI

SPARK ARRESTER ····························· 3-35

RADIATOR COOLANT ························· 3-22
CA SU

NUTS, BOLTS, FASTENERS ················· 3-35

COOLING SYSTEM······························ 3-22
WHEELS/TIRES ·································· 3-36
24 O

EVAPORATIVE EMISSION CONTROL

-20 BID

SYSTEM (After '19 AC type)·················· 3-24 TIE-ROD AND JOINT BOOTS ················ 3-36

DRIVE TRAIN BOOTS ·························· 3-24 STEERING SHAFT HOLDER BEARING···· 3-36
-07 HI

STEERING SYSTEM ···························· 3-37

28 O
PR

3-1
 dummyhead

MAINTENANCE
SERVICE INFORMATION
MAINTENANCE

GENERAL
• Place the vehicle on level ground before starting any work.

S. O
L.
S AD
TOOLS

R.
Valve adjusting wrench set

OR RIZ
07908-3230000

OT TO
LM U
RA O A
AB N
-C O
MAINTENANCE MINDER INDICATOR

L. US
The maintenance minder indicator [1] appears when the mileage or
[1]
operating hour reaches the maintenance interval specified on the
maintenance schedule (page 3-3).
S. N O
Maintenance minder indicators:
Initial Maintenance
Appears at 100 miles (150 km) or 20 operating hours,
whichever comes first.
R.
RS IÓ

Regular Maintenance Interval 1

Appears 600 miles (1,000 km) or 100 operating hours
TO UC

after the Initial Maintenance or Regular Maintenance

Interval 2 is performed and maintenance minder is
reset, whichever comes first in the maintenance
MO RIB

schedule. [2]
Regular Maintenance Interval 2
Appears 600 miles (1,000 km) or 100 operating hours
after Regular Maintenance Interval 1 is performed and
AL ST

maintenance minder is reset, whichever comes first in

the maintenance schedule.
BR DI

When the maintenance tripmeter or maintenance hourmeter reaches to 0,

the maintenance minder indicator changes its display. When the
maintenance tripmeter or maintenance hourmeter is selected, the
CA SU

maintenance minder indicator and lower part of the multi-function display

start blinking. When another mode is selected, the maintenance minder
indicator appears in the display.
Reset the maintenance tripmeter/maintenance hourmeter after
24 O

maintenances.
-20 BID

To reset the maintenance tripmeter/maintenance hourmeter, press and hold

the mode select button [2] and turn the ignition switch ON.
The maintenance minder indicator will appear, then it will blink twice, and
-07 HI

the multi-function display will temporarily show all the modes and digital
segments.
28 O

• Reset operation will be cancelled, if the mode select button is released

PR

before the indicator blinks twice.

3-2
dummyhead

MAINTENANCE
MAINTENANCE SCHEDULE
’14 – ’19 (Except FA models)
Perform the PRE-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period.

S. O
I: Inspect and clean, adjust, lubricate or replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.

L.
S AD
FREQUENCY WHICHEVER
INITIAL REGULAR MAINTENANCE

R.
COMES
MAINTENANCE INTERVAL
FIRST

OR RIZ
REFER
mi 100 600 1,200 TO
km 150 1,000 2,000 PAGE
MONTH 1 6 12

OT TO
ITEMS HOURS 20 100 200
* FUEL LINE I 3-8
* THROTTLE OPERATION I 3-8

LM U
AIR CLEANER NOTE 1 C C 3-9
AIR CLEANER HOUSING NOTE 2

RA O A
I I 3-12
DRAIN TUBE
SPARK PLUG I I 3-12
* VALVE CLEARANCE I I I 3-13

AB N
ENGINE OIL INITIAL = 100 mi (150 km), 20 operating hours or 1 month: R 3-17
REGULAR = Every 600 mi (1,000 km), 100 operating hours or 12
ENGINE OIL FILTER 3-20
months: R

-C O
* ENGINE IDLE SPEED I I I 3-21

L. US
RADIATOR COOLANT NOTE 3 I I 3-22
* COOLING SYSTEM NOTE 2 I I 3-22
DRIVE TRAIN BOOTS I I 3-24
FRONT AND REAR FINAL
(R: Every
S. N O
GEAR OIL I 3-25
2 years)
(Except TM1/TE1 models)
REAR FINAL GEAR OIL (R: Every
I 3-25
(TM1/TE1 models) 2 years)
R.
RS IÓ

* 2WD/4WD SELECT SYSTEM

I 3-28
(Except TM1/TE1 models)
TO UC

* BRAKE FLUID NOTE 3 I I 3-28

* BRAKE SHOES WEAR NOTE 1, 2 I 3-29
* BRAKE PADS WEAR NOTE 1, 2 I 3-30
* BRAKE LIGHT SWITCH I I I 3-30
MO RIB

BRAKE SYSTEM I I I 3-31

* REVERSE INHIBITOR 3-33
I I I
SYSTEM 3-34
AL ST

GUARDS I I 3-34
* CLUTCH SYSTEM I I I 3-35
* SUSPENSION I I 3-35
BR DI

* SPARK ARRESTER C C 3-35

* NUTS, BOLTS, FASTENERS I I 3-35
** WHEELS/TIRES I I I 3-36
CA SU

** TIE-ROD AND JOINT BOOTS I I I 3-36

** STEERING SHAFT HOLDER
I 3-36
BEARING
24 O

** STEERING SYSTEM I 3-37

-20 BID

* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified.
** In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
-07 HI

NOTES:
1. Service more frequently when riding in dusty areas, sand or snow.
28 O

2. Service more frequently after riding in very wet or muddy conditions.

3. Replace every 2 years. Replacement requires mechanical skill.
PR

3-3
 dummyhead

MAINTENANCE
’14 – ’19 (FA1/FA2 models)
Perform the PRE-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and clean, adjust, lubricate or replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.

S. O
FREQUENCY WHICHEVER
INITIAL REGULAR MAINTENANCE

L.
S AD
COMES
MAINTENANCE INTERVAL
FIRST REFER

R.
mi 100 600 1,200 TO
km 150 1,000 2,000 PAGE

OR RIZ
MONTH 1 6 12
ITEMS HOURS 20 100 200
* FUEL LINE I 3-8

OT TO
* THROTTLE OPERATION I 3-8
AIR CLEANER NOTE 1 C C 3-9
AIR CLEANER HOUSING NOTE 2
I I 3-12

LM U
DRAIN TUBE
SPARK PLUG I I 3-12

RA O A
* VALVE CLEARANCE I I I 3-13
ENGINE OIL INITIAL = 100 mi (150 km), 20 operating hours or 1 month: R 3-19
REGULAR = Every 600 mi (1,000 km), 100 operating hours or 12
ENGINE OIL FILTER 3-21
months: R

AB N
* ENGINE IDLE SPEED I I I 3-21
RADIATOR COOLANT NOTE 3 I I 3-22

-C O
* COOLING SYSTEM NOTE 2 I I 3-22

L. US
DRIVE TRAIN BOOTS I I 3-24
FRONT AND REAR FINAL (R: Every
I 3-25
GEAR OIL 2 years)
* 2WD/4WD SELECT SYSTEM I 3-28
S. N O
* BRAKE FLUID NOTE 3 I I 3-28
* BRAKE SHOES WEAR NOTE 1, 2 I 3-29
* BRAKE PADS WEAR NOTE 1, 2 I 3-30
* BRAKE LIGHT SWITCH I I I 3-30
R.
RS IÓ

BRAKE SYSTEM I I I 3-31

* REVERSE INHIBITOR 3-33
I I I
TO UC

SYSTEM 3-34
GUARDS I I 3-34
* SUSPENSION I I 3-35
MO RIB

* SPARK ARRESTER C C 3-35

* NUTS, BOLTS, FASTENERS I I 3-35
** WHEELS/TIRES I I I 3-36
** TIE-ROD AND JOINT BOOTS I I I 3-36
AL ST

** STEERING SHAFT HOLDER

I 3-36
BEARING
** STEERING SYSTEM I 3-37
BR DI

* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified.
CA SU

** In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES:
1. Service more frequently when riding in dusty areas, sand or snow.
24 O

2. Service more frequently after riding in very wet or muddy conditions.

-20 BID

3. Replace every 2 years. Replacement requires mechanical skill.

-07 HI
28 O
PR

3-4
dummyhead

MAINTENANCE
’14 – ’19 (FA5/FA6 models)
Perform the PRE-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and clean, adjust, lubricate or replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.

S. O
FREQUENCY WHICHEVER
INITIAL REGULAR MAINTENANCE

L.
S AD
COMES
MAINTENANCE INTERVAL
FIRST REFER

R.
mi 100 600 1,200 TO
km 150 1,000 2,000 PAGE

OR RIZ
MONTH 1 6 12
ITEMS HOURS 20 100 200
* FUEL LINE I 3-8

OT TO
* THROTTLE OPERATION I 3-8
AIR CLEANER NOTE 1 C C 3-9
AIR CLEANER HOUSING NOTE 2
I I 3-12

LM U
DRAIN TUBE
SPARK PLUG I I 3-12

RA O A
* VALVE CLEARANCE I I I 3-13
ENGINE OIL INITIAL = 100 mi (150 km), 20 operating hours or 1 month: R 3-19
REGULAR = Every 600 mi (1,000 km), 100 operating hours or 12
ENGINE OIL FILTER 3-21
months: R

AB N
RADIATOR COOLANT NOTE 3 I I 3-22
* COOLING SYSTEM NOTE 2 I I 3-22

-C O
DRIVE TRAIN BOOTS I I 3-24

L. US
FRONT AND REAR FINAL (R: Every
I 3-25
GEAR OIL 2 years)
* 2WD/4WD SELECT SYSTEM I 3-28
* BRAKE FLUID NOTE 3 I I 3-28
S. N O
* BRAKE PADS WEAR NOTE 1, 2 I 3-30
* BRAKE LIGHT SWITCH I I I 3-30
BRAKE SYSTEM I I I 3-31
* REVERSE INHIBITOR 3-33
R.
RS IÓ

I I I
SYSTEM 3-34
GUARDS I I 3-34
TO UC

* SUSPENSION I I 3-35
* SPARK ARRESTER C C 3-35
* NUTS, BOLTS, FASTENERS I I 3-35
MO RIB

** WHEELS/TIRES I I I 3-36
** TIE-ROD AND JOINT BOOTS I I I 3-36
** STEERING SHAFT HOLDER
I 3-36
BEARING
AL ST

** STEERING SYSTEM I 3-37

* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
BR DI

qualified.
** In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
CA SU

NOTES:
1. Service more frequently when riding in dusty areas, sand or snow.
2. Service more frequently after riding in very wet or muddy conditions.
3. Replace every 2 years. Replacement requires mechanical skill.
24 O
-20 BID
-07 HI
28 O
PR

3-5
 dummyhead

MAINTENANCE
After ’19 (TM1/TE1/FM1/FM2/FE1/FA2 models)
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.

S. O
FREQUENCY WHICHEVER
INITIAL REGULAR MAINTENANCE

L.
S AD
COMES
MAINTENANCE INTERVAL
FIRST REFER

R.
mi 100 600 1,200 TO
km 150 1,000 2,000 PAGE

OR RIZ
MONTH 1 6 12
ITEMS HOURS 20 100 200
* FUEL LINE I 3-8

OT TO
* THROTTLE OPERATION I 3-8
AIR CLEANER NOTE 1 C C 3-9
AIR CLEANER HOUSING NOTE 2
I I 3-12

LM U
DRAIN TUBE
SPARK PLUG I I 3-12

RA O A
* VALVE CLEARANCE I I I 3-13
3-17
ENGINE OIL INITIAL = 100 mi (150 km), 20 operating hours or 1 month: R 3-19
REGULAR = Every 600 mi (1,000 km), 100 operating hours or 12

AB N
3-20
ENGINE OIL FILTER months: R
3-21
* ENGINE IDLE SPEED I I I 3-21

-C O
* EVAPORATIVE EMISSION NOTE 4

L. US
CONTROL SYSTEM (I: Every 2 years) 3-24
(For AC type)
RADIATOR COOLANT NOTE 3 I I 3-22
* COOLING SYSTEM NOTE 2 I I 3-22
S. N O
DRIVE TRAIN BOOTS I I 3-24
FRONT AND REAR FINAL
(R: Every
GEAR OIL I 3-25
2 years)
(Except TM1/TE1 models)
R.
RS IÓ

REAR FINAL GEAR OIL (R: Every

I 3-25
(For TM1/TE1 models) 2 years)
TO UC

* 2WD/4WD SELECT SYSTEM

I 3-28
(Except TM1/TE1 models)
* BRAKE FLUID NOTE 3 I I 3-28
* BRAKE SHOES WEAR NOTE 1, 2 I 3-29
MO RIB

* BRAKE PADS WEAR NOTE 1, 2 I 3-30

* BRAKE LIGHT SWITCH I I I 3-30
BRAKE SYSTEM I I I 3-31
AL ST

* REVERSE INHIBITOR
SYSTEM I I I 3-34
(For TM1/FM1/FM2 models)
BR DI

GUARDS I I 3-34
* CLUTCH SYSTEM
I I I 3-35
(Except FA2 model)
CA SU

* SUSPENSION I I 3-35
* SPARK ARRESTER C C 3-35
* NUTS, BOLTS, FASTENERS I I 3-35
** WHEELS/TIRES I I I 3-36
24 O

** TIE-ROD AND JOINT BOOTS I I I 3-36

-20 BID

** STEERING SHAFT HOLDER

I 3-36
BEARING
** STEERING SYSTEM I 3-37
-07 HI

* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
28 O

NOTES:
PR

1. Service more frequently when riding in dusty areas, sand or snow.

2. Service more frequently after riding in very wet or muddy conditions.
3. Replace every 2 years. Replacement requires mechanical skill.
4. California type only

3-6
dummyhead

MAINTENANCE
After ’19 (FA5/FA6 models)
Perform the Pre-ride Inspection in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.

S. O
FREQUENCY WHICHEVER
INITIAL REGULAR MAINTENANCE

L.
S AD
COMES
MAINTENANCE INTERVAL
FIRST REFER

R.
mi 100 600 1,200 TO
km 150 1,000 2,000 PAGE

OR RIZ
MONTH 1 6 12
ITEMS HOURS 20 100 200
* FUEL LINE I 3-8

OT TO
* THROTTLE OPERATION I 3-8
AIR CLEANER NOTE 1 C C 3-9
AIR CLEANER HOUSING NOTE 2
I I 3-12

LM U
DRAIN TUBE
SPARK PLUG I I 3-12

RA O A
* VALVE CLEARANCE I I I 3-13
ENGINE OIL INITIAL = 100 mi (150 km), 20 operating hours or 1 month: R 3-19
REGULAR = Every 600 mi (1,000 km), 100 operating hours or 12
ENGINE OIL FILTER 3-21
months: R

AB N
* ENGINE IDLE SPEED I I I 3-21
* EVAPORATIVE EMISSION NOTE 4

-C O
CONTROL SYSTEM (I: Every 2 years) 3-24
(For AC type)

L. US
RADIATOR COOLANT NOTE 3 I I 3-22
* COOLING SYSTEM NOTE 2 I I 3-22
DRIVE TRAIN BOOTS I I 3-24
S. N O
FRONT AND REAR FINAL (R: Every
I 3-25
GEAR OIL 2 years)
* 2WD/4WD SELECT SYSTEM I 3-28
* BRAKE FLUID NOTE 3 I I 3-28
R.
RS IÓ

* BRAKE PADS WEAR NOTE 1, 2 I 3-30

* BRAKE LIGHT SWITCH I I I 3-30
TO UC

BRAKE SYSTEM I I I 3-31

GUARDS I I 3-34
* SUSPENSION I I 3-35
MO RIB

* SPARK ARRESTER C C 3-35

* NUTS, BOLTS, FASTENERS I I 3-35
** WHEELS/TIRES I I I 3-36
** TIE-ROD AND JOINT BOOTS I I I 3-36
AL ST

** STEERING SHAFT HOLDER

I 3-36
BEARING
** STEERING SYSTEM I 3-37
BR DI

* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
CA SU

NOTES:
1. Service more frequently when riding in dusty areas, sand or snow.
2. Service more frequently after riding in very wet or muddy conditions.
24 O

3. Replace every 2 years. Replacement requires mechanical skill.

-20 BID

4. California type only

-07 HI
28 O
PR

3-7
 dummyhead

MAINTENANCE
FUEL LINE
Remove the tank cover assembly (page 2-4).
[1]
Check the fuel feed hose [1] for deterioration, cracks,

S. O
damage or leakage.

L.
S AD
Replace the fuel feed hose if necessary.

R.
OR RIZ
OT TO
LM U
THROTTLE OPERATION

RA O A
Check for any deterioration or damage to the throttle
[1]
cable. Check the throttle lever [1] for smooth operation.

AB N
Check that the throttle opens and automatically closes
in all steering positions.

-C O
If the throttle lever does not return properly, overhaul
and lubricate the throttle housing (page 17-9).

L. US
If the throttle lever still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
S. N O
the right and left to ensure that the idle speed does not 3 – 8 mm
change. If idle speed increases, check the throttle lever (1/8 – 5/16 in)
freeplay and the throttle cable connections.
R.
Measure the throttle lever freeplay at the tip of the
RS IÓ

throttle lever.
TO UC

THROTTLE LEVER FREEPLAY:

3 – 8 mm (1/8 – 5/16 in)
Throttle lever freeplay can be adjusted at either end of
MO RIB

[3] [2]
the throttle cable. Minor adjustments are made with the
upper adjuster.
Slide the rubber boot [1] off the adjuster.
AL ST

Loosen the lock nut [2], turn the adjuster [3] as required
and tighten the lock nut.
Install the rubber boot securely.
BR DI
CA SU

[1]
24 O
-20 BID
-07 HI
28 O
PR

3-8
dummyhead

MAINTENANCE
Major adjustments are made with the lower adjuster.
[1]
Remove the seat (page 2-3).
Slide the rubber boot [1] off the adjuster.

S. O
Loosen the lock nut [2], turn the adjuster [3] as required
and tighten the lock nut.

L.
S AD
Install the rubber boot securely.
Recheck the throttle operation and install the seat

R.
(page 2-3).

OR RIZ
OT TO
[2] [3]

AIR CLEANER

LM U
RA O A
• If the vehicle is used in dusty areas, sand or snow,
more frequent inspections are required.
Remove the seat (page 2-3).

AB N
Except FA5/FA6: [2]
Except FA5/FA6: Release the four retaining clips [1] and remove the air
cleaner cover [2].

-C O
FA5/FA6: Release the six retaining clips [1] and remove the air

L. US
cleaner cover [2].
S. N O
R.
RS IÓ

[1]
TO UC

FA5/FA6:

[2]
MO RIB
AL ST
BR DI
CA SU

[1]

Loosen the band screw [1] and remove the air cleaner
[1] [2]
element assembly [2].
24 O
-20 BID
-07 HI
28 O
PR

3-9
 dummyhead

MAINTENANCE
Remove the dust filter [1] from the element holder in the
air cleaner housing.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

Remove the element band [1] and the element core [2]

LM U
[1]
from the air cleaner element [3].

RA O A
AB N
-C O
L. US [2] [3]
S. N O
Wash the element and filter in non-flammable or high
flash point solvent.
Squeeze out the solvent thoroughly, and allow the
R.
RS IÓ

element and filter to dry.

TO UC
MO RIB

Wash Squeeze out

AL ST

Apply 17 – 23 g (0.6 – 0.8 oz) of Pro Honda Foam Filter

BR DI

[1]
Oil [1] or equivalent oil from the inside of the element.
Place the element into a plastic bag [2] and spread the
CA SU

oil evenly by hand.

24 O
-20 BID
-07 HI

[2]
28 O
PR

3-10
dummyhead

MAINTENANCE
Install the element core [1] into the air cleaner element
[1] [2]
[2] properly.
Install the element band [3] onto the element flange.

S. O
L.
S AD
R.
OR RIZ
OT TO
[3]

Clean the inside of the air cleaner housing and cover.

LM U
Install the dust filter [1] into the element holder.

RA O A
Install the element assembly [2] over the connecting
tube on the housing.
Be sure to rest the element onto the stepped area [3] of

AB N
the element holder and tighten the band screw [4].

-C O
L. US [1] [3]
S. N O
[4] [2]
R.
RS IÓ
TO UC
MO RIB
AL ST

Make sure the air cleaner cover seal [1] is in good

BR DI

[3] [2]
condition and replace it if necessary.
Install the air cleaner cover [2] with the arrow [3] facing
CA SU

forward by aligning the stepped area [4] with the

element.
Secure the cover with the four retaining clips. [4]

Install the seat (page 2-3).

24 O
-20 BID
-07 HI

[1]
28 O
PR

3-11
 dummyhead

MAINTENANCE
AIR CLEANER HOUSING DRAIN TUBE
• If the vehicle is used in very wet or muddy

S. O
conditions, more frequent inspections are required.

L.
S AD
Remove the drain tube [1] from the bottom of the air
cleaner housing to empty any deposits. Except FA5/FA6:

R.
Install the drain tube securely.

OR RIZ
OT TO
LM U
RA O A
[1]

FA5/FA6:

AB N
-C O
L. US
S. N O
R.
RS IÓ

[1]

SPARK PLUG
TO UC

Remove the tank cover assembly (page 2-4).

[1]
MO RIB

Clean with Disconnect the spark plug cap [1] and clean around the
compressed air spark plug base.
before removing the
Remove the spark plug [2].
plug, and be sure
AL ST

that no debris is
allowed to enter into
the combustion
BR DI

chamber.
CA SU

[2]
24 O

Check the insulator [1] for cracks or damage, and the

[2] [3]
electrodes for wear, fouling or discoloration. Replace
-20 BID

the plug if necessary.

RECOMMENDED SPARK PLUG:
BKR5E-11 (NGK), K16PR-U11 (DENSO)
-07 HI

Clean the center electrode [2] and side electrode [3]

28 O

with a wire type brush or special plug cleaner.

PR

[1]

3-12
dummyhead

MAINTENANCE
Check the gap between the center and side electrodes
with a wire-type feeler gauge.

SPARK PLUG GAP: 1.0 – 1.1 mm (0.039 – 0.043 in) 1.0 – 1.1 mm
(0.039 – 0.043 in)

S. O
If necessary, adjust the gap by bending the side
electrode carefully.

L.
S AD
Thread the spark plug in by hand to prevent cross-

R.
threading and tighten it with a spark plug wrench.

OR RIZ
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)
Connect the spark plug cap and install the tank cover
assembly (page 2-4).

OT TO
VALVE CLEARANCE

LM U
RA O A
• Inspect and adjust the valve clearance while the
engine is cold (below 35°C/95°F).
Remove the tank cover assembly (page 2-4).

AB N
[3] [1] [4]
Disconnect the fuel pump unit 4P connector [1].

-C O
Remove the following from the ECM stay [2]:
– fuel pump breather hose [3]

L. US
– wire harness clip [4]
– joint connector [5]
– PCM/ECM [6]
S. N O
R.
RS IÓ

[6] [2] [5]

TO UC

– fuel hose [1]

[1] [2]
– bolt [2]
Remove the wire harness clip [3] from the snorkel duct.
MO RIB
AL ST
BR DI
CA SU

[3]

Disconnect the ECT sensor 2P connector [1] and spark

[4] [7] [5]
plug cap [2], and remove the plug wire [3] from the heat
24 O

guard [4].
-20 BID

Except FA5/FA6: Remove the rear final gear breather hose [5] from the
ECM stay [6].
Release the ECM stay from the tab [7].
-07 HI
28 O
PR

[3] [1] [2] [6]

3-13
 dummyhead

MAINTENANCE
Remove the ECM stay [1] by releasing its bosses [2]
[4] [2] [1]
from the grommets [3].
Remove the main wire harness [4] from the heat
protector.

S. O
Except FA5/FA6: Remove the brake panel breather hose [5] from the

L.
S AD
ECM stay.

R.
FA5/FA6: Remove the rear final gear case breather hose [5] from
the ECM stay.

OR RIZ
OT TO
[3] [5]

Remove the trim clip [1], loosen the band screw [2] and

LM U
[1] [2]
remove the snorkel duct [3].

RA O A
AB N
-C O
L. US [3]
S. N O
Remove the fuel hose [1] from the heat protector.
[1] [2]
Remove the fuel tank mounting bolt [2].
R.
Release the heat protector retaining tab [3].
RS IÓ
TO UC
MO RIB
AL ST

[3]

Remove the two trim clip [1] from the front center cover.
BR DI
CA SU
24 O
-20 BID
-07 HI

[1]
28 O
PR

3-14
dummyhead

MAINTENANCE
Raise the rear of the fuel tank [1] and support it with a
[2]
socket wrench [2].
Remove the heat protector [3] from the left frame pipe
and raise it.

S. O
L.
S AD
R.
OR RIZ
OT TO
[3] [1]

Remove the valve adjusting hole caps [1].

LM U
[1]

RA O A
AB N
-C O
L. US
S. N O
Remove the following:
[1]
– Except CM type FM1/FM2/FE1: three bolts [1]
– Except CM type FM1/FM2/FE1: crankshaft hole cap
R.
RS IÓ

[2]
– timing hole cap [3]
TO UC
MO RIB
AL ST

[2] [3]
If the "T" mark is Rotate the crankshaft clockwise to align the "T" mark [1]
BR DI

[2]
passed when trying on the flywheel with the index notch [2] on the
to align it with the crankcase.
index notch, rotate Make sure the piston is at TDC (Top Dead Center) on
CA SU

the crankshaft only the compression stroke.

clockwise again This position can be obtained by confirming that there is
and align. This slack in both rocker arms. If there is no slack, rotate the
must be done to crankshaft one full turn and match up the T mark again.
24 O

prevent the one-

• Recoil starter equipment model only: Rotate the
way decompressor
-20 BID

crankshaft using the recoil starter.

system from [1]
functioning and to
obtain the correct
-07 HI

valve clearance.
28 O
PR

3-15
 dummyhead

MAINTENANCE
When checking the Check the valve clearances by inserting a feeler gauge
clearance, slide the [1] between the adjusting screw and valve stem.
feeler gauge from
the center toward VALVE CLEARANCE:
IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in)

S. O
the outside.
EX: 0.23 ± 0.02 mm (0.009 ± 0.001 in)

L.
S AD
R.
OR RIZ
OT TO
[1]

Adjust by loosening the lock nut [1] and turning the

LM U
[3]
adjusting screw [2] with the special tool until there is a
slight drag on the feeler gauge.

RA O A
TOOL:
Valve adjusting wrench set [3] 07908-3230000

AB N
Hold the adjusting screw and tighten the lock nut.
TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft)

-C O
After tightening the lock nut, recheck the valve

L. US
clearance.

[2] [1]
S. N O
Coat new O-rings [1] with engine oil and install them
[1]
into the groove in the valve adjusting hole caps [2].
Install the valve adjusting hole caps and tighten them.
R.
RS IÓ

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

TO UC
MO RIB
AL ST

[2]

Coat a new O-ring [1] with engine oil and install it onto
BR DI

[1]
the timing hole cap [2].
Install the timing hole cap and tighten it.
CA SU

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

24 O
-20 BID
-07 HI

[2]
28 O
PR

3-16
dummyhead

MAINTENANCE
CM type FM1/FM2/ Coat a new O-ring [1] with engine oil and install it into
[3]
FE1: the crankcase cover groove.
Install the crankshaft hole cap [2] and tighten the three
bolts [3].

S. O
L.
S AD
R.
OR RIZ
OT TO
[1] [2]

Install the removed parts in the reverse order of

LM U
removal.

RA O A
• Align the lug of the snorkel duct with the groove in
the snorkel hose.
• Route the wire harness and hoses properly
(page 1-30).

AB N
-C O
L. US Align
S. N O
ENGINE OIL (Except FA models)
LEVEL CHECK
R.
RS IÓ

Remove the oil check lid (page 2-3).

Place the vehicle on level ground.
TO UC

[1]
Start the engine and let it idle for 3 – 5 minutes.
If the air temperature is below 10°C (50°F), let the
engine idle for an additional 5 minutes (a total of
MO RIB

10 minutes).
Stop the engine and wait 2 – 3 minutes.
Remove the oil filler cap/dipstick [1] and wipe it clean.
AL ST

Check the oil level by inserting the oil filler cap/dipstick

into the engine without screwing it in.
The engine contains a sufficient amount of oil if the oil [2]
BR DI

level is between the upper level mark [2] and lower level
mark [3] on the dipstick. [3]
CA SU

If the oil level is near or below the lower level mark, add
the recommended engine oil to the upper level mark.
RECOMMENDED ENGINE OIL:
24 O

Pro Honda GN4 4-stroke oil (U.S.A. & Canada) or

equivalent motorcycle oil
-20 BID

API service classification: SG or higher

JASO T903 standard: MA
Viscosity: SAE 10W-30
-07 HI
28 O
PR

3-17
 dummyhead

MAINTENANCE

• Other viscosities shown in the chart may be used

when the average temperature in your riding area is
within the indicated range. OIL VISCOSITIES

S. O
Reinstall the oil filler cap/dipstick.

L.
S AD
Install the oil check lid (page 2-3).

R.
OR RIZ
OT TO
LM U
OIL CHANGE

RA O A
• Change the oil with the engine warm to assure
[2]
complete and rapid draining.

AB N
Remove the oil check lid (page 2-3).
Place the vehicle on level ground.

-C O
Start the engine and let it idle for a few minutes.

L. US
Stop the engine.
Remove the drain bolt [1], sealing washer [2] and the oil
filler cap/dipstick [3] to drain the engine oil.
S. N O
After the oil has drained, install the drain bolt with a new
sealing washer.
TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft)
[1]
R.
RS IÓ

Pour the recommended oil (page 3-17)into the engine

to the upper level mark on the dipstick. [3]
TO UC

OIL CAPACITY:
After draining:
2.6 liters (2.7 US qt, 2.3 Imp qt)
MO RIB

After draining/filter change:

2.7 liters (2.9 US qt, 2.4 Imp qt)
After disassembly:
3.3 liters (3.5 US qt, 2.9 Imp qt)
AL ST

Install the filler cap/dipstick.

Check the oil level (page 3-17).
BR DI

Reset the maintenance minder indicator after changing

the engine oil (page 3-2).
CA SU
24 O
-20 BID
-07 HI
28 O
PR

3-18
dummyhead

MAINTENANCE
ENGINE OIL (FA models)
LEVEL CHECK
Remove the oil check lid (page 2-3).

S. O
[1]
Place the vehicle on level ground.

L.
S AD
Start the engine and let it idle for 3 – 5 minutes.

R.
If the air temperature is below 10°C (50°F), let the
engine idle for an additional 5 minutes (a total of

OR RIZ
10 minutes).
Stop the engine and wait 2 – 3 minutes.
Remove the dipstick [1] and wipe it clean.

OT TO
Check the oil level by inserting the dipstick into the
engine without screwing it in.
The engine contains a sufficient amount of oil if the oil

LM U
level is between the upper level mark [2] and lower level
mark [3] on the dipstick.

RA O A
AB N
-C O
L. US
S. N O
[2]
[3]
R.
RS IÓ

If the oil level is near or below the lower level mark,

[1]
remove the tank cover assembly (page 2-4)and the oil
TO UC

filler cap [1], and add the recommended engine oil to

the upper level mark on the dipstick.
RECOMMENDED ENGINE OIL:
MO RIB

Pro Honda GN4 4-stroke oil (U.S.A. & Canada) or

equivalent motorcycle oil
API service classification: SG or higher
JASO T903 standard: MA
AL ST

Viscosity: SAE 10W-30

BR DI
CA SU

• Other viscosities shown in the chart may be used

when the average temperature in your riding area is
24 O

within the indicated range. OIL VISCOSITIES

Reinstall the filler cap and the dipstick.
-20 BID

Install the tank cover assembly (page 2-4).

-07 HI
28 O
PR

3-19
 dummyhead

MAINTENANCE
OIL CHANGE

• Change the oil with the engine warm to assure

[2]
complete and rapid draining.

S. O
Place the vehicle on level ground.

L.
S AD
Remove the tank cover assembly (page 2-4).

R.
Start the engine and let it idle for a few minutes.

OR RIZ
Stop the engine.
Remove the drain bolt [1], sealing washer [2] and the oil
filler cap [3] to drain the engine oil.

OT TO
After the oil has drained, install the drain bolt with a new
sealing washer.
TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft)

LM U
[1]
Pour the recommended oil into the engine through the

RA O A
oil filler hole to the upper level mark on the dipstick [3]
(page 3-19).
OIL CAPACITY:

AB N
After draining:
3.4 liters (3.6 US qt, 3.0 Imp qt)

-C O
After draining/filter change:
3.6 liters (3.8 US qt, 3.2 Imp qt)

L. US
After disassembly:
4.0 liters (4.2 US qt, 3.5 Imp qt)
Install the filler cap and the dipstick.
S. N O
Check the oil level (page 3-19).
Reset the maintenance minder indicator after changing
the engine oil (page 3-2).
R.
RS IÓ

ENGINE OIL FILTER (Except FA

TO UC

models)
Remove the tank cover assembly (page 2-4).
MO RIB

Drain the engine oil (page 3-18). [5] [6]

Place shop towels Remove the following:
AL ST

under the filter [8]

– three bolts [1]
cover because oil
– filter cover [2] and O-ring [3]
will flow out.
– oil filter [4]
BR DI

– setting spring [5]

– O-ring [6]
[4]
CA SU

Coat new O-rings with engine oil and install them into
each groove in the filter cover and front crankcase [7]
cover.
Installing the oil filter Install the setting spring onto the lugs and a new oil filter
24 O

backwards will with the rubber seal [7] facing out, away from the [1]
engine (OUT-SIDE mark [8] on the filter is visible), then
-20 BID

result in severe
engine damage. set the filter cover onto the filter and tighten the bolts
[3] [2]
while holding the cover.
Fill the crankcase with the engine oil (page 3-18)
-07 HI

Install the tank cover assembly (page 2-4).

28 O
PR

3-20
dummyhead

MAINTENANCE
ENGINE OIL FILTER (FA models)
Remove the tank cover assembly (page 2-4).
[1] [7]
Drain the engine oil (page 3-20).

S. O
Place shop towels Remove the following:

L.
S AD
under the filter
– three bolts [1]
cover because oil

R.
– filter cover [2] and O-ring [3]
will flow out.
– setting spring [4]

OR RIZ
– oil filter [5]
Coat a new O-ring with engine oil and install it into the
groove in the filter cover.

OT TO
Installing the oil filter Install a new oil filter onto the engine boss with the
backwards will "OUT-SIDE" mark [6] facing out (rubber seal side facing
result in severe in). [2]

LM U
engine damage. Install the spring onto the filter boss, then install the
filter cover with the triangular mark [7] facing up and

RA O A
[3] [6]
with the spring between the locating tabs [8].
Tighten the bolts securely while holding the cover.
Fill the crankcase with the engine oil (page 3-20).

AB N
Install the tank cover assembly (page 2-4)

-C O
L. US
S. N O
[8] [5] [4]

ENGINE IDLE SPEED

R.
RS IÓ

• Inspect the idle speed after all other engine

maintenance items have been performed and are
TO UC

within specifications.
• Before checking the idle speed, inspect the following
items.
MO RIB

– No DTC and MIL blinking (page 4-10)

– Spark plug condition (page 3-12)
– Air cleaner condition (page 3-9)
• The engine must be warm for accurate idle speed
AL ST

inspection.
• This system eliminates the need for manual idle
speed adjustment compared to previous designs.
BR DI

• Use a tachometer with graduations of 50 rpm or

smaller that will accurately indicate a 50 rpm
change.
CA SU

Remove the tank cover assembly (page 2-4).

Start the engine and warm it up to coolant temperature
80°C (176°F).
24 O

Stop the engine and connect a tachometer according to

the tachometer manufacturer’s operating instructions.
-20 BID

Start the engine and let it idle. Check the idle speed.
ENGINE IDLE SPEED: 1,400 ± 100 rpm
If the idle speed is out of the specification, check the
-07 HI

following:
• Throttle operation and throttle lever freeplay (page
28 O

3-8)
PR

• Intake air leak or engine top-end problem

(page 10-3)
• IACV operation (page 7-21)

3-21
 dummyhead

MAINTENANCE
RADIATOR COOLANT
Check the coolant level of the reserve tank [1] with the
[2] [1]
engine running at normal operating temperature.

S. O
The level should be between the upper level line [2] and
lower level line [3] with the vehicle upright on a level

L.
S AD
surface.

R.
If the level is low, add the coolant as follows:

OR RIZ
Remove the radiator cap lid (page 2-3).

OT TO
[3]

LM U
Remove the reserve tank cap [1], and fill the tank up to

RA O A
[1]
the upper level line with a 1:1 mixture of distilled water
and antifreeze.
RECOMMENDED ANTIFREEZE:

AB N
Pro Honda HP coolant or an equivalent high
quality ethylene glycol antifreeze containing

-C O
corrosion protection inhibitors

L. US
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.
S. N O
Be sure to remove any air from the cooling system
(page 8-5).
R.
RS IÓ

COOLING SYSTEM
TO UC

• If the vehicle is used in very wet or muddy

conditions, more frequent inspections are required.
MO RIB

Remove the tank cover assembly (page 2-4).

Check for any coolant leakage from the water pump,
water hoses [1] and hose joints.
AL ST

Check the water hoses for cracks or deterioration and

replace if necessary.
Check that all hose clamps are tight.
BR DI
CA SU
24 O

[1]
-20 BID
-07 HI
28 O
PR

3-22
dummyhead

MAINTENANCE
Except FM2/FA2/ Remove the trim clips [1] and radiator grille cover [2]
[1] [2]
FA6: from the right side while releasing the tabs and fan
motor breather hose [3].
[3]

S. O
L.
S AD
R.
OR RIZ
OT TO
FM2/FA2/FA6: Remove the radiator reserve tank (page 8-9).
[3]

LM U
Remove the trim clips [1] and radiator grille cover [2]

RA O A
from the left side while releasing the tabs and front final
drive breather hose [3].

AB N
-C O
L. US [1] [2]
S. N O
Remove the center radiator grille cover [1] by releasing
[1]
the tab from the radiator grille cover.
R.
RS IÓ
TO UC
MO RIB
AL ST

Check the radiator air passage for clogs or damage.

BR DI

Straighten bent fins with a small, flat blade screwdriver

and remove insects, mud or other obstructions with
compressed air or low pressure water.
CA SU

Also, clean the radiator grille thoroughly.

Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
24 O

Install the removed parts in the reverse order of

removal.
-20 BID
-07 HI
28 O
PR

3-23
 dummyhead

MAINTENANCE
EVAPORATIVE EMISSION CONTROL
SYSTEM (After '19 AC type)
Remove the fuel tank (page 7-16).

S. O
Check the hoses between the fuel tank [1], EVAP [1]
canisters [2], EVAP purge control solenoid valve [3],

L.
S AD
and throttle body [4] for deterioration, damage or loose

R.
connection.
Also, check that the hoses are not kinked, pinched or

OR RIZ
cracked.
Check the EVAP canisters for cracks or other damage.
Refer to the "CABLE & HARNESS ROUTING (After '19 [4]
model)" for hose connections and routing (page 1-44).

OT TO
LM U
[3]

RA O A
AB N
-C O
L. US FRESH AIR
S. N O
[2] FUEL
VAPOR
R.
RS IÓ

DRIVE TRAIN BOOTS

TO UC

Raise all the wheels off the ground by supporting the

[1]
frame securely.
Check the drive shaft boots (except TM1/TE1) [1],
MO RIB

propeller shaft boot (except TM1/TE1) [2] and universal

joint boot [3] for cuts, damage or leaking grease.
If the boot is damaged, replace it.
AL ST

– front driving mechanism (page 20-5)

– rear driving mechanism (page 21-5)
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

[2] [3]

3-24
dummyhead

MAINTENANCE
FRONT AND REAR FINAL GEAR OIL
REAR FINAL GEAR OIL (Except FA5/
FA6)

S. O
LEVEL CHECK

L.
S AD
Place the vehicle on a level surface.
[1]

R.
Remove the oil check bolt [1] and check that the oil
flows out of the check bolt hole.

OR RIZ
Check for leaks if there is no oil flow.
Remove the oil filler cap [2] and pour the oil slowly
through the filler hole until oil starts to flow out of the

OT TO
check bolt hole.
RECOMMENDED OIL: Hypoid gear oil SAE #80W-90

LM U
Install the check bolt with a new sealing washer [3] and

RA O A
tighten it.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[3]
Coat a new O-ring [4] with grease and install it into the

AB N
cap groove. [4] [2]
Install the filler cap and tighten it.

-C O
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

L. US
S. N O
R.
RS IÓ
TO UC

OIL CHANGE
Place the vehicle on a level surface.
[3] [2]
MO RIB

Remove the drain bolt [1] and sealing washer [2], and
the filler cap [3] to drain the oil.
When the oil is completely drained, install the drain bolt
with a new sealing washer.
AL ST

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Fill the rear final gear case with the recommended oil
BR DI

(page 3-25).
OIL CAPACITY:
CA SU

85 cm3 (2.9 US oz, 3.0 Imp oz) after draining

100 cm3 (3.4 US oz, 3.5 Imp oz) after disassembly
[1]
24 O
-20 BID
-07 HI
28 O
PR

3-25
 dummyhead

MAINTENANCE
REAR FINAL GEAR OIL (FA5/FA6)
LEVEL CHECK
Place the vehicle on level ground.

S. O
Remove the oil filler cap [1] and check that the oil level
is up to the lower edge of the oil filler hole. [1]

L.
S AD
Check for leaks if the oil level is low.

R.
Pour the oil into the filler hole until it reaches the lower
edge of the hole.

OR RIZ
RECOMMENDED OIL: Hypoid gear oil SAE #80W-90
Coat a new O-ring [2] with grease and install it into the

OT TO
cap groove.
Install the filler cap and tighten it to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

LM U
[2]

RA O A
OIL CHANGE
Place the vehicle on level ground.
Remove the drain bolt [1] and sealing washer [2], and

AB N
the oil filler cap [3] to drain the oil. [3]
When the oil is completely drained, install the drain bolt [2]

-C O
with a new sealing washer and tighten it to the specified
torque.

L. US
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Fill the gear case with the recommended oil
(page 3-26).
S. N O
OIL CAPACITY:
After draining: 125 cm3 (4.2 US oz, 4.4 Imp oz)
After disassembly: [1]
R.
RS IÓ

145 cm3 (4.9 US oz, 5.5 Imp oz)

TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

3-26
dummyhead

MAINTENANCE
FRONT FINAL GEAR OIL (Except TM1/
TE1)
LEVEL CHECK

S. O
Place the vehicle on a level surface.
[1]
Remove the oil filler cap [1] and check that the oil level

L.
S AD
is up to the lower edge [2] of the oil filler hole.

R.
Check for leaks if the oil level is low.

OR RIZ
Pour the oil into the filler hole until it reaches the lower
edge of the hole.
RECOMMENDED OIL: Hypoid gear oil SAE #80W-90

OT TO
Coat a new O-ring [3] with grease and install it into the
cap groove.
Install the filler cap and tighten it.

LM U
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

RA O A
[3]

AB N
-C O
L. US
S. N O

[2]
R.
RS IÓ

OIL CHANGE
TO UC

Place the vehicle on a level surface.

[3] [2]
Remove the drain bolt [1] and the oil filler cap [2] to
drain the oil.
MO RIB

When the oil is completely drained, install the drain bolt

with a new sealing washer [3].
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
AL ST

Fill the front final gear case with the recommended oil
(page 3-27).
BR DI

OIL CAPACITY:
210 cm3 (7.1 US oz, 7.4 Imp oz) after draining
250 cm3 (8.5 US oz, 8.8 Imp oz) after disassembly
CA SU

[1]
24 O
-20 BID
-07 HI
28 O
PR

3-27
 dummyhead

MAINTENANCE
2WD/4WD SELECT SYSTEM (Except
TM1/TE1 models)
2WD/4WD SELECTOR CABLE

S. O
ADJUSTMENT

L.
S AD
Remove the bolt [1] and the clutch arm cover [2] by
[3]

R.
releasing the two tabs [3].

OR RIZ
Shift the select lever to the 2WD position.
Be sure the clutch arm [4] position is between the 2WD
marks [5].
Temporarily loosen the adjusting nut [6] by turning it

OT TO
counterclockwise.
Turn the adjusting nut clockwise until the joint pin [7]
just touches the clutch arm slot [8] with the nut ends [9]

LM U
are contacted the joint pin (cutout is not seated). Then
further turn it clockwise 1/4 of a turn to seat the cutout in

RA O A
the nut onto the joint pin.
Make sure that the clearance between the joint pin and [2] [1]
arm slot is 0.25 – 2 mm (0.01 – 0.08 in).

AB N
After adjustment, check the select lever for smooth [8] [4] [9]
operation.

-C O
Install the arm cover by aligning the slits with the tabs
and tighten the bolt.

L. US
1/4 turn
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
S. N O
R.
RS IÓ

Touches 0.25 – 2 mm
[6] [7] [5] the slot (0.01 – 0.08 in)
TO UC

BRAKE FLUID
MO RIB

• Spilling fluid can damage painted, plastic or rubber

parts. Place a rag over these parts whenever the
AL ST

system is serviced.

• Do not mix different types of fluid, as they may not

BR DI

be compatible with each other.

• Do not allow foreign material to enter the system
when filling the reservoir.
CA SU

• When the fluid level is low, check the brake pads for
wear (page 3-30). A low fluid level may be due to
wear of the brake pads. If the brake pads are worn
and the caliper pistons are pushed out, this accounts
24 O

for a low reservoir level. If the brake pads are not

worn and the fluid level is low, check the entire
-20 BID

system for leaks (page 3-31).

-07 HI
28 O
PR

3-28
dummyhead

MAINTENANCE
FRONT
Turn the handlebar to the left side so the reservoir is
[3] [4]
level and check the reservoir fluid level through the
sight glass [1].

S. O
If the fluid level is near the "LOWER" level mark [2],

L.
S AD
remove the screws [3] reservoir cap [4], set plate and
diaphragm and fill the reservoir with DOT 4 brake fluid

R.
from a sealed container to the casting ledge [5].

OR RIZ
Install the diaphragm, set plate and reservoir cap, and
tighten the cap screws.
TORQUE: 2 N·m (0.2 kgf·m, 1.5 lbf·ft)

OT TO
[1] [2]

LM U
RA O A
[5]

AB N
-C O
L. US
S. N O
REAR (FA5/FA6)
R.
RS IÓ

Place the vehicle on level ground so the reservoir is

level and check the reservoir fluid level. [2]
TO UC

If the fluid level is near the "LOWER" level line [1],

[3]
remove the reservoir cap [2], set plate and diaphragm
and fill the reservoir with DOT 4 brake fluid from a
sealed container to the "UPPER" level line [3].
MO RIB

Install the diaphragm, set plate and reservoir cap.

AL ST
BR DI

[1]

BRAKE SHOE WEAR (Except FA5/FA6)

CA SU

Replace the brake shoes if the wear indicator plate [1]

[2]
aligns with the reference mark [2] on the brake panel
24 O

when the rear brake lever or brake pedal is applied.

See Brake System section for brake shoe replacement
-20 BID

(page 19-16).
-07 HI
28 O
PR

[1]

3-29
 dummyhead

MAINTENANCE
BRAKE PAD WEAR
FRONT
Replace the brake pads if the wear indicator [1] aligns

S. O
with the reference mark (lug) [2] on the caliper body
when the front brake is applied. [1]

L.
S AD
See Brake System section for brake pad replacement

R.
(page 19-10).

OR RIZ
OT TO
LM U
[2]

RA O A
REAR (FA5/FA6)
Replace the brake pads if the wear limit indicator mark
[1] on the caliper aligns with the reference mark [2] on [2]

AB N
the caliper bracket when the brake is applied.

-C O
See Brake System section for brake pad replacement
(page 19-11).

L. US
S. N O
R.
RS IÓ

[1]

BRAKE LIGHT SWITCH

TO UC

The front brake Check that the brake light comes on just prior to the
[1]
switch does not brake actually being engaged.
MO RIB

require adjustment.
If the light fails to come on, adjust the rear brake switch
so that the light comes on at the proper time.
Hold the switch body [1] and turn the adjusting nut [2].
Do not turn the switch body.
AL ST
BR DI
CA SU

[2]
24 O
-20 BID
-07 HI
28 O
PR

3-30
dummyhead

MAINTENANCE
BRAKE SYSTEM
FRONT BRAKE
Firmly apply the front brake lever and check that no air

S. O
[1]
has entered the system.
If the brake lever feels soft or spongy when operated,

L.
S AD
bleed the system.

R.
See Brake System section for air bleeding procedures
(page 19-8).

OR RIZ
Inspect the brake hoses [1] and fittings for deterioration,
cracks, damage or signs of leakage.
Tighten any loose fittings.

OT TO
Replace hoses, pipes and fittings as required.

LM U
RA O A
REAR DRUM BRAKE (Except FA5/FA6)
Make sure the Check the brake cable, brake lever and brake pedal for

AB N
brake pedal loose connections, excessive play or other damage.
operates smoothly Replace or repair if necessary.
and that the brake

-C O
For cable lubrication: Disconnect the brake cable at the
pedal position is
brake lever or pedal. Thoroughly lubricate the cables
correct.

L. US
and their pivot points with a commercially available
Make sure the
cable lubricant or a lightweight oil.
brakes do not drag.
Measure the rear brake lever freeplay at the end of the
lever. ’14 model shown:
S. N O
FREEPLAY: 15 – 20 mm (19/32 – 25/32 in)
R.
RS IÓ
TO UC

15 – 20 mm
(19/32 – 25/32 in)
MO RIB
AL ST

Measure the rear brake pedal freeplay at the end of the

pedal.
BR DI

FREEPLAY: 15 – 20 mm (19/32 – 25/32 in)

CA SU
24 O
-20 BID

15 – 20 mm
(19/32 – 25/32 in)
-07 HI
28 O
PR

3-31
 dummyhead

MAINTENANCE
Make sure the Adjust the brake lever freeplay by turning the upper
[1]
cutout in the adjusting nut [1] at the brake arm.
adjusting nut is
Adjust the brake pedal freeplay by turning the lower
seated on the brake
adjusting nut [2] at the brake arm.

S. O
arm pin.

L.
S AD
R.
OR RIZ
OT TO
[2]

REAR HYDRAULIC DISC BRAKE (FA5/

LM U
FA6)

RA O A
Firmly apply the rear brake pedal and check that no air
has entered the system.
If the brake pedal feels soft or spongy when operated,
bleed the system.

AB N
See Brake System section for air bleeding procedures
(page 19-8).

-C O
Inspect the brake hose [1] and fittings for deterioration,
cracks, damage or signs of leakage.

L. US
Tighten any loose fittings.
Replace hose and fittings as required.
S. N O
[1]

PARKING BRAKE (FA5/FA6)

R.
RS IÓ

Measure the rear brake lever freeplay at the end of the

lever.
TO UC

FREEPLAY: 25 – 30 mm (1 – 1 3/16 in)

MO RIB
AL ST

25 – 30 mm
BR DI

(1 – 1 3/16 in)
CA SU

Make sure the Adjust the brake lever freeplay by turning the adjusting
cutout in the nut [1].
adjusting nut is
Release the parking brake lever, and check that the
24 O

seated on the joint

brakes do not drag when the rear wheels are turned.
pin [2].
Readjust if necessary.
-20 BID

[2]
-07 HI
28 O
PR

[1]

3-32
dummyhead

MAINTENANCE
BRAKE PEDAL HEIGHT ADJUSTMENT
(FA5/FA6)
Loosen the lock nut [1] and turn the push rod [2] until
the correct pedal height is obtained. [2]

S. O
For standard push rod length (page 19-22).

L.
S AD
After adjustment, tighten the push rod lock nut to the

R.
specified torque.

OR RIZ
TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft)

OT TO
LM U
[1]

RA O A
REVERSE INHIBITOR SYSTEM (’14
model)

AB N
Check the reverse selector cable and lever for loose
[1]
connections, excessive play or other damage.
Replace or repair if necessary.

-C O
Release the dust cover [1].

L. US
Measure the lever freeplay at the lever end near the
cable.
FREEPLAY: 2 – 4 mm (3/32 – 5/32 in)
S. N O
• If necessary, watch the reverse selector arm on the 2 – 4 mm
crankcase to see when it moves while determining (3/32 – 5/32 in)
freeplay.
R.
RS IÓ
TO UC

Slide the rubber boot [1] off the adjuster.

[1] [3]
Adjust by loosening the lock nut [2] and turning the
adjuster [3].
MO RIB

Tighten the lock nut.

Install the dust cover properly.
AL ST
BR DI
CA SU

[2]
24 O
-20 BID
-07 HI
28 O
PR

3-33
 dummyhead

MAINTENANCE
REVERSE INHIBITOR SYSTEM (Except
’14 models and after ’19 TE/FE/FA
models)

S. O
Check the reverse selector cable and lever for loose

L.
S AD
[1]
connections, excessive play or other damage.
Replace or repair if necessary.

R.
Release the dust cover [1].

OR RIZ
Squeeze the levers [2] lightly, and measure the lever
freeplay at the lever end near the cable.
FREEPLAY: 2 – 4 mm (3/32 – 5/32 in)

OT TO
• If necessary, watch the reverse selector arm on the

LM U
crankcase to see when it moves while determining
freeplay. 2 – 4 mm
[2]

RA O A
(3/32 – 5/32 in)

Slide the rubber boot [1] off the adjuster.

[1] [3]
Adjust by loosening the lock nut [2] and turning the

AB N
adjuster [3].
Tighten the lock nut.

-C O
Install the dust cover properly.

L. US
S. N O
R.
RS IÓ

[2]

GUARDS
TO UC

Check the inboard guard (except TM1/TE1) [1],

[2] [1]
outboard guard (except TM1/TE1) [2], engine guard [3]
MO RIB

and skid plate [4] for cracks, damage or looseness.

Tighten any loose fasteners. Replace the guard or skid
plate as required.
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

[3] [4]

3-34
dummyhead

MAINTENANCE
CLUTCH SYSTEM (Except FA models)
Remove the tank cover assembly (page 2-4).
Loosen the lock nut [1] and turn the adjusting screw [2]

S. O
one full turn clockwise.
Slowly turn the adjusting screw counterclockwise until

L.
S AD
resistance is felt, then turn the adjusting screw 1/4 turn

R.
clockwise.

OR RIZ
Hold the adjusting screw and tighten the lock nut.
Start the engine and check for proper clutch operation.
Install the tank cover assembly (page 2-4).

OT TO
[2] [1]

LM U
SUSPENSION

RA O A
Loose, worn or Check the action of the front and rear shock absorbers
damaged by compressing them several times.
suspension parts Check the entire shock absorber assembly for signs of

AB N
impair vehicle leaks, damage or loose fasteners.
stability and control. Replace damaged components which cannot be

-C O
repaired.
Tighten all nuts and bolts.

L. US
Raise the rear wheel off the ground by supporting the
frame securely.
Check for worn swingarm bushings by grabbing the rear
S. N O
axle and attempting to move the swingarm side to side.
Replace the swingarm if any looseness is noted (page
18-9).
R.
RS IÓ

SPARK ARRESTER
TO UC

Remove the arrester bolt [1].

Block the end of the muffler with a shop towel.
Start the engine with the transmission in neutral, and
MO RIB

purge accumulated carbon from the muffler by

momentarily revving the engine several times.
Stop the engine and allow the exhaust system to cool.
AL ST

Install the bolt and tighten it securely.

BR DI
CA SU

[1]

NUTS, BOLTS, FASTENERS

24 O

Check that all chassis nuts and bolts are tightened to

-20 BID

their correct torque values (page 1-17).

Check that all cotter pins, safety clips, hose clamps and
cable stays are in place and properly secured.
-07 HI
28 O
PR

3-35
 dummyhead

MAINTENANCE
WHEELS/TIRES
Tire pressure Check the tire pressure with a tire pressure gauge.
should be checked
RECOMMENDED TIRE PRESSURE

S. O
when the tires are
cold. Standard: 30 kPa (0.30 kgf/cm2, 4.4 psi)
With cargo: 30 kPa (0.30 kgf/cm2, 4.4 psi)

L.
S AD
Check the tires for cuts, embedded nails, or other

R.
damage.

OR RIZ
Raise the wheel off the ground and check the bearings
in the knuckle for excessive play or abnormal noise.

OT TO
TIE-ROD AND JOINT BOOTS
Check the tie-rod ball joint nuts [1] and the suspension

LM U
[4] [1]
arm ball joint nuts [2] for looseness.

RA O A
Check the boots of the tie-rod ball joints [3] and
suspension arm ball joints [4] for tears or other damage.
Check for looseness of the tie-rod ball joints or

AB N
suspension arm ball joints by grabbing each front wheel
side to side with the wheels on the ground.

-C O
If any looseness is noted, inspect the following.
– tie-rod (page 17-32)

L. US
– suspension arm (page 17-20)

[2]
S. N O
[3]
R.
RS IÓ
TO UC
MO RIB
AL ST

STEERING SHAFT HOLDER BEARING

BR DI

Make sure the Raise the front wheels off the ground and support the
CA SU

cables do not vehicle securely.

interfere with the Check that the handlebar moves freely from side to
rotation of the side.
handlebar. If the handlebar moves unevenly, binds, or has
24 O

horizontal or vertical movement, inspect the steering

shaft holder bushing and bearing.
-20 BID

– Except FM2/FA2/FA6: page 17-24

– FM2/FA2/FA6: page 17-27
FM2/FA2/FA6 only: Place the vehicle on the ground.
-07 HI

Compare the required steering force with the engine

running and with the engine stopped.
28 O

If the steering force is same, check the EPS system

(page 25-2).
PR

3-36
dummyhead

MAINTENANCE
STEERING SYSTEM
Place the vehicle on level ground with the front wheels
facing straight ahead.

S. O
Mark the centers of the tires with chalk to indicate the
axle center height.

L.
S AD
Align the toe-gauge [1] with the marks on the tires as
shown.

R.
Check the readings on the gauge scales.

OR RIZ
OT TO
[1]

LM U
Slowly move the vehicle back until the wheels have

RA O A
Front
turned 180° so the marks on the tires are aligned with
the gauge height on the rear side.
Measure the toe on the rear part of the tires at the same
points with no load on the vehicle.

AB N
’14 – ’19:

-C O
Except FA5/FA6:
Toe-out: 15 ± 15 mm (9/16 ± 9/16 in)

L. US
FA5/FA6:
Toe-out: 13 ± 15 mm (1/2 ± 9/16 in)

After ’19:
S. N O
TM1/TE1:
Toe-out: 9 ± 15 mm (3/8 ± 9/16 in) Rear
FM1/FM2/FE1/FA2:
Toe-out: 7 ± 15 mm (1/4 ± 9/16 in)
R.
RS IÓ

FA5/FA6:
Front Toe-in: 1 ± 15 mm (1/16 ± 9/16 in)
TO UC

Rear Toe-in: 0 ± 15 mm (0 ± 9/16 in)

MO RIB

• Toe-in means the rear measurement is greater than

the front measurement.
• Toe-out means the front measurement is greater
than the rear measurement.
AL ST

When the toe is out of specification, adjust it by

[1]
changing the length of the tie-rods [1] equally by
loosening the lock nuts [2] and turning the tie-rods while
BR DI

holding the ball joints.

After adjusting each tie-rod, rotate both ball joints in the
CA SU

same direction, along the tie-rod axis until they stop

against the ball joint stud.
24 O
-20 BID

[2]
-07 HI
28 O
PR

3-37
 dummyhead

MAINTENANCE
Using a 22 mm wrench, hold the ball joint ends (flats)
[2] [1]
[1] so that the relative angle of both ball joints may turn
into specified angle. Then, tighten each lock nut [2],
making sure not to force the ball joint end against the

S. O
ball joint stud [3].

TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)

L.
S AD
After tightening the lock nuts, rotate the tie-rods to

R.
make sure the ball joints operate properly and have an

OR RIZ
equal range of movement.

OT TO
LM U
[2] [1] [3]

RA O A
Steering Side

AB N
-C O
L. US
16°30’
Knuckle Side
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

3-38
dummytext

4. PGM-FI SYSTEM

S. O
L.
S AD
R.
OR RIZ
4

OT TO
LM U
SERVICE INFORMATION························ 4-2 MIL CIRCUIT INSPECTION ··················· 4-36

RA O A
COMPONENT LOCATION ······················· 4-3 SENSOR UNIT (MAP/TP SENSOR)········· 4-39

AB N
SYSTEM DIAGRAM ······························· 4-4 ECT SENSOR ····································· 4-41

-C O
TROUBLESHOOTING INFORMATION ······ 4-9 BANK ANGLE SENSOR ······················· 4-41

L. US
SYMPTOM TROUBLESHOOTING ·········· 4-12
S. N O PCM/ECM··········································· 4-42

DTC INDEX········································· 4-13 O2 SENSOR ········································ 4-44

DTC TROUBLESHOOTING ··················· 4-16

R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-1
 dummyhead

PGM-FI SYSTEM
SERVICE INFORMATION
PGM-FI SYSTEM

GENERAL
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before

S. O
proceeding.
• Use a digital tester for PGM-FI system inspection.

L.
S AD
• The engine stop switch line is connected to the PCM/ECM via the fuel pump relay coil. Its signal permits the PCM/ECM to

R.
control the fuel pump, fuel injector and ignition coil.
• The following color codes are used throughout this section.

OR RIZ
Bl: Black Bu: Blue Gr: Gray Lg: Light green P: Pink V: Violet Y: Yellow
Br: Brown G: Green Lb: Light blue O: Orange R: Red W: White

OT TO
TOOLS

LM U
SCS Short Connector Pin Probe Male (2 pack)

RA O A
070PZ-ZY30100 07ZAJ-RDJA110

AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-2
dummyhead

PGM-FI SYSTEM
COMPONENT LOCATION
'14 – '19 models and after '19 TM/FM models

S. O
FA2 model shown: ENGINE STOP SWITCH
IGNITION SWITCH

L.
S AD
FUEL INJECTOR
BANK ANGLE SENSOR

R.
PCM/ECM
DLC

OR RIZ
O2 SENSOR

FUEL PUMP UNIT

FUSE BOX

OT TO
– MAIN FUSE 1 (30 A)
– MAIN FUSE 2 (10 A) RELAY BOX
– IGN FUSE (20 A) – MAIN POWER RELAY

LM U
– ACC FUSE (20 A) – FUEL PUMP RELAY
– DIODE

RA O A
ECT SENSOR

AB N
IACV

-C O
L. US
SENSOR UNIT (MAP/TP SENSORS)
S. N O
CKP SENSOR

VS SENSOR Except FA models: GEAR POSITION SWITCH

FA models: SHIFT DRUM POSITION SWITCH
R.
RS IÓ

IAT SENSOR

After '19 TE/FE/FA models

TO UC

FA6 model shown: IGNITION SWITCH

RELAY BOX ENGINE STOP SWITCH
MO RIB

– MAIN POWER RELAY BANK ANGLE SENSOR

– FUEL PUMP RELAY PCM
DLC
FUEL INJECTOR
AL ST

FUEL PUMP UNIT

IAT SENSOR
FUSE BOX
BR DI

– MAIN FUSE 1 (30 A)

– MAIN FUSE 2 (10 A)
CA SU

– IGN FUSE (20 A)

– ACC FUSE (20 A)
– DIODE
O2 SENSOR ECT SENSOR
24 O
-20 BID

BATTERY IACV
-07 HI

SENSOR UNIT
REAR VS SENSOR
(MAP/TP SENSORS)
28 O

CKP SENSOR
PR

TR SENSOR

4-3
 dummyhead

PGM-FI SYSTEM
SYSTEM DIAGRAM
'14 – '19 TM/FM/TE/FE models

S. O
TM1/FM1/FM2: FAN FUSE (20 A)
TE1/FE1: ES FUSE (30 A)

L.
S AD
R R/W

REGULATOR/

R.
MAIN POWER RECTIFIER
RELAY

OR RIZ
IGNITION SWITCH IGN FUSE (20A) R/Bl R R

R Bl Bl/R Bl/R V/W

BATTERY MAIN FUSE 1 (30 A)
R R/Bl R/Bl P W/Bl

OT TO
ACC FUSE (20A)

R/Bl R/Y R

MAIN FUSE 2 (10A) DIODE

LM U
O2 SENSOR
Bl/R
HEATER

RA O A
(23) G/O A11 O2HT MAIN B1 Bl/R
O2 SENSOR Y/R A10 O2
PRC B31 V/W
(21) G/W

FUEL PUMP RELAY

CKP Bu/Y B23 PCP

AB N
SENSOR G FLR B20 Gr/R Bl/W Bl/R

Bl/R ENGINE STOP

SWITCH
Bl/G B6 BA

-C O
G/W
BANK Br G
Br/W
ANGLE

L. US
SENSOR
(54) M
SENSOR UNIT FUEL PUMP

TP Br/W B3 VCC INJ B33 G/Bl Bl/R

S. N O
SENSOR Bu/Bl B14 TH
FUEL
(8) G/W G/W B2 SG
INJECTOR
(12)
MAP
SENSOR Lg B25 PB
IGN B11 G/Y Bl/R
(1)
R.
RS IÓ

IGNITION
IAT Gr B26 TA COIL
SENSOR G/W
TO UC

(9) PCM/ECM SPARK

G/W PLUG
Bl/Bu B27 TW
IACV-1A B8 Y
ECT IACV-1B B5 Y/G IACV
M
MO RIB

SENSOR IACV-2A B30 Y/Bu (29)

IACV-2B B9 Br/Y
(7)

WARN A21 Br/W Bl/R

AL ST

TM model MIL

IGN Bl/R
M-TXD/RXD A21 P UART
MIL GND G
Except
BR DI

TM model COMBINATION METER

W/Bl
CA SU

K - LINE B17 O/W

Gr A25 GP R
SCS B29 Br/R
R
N Lg/R A17 GP N G

1 W/G A24 GP 1 DLC SCS SERVICE CONNECTOR

2 W/R A27 GP 2 FAN C3 G/Bl G M Bu R/W

24 O

3 Bu A26 GP 3 COOLING FAN MOTOR

-20 BID

4 Y A2 GP 4 LG B13 G
5
Lb/W A13 GP 5 PG1 B21 G
SHIFT DRUM
POSITION SWITCH PG2 B10 G
(41) PG3 C5 G
-07 HI

PCM C-1 C-3

A-1 A-11 B-1 B-11
28 O

A-12 A-22 B-12 B-22

( ): MIL Blink
PR

: Engine does not start

when detecting DTC
: Short terminals for
reading DTC

C-4 C-5 A-23 A-33 B-23 B-33

4-4
dummyhead

PGM-FI SYSTEM
’14 – ’19 FA models

ES FUSE (30 A)

S. O
R R/W

L.
S AD
REGULATOR/
MAIN POWER RECTIFIER
RELAY

R.
IGNITION SWITCH IGN FUSE (20A) R/Bl R R

OR RIZ
R Bl Bl/R Bl/R V/W
BATTERY MAIN FUSE 1 (30 A)
R R/Bl R/Bl P W/Bl

ACC FUSE (20A)

OT TO
R/Bl R/Y R

MAIN FUSE 2 (10A) DIODE

O2 SENSOR
W Bl/R
HEATER

LM U
(23) W G/O A11 O2HT MAIN B1 Bl/R
O2 SENSOR Bl Y/R A10 O2

RA O A
PRC B31 V/W
(21) Gr G/W

FUEL PUMP RELAY

CKP Bu/Y B23 PCP
SENSOR G FLR B20 Gr/R Bl/W Bl/R

AB N
Bl/R ENGINE STOP
SWITCH
Bl/G B6 BA
G/W
BANK Br G

-C O
Br/W
ANGLE
SENSOR
(54) M

L. US
SENSOR UNIT FUEL PUMP

TP Br/W B3 VCC INJ B33 G/Bl Bl/R

SENSOR Bu/Bl B14 TH
FUEL
(8) G/W G/W B2 SG
S. N O
INJECTOR
(12)
MAP
SENSOR Lg B25 PB
IGN B11 G/Y Bl/R
(1)
R.
IGNITION
RS IÓ

IAT Gr B26 TA COIL

SENSOR G/W
(9) PCM SPARK
PLUG
TO UC

G/W
Bl/Bu B27 TW

ECT IACV-1A B8 Y
SENSOR IACV-1B B5 Y/G IACV
M
MO RIB

IACV-2A B30 Y/Bu (29)

(7)
IACV-2B B9 Br/Y

Bl/W Bl/R A5 SEN VB1

P P/G B16 RR VSP MIL
IGN Bl/R
AL ST

REAR VS M-TXD/RXD A21 P UART

G
SENSOR GND G
(66)
COMBINATION METER
BR DI

Bl/R
Bl/Y B15 FR VSP

FRONT VS W/Bl
G
SENSOR K - LINE B17 O/W
CA SU

SCS B29 Br/R

(67)
G
Gr A25 DP 5R DLC SCS SERVICE CONNECTOR
Lg/R A17 DP N
5R N
12 W/G A27 DP 12 FAN C3 G/Bl G M Bu R/W
24 O

N2 Bu/Bl A1 DP N2
32 Y A26 DP 32 COOLING FAN MOTOR
3N Bu/R A29 DP 3N LG B13 G
-20 BID

34 Bu/W A2 DP34
PG1 B21 G
N4 Bu/G A24 DP N4
5N 54 Bu A13 DP 54 PG2 B10 G
W/Bu Lb A12 DP 5N
SHIFT DRUM PG3 C5 G
POSITION SWITCH
-07 HI

(41)
PCM C-1 C-3
A-1 A-11 B-1 B-11
A-12 A-22 B-12 B-22
28 O

( ): MIL Blink
PR

: Engine does not start

when detecting DTC
: Short terminals for
reading DTC

C-4 C-5 A-23 A-33 B-23 B-33

4-5
 dummyhead

PGM-FI SYSTEM
After ’19 TM/FM models
FAN FUSE (20 A)
Bl R R/Bl R/Bl R/W

S. O
REGULATOR/
R/Bl MAIN POWER RECTIFIER

L.
S AD
RELAY
BATTERY IGNITION SWITCH IGN FUSE (20A) R/Bl R R

R.
R Bl Bl/R Bl/R V/W
MAIN FUSE 1 (30 A)

OR RIZ
R R/Bl R/Bl P W/Bl

ACC FUSE (20A)

R/Bl R/Y R

OT TO
MAIN FUSE 2 (10A) DIODE
W Bl/R
O2 SENSOR
HEATER W G/O A11 O2HT MAIN B1 Bl/R

LM U
Bl Y/R A10 O2
O2 SENSOR
PRC B31 V/W
Gr G/W

RA O A
FUEL PUMP RELAY

FLR B20 Gr/R Bl/W Bl/R

Br Bl/R ENGINE STOP

M SWITCH

AB N
G
FUEL PUMP
BANK Bl/G B6 BA

-C O
ANGLE G/W Bl/R
SENSOR Br/W
FUEL
INJ B33 G/Bl

L. US
INJECTOR
SENSOR UNIT
Br/W B3 VCC
TP
Bu/Bl B14 TH IG B11 G/Y Bl/R
SENSOR
G/W G/W B2 SG
IGNITION
S. N O
COIL
MAP
Lg B25 PB
SENSOR SPARK
PLUG

IAT Gr B26 TA
AC type only
R.
RS IÓ

SENSOR G/W PCS B32 O/Bl Bl/R

EVAP PURGE CONTROL

SOLENOID VALVE
ECT Bl/Bu B27 TW
TO UC

SENSOR G/W
ECM
TM model
WARN A21 Br/W Bl/R
MO RIB

MIL
Bu/Y B23 PCP
FM model
G IGN Bl/R
M-TXDRXD A21 P UART
GND G
CKP MIL
SENSOR
AL ST

COMBINATION METER
FM model
Bl/W Bl/R A5 SEN VB IACV 1A B8 Y
P P/G B16 RR VSP IACV 1B B5 Y/G
G IACV 2A B30 Y/Bu M IACV
BR DI

IACV 2B B9 Br/Y
VS SENSOR
CA SU

W/Bl
K - LINE B17 O/W
Gr A25 GP R SCS B29 Br/R
R G DLC
N Lg/R A17 DP N

1 W/G A24 GP 1
24 O

2 W/R A27 GP 2
FAN C3 G/Bl G M Bu R/W

COOLING FAN MOTOR

-20 BID

3 Bu A26 GP 3 LG B13 G
PG1 B21 G
4 Y A2 GP 4
5 PG2 B10 G
Lb/W A13 GP 5 PG3 C5 G
GEAR POSITION
SWITCH
-07 HI
28 O

Bl .... Black O .... Orange

1 2 3 Br .... Brown P .... Pink
PR

Bu .... Blue R .... Red

4 5 G .... Green V .... Violet
Gr .... Gray W .... White
Lg .... Light green Y .... Yellow

ECM 5P (Black) ECM 33P (Black) CONNECTOR A ECM 33P (Gray) CONNECTOR B
CONNECTOR C (ECM SIDE) (ECM SIDE)
(ECM side)

4-6
dummyhead

PGM-FI SYSTEM
After ’19 TE/FE models
ES FUSE (30 A)
Bl R R R/W

S. O
REGULATOR/
MAIN POWER RECTIFIER

L.
S AD
RELAY
BATTERY IGNITION SWITCH IGN FUSE (20A) R/Bl R R

R.
R Bl Bl/R Bl/R V/W
MAIN FUSE 1 (30 A)

OR RIZ
R R/Bl R/Bl P W/Bl

ACC FUSE (20A)

R/Bl R/Y R

OT TO
MAIN FUSE 2 (10A) DIODE
W Bl/R
O2 SENSOR
HEATER W G/O A11 O2HT MAIN B1 Bl/R

LM U
Bl Y/R A10 O2
O2 SENSOR
PRC B31 V/W
G/W

RA O A
FUEL PUMP RELAY

Bu A26 DRUM POS FLR B20 Gr/R Bl/W Bl/R

TR G/W
SENSOR Br Bl/R ENGINE STOP
Br Br/W
M SWITCH

AB N
G
FUEL PUMP
BANK Bl/G B6 BA

-C O
ANGLE G/W Bl/R
SENSOR Br/W
FUEL
INJ B33 G/Bl

L. US
INJECTOR
SENSOR UNIT
Br/W B3 VCC
TP
Bu/Bl B14 TH IG B11 G/Y Bl/R
SENSOR
G/W G/W B2 SG
IGNITION
S. N O
COIL
MAP
Lg B25 PB
SENSOR SPARK
PLUG

IAT Gr B26 TA
R.
RS IÓ

SENSOR G/W AC type only

PCS B32 O/Bl Bl/R

EVAP PURGE CONTROL

ECT Bl/Bu B27 TW SOLENOID VALVE
TO UC

SENSOR G/W

PCM
MIL IGN Bl/R
MO RIB

M-TXD A21 P UART

Bu/Y B23 PCP GND G
G

CKP COMBINATION
SENSOR METER
AL ST

Bl/R Bl/R A5 SEN VB IACV 1A B8 Y

W P/G B16 RR VSP IACV 1B B5 Y/G
G IACV 2A B30 Y/Bu M IACV
BR DI

IACV 2B B9 Br/Y
VS SENSOR
CA SU

W/Bl
K - LINE B17 O/W
SCS B29 Br/R
G DLC
24 O

FAN C3 G/Bl G M Bu R/W

COOLING FAN MOTOR

-20 BID

Lg Lg A17 DP N LG B13 G
PG1 B21 G
NEUTRAL
PG2 B10 G
SWITCH
PG3 C5 G
-07 HI
28 O

Bl .... Black O .... Orange

1 2 3 Br .... Brown P .... Pink
PR

Bu .... Blue R .... Red

4 5 G .... Green V .... Violet
Gr .... Gray W .... White
Lg .... Light green Y .... Yellow

PCM 5P (Black) PCM 33P (Black) CONNECTOR A PCM 33P (Gray) CONNECTOR B
CONNECTOR C (PCM SIDE) (PCM SIDE)
(PCM side)

4-7
 dummyhead

PGM-FI SYSTEM
After ’19 FA models
ES FUSE (30 A)
Bl R R R/W

S. O
REGULATOR/
MAIN POWER RECTIFIER

L.
S AD
RELAY
BATTERY IGNITION SWITCH IGN FUSE (20A) R/Bl R R

R.
R Bl Bl/R Bl/R V/W
MAIN FUSE 1 (30 A)

OR RIZ
R R/Bl R/Bl P W/Bl

ACC FUSE (20A)

R/Bl R/Y R

OT TO
MAIN FUSE 2 (10A) DIODE
W Bl/R
O2 SENSOR
HEATER W G/O A11 O2HT MAIN B1 Bl/R

LM U
Bl Y/R A10 O2
O2 SENSOR
PRC B31 V/W
Gr G/W

RA O A
FUEL PUMP RELAY

Bu A26 DP FLR B20 Gr/R Bl/W Bl/R

TR G/W
SENSOR Br Bl/R ENGINE STOP
Br/W
Br
M SWITCH

AB N
G
FUEL PUMP
BANK Bl/G B6 BA

-C O
ANGLE G/W Bl/R
SENSOR Br/W
FUEL
INJ B33 G/Bl

L. US
INJECTOR
SENSOR UNIT
Br/W B3 VCC
TP
Bu/Bl B14 TH IG B11 G/Y Bl/R
SENSOR
G/W G/W B2 SG
IGNITION
S. N O
COIL
MAP
Lg B25 PB
SENSOR SPARK
PLUG

IAT Gr B26 TA
R.
RS IÓ

SENSOR G/W AC type only

PCS B32 O/Bl Bl/R

EVAP PURGE CONTROL

ECT Bl/Bu B27 TW SOLENOID VALVE
TO UC

SENSOR G/W

PCM
MIL IGN Bl/R
MO RIB

M-TXD A21 P UART

Bu/Y B23 PCP GND G
G

CKP COMBINATION
SENSOR METER
AL ST

W/G Bl/R Bl/R A5 SEN VB IACV 1A B8 Y

P P/G B16 RR VSP IACV 1B B5 Y/G
G IACV 2A B30 Y/Bu M IACV
BR DI

REAR VS IACV 2B B9 Br/Y

SENSOR
CA SU

Bl/R W/Bl
Bl/Y B15 FR VSP K - LINE B17 O/W
G SCS B29 Br/R
FRONT VS G DLC
SENSOR
24 O

FAN C3 G/Bl G M Bu R/W

COOLING FAN MOTOR

-20 BID

Lg Lg A17 DP N LG B13 G
PG1 B21 G
NEUTRAL
PG2 B10 G
SWITCH
PG3 C5 G
-07 HI
28 O

Bl .... Black O .... Orange

1 2 3 Br .... Brown P .... Pink
PR

Bu .... Blue R .... Red

4 5 G .... Green V .... Violet
Gr .... Gray W .... White
Lg .... Light green Y .... Yellow

PCM 5P (Black) PCM 33P (Black) CONNECTOR A PCM 33P (Gray) CONNECTOR B
CONNECTOR C (PCM SIDE) (PCM SIDE)
(PCM side)

4-8
dummyhead

PGM-FI SYSTEM
TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure

S. O
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check

L.
S AD
for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out,
the original problem may be intermittent.

R.
Opens and Shorts

OR RIZ
"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With PCM/
ECMs this can mean something may work, but not the way it’s supposed to.

OT TO
If the MIL has come on
Refer to DTC READOUT (page 4-10).

LM U
If the MIL did not stay on

RA O A
If the MIL did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 4-12).

SYSTEM DESCRIPTION

AB N
SELF-DIAGNOSIS SYSTEM
The PGM-FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system, the PCM/ECM turns

-C O
on the MIL and stores a DTC in its erasable memory.

L. US
FAIL-SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system. When any abnormality is detected by the self-diagnosis function, running capability is maintained by pre-programmed
values in the simulated program map. When any abnormality is detected in the fuel injector and/or CKP sensor, the fail-safe
S. N O
function stops the engine to protect it from damage.
MIL Blink Pattern
• If the MCS is not available, DTC can be read from the PCM/ECM
[1]
R.
RS IÓ

memory by blink pattern of the MIL [1].

• The number of MIL blinks is equivalent to the main code of the DTC (the
sub code cannot be displayed by the MIL).
TO UC

• The MIL will blink the current DTC, in case the PCM/ECM detects the
problem at present, when the ignition switch ON or idling. The MIL will
stay ON when driving.
MO RIB

• The MIL has two types of blinks, a long blink and short blink. The long
blinking lasts for 1.3 seconds, the short blinking lasts for 0.5 seconds.
One long blink is the equivalent of ten short blinks. For example, when
two long blinks are followed by five short blinks, the MIL is 25 (two long
AL ST

blinks = 20 blinks, plus five short blinks).

• When the PCM/ECM stores more than one DTC, the MIL will indicate
them by blinking in the order from the lowest number to highest number.
BR DI

MIL Check
When the ignition switch is turned ON, the MIL will stay on for a few seconds, then go off. If the MIL does not come on, troubleshoot
CA SU

the MIL circuit (page 4-36).

CURRENT DTC/FREEZE DTC
The DTC is indicated in two ways according to the failure status.
24 O

• In the case that the PCM/ECM detects a problem at present, the MIL will come on and will start to blink as its DTC. It is possible
to readout the MIL blink pattern as the current DTC.
-20 BID

• In the case that the PCM/ECM does not detect any problem at present but has a problem stored in its memory, the MIL will not
light and blink. To retrieve the past problem code, readout the freeze DTC by following the DTC readout procedure.
-07 HI
28 O
PR

4-9
 dummyhead

PGM-FI SYSTEM
MCS INFORMATION
• The MCS can readout the DTC, freeze data, current data and other PCM/ECM condition.
How to connect the MCS

S. O
Remove the radiator cap lid (page 2-3).
[2]

L.
S AD
Turn the ignition switch OFF.
Remove the dummy connector [1] from the DLC [2].

R.
Connect the MCS to the DLC.

OR RIZ
Turn the ignition switch ON, and check the DTC and freeze data.

• Freeze data indicates the engine conditions when the first malfunction

OT TO
was detected.

LM U
RA O A
[1]

DTC READOUT
Start the engine and check the MIL [1].

AB N
• When the ignition switch is turned ON, the MIL will stay on for a few [1]
seconds, then go off.

-C O
If the MIL stays on or blinks, connect the MCS to the DLC (page 4-10), read

L. US
the DTC, freeze data and follow the troubleshooting index (page 4-13).
To read the DTC with the MIL blinking, refer to the following procedure.
S. N O
R.
RS IÓ
TO UC

Reading DTC with the MIL

Remove the dummy connector (page 4-10).
MO RIB

Turn the ignition switch OFF.

Short DLC terminals using the special tool.
Connection: Brown/red – Green
AL ST

TOOL:
SCS Short Connector [1] 070PZ-ZY30100
BR DI

Turn the ignition switch ON, read, note the MIL blinks and refer to the
troubleshooting index (page 4-13).
CA SU

If the PCM/ECM has any DTC in its memory, the MIL will start blinking.
[1]
24 O

ERASING DTC
-20 BID

• When erasing the PGM-FI DTC, the DCT DTC or ESP DTC would also be erased at the same time. Check the gear position
indicator blinks and troubleshoot the DCT or ESP system before erasing the PGM-FI DTC.
-07 HI

Connect the MCS to the DLC (page 4-10).

28 O

Erase the DTC with the MCS while the engine is stopped.
PR

To erase the DTC without MCS, refer to the following procedure.

4-10
dummyhead

PGM-FI SYSTEM
How to erase the DTC with SCS service connector
1. Turn the ignition switch OFF.
2. Remove the dummy connector (page 4-10).

S. O
3. Short DLC terminals using the special tool.

L.
S AD
TOOL:
SCS Short Connector [1] 070PZ-ZY30100

R.
OR RIZ
Connection: Brown/red – Green
4. Turn the ignition switch ON.
5. Remove the special tool from the DLC.

OT TO
6. The MIL will light for approximately 5 seconds. While the MIL lights,
short the DLC terminals again with the special tool. The self-diagnostic
memory is erased if the MIL goes off and starts blinking.

LM U
RA O A
[1]
• The DLC must be jumped while the MIL is illuminated. If not, the MIL will
not start blinking.
• Note that the self-diagnostic memory cannot be erased if the ignition switch is turned OFF before the MIL starts blinking.

AB N
CIRCUIT INSPECTION

-C O
INSPECTION AT PCM/ECM CONNECTOR

L. US
• Always clean around and keep any foreign material away from the PCM/
[1]
ECM connector before disconnecting it.
• A faulty PGM-FI system is often related to poorly connected or corroded
connections. Check those connections before proceeding.
S. N O
• In testing at PCM/ECM connector (wire harness side) terminal, always
use the test probe. Insert the test probe into the connector terminal, then
attach the digital multimeter probe to the test probe.
R.
RS IÓ

TOOL:
Pin Probe Male (2 pack) [1] 07ZAJ-RDJA110
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-11
 dummyhead

PGM-FI SYSTEM
SYMPTOM TROUBLESHOOTING
When the vehicle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 4-13) and begin the
appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the PCM/ECM memory, do the diagnostic

S. O
procedure for the symptom, in sequence listed below, until you find cause.
Symptom Diagnosis procedure Also check for

L.
S AD
Engine cranks, but won’t start 1. Inspect the spark plug condition (page 3-12). • No fuel to fuel injector

R.
(No DTC and MIL blinking) 2. Inspect the ignition system (page 5-5). – Clogged fuel strainer screen
3. Inspect the cylinder compression – Pinched or clogged fuel hose

OR RIZ
(page 10-6). – Pinched or clogged fuel pump
4. Inspect the fuel supply system (page 7-12). breather hose
5. Check the IACV (page 7-21). – Faulty fuel pump
– Faulty fuel pump circuits

OT TO
• Intake air leak
• Contaminated/deteriorated fuel
• Faulty fuel injector

LM U
Engine cranks, but won’t start 1. PCM/ECM power/ground circuits • Faulty bank angle sensor or

RA O A
(No fuel pump operation sound malfunction (page 4-42) related circuit
when turning the ignition 2. Inspect the fuel supply system (page 7-12). • Faulty fuel pump relay or related
switch ON and engine stop circuit
switch " ")

AB N
Engine stalls, hard to start, 1. Check the IACV (page 7-21). • Restricted fuel hose
rough idling 2. Inspect the fuel pressure (page 7-10). • Contaminated/deteriorated fuel
3. Inspect the fuel flow (page 7-11). • Intake air leak

-C O
4. Inspect the ignition system (page 5-5). • Restricted fuel pump breather
5. Inspect the cylinder compression hose

L. US
(page 10-6).
Afterburn when engine braking Inspect the ignition system (page 5-5).
is used
S. N O
Backfiring or misfiring during Inspect the ignition system (page 5-5).
acceleration
Poor performance (driveability) 1. Inspect the fuel pressure (page 7-10). • Pinched or clogged fuel hose
and poor fuel economy 2. Inspect the fuel flow (page 7-11). • Faulty pressure regulator
R.
RS IÓ

3. Inspect the air cleaner element (page 3-9). • Faulty fuel injector
4. Inspect the ignition system (page 5-5).
Idle speed is below 1. Check the IACV (page 7-21).
TO UC

specifications or fast idle too 2. Inspect the fuel pressure (page 7-10).
low 3. Inspect the fuel flow (page 7-11).
(No DTC and MIL blinking) 4. Inspect the ignition system (page 5-5).
MO RIB

Idle speed is above 1. Check the throttle operation and freeplay • Intake air leak
specifications or fast idle too (page 3-8). • Engine top end problem
high 2. Check the IACV (page 7-21)
(No DTC and MIL blinking) 3. Inspect the ignition system (page 5-5).
AL ST

4. Inspect the air cleaner element (page 3-9).

MIL never comes ON at all Inspect the MIL circuit (page 4-36).
MIL stays ON at all Inspect the MIL circuit (page 4-36).
BR DI

(No DTC set)

CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-12
dummyhead

PGM-FI SYSTEM
DTC INDEX
'14 – '19 models

S. O
DTC
Refer
(MIL Function Failure Symptom/Fail-safe function
to

L.
S AD
blinks)
MAP sensor circuit low voltage • Engine operates normally

R.
1-1 (1) 4-16
• MAP sensor or its circuit malfunction • Pre-program value: 64 kPa

OR RIZ
MAP sensor circuit high voltage • Engine operates normally
1-2 (1) • Loose or poor contact of the MAP sensor connector • Pre-program value: 64 kPa 4-18
• MAP sensor or its circuit malfunction
ECT sensor circuit low voltage • Hard to start at a low

OT TO
• ECT sensor or its circuit malfunction temperature
7-1 (7) • Pre-program value: 78.6°C/ 4-19
173.5°F

LM U
• Cooling fan turns on
ECT sensor circuit high voltage • Hard to start at a low

RA O A
• Loose or poor contact of the ECT sensor connector temperature
7-2 (7) • ECT sensor or its circuit malfunction • Pre-program value: 78.6°C/ 4-20
173.5°F
• Cooling fan turns on

AB N
TP sensor circuit low voltage • Poor engine acceleration
8-1 (8) • Loose or poor contact of the TP sensor connector • Pre-program value: 0° 4-21

-C O
• TP sensor or its circuit malfunction
TP sensor circuit high voltage • Poor engine acceleration

L. US
8-2 (8) 4-23
• TP sensor or its circuit malfunction • Pre-program value: 0°
IAT sensor circuit low voltage • Engine operates normally
9-1 (9)
• IAT sensor or its circuit malfunction • Pre-program value: 34.8°C/ 4-24
94.6°F
S. N O
IAT sensor circuit high voltage • Engine operates normally
9-2 (9) • Loose or poor contact of the IAT sensor connector • Pre-program value: 34.8°C/ 4-25
• IAT sensor or its circuit malfunction 94.6°F
11-1 (11) VS sensor no signal • Engine operates normally
R.
RS IÓ

(Except • Loose or poor contact of the VS sensor connector • ESP does not work (TE1/FE1
TM1/FA1/ • VS sensor or its circuit malfunction only) 24-12
TO UC

FA2/FA5/
FA6)
Fuel Injector circuit malfunction • Engine does not start
12-1 (12) • Loose or poor contact of the fuel injector connector • Fuel Injector, fuel pump and 4-26
MO RIB

• Fuel Injector or its circuit malfunction ignition shut down

O2 sensor malfunction • Engine operates normally
21-1 (21) • Loose or poor contact of the O2 sensor connector 4-28
AL ST

• O2 sensor or its circuit malfunction

O2 sensor heater circuit malfunction • Engine operates normally
23-1 (23) • Loose or poor contact of the O2 sensor connector 4-30
BR DI

• O2 sensor heater or its circuit malfunction

IACV circuit malfunction • Engine stalls, hard to start, rough
29-1 (29) • Loose or poor contact of the IACV connector idling 4-31
CA SU

• IACV or its circuit malfunction

41-1 (41) Gear position switch malfunction • Engine operates normally
(Except • Loose or poor contact of the gear position switch • ESP does not work
24-21
FA connector • Gear position indicator blinks "–"
24 O

models) • Gear position switch or its circuit malfunction

41-1 (41) Shift drum position switch malfunction • Engine operates normally
-20 BID

(FA • Loose or poor contact of the shift drum position switch • Gearshift function does not work
13-43
models connector (2nd, 4th or reverse gear only)
only) • Shift drum position switch or its circuit malfunction • Gear position indicator blinks "–"
EOT sensor circuit low voltage • Engine operates normally
-07 HI

44-1 (44)
• EOT sensor or its circuit malfunction • Gearshift function does not work
(FA
(2nd, 4th or reverse gear only) 13-45
28 O

models
• Gear position indicator blinks "–"
only)
• Cooling fan turns on
PR

EOT sensor circuit high voltage • Engine operates normally

44-2 (44)
• Loose or poor contact of the EOT sensor connector • Gearshift function does not work
(FA
• EOT sensor or its circuit malfunction (2nd, 4th or reverse gear only) 13-46
models
• Gear position indicator blinks "–"
only)
• Cooling fan turns on

4-13
 dummyhead

PGM-FI SYSTEM
DTC
Refer
(MIL Function Failure Symptom/Fail-safe function
to
blinks)
Bank angle sensor circuit low voltage • Engine operates normally

S. O
• Loose or poor contact of the bank angle sensor • Bank angle sensor control stops
54-1 (54) 4-33
connector

L.
S AD
• Bank angle sensor or its circuit malfunction
Bank angle sensor circuit high voltage • Engine operates normally

R.
54-2 (54) 4-34
• Bank angle sensor or its circuit malfunction • Bank angle sensor control stops

OR RIZ
66-1 (66) Rear VS sensor no signal • Engine operates normally
(FA • Loose or poor contact of the rear VS sensor connector • Gearshift function does not work
13-51
models • Rear VS sensor or its circuit malfunction (2nd, 4th or reverse gear only)
only)

OT TO
67-1 (67) Front VS sensor no signal • Engine operates normally
(FA • Loose or poor contact of the front VS sensor connector • Gearshift function does not work
13-52
models • Front VS sensor or its circuit malfunction (2nd, 4th or reverse gear only)

LM U
only)

RA O A
AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-14
dummyhead

PGM-FI SYSTEM
After ’19 model
• If the MCS is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the DTC.
Refer
DTC Function Failure Symptom/Fail-safe function

S. O
to
MAP sensor circuit low voltage (less than 0.195 V) • Engine operates normally

L.
S AD
1-1 4-16
• MAP sensor or its circuit malfunction
MAP sensor circuit high voltage (more than 3.804 V) • Engine operates normally

R.
1-2 • Loose or poor contact of the MAP sensor connector 4-18

OR RIZ
• MAP sensor or its circuit malfunction
ECT sensor circuit low voltage (less than 0.078 V) • Hard to start at a low
7-1 • ECT sensor or its circuit malfunction temperature 4-19
• Cooling fan turns on

OT TO
ECT sensor circuit high voltage (more than 4.922 V) • Hard to start at a low
7-2 • Loose or poor contact of the ECT sensor connector temperature 4-20
• ECT sensor or its circuit malfunction • Cooling fan turns on

LM U
TP sensor circuit low voltage (less than 0.225 V) • Poor engine acceleration
8-1 • Loose or poor contact of the TP sensor connector 4-21

RA O A
• TP sensor or its circuit malfunction
TP sensor circuit high voltage (more than 4.922 V) • Poor engine acceleration
8-2 4-23
• TP sensor or its circuit malfunction

AB N
IAT sensor circuit low voltage (less than 0.078 V) • Engine operates normally
9-1 4-24
• IAT sensor or its circuit malfunction
IAT sensor circuit high voltage (more than 4.922 V) • Engine operates normally

-C O
9-2 • Loose or poor contact of the IAT sensor connector 4-25
• IAT sensor or its circuit malfunction

L. US
11-1 VS sensor no signal • Engine operates normally
(Except • Loose or poor contact of the VS sensor connector
24-12
TM/FA • VS sensor or its circuit malfunction
S. N O
models)
Fuel Injector circuit malfunction • Engine does not start
12-1 • Loose or poor contact of the fuel injector connector • Fuel Injector, fuel pump and 4-26
• Fuel Injector or its circuit malfunction ignition shut down
R.
RS IÓ

O2 sensor malfunction • Engine operates normally

21-1 • Loose or poor contact of the O2 sensor connector 4-28
• O2 sensor or its circuit malfunction
TO UC

O2 sensor heater circuit malfunction • Engine operates normally

23-1 • Loose or poor contact of the O2 sensor connector 4-30
• O2 sensor heater or its circuit malfunction
MO RIB

IACV circuit malfunction • Engine stalls, hard to start, rough

29-1 • Loose or poor contact of the IACV connector idling 4-31
• IACV or its circuit malfunction
PCM/ECM EEPROM malfunction • Rough idling
AL ST

33-2* • Does not hold the self-diagnosis 4-33

data
41-1 Gear position switch malfunction • Engine operates normally
BR DI

(TM/FM • Loose or poor contact of the gear position switch • Gear position indicator blinks "–"
24-21
models connector
only) • Gear position switch or its circuit malfunction
CA SU

Bank angle sensor circuit low voltage (less than 0.352 V) • Engine operates normally
• Loose or poor contact of the bank angle sensor • Bank angle sensor control stops
54-1 4-33
connector
• Bank angle sensor or its circuit malfunction
24 O

Bank angle sensor circuit high voltage (more than 4.531 V) • Engine operates normally
54-2 4-34
-20 BID

• Bank angle sensor or its circuit malfunction • Bank angle sensor control stops
66-1 Rear VS sensor no signal • Engine operates normally
(FA • Loose or poor contact of the rear VS sensor connector • Gearshift function does not work
13-51
models • Rear VS sensor or its circuit malfunction
-07 HI

only)
67-1 Front VS sensor no signal • Engine operates normally
28 O

(FA • Loose or poor contact of the front VS sensor connector • Gearshift function does not work
13-52
models • Front VS sensor or its circuit malfunction
PR

only)

* DTC can be readout/erased only by MCS.

4-15
 dummyhead

PGM-FI SYSTEM
DTC TROUBLESHOOTING
DTC 1 (MAP SENSOR)
• Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and

S. O
PCM/ECM 33P connectors, and recheck the DTC.

L.
S AD
R.
5V

OR RIZ
MAP SENSOR 5V

Br/W PCM/ECM

OT TO
Lg

LM U
G/W

RA O A
AB N
Probable cause
• Open circuit in Brown/white wire between the MAP
sensor and PCM/ECM

-C O
• Open or short circuit in Light green wire between the
MAP sensor and PCM/ECM

L. US
• Open circuit in Green/white wire between the MAP
sensor and PCM/ECM
• Faulty sensor unit (MAP sensor)
• Faulty ECM
S. N O
DTC 1-1 (MAP SENSOR LOW VOLTAGE)
1. MAP Sensor System Inspection
R.
RS IÓ

Turn the ignition switch ON.

Check the MAP sensor with the MCS.
TO UC

Is about 0 V indicated?
YES – GO TO STEP 2.
NO – Intermittent failure.
MO RIB

2. MAP Sensor Input Voltage Inspection

Turn the ignition switch OFF.
[1]
Disconnect the sensor unit 5P (Black) connector
AL ST

(page 4-39).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 5P
BR DI

connector [1] terminals.

Connection: Brown/white (+) – Green/white (–)
CA SU

Is the voltage within 4.75 – 5.25 V?

YES – GO TO STEP 4.
Br/W G/W
NO – GO TO STEP 3.
24 O
-20 BID
-07 HI
28 O
PR

4-16
dummyhead

PGM-FI SYSTEM
3. MAP Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) connector Br/W
(page 4-42). B3

S. O
Check for continuity between the wire harness side
33P (Gray) connector [1] and 5P (Black) connector

L.
S AD
[2] terminals.

R.
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

OR RIZ
Connection: B3 – Brown/white
Is there continuity?

OT TO
YES – Replace the PCM/ECM with a known good
one (page 4-43), and recheck. [1] [2]

LM U
NO – Open circuit in the Brown/white wire

RA O A
4. MAP Sensor Output Line Short Circuit
Inspection
Turn the ignition switch OFF.
[1]
Check for continuity between the wire harness side

AB N
5P (Black) connector [1] terminal and ground.
Connection: Light green – ground

-C O
Is there continuity?

L. US
YES – Short circuit in the Light green wire
NO – GO TO STEP 5.
S. N O
Lg
R.
RS IÓ

5. MAP Sensor Inspection

TO UC

Replace the sensor unit with a known good one.

Erase the DTC (page 4-10).
Turn the ignition switch OFF and ON.
MO RIB

Check the MAP sensor with the MCS.

Is DTC 1-1 indicated?
YES – Replace the PCM/ECM with a known good
AL ST

one (page 4-43), and recheck.

NO – Faulty original sensor unit (MAP sensor)
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-17
 dummyhead

PGM-FI SYSTEM
DTC 1-2 (MAP SENSOR HIGH VOLTAGE)
1. MAP Sensor System Inspection
Turn the ignition switch ON.
Check the MAP sensor with the MCS.

S. O
Is about 5 V indicated?

L.
S AD
YES – GO TO STEP 2.

R.
NO – • Intermittent failure

OR RIZ
• Loose or poorly connected sensor unit
5P connector.
2. MAP Sensor Inspection

OT TO
Turn the ignition switch OFF.
[1]
Disconnect the sensor unit 5P (Black) connector
(page 4-39).

LM U
Connect the wire harness side 5P (Black) connector
[1] terminals with a jumper wire [2].

RA O A
Connection: Light green – Green/white
Turn the ignition switch ON.
Check the MAP sensor with the MCS.

AB N
Is about 0 V indicated?

-C O
YES – Faulty sensor unit (MAP sensor) Lg
G/W
NO – GO TO STEP 3.

L. US
[2]

3. MAP Sensor Input Voltage Inspection

S. N O
Turn the ignition switch OFF.
[1]
Remove the jumper wire.
Turn the ignition switch ON.
Measure the voltage between the wire harness side
R.
RS IÓ

5P connector [1] terminals.

Connection: Brown/white (+) – Green/white (–)
TO UC

Is the voltage within 4.75 – 5.25 V?

YES – GO TO STEP 4.
MO RIB

NO – Open circuit in the Green/white wire Br/W G/W

AL ST

4. MAP Sensor Output Line Open Circuit

Inspection
BR DI

Turn the ignition switch OFF.

[1] [2]
Disconnect the PCM/ECM 33P (Gray) connector
CA SU

(page 4-42).
Check for continuity between the wire harness side
33P (Gray) connector [1] and 5P (Black) connector
[2] terminals.
24 O

TOOL:
-20 BID

Pin Probe Male (2 pack) 07ZAJ-RDJA110

Connection: B25 – Light green

Is there continuity?
-07 HI

B25 Lg
YES – Replace the PCM/ECM with a known good
one (page 4-43), and recheck.
28 O

NO – Open circuit in the Light green wire

PR

4-18
dummyhead

PGM-FI SYSTEM
DTC 7 (ECT SENSOR)
• Before starting the inspection, check for loose or poor contact on the ECT sensor 2P (Black) connector and
PCM/ECM 33P connectors, and recheck the DTC.

S. O
L.
S AD
5V

R.
ECT SENSOR

OR RIZ
PCM/ECM
Bl/Bu

OT TO
G/W

LM U
RA O A
Probable cause
• Open or short circuit in Black/blue wire between the

AB N
ECT sensor and PCM/ECM
• Open circuit in Green/white wire between the ECT
sensor and PCM/ECM

-C O
• Faulty ECT sensor
• Faulty PCM/ECM

L. US
DTC 7-1 (ECT SENSOR LOW VOLTAGE)
1. ECT Sensor System Inspection
S. N O
Turn the ignition switch ON.
Check the ECT sensor with the MCS.
Is about 0 V indicated?
R.
RS IÓ

YES – GO TO STEP 2.
NO – Intermittent failure
TO UC

2. ECT Sensor Inspection

Turn the ignition switch OFF.
Disconnect the ECT sensor 2P (Black) connector
MO RIB

(page 4-41).
Turn the ignition switch ON.
Check the ECT sensor with the MCS.
AL ST

Is about 0 V indicated?
YES – GO TO STEP 3.
BR DI

NO – Faulty ECT sensor

3. ECT Sensor Short Circuit Inspection
CA SU

Disconnect the PCM/ECM 33P (Gray) connector

[1]
(page 4-42).
Check for continuity between the wire harness side
ECT sensor 2P black [1] connector terminal and
24 O

ground.
Connection: Black/blue – ground
-20 BID

Is there continuity?
YES – Short circuit in the Black/blue wire
-07 HI

NO – Replace the PCM/ECM with a known good

one (page 4-43), and recheck.
Bl/Bu
28 O
PR

4-19
 dummyhead

PGM-FI SYSTEM
DTC 7-2 (ECT SENSOR HIGH VOLTAGE)
1. ECT Sensor System Inspection
Turn the ignition switch ON.
Check the ECT sensor with the MCS.

S. O
Is about 5 V indicated?

L.
S AD
YES – GO TO STEP 2.

R.
NO – • Intermittent failure

OR RIZ
• Loose or poorly connected ECT sensor
2P (Black) connector
2. ECT Sensor Inspection

OT TO
Turn the ignition switch OFF.
[1]
Disconnect the ECT sensor 2P (Black) connector
(page 4-41).

LM U
Connect the wire harness side 2P (Black) connector
[1] terminals with a jumper wire [2].

RA O A
Connection: Black/blue – Green/white
Turn the ignition switch ON.
Check the ECT sensor with the MCS.

AB N
Is about 0 V indicated?
Bl/Bu G/W

-C O
YES – Faulty ECT sensor
NO – GO TO STEP 3.

L. US
[2]

3. ECT Sensor Line Open Circuit Inspection

S. N O
Turn the ignition switch OFF.
[1] [2]
Remove the jumper wire.
Disconnect the PCM/ECM 33P (Gray) connector B2
(page 4-42).
R.
RS IÓ

Check for continuity between the 33P (Gray)

connector [1] and ECT sensor 2P (Black) connector
[2] terminals.
TO UC

TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
MO RIB

Connection: Bl/Bu
B27 – Black/blue
B27 G/W
B2 – Green/white
AL ST

Is there continuity?
YES – Replace the PCM/ECM with a known good
BR DI

one (page 4-43), and recheck.

NO – • Open circuit in the Black/blue wire
• Open circuit in the Green/white wire
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-20
dummyhead

PGM-FI SYSTEM
DTC 8 (TP SENSOR)
• Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) connector and
PCM/ECM 33P connectors, and recheck the DTC.

S. O
L.
S AD
R.
5V
TP SENSOR

OR RIZ
Br/W PCM/ECM

Bu/Bl

OT TO
G/W

LM U
RA O A
Probable cause
• Open or short circuit in Brown/white wire between
the TP sensor and PCM/ECM

AB N
• Open or short circuit in Blue/black wire between the
TP sensor and PCM/ECM

-C O
• Open circuit in Green/white wire between the TP
sensor and PCM/ECM

L. US
• Faulty sensor unit (TP sensor)
• Faulty PCM/ECM
DTC 8-1 (TP SENSOR LOW VOLTAGE)
S. N O
1. TP Sensor System Inspection
Turn the ignition switch ON.
Check the TP sensor with the MCS with the throttle
R.
fully closed.
RS IÓ

Is about 0 V indicated?
TO UC

YES – GO TO STEP 3.
NO – GO TO STEP 2.
MO RIB

2. TP Sensor Inspection
Check that the TP sensor voltage increases
continuously when the throttle is moved to fully
closed position to fully open position, using the data
AL ST

list menu of the MCS.

Does the voltage increase continuously?
BR DI

YES – • Intermittent failure

• Loose or poorly connected sensor unit
5P connector.
CA SU

NO – Faulty sensor unit (TP sensor)

3. TP Sensor Input Voltage Inspection
24 O

Turn the ignition switch OFF.

[1]
Disconnect the sensor unit 5P (Black) connector
-20 BID

(page 4-39).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
5P (Black) connector [1] terminals.
-07 HI

Connection: Brown/white (+) – Green/white (–)

28 O

Is the voltage within 4.75 – 5.25 V?

YES – GO TO STEP 5.
PR

Br/W G/W
NO – GO TO STEP 4.

4-21
 dummyhead

PGM-FI SYSTEM
4. TP Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) connector Br/W
B3
(page 4-42).

S. O
Check for continuity between the wire harness side
33P (Gray) connector [1] and 5P (Black) connector

L.
S AD
[2] terminals.

R.
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

OR RIZ
Connection: B3 – Brown/white
Is there continuity?

OT TO
YES – Replace the PCM/ECM with a known good
one (page 4-43), and recheck. [1] [2]

LM U
NO – Open circuit in the Brown/white wire

RA O A
5. TP Sensor Output Line Open Circuit Inspection
Turn the ignition switch OFF.
[1] [2]
Disconnect the PCM/ECM 33P (Gray) connector
(page 4-42).

AB N
Check for continuity between the wire harness side
33P (Gray) connector [1] and 5P (Black) connector Bu/Bl

-C O
[2] terminals.
TOOL:

L. US
Pin Probe Male (2 pack) 07ZAJ-RDJA110

Connection: B14 – Blue/black

S. N O
Is there continuity?
YES – GO TO STEP 6. B14

NO – Open circuit in the Blue/Black wire

R.
RS IÓ

6. TP Sensor Output Line Short Circuit Inspection

Check the Blue/Black wire for continuity between
TO UC

[1]
the wire harness side 5P (Black) connector [1]
terminal and ground.
Connection: Blue/Black – ground
MO RIB

Is there continuity?
YES – Short circuit in the Blue/Black wire
AL ST

NO – GO TO STEP 7.
BR DI

Bu/Bl
CA SU

7. TP Sensor Inspection
Replace the sensor unit with a known good one
24 O

(page 4-39).
Erase the DTC (page 4-10).
-20 BID

Turn the ignition switch ON.

Check the TP sensor with the MCS.
Is DTC 8-1 indicated?
-07 HI

YES – Replace the PCM/ECM with a known good

one (page 4-43), and recheck.
28 O

NO – Faulty original sensor unit (TP sensor)

PR

4-22
dummyhead

PGM-FI SYSTEM
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
1. TP Sensor System Inspection
Turn the ignition switch ON.
Check the TP sensor with the MCS with the throttle

S. O
fully closed.

L.
S AD
Is about 5 V indicated?

R.
YES – GO TO STEP 3.

OR RIZ
NO – GO TO STEP 2.
2. TP Sensor Inspection
Check that the TP sensor voltage increases

OT TO
continuously when the throttle is moved to fully
closed position to fully open position, using the data
list menu of the MCS.

LM U
Does the voltage increase continuously?

RA O A
YES – Intermittent failure
NO – Faulty sensor unit (TP sensor)
3. TP Sensor Resistance Inspection

AB N
Turn the ignition switch OFF.
[1]
Disconnect the sensor unit 5P (Black) connector

-C O
(page 4-39).
Measure the resistance between the TP sensor side

L. US
5P (Black) connector [1] terminals.
Connection: C – D
Is the resistance within 1.0 – 3.0 kΩ
S. N O
YES – GO TO STEP 4.
NO – Faulty sensor unit (TP sensor)
R.
RS IÓ

C D
TO UC

4. TP Sensor Input Voltage Inspection

Turn the ignition switch ON.
MO RIB

[1]
Measure the voltage between the wire harness side
5P (Black) connector [1] terminals.
Connection: Brown/white (+) – Green/white (–)
AL ST

Is the voltage within 4.75 – 5.25 V?

YES – Replace the PCM/ECM with a known good
BR DI

one (page 4-43), and recheck.

NO – Open circuit in the Green/white wire
CA SU

Br/W G/W
24 O
-20 BID
-07 HI
28 O
PR

4-23
 dummyhead

PGM-FI SYSTEM
DTC 9 (IAT SENSOR)
• Before starting the inspection, check for loose or poor contact on the IAT sensor 2P (Black) connector and
PCM/ECM 33P connectors, and recheck the DTC.

S. O
L.
S AD
5V

R.
OR RIZ
IAT SENSOR
PCM/ECM
Gr

OT TO
G/W

LM U
RA O A
Probable cause
• Open or short circuit in Gray wire between the IAT

AB N
sensor and PCM/ECM
• Open circuit in Green/white wire between the IAT
sensor and PCM/ECM

-C O
• Faulty IAT sensor
• Faulty PCM/ECM

L. US
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
1. IAT Sensor System Inspection
S. N O
Turn the ignition switch ON.
Check the IAT sensor with the MCS.
Is about 0 V indicated?
R.
RS IÓ

YES – GO TO STEP 2.
NO – Intermittent failure
TO UC

2. IAT Sensor Inspection

Turn the ignition switch OFF.
Disconnect the IAT sensor 2P (Black) connector
MO RIB

(page 7-17).
Turn the ignition switch ON.
Check the IAT sensor with the MCS.
AL ST

Is about 0 V indicated?
YES – GO TO STEP 3.
BR DI

NO – Faulty IAT sensor

3. IAT Sensor Output Line Short Circuit Inspection
CA SU

Turn the ignition switch OFF.

Disconnect the PCM/ECM 33P (Gray) connector
[1]
(page 4-42).
Check for continuity between the wire harness side
24 O

IAT sensor 2P (Black) connector [1] terminal and

ground.
-20 BID

Connection: Gray – ground

Is there continuity?
-07 HI

YES – Short circuit in the Gray wire

NO – Replace the PCM/ECM with a known good
28 O

one (page 4-43), and recheck.

Gr
PR

4-24
dummyhead

PGM-FI SYSTEM
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)
1. IAT Sensor System Inspection
Turn the ignition switch ON.
Check the IAT sensor with the MCS.

S. O
Is about 5 V indicated?

L.
S AD
YES – GO TO STEP 2.

R.
NO – • Intermittent failure

OR RIZ
• Loose or poorly connected IAT sensor
2P (Black) connector
2. IAT Sensor Inspection

OT TO
Turn the ignition switch OFF.
[1]
Disconnect the IAT sensor 2P (Black) connector
(page 7-17).

LM U
Connect the wire harness side 2P (Black) connector
[1] terminals with a jumper wire [2].

RA O A
Connection: Gray – Green/white
Turn the ignition switch ON.
Check the IAT sensor with the MCS.

AB N
Is about 0 V indicated?
Gr G/W

-C O
YES – Faulty IAT sensor
NO – GO TO STEP 3.

L. US
[2]

3. IAT Sensor Open Circuit Inspection

S. N O
Turn the ignition switch OFF.
[1]
Remove the jumper wire. B2
Disconnect the PCM/ECM 33P (Gray) connector
(page 4-42).
R.
RS IÓ

Check for continuity between the wire harness side

33P (Gray) connector [1] and 2P (Black) connector
[2] terminals.
TO UC

TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
MO RIB

Connection: B26 – Gray

B2 – Green/white
B26
Is there continuity? Gr
AL ST

[2] G/W
YES – Replace the PCM/ECM with a known good
one (page 4-43), and recheck.
BR DI

NO – • Open circuit in the Gray wire

• Open circuit in the Green/white wire
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-25
 dummyhead

PGM-FI SYSTEM
DTC 12 (FUEL INJECTOR)
• Before starting the inspection, check for loose or poor contact on the fuel injector 2P (Black) connector and
PCM/ECM 33P connectors, and recheck the DTC.

S. O
ECM
From IGN

L.
S AD
FUSE (20 A)

R.
OR RIZ
FUEL
INJECTOR
Bl/R

OT TO
LM U
G/Bl

RA O A
Probable cause

AB N
• Open circuit in Black/red wire between the engine
stop relay and fuel injector

-C O
• Open or short circuit in Green/black wire between
the fuel injector and PCM/ECM

L. US
• Faulty fuel injector
• Faulty PCM/ECM
DTC 12-1 (FUEL INJECTOR)
S. N O
1. Fuel Injector System Inspection
Erase the DTC (page 4-10).
Turn the ignition switch OFF and ON, and check the
fuel injector with the MCS.
R.
RS IÓ

Is the DTC 12-1 indicated?

TO UC

YES – GO TO STEP 2.
NO – • Intermittent failure
• Loose or poorly connected fuel injector
MO RIB

2P (Black) connector.
2. Fuel Injector Resistance Inspection
Turn the ignition switch OFF.
[1]
AL ST

Disconnect the fuel injector 2P (Black) connector

(page 7-22).
Measure the resistance between the injector side
BR DI

2P connector [1] terminals.

Standard: 11.1 – 12.3 Ω (20°C/68°F)
CA SU

Is the resistance within the standard values?

YES – GO TO STEP 3.
NO – Faulty fuel injector
24 O
-20 BID
-07 HI
28 O
PR

4-26
dummyhead

PGM-FI SYSTEM
3. Fuel Injector Input Voltage Inspection
Turn the ignition switch ON.
[1]
Measure the voltage between the wire harness side
2P (Black) connector [1] terminal and ground.

S. O
Connection: Black/red(+) – ground (–)

L.
S AD
Is there battery voltage?

R.
YES – GO TO STEP 4.

OR RIZ
NO – Open circuit in the Black/red wire

OT TO
Bl/R

LM U
4. Fuel Injector Signal Line Open Circuit Inspection

RA O A
Turn the ignition switch OFF.
[1] [2]
Disconnect the PCM/ECM 33P (Gray) connector
(page 4-42).
Check for continuity between the wire harness side

AB N
33P (Gray) connector [1] and fuel injector 2P (Black)
connector [2] terminals.

-C O
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

L. US
Connection: B33 – Green/black
Is there continuity?
S. N O
YES – GO TO STEP 5. B33 G/Bl
NO – Open circuit in the Green/black wire
R.
5. Fuel Injector Signal Line Short Circuit Inspection
RS IÓ

Check for continuity between the wire harness side

[1]
2P (Black) connector [1] terminal and ground.
TO UC

Connection: Green/black – Ground

Is there continuity?
MO RIB

YES – Short circuit in the Green/black wire

NO – Replace the PCM/ECM with a known good
one (page 4-43), and recheck.
AL ST
BR DI

G/Bl
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-27
 dummyhead

PGM-FI SYSTEM
DTC 21 (O2 SENSOR)
• Before starting the inspection, check for loose or poor contact on the O2 sensor 4P (Black) connector and
PCM/ECM 33P connectors, then recheck the DTC.

S. O
L.
S AD
5V

R.
OR RIZ
O2 SENSOR

Bl Y/R PCM/ECM

OT TO
Gr G/W

LM U
RA O A
Probable cause

AB N
• Open circuit in Gray or Green/white wire between
the O2 sensor and PCM/ECM

-C O
• Open or short circuit in Black or Yellow/red wire
between the O2 sensor and PCM/ECM

L. US
• Faulty O2 sensor
• Faulty PCM/ECM
DTC 21-1 (O2 SENSOR)
S. N O
1. O2 Sensor System Inspection
Warm the engine until the coolant temperature is
80°C (176°F).
Check the O2 sensor with the MCS.
R.
RS IÓ

Standard: 0.1 V – 1.2 V

TO UC

Is the voltage as specified?

YES – Check the fuel pressure (page 7-10). If the
system is correct, GO TO STEP 4.
MO RIB

NO – GO TO STEP 2.
2. O2 Sensor Open Circuit Inspection
Turn the ignition switch OFF.
AL ST

Disconnect the O2 sensor 4P (Black) connector [1] [2]

(page 2-14)and PCM/ECM 33P connectors (page 4-
42).
BR DI

Check for continuity between the wire harness side

33P (Black) connector [1] and 4P (Black) connector
[2], and between the 33P (Gray) connector [3] and
CA SU

4P (Black) connector.
TOOL: A10 Y/R
Pin Probe Male (2 pack) 07ZAJ-RDJA110
24 O

Connection: A10 – Yellow/red

-20 BID

B2 – Green/white
Is there continuity? [3] [2]

YES – GO TO STEP 3.
-07 HI

NO – • Open circuit in the Yellow/red wire

• Open circuit in the Green/white wire
28 O

G/W
PR

B2

4-28
dummyhead

PGM-FI SYSTEM
3. O2 Sensor System Short Circuit Inspection
Connect the ECM 33P connectors.
[1]
Check for continuity between the O2 sensor 4P
(Black) connector [1] at the wire side and ground.

S. O
Connection: Yellow/red – Ground

L.
S AD
Is there continuity?

R.
YES – Short circuit in the Yellow/red wire

OR RIZ
NO – GO TO STEP 4.

Y/R

OT TO
LM U
4. O2 Sensor Inspection

RA O A
Connect the ECM 33P (Black) connector.
Replace the O2 sensor with a known good one
(page 4-44).
Erase the DTCs (page 4-10).

AB N
Warm the engine until the coolant temperature is
80°C (176°F).

-C O
Check the O2 sensor with the MCS.
Is DTC 21 – 1 indicated?

L. US
YES – Replace the PCM/ECM with a known good
one (page 4-43), and recheck.
S. N O
NO – Faulty original O2 sensor

DTC 23 (O2 SENSOR HEATER)

R.
RS IÓ

• Before starting the inspection, check for loose or poor contact on the O2 sensor 4P (Black) connector and
PCM/ECM 33P connectors, then recheck the DTC.
TO UC

From IGNITION
MO RIB

SWITCH

O2 SENSOR HEATER
AL ST

Bl/R
PCM/ECM
W
BR DI

W G/O
CA SU
24 O

Probable cause
• Open circuit in Green/orange or White wire between
-20 BID

the O2 sensor heater and PCM/ECM

• Open circuit in Black/red or White wire between the
O2 sensor heater and ING fuse (20 A)
• Faulty O2 sensor heater
-07 HI

• Faulty PCM/ECM
28 O
PR

4-29
 dummyhead

PGM-FI SYSTEM
DTC 23-1 (O2 SENSOR HEATER)
1. O2 Sensor System Inspection
Erase the DTCs (page 4-10).
Start the engine and check the O2 sensor heater

S. O
with the MCS.

L.
S AD
Is DTC 23-1 indicated?

R.
YES – GO TO STEP 2.

OR RIZ
NO – Intermittent failure
2. O2 Sensor Heater Resistance Inspection
Turn the ignition switch OFF.

OT TO
[1]
Disconnect the O2 sensor 4P (Black) connector
(page 2-14).
Measure the resistance between the sensor side 4P

LM U
(Black) connector [1] terminals.
Connection: White – White

RA O A
Is the resistance within 6.7 – 9.5 Ω (20°C/68°F)? W W
YES – GO TO STEP 3.

AB N
NO – Faulty O2 sensor

-C O
L. US
3. O2 Sensor Heater Input Voltage Inspection
Turn the ignition switch ON.
[1]
S. N O
Measure the voltage between the wire harness side
4P (Black) connector [1] and ground.
Connection: Black/red (+) – Ground (–)
Bl/R
R.
RS IÓ

Dose the battery voltage exist?

YES – GO TO STEP 4.
TO UC

NO – Open circuit in the Black/red wire

MO RIB
AL ST

4. O2 Sensor Heater Line Open Circuit Inspection

Turn the ignition switch OFF.
BR DI

Disconnect the ECM 33P (Gray) connector (page 4- [2] A11 [1]
42).
Check for continuity between the wire harness side
CA SU

33P (Black) connector [1] and 4P (Black) connector

[2].
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
24 O
-20 BID

Connection: A11 – Green/orange G/O

Is there continuity?
YES – GO TO STEP 5.
-07 HI

NO – Open circuit in the Green/orange wire

28 O
PR

4-30
dummyhead

PGM-FI SYSTEM
5. O2 Sensor Heater Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
4P (Black) connector [1] and ground.
Connection: Green/orange – Ground

S. O
Is there continuity?

L.
S AD
YES – Short circuit in the Green/orange wire G/O

R.
NO – Replace the PCM/ECM with a known good

OR RIZ
one (page 4-43), and recheck.

OT TO
LM U
DTC 29 (IACV)

RA O A
• Before starting the inspection, check for loose or poor contact on the IACV 4P (Black) connector and PCM/
ECM 33P (Gray) connector, then recheck the DTC.

AB N
PCM/ECM

-C O
L. US
IACV

Y
S. N O
Y/G

Y/Bu
R.
RS IÓ

Br/Y
TO UC

Probable cause
• Open or short circuit in the Yellow wire, Yellow/green
MO RIB

wire, Yellow/blue wire and/or Brown/yellow wire

between the IACV and PCM/ECM
• Faulty IACV
• Faulty PCM/ECM
AL ST

DTC 29-1 (IACV)

1. DTC Recheck
BR DI

Erase the DTC (page 4-10).

Start the engine and recheck the DTC with the
MCS.
CA SU

Is the DTC 29-1 indicated?

YES – GO TO STEP 2.
24 O

NO – • Intermittent failure
• Loose or poorly connected IACV 2P
-20 BID

connector.
-07 HI
28 O
PR

4-31
 dummyhead

PGM-FI SYSTEM
2. IACV Short Circuit Inspection
Turn the ignition switch OFF.
[1]
Disconnect the IACV 4P (Black) connector (page 7-
21). Br/Y

S. O
Y/Bu
Check for continuity between the wire harness side
4P connector [1] terminals and ground.

L.
S AD
Connection: Yellow – Ground

R.
Yellow/blue – Ground
Brown/yellow – Ground

OR RIZ
Yellow/green – Ground Y Y/G

Is there continuity?

OT TO
YES – Short circuit in the following:
• Short circuit in the Yellow or Yellow/
green wire

LM U
• Short circuit in the Yellow/blue or
Brown/yellow wire

RA O A
NO – GO TO STEP 3.
3. IACV Circuit Continuity Inspection
Disconnect the PCM/ECM 33P (Gray) connector

AB N
(page 4-42). [2]
Check the IACV wires for continuity between the

-C O
wire harness side 33P (Gray) connector [1] and 4P
(Black) connector [2] terminals. B9

L. US
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
S. N O
Connection: B8 – Yellow
B5 – Yellow/green
Y
B30 – Yellow/blue
B9 – Brown/yellow B8 B5 Y/G
R.
RS IÓ

Are there continuities? [1] B30 Y/Bu Br/Y

YES – GO TO STEP 4.
TO UC

NO – Open circuit in the following:

• Open circuit in the Yellow or Yellow/
MO RIB

green wire
• Open circuit in the Yellow/blue or
Brown/yellow wire
4. IACV Resistance Inspection
AL ST

Measure the resistance between the wire harness

[1]
side IACV 4P connector [1] terminals.
BR DI

Connection: 1A – 1B
2A – 2B
CA SU

Standard: 99 – 121 Ω (20°C/68°F) 1B 1A

Is the resistance within the standard values?
YES – Replace the PCM/ECM with a known good
24 O

one (page 4-43), and recheck.

2B 2A
-20 BID

NO – Faulty IACV
-07 HI
28 O
PR

4-32
dummyhead

PGM-FI SYSTEM
DTC 33-2 (EEPROM) (After ’19 model)
• Before starting the inspection, check for loose or
poor contact on the PCM/ECM 33P connectors, and
recheck the DTC.

S. O
1. DTC Recheck

L.
S AD
Erase the DTC (page 4-10).

R.
Check the DTC with the MCS.

OR RIZ
Is DTC 33-2 indicated?
YES – Replace the PCM/ECM with a known good
one (page 4-42), and recheck.

OT TO
NO – Intermittent failure.

DTC 54 (BANK ANGLE SENSOR)

LM U
• Before starting the inspection, check for loose or poor contact on the bank angle sensor 3P (Black)

RA O A
connector and PCM/ECM 33P connectors, and recheck the DTC.

5V

AB N
BANK ANGLE 5V

-C O
SENSOR

L. US
PCM/ECM
Br/W
Bl/G
S. N O
G/W
R.
RS IÓ

Probable cause
TO UC

• Open circuit in the Brown/white wire between the

bank angle sensor and PCM/ECM
• Open or short circuit in Black/green wire between
the bank angle sensor and PCM/ECM
MO RIB

• Open circuit in Green/white wire between the bank

angle sensor and PCM/ECM
• Faulty bank angle sensor
• Faulty PCM/ECM
AL ST

DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)

BR DI

1. Recheck DTC
Erase the DTC (page 4-10).
CA SU

Check the bank angle sensor with the MCS.

Is about 0 V indicated?
YES – GO TO STEP 2.
24 O

NO – • Intermittent failure
-20 BID

• Loose or poor contact of the bank angle

sensor 3P (Black) connector
-07 HI
28 O
PR

4-33
 dummyhead

PGM-FI SYSTEM
2. Bank Angle Sensor Power Input Voltage
Inspection
Turn the ignition switch OFF.
[1]
Disconnect the bank angle sensor 3P (Black)

S. O
connector (page 4-41).
Turn the ignition switch ON.

L.
S AD
Measure the voltage between the wire harness side
bank angle sensor 3P (Black) connector [1]

R.
terminals. Br/W
G/W

OR RIZ
Connection: Brown/white (+) – Green/white (–)
Is the voltage within 4.75 – 5.25 V?

OT TO
YES – GO TO STEP 3.
NO – Replace the PCM/ECM with a known good
one (page 4-43), and recheck.

LM U
RA O A
3. Bank Angle Sensor Output Line Short Circuit
Inspection
Turn the ignition switch OFF.
[1]
Disconnect the PCM/ECM 33P (Gray) connector

AB N
(page 4-42).
Check for continuity between the wire harness side

-C O
bank angle sensor 3P (Black) connector [1] terminal
and ground.

L. US
Connection: Black/green – Ground
Is there continuity?
S. N O
YES – Short circuit in the Black/green wire.
Bl/G
NO – GO TO STEP 4.
R.
RS IÓ

4. Bank Angle Sensor Inspection

TO UC

Replace the bank angle sensor with a known good

one (page 4-41).
Erase the DTC (page 4-10).
MO RIB

Connect the bank angle sensor 3P (Black)

connector.
Turn the ignition switch ON.
Check the bank angle sensor with the MCS.
AL ST

Is DTC 54-1 indicated?

YES – Replace the PCM/ECM with a known good
BR DI

one (page 4-43), and recheck.

NO – Faulty original bank angle sensor.
CA SU

DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)

1. Recheck DTC
24 O

Erase the DTC (page 4-10).

-20 BID

Check the bank angle sensor with the MCS.

Is about 5 V indicated?
YES – GO TO STEP 2.
-07 HI

NO – • Intermittent failure.
• Loose or poor contact of the bank angle
28 O

sensor 3P (Black) connector.

PR

4-34
dummyhead

PGM-FI SYSTEM
2. Bank Angle Sensor Inspection
Turn the ignition switch OFF.
[1]
Disconnect the bank angle sensor 3P (Black)
connector (page 4-41).

S. O
Connect the wire harness side 3P (Black) connector
[1] terminals with a jumper wire [2].

L.
S AD
Connection: Black/green – Green/white

R.
Turn the ignition switch ON.

OR RIZ
Check the bank angle sensor with the MCS.
Is about 0 V indicated?
YES – Faulty bank angle sensor

OT TO
G/W Bl/G
NO – GO TO STEP 3.
[2]

LM U
3. Bank Angle Sensor Power Input Voltage

RA O A
Inspection
Turn the ignition switch OFF.
[1]
Disconnect the bank angle sensor 3P (Black)
connector (page 4-41).

AB N
Turn the ignition switch ON.
Measure the voltage between the wire harness side

-C O
bank angle sensor 3P (Black) connector [1]
terminals. Br/W
G/W

L. US
Connection: Brown/white (+) – Green/white (–)
Is the voltage within 4.75 – 5.25 V?
S. N O
YES – GO TO STEP 4.
NO – Open circuit in the Green/white wire
R.
RS IÓ

4. Bank Angle Sensor Input Line Open Circuit

Inspection
TO UC

Turn the ignition switch OFF.

Disconnect the PCM/ECM 33P (Gray) connector
(page 4-42). B3
MO RIB

Check for continuity between the wire harness side

33P (Gray) connector [1] and 3P (Black) connector
[2] terminals.
TOOL:
AL ST

Pin Probe Male (2 pack) 07ZAJ-RDJA110

BR DI

Connection: B3 – Brown/white
Is there continuity?
CA SU

YES – GO TO STEP 5.
Br/W
NO – Open circuit in the Brown/white wire [1] [2]
24 O
-20 BID
-07 HI
28 O
PR

4-35
 dummyhead

PGM-FI SYSTEM
5. Bank Angle Sensor Output Line and Ground
Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the PCM/ECM 33P (Gray) connector G/W Bl/G B6 B2

S. O
(page 4-42).
Check for continuity between the wire harness side

L.
S AD
PCM/ECM 33P (Gray) connector [1] and bank angle
sensor 3P (Black) connector [2] terminals.

R.
TOOL:

OR RIZ
Pin Probe Male (2 pack) 07ZAJ-RDJA110

Connection: B6 – Black/green

OT TO
B2 – Green/white
Is there continuity?
[2] [1]

LM U
YES – Replace the PCM/ECM with a known good
one (page 4-43), and recheck.

RA O A
NO – • Open circuit in the Black/green wire
• Open circuit in the Green/white wire

AB N
MIL CIRCUIT INSPECTION

-C O
Except TM1 model

L. US
Turn the ignition switch ON and check that the MIL [1]
[1]
comes on for about 2 seconds and goes off.
If the MIL does not come on at all, inspect the
combination meter (page 23-6).
S. N O
If the MIL stays on with the gear position indicator
continuously blinking "–", check the serial
communication line (page 23-8).
R.
RS IÓ
TO UC
MO RIB

If the MIL stays on, check as follows:

[1]
Turn the ignition switch OFF.
AL ST

Disconnect the PCM/ECM 33P (Gray) connector (page

4-42).
BR DI

Check for continuity between the wire harness side

PCM/ECM 33P (Gray) connector [1] and ground.
CA SU

TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

Connection: B29 – Ground B29

24 O

• If there is continuity, check for short circuit in the

-20 BID

Brown/red wire between the DLC and PCM/ECM.

• If there is no continuity, replace the PCM/ECM with
a known good one (page 4-43), and recheck.
-07 HI
28 O
PR

4-36
dummyhead

PGM-FI SYSTEM
TM1 model
Turn the ignition switch ON and check that the MIL [1]
comes on for about 2 seconds and goes off.

S. O
If the MIL does not come on, check as follows:

L.
S AD
R.
OR RIZ
OT TO
[1]

LM U
1. Indicator Power Input Line Inspection

RA O A
Check the other indicator operation.
Do they operate properly?
YES – GO TO STEP 2.

AB N
NO – Open circuit in the Black/red wire between
the fuse box and joint connector

-C O
2. MIL Line Open Circuit Inspection

L. US
Turn the ignition switch OFF.
[1]
Disconnect the PCM/ECM 33P (Black) connector
(page 4-42).
S. N O
Ground the wire harness side 33P (Black) connector
[1] terminal with a jumper wire.
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
R.
RS IÓ

Connection: A21 – ground

TO UC

Turn the ignition switch ON and check the MIL.

Does the MIL come on? A21
MO RIB

YES – Replace the PCM/ECM with a known good

one (page 4-43), and recheck.
NO – • Open circuit in the Brown/white wire
between the ECM and MIL
AL ST

• Faulty MIL bulb

• Open circuit in the Black/red wire
between the MIL and joint connector
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-37
 dummyhead

PGM-FI SYSTEM
If the MIL does not go off within about 2 seconds after
the ignition switch is turned ON, check as follows:
1. MIL Line Short Circuit Inspection
Turn the ignition switch OFF.

S. O
[1]
Disconnect the PCM/ECM 33P (Black) connector

L.
S AD
(page 4-42).
Check for continuity between the wire harness side

R.
33P (Black) connector [1] terminal and ground.

OR RIZ
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

Connection: A21 – ground

OT TO
Is there continuity?
YES – Short circuit in the Brown/white wire A21

LM U
NO – GO TO STEP 2.

RA O A
2. SCS Line Short Circuit Inspection
Disconnect the PCM/ECM 33P (Gray) connector
[1]

AB N
(page 4-42).
Check for continuity between the wire harness side
33P (Gray) connector [1] terminal and ground.

-C O
TOOL:

L. US
Pin Probe Male (2 pack) 07ZAJ-RDJA110

Connection: B29 – ground

S. N O
Is there continuity?
YES – Short circuit in the Brown/red wire
B29
NO – Replace the PCM/ECM with a known good
one (page 4-43), and recheck.
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-38
dummyhead

PGM-FI SYSTEM
SENSOR UNIT (MAP/TP SENSOR)
REMOVAL/INSTALLATION

S. O
• If the sensor unit has been removed, perform the TP

L.
S AD
sensor reset procedure (page 4-39).
• Always clean around the throttle body before the

R.
sensor unit removal to prevent dirt and debris from
entering the air passage.

OR RIZ
• Do not remove the sensor unit unless it is replaced.
Remove the left center mudguard (page 2-5).
[3]

OT TO
Disconnect the sensor unit 5P (Black) connector [1].
Remove the three torx screws (T25) [2] and the sensor
unit [3] from the throttle body.

LM U
RA O A
AB N
-C O
[2] [1]

L. US
Install a new O-ring [1] into the groove of the throttle
[1] [2]
body.
Install the sensor unit [2] to the throttle body by aligning
S. N O
the slot with the throttle shaft end.
Install and tighten the torx screws (T25) to the specified
torque.
R.
RS IÓ

TORQUE: 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)

Install the removed parts in the reverse order of
TO UC

removal.
Perform the TP sensor reset procedure (page 4-39).
MO RIB

Align

TP SENSOR RESET PROCEDURE

AL ST

• Make sure that the DTC is not stored in the PCM/

ECM memory. If the DTC is stored, the reset mode
BR DI

will not start.

1. Remove the DLC from the dummy connector
(page 4-10).
CA SU

2. Short the DLC [1] terminals using the special tool.

Connection: Brown/red – Green
24 O

TOOL:
-20 BID

[2] SCS Short Connector 070PZ-ZY30100

-07 HI
28 O

[1]
PR

4-39
 dummyhead

PGM-FI SYSTEM
3. Disconnect the ECT sensor 2P (Black) connector
[1]
[1].
Short the wire harness side connector terminals with
a jumper wire [2].

S. O
Connection: Black/blue – Green/red

L.
S AD
4. Turn the ignition switch ON, then disconnect the

R.
jumper wire from the ECT sensor 2P (Black)
connector within 10 seconds while the MIL is

OR RIZ
blinking (reset receiving pattern).

OT TO
[2]

5. When the reset procedure is complete, the MIL

LM U
blinking changes from Reset Receiving Pattern to
Confirmation Pattern.

RA O A
Turn the ignition switch OFF.
If more than 10 seconds elapse or the procedures are incorrect, the MIL stays on. Repeat the reset
procedures from the step 4.

AB N
Within 10 sec.

-C O
1.3 sec.

L. US
0.1 sec. 0.3 sec. 0.3 sec.
ON
MIL
S. N O
OFF

Reset Receiving Pattern Reset Confirmation Pattern

(Stay on: Reset procedure is not complete)
R.
RS IÓ

ON
IGNITION
TO UC

SWITCH
OFF
MO RIB

6. Connect the ECT sensor 2P (Black) connector.

7. Disconnect the special tool from the DLC.
8. Install the dummy connector to the DLC (page 4-10).
AL ST

9. Check the engine idle speed (page 3-21).

10.Install the removed parts in the reverse order of
BR DI

removal.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-40
dummyhead

PGM-FI SYSTEM
ECT SENSOR
REMOVAL/INSTALLATION
Drain the coolant (page 8-5).

S. O
[2] [3]
Remove the tank cover assembly (page 2-4).

L.
S AD
Disconnect the spark plug cap [1] and ECT sensor 2P

R.
connector [2].

OR RIZ
Replace the ECT Remove the ECT sensor [3] and O-ring [4].
sensor while the
Coat a new O-ring with engine oil and install it onto the
engine is cold.
ECT sensor.
Install the ECT sensor into the cylinder head and

OT TO
tighten it.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

LM U
Connect the ECT sensor 2P connector and spark plug [1] [4]

RA O A
cap.
Install the tank cover assembly (page 2-4).
Fill the cooling system with recommended coolant

AB N
(page 8-5).

-C O
BANK ANGLE SENSOR

L. US
REMOVAL/INSTALLATION
Remove the front fender/carrier (page 2-8).
[3] [1]
S. N O
Disconnect the bank angle sensor 3P (Black) connector
[1].
Remove the two mounting bolts [2] and bank angle
sensor [3] from the frame.
R.
RS IÓ
TO UC
MO RIB

[2]
AL ST

Install the bank angle sensor [1] with its "UP" mark [2]
After ’19 shown: [1]
facing up.
Install the removed parts in the reverse order of
BR DI

removal.
TORQUE:
CA SU

Mounting bolt: 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

24 O
-20 BID

[2]
-07 HI
28 O
PR

4-41
 dummyhead

PGM-FI SYSTEM
OPERATION INSPECTION

• Before you perform this inspection, check that the

engine idle speed is normal (page 3-21).

S. O
Remove the bank angle sensor [1] with the bank angle

L.
S AD
60° ± 5° BANK ANGLE POSITION
sensor 3P (Black) connector is connected (page 4-41).
[1]

R.
• Do not disconnect the bank angle sensor 3P (Black)
connector during inspection.

OR RIZ
Place the bank angle sensor is horizontal (normal
position) as shown, and turn the ignition switch ON.
60° ± 5°

OT TO
Start the engine.
Incline the bank angle sensor 60° ± 5° to the left or right
with keeping with the engine running.

LM U
The bank angle sensor is normal if the engine stops HORIZONTAL

RA O A
when the bank angle sensor Inclined.

60° ± 5°

INSPECTION WITH MCS

AB N
Connect the MCS (page 4-10).
60° ± 5° BANK ANGLE POSITION

-C O
Remove the bank angle sensor [1] with the bank angle [1]
sensor 3P (Black) connector is connected (page 4-41).

L. US
Place the bank angle sensor horizontal as shown.
Turn the ignition switch ON.
S. N O
Read the voltage with the MCS. 60° ± 5°
Standard: 3.6 – 4.4 V
Incline the bank angle sensor 60° ± 5° to the left or right
R.
RS IÓ

with keeping the ignition switch ON. HORIZONTAL

Read the voltage with MCS.
TO UC

Standard: 0.7 – 1.3 V 60° ± 5°

MO RIB

PCM/ECM
POWER/GROUND LINE INSPECTION
AL ST

Remove the front fender/carrier (page 2-8).

[1]
Turn the ignition switch OFF.
BR DI

Disconnect the PCM/ECM 33P (Gray) connector [1].

CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-42
dummyhead

PGM-FI SYSTEM
GROUND LINE
Check for continuity between the wire harness side 33P
[1]
connector [1] terminals and ground.
B10 B2

S. O
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

L.
S AD
Connection:

R.
Power ground: B10 – ground

OR RIZ
B21 – ground
Sensor ground: B2 – ground
B13
Logic ground: B13 – ground

OT TO
There should be continuity at all times. B21
If there is no continuity, check for an open circuit in the
Green or Green/white wires.

LM U
POWER INPUT LINE

RA O A
Turn the ignition switch ON.
[1]
Measure the voltage between the wire harness side
33P connector [1] terminal and ground.

AB N
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

-C O
Connection: B1 (+) – ground (–)

L. US
There should be battery voltage.
If there is no voltage, check the following;
S. N O
– discharged battery (page 22-5) (–) (+) B1
– open circuit in the Red wire between the battery and
MAIN fuse (30 A)
– blown MAIN fuse 1 (30 A)
R.
RS IÓ

– open circuit in the Red/black wire between the MAIN

fuse 1 (30 A) and MAIN fuse 2 (10 A)
– blown MAIN fuse 2 (10 A)
TO UC

– open circuit in the Red/yellow wire between the

MAIN fuse 2 (10 A) and diode
– faulty diode (page 22-8)
MO RIB

– open circuit in the Red wire between the diode and

ignition switch
– ignition switch (page 23-10)
– open circuit in the Black wire between the ignition
AL ST

switch and IGN fuse (20 A)

– blown IGN fuse (20 A)
– open circuit in the Black/red wire between the IGN
BR DI

fuse (20 A) and PCM/ECM

CA SU

REMOVAL/INSTALLATION
Remove the tank cover assembly (page 2-4).
[3] [2]
Turn the ignition switch OFF.
24 O

Remove the following from the ECM stay [1]:

-20 BID

– joint connector [2]

– PCM/ECM [3]
Disconnect the following connectors from the PCM/
-07 HI

ECM:
– 33P (Gray) connector [4]
28 O

– 33P (Black) connector [5]

– 5P (Black) connector [6]
PR

Installation is in the reverse order of removal.

[4] [5] [6] [1]

4-43
 dummyhead

PGM-FI SYSTEM
O2 SENSOR
REMOVAL/INSTALLATION

S. O
L.
S AD
• Do not get grease, oil or other materials in the O2
sensor air hole.

R.
• The O2 sensor may be damaged if dropped.
Replace it with a new one, if dropped.

OR RIZ
• Do not service the O2 sensor while it is hot.
• Do not use an impact wrench while removing or

OT TO
installing the O2 sensor, or it may be damaged.
Remove the muffler (page 2-14).
[2]

LM U
Remove the O2 sensor [1] using the special tool.

RA O A
TOOL:
FRXM17 (Snap on) or equivalent [2]
Installation is in the reverse order of removal.

AB N
TORQUE: 24.5 N·m (2.5 kgf·m, 18 lbf·ft)

-C O
L. US
[1]
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

4-44
dummytext

5. IGNITION SYSTEM

S. O
L.
S AD
R.
OR RIZ
5

OT TO
LM U
SERVICE INFORMATION························ 5-2 IGNITION SYSTEM INSPECTION ············· 5-5

RA O A
TROUBLESHOOTING ···························· 5-3 IGNITION COIL ····································· 5-7

AB N
COMPONENT LOCATION ······················· 5-4 IGNITION TIMING ·································· 5-7

-C O
SYSTEM DIAGRAM ······························· 5-4 CONDENSER (CM type only) ·················· 5-8

L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

5-1
 dummyhead

IGNITION SYSTEM
SERVICE INFORMATION
IGNITION SYSTEM

GENERAL

S. O
L.
S AD
• The PCM/ECM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the PCM/ECM. Always turn the ignition switch OFF before servicing.

R.
• Use spark plugs with the correct heat range. Using spark plugs with an incorrect heat range can damage the engine.

OR RIZ
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• When servicing the ignition system, always follow the checks described in the troubleshooting chart (page 5-3).
• This ignition system is controlled by PCM/ECM.

OT TO
• The transistorized ignition system uses an electrically controlled ignition timing system. No adjustments can be made to the
ignition timing.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.

LM U
• 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.

RA O A
• The engine stop switch line is connected to the PCM/ECM via the fuel pump relay coil. Its signal permits the PCM/ECM to
control the fuel pump, fuel injector and ignition coil.
• CKP sensor removal/installation (page 14-7).
• Ignition switch servicing (page 23-10)

AB N
• Engine stop switch inspection (page 23-11)
• The following color codes are used throughout this section.

-C O
Bl: Black Bu: Blue Gr: Gray Lg: Light green P: Pink V: Violet Y: Yellow

L. US
Br: Brown G: Green Lb: Light blue O: Orange R: Red W: White

TOOLS
S. N O
IgnitionMate peak voltage tester Peak voltage adaptor Test probe, 2 pack
MTP07-0286 (U.S.A. only) 07HGJ-0020100 (not available in 07ZAJ-RDJA110
U.S.A.)
R.
RS IÓ
TO UC
MO RIB
AL ST

with commercially available digital

BR DI

multimeter (impedance 10 MΩ/DCV

minimum)
CA SU
24 O
-20 BID
-07 HI
28 O
PR

5-2
dummyhead

IGNITION SYSTEM
TROUBLESHOOTING
• Inspect the following before diagnosing the system:
– Faulty spark plug

S. O
– Loose spark plug cap or spark plug wire connection
– Water got into the spark plug cap (leaking the ignition coil secondary voltage)

L.
S AD
• "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.)

R.
No spark at spark plug

OR RIZ
UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order)
Ignition coil No initial voltage with the 1. Faulty circuit between the battery and IGN fuse (20 A) (page 4-43)
primary ignition switch turned to ON. 2. An open circuit in the Black/red wire between the IGN fuse (20 A) and

OT TO
voltage (Other electrical components ignition coil
are normal.) 3. Loose or poor connection of the primary terminal, or an open circuit in
the primary coil
4. Faulty PCM/ECM (in case when the initial voltage is normal with the

LM U
PCM/ECM (Gray) connector disconnected)

RA O A
Initial voltage is normal, but it 1. Incorrect peak voltage adaptor connections (System is normal if
drops by 2 – 4 V while cranking measured voltage is over the specifications with reverse
the engine. connections.)
2. Battery is undercharged. (Voltage drops largely when the engine is

AB N
started.)
3. No voltage at the Black/red wire of the PCM/ECM (Gray) connector,
or loose or poorly connected PCM/ECM (Gray) connector

-C O
4. Loose or poor connection, or an open circuit in the Green (ground)
wire of the PCM/ECM

L. US
5. Loose or poor connection, or an open circuit in the Green/yellow wire
between the ignition coil and PCM/ECM
6. A short circuit in the ignition primary coil
S. N O
7. No voltage at the Gray/red wire of the PCM/ECM (Gray) connector, or
loose or poorly connected PCM/ECM (Gray) connector.
8. Faulty CKP sensor (Measure the peak voltage.)
9. Faulty PCM/ECM (in case when above No. 1 through 8 are normal)
R.
Initial voltage is normal, but 1. Incorrect peak voltage adaptor connections (System is normal if
RS IÓ

there is no peak voltage while measured voltage is over the specifications with reverse
cranking the engine. connections.)
TO UC

2. Faulty peak voltage adaptor

3. Faulty CKP sensor (Measure the peak voltage.)
4. Faulty PCM/ECM (in case when above No. 1 and 3 are normal)
MO RIB

Initial voltage is normal, but 1. The multimeter impedance is too low; below 10 MΩ/DCV.
peak voltage is lower than the 2. Cranking speed is too slow. (Battery is undercharged.)
standard value. 3. The sampling timing of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
AL ST

standard voltage at least once.)

4. Faulty PCM/ECM (in case when above No. 1 through 3 are normal)
Initial and peak voltages are 1. Faulty spark plug or leaking ignition coil secondary current
BR DI

normal, but no spark jumps. 2. Faulty ignition coil.

CKP sensor Low peak voltage. 1. The multimeter impedance is too low; below 10 MΩ/DCV.
2. Cranking speed is too slow. (Battery is undercharged.)
CA SU

3. The sampling timing of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Faulty CKP sensor (in case when above No. 1 through 3 are normal)
24 O

No peak voltage. 1. Faulty peak voltage adaptor

2. Faulty CKP sensor
-20 BID
-07 HI
28 O
PR

5-3
 dummyhead

IGNITION SYSTEM
COMPONENT LOCATION
FA2 model shown:
IGNITION SWITCH

S. O
ENGINE STOP SWITCH

L.
S AD
IGNITION COIL

R.
OR RIZ
PCM/ECM

OT TO
FUSE BOX:
– MAIN FUSE 1 (30 A)
– MAIN FUSE 2 (10 A)

LM U
– IGN FUSE (10 A)

RA O A
– DIODE

AB N
-C O
L. US
SPARK PLUG
BATTERY
S. N O
CONDENSER
(CM type only) CKP SENSOR
R.
RS IÓ

SYSTEM DIAGRAM
TO UC

CONDENSER
(CM type only)
PCM/ECM
MO RIB

G R
Bl/R
AL ST

From regulator/
R rectifier
BR DI

FUEL PUMP RELAY ENGINE STOP SWITCH

CA SU

Gr/R Bl/W

Bu/Y G/Y
Bl/R
24 O

G Bl/R DIODE IGNITION SWITCH

-20 BID

CKP SENSOR
R/Y R R Bl
IGNITION
COIL IGN FUSE
G
(20 A)
-07 HI

R/Bl R
28 O

MAIN FUSE 2 MAIN FUSE 1

(10 A) (30 A)
PR

SPARK PLUG
BATTERY

5-4
dummyhead

IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• If there is no spark at the plug, check all connections

S. O
for loose or poor contact before measuring the peak
voltage.

L.
S AD
• Use a commercially available digital multimeter with
an impedance of 10 MΩ/DCV minimum.

R.
• The display value differs depending upon the

OR RIZ
internal impedance of the multimeter.
Use the peak voltage tester or connect the peak voltage
adaptor [1] to the digital multimeter [2]. [2]

OT TO
TOOL:
IgnitionMate peak voltage tester MTP07-0286
(U.S.A. only) or

LM U
Peak Voltage Adaptor 07HGJ-0020100
(not available in

RA O A
U.S.A.)
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)

AB N
-C O
[1]

L. US
IGNITION COIL PRIMARY PEAK
VOLTAGE S. N O
• Check all system connections before this inspection.
Poor connected connectors can cause incorrect
readings.
• Check that the cylinder compression is normal and
R.
RS IÓ

the spark plug is installed correctly in the cylinder

head.
TO UC

Remove the tank cover assembly (page 2-4).

[2]
Disconnect the spark plug cap [1] from the spark plug.
Connect a known good spark plug [2] to the spark plug
MO RIB

cap and ground the spark plug to the cylinder head as

done in a spark test.
With the connector connected, connect the peak
AL ST

voltage tester or adaptor probes to the ignition coil

primary terminals.
Connection: Green/yellow (+) – Ground (–)
BR DI

Turn the ignition switch ON and engine stop switch " ".
Check the initial voltage at this time.
CA SU

The battery voltage should be measured. [1]

If the initial voltage cannot be measured, follow the
checks in the troubleshooting chart (page 5-3).
24 O

Shift the transmission into neutral.

-20 BID

Crank the engine with the starter motor and read the
ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
-07 HI

If the peak voltage is lower than the standard value,

follow the checks described in the troubleshooting chart
28 O

(page 5-3).
PR

5-5
 dummyhead

IGNITION SYSTEM
CKP SENSOR PEAK VOLTAGE

• Check that the cylinder compression is normal and

the spark plug is installed correctly in the cylinder

S. O
head.

L.
S AD
Remove the tank cover assembly (page 2-4).
[1]

R.
Turn the ignition switch OFF and disconnect the PCM/
ECM 33P (Gray) connector [1].

OR RIZ
Connect the peak voltage tester or adaptor [2] probes to
the wire harness side 33P (Gray) connector terminals
TOOL:

OT TO
Test probe, 2 pack 07ZAJ-RDJA110

Connection: B23 (+) – Ground (–)

LM U
Shift the transmission into neutral.

RA O A
Turn the ignition switch ON and engine stop switch " ".
Crank the engine with the starter motor and measure
the CKP sensor peak voltage.

AB N
PEAK VOLTAGE: 0.7 V minimum
[1]

-C O
If the voltage measured at the PCM/ECM connector is
abnormal, measure the peak voltage at the CKP sensor

L. US
connector.
B23
S. N O
R.
RS IÓ

[2]
TO UC

Remove the air cleaner housing (page 7-17).

Turn the ignition switch OFF and disconnect the CKP
sensor 2P (Gray) connector [1].
MO RIB

Connect the peak voltage tester or adaptor [2] probes to

the CKP sensor side connector terminals.
Connection: Blue/yellow (+) – Green (–)
AL ST

In the same manner as at the PCM/ECM connector,

measure the peak voltage and compare it to the voltage
BR DI

measured at the PCM/ECM connector.

• If the peak voltage measured at the PCM/ECM
CA SU

connector is abnormal and the one measured at the

CKP sensor connector is normal, the Blue/yellow or [1]
Green wire has an open or short circuit, or loose
connection.
24 O

• If both peak voltages are abnormal, follow the

[1]
checks described in the troubleshooting chart (page
-20 BID

5-3).
If the CKP sensor is faulty, replace the alternator stator/
CKP sensor assembly (page 14-7).
-07 HI

G Bu/Y
28 O
PR

[2]

5-6
dummyhead

IGNITION SYSTEM
IGNITION COIL
REMOVAL/INSTALLATION
Remove the ECM stay (page 3-13).

S. O
[3]
Disconnect the ignition coil primary wire connectors [1].

L.
S AD
Remove the bolts [2] and ignition coil [3].

R.
Installation is in the reverse order of removal.

OR RIZ
OT TO
LM U
[1] [2]

RA O A
IGNITION TIMING

AB N
• Before you performing this inspection, check the
engine idle speed (page 3-21).

-C O
Remove the right center mudguard (page 2-5).

L. US
Start the engine and warm it up to operating
temperature.
Stop the engine and remove the timing hole cap from
S. N O
the rear crankcase cover.
Connect the timing light [1] and tachometer.
Start the engine, let it idle and check the ignition timing.
R.
RS IÓ

[1]
TO UC

The ignition timing is correct if the "F" mark [1] on the

[2]
flywheel aligns with the index notch [2] on the rear
MO RIB

crankcase cover at idle.

AL ST
BR DI

[1]
CA SU

Coat a new O-ring [1] with engine oil and install it onto
24 O

the timing hole cap [2]. [2]

-20 BID

Install and tighten the timing hole cap to the specified

torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
-07 HI

Install the removed parts in the reverse order of

removal.
28 O
PR

[1]

5-7
 dummyhead

IGNITION SYSTEM
CONDENSER (CM type only)
REMOVAL/INSTALLATION
Remove the rear fender cover (page 2-12).

S. O
’14 model shown:
Disconnect the battery negative (–) cable (page 22-5).

L.
S AD
Disconnect the condenser 2P connector [1] and remove [1]
the condenser [2].

R.
• After ’14: condenser 2P (Black) connector.

OR RIZ
Installation is in the reverse order of removal.

OT TO
LM U
[2]

RA O A
INSPECTION

AB N
• Perform this inspection using a fully charged battery.
Disconnect the condenser 2P connector [1] (page 5-8).
[1]

-C O
Connect the battery negative (–) cable (page 22-5).

L. US
Measure the voltage between the wire harness side
condenser 2P connector terminals. R G

Connection: Red (+) – Green (–)

S. N O
Standard: Battery voltage at all time
If there is no voltage, check the following:
R.
RS IÓ

– MAIN fuse 1 (30 A), MAIN fuse 2 (10 A) and/or

related circuits
– diode
TO UC

– open circuit in the Red or Green wires

If there is voltage, check the condenser as follows:

[1]
MO RIB

1. Disconnect the battery negative (–) cable and

connect the condenser 2P connector [1].
2. Connect the battery negative (–) cable for a few
AL ST

seconds and charge the condenser.

3. Disconnect the battery negative (–) cable and
discharge the condenser.
BR DI

4. Disconnect the condenser 2P connector and check

the resistance between the condenser side
CA SU

connector terminals.
Select the kΩ range The condenser is normal if the resistance comes
of the tester. near 0Ω once and eventually becomes .
24 O

If the resistance stays at 0Ω or does not change,

replace the condenser.
-20 BID

• If the inspection is interrupted, connect the

condenser 2P connector and restart the procedure
-07 HI

from the step 1.

28 O
PR

5-8
dummytext

6. ELECTRIC STARTER

S. O
L.
S AD
R.
OR RIZ
OT TO
6

LM U
SERVICE INFORMATION························ 6-2 STARTER MOTOR································· 6-7

RA O A
TROUBLESHOOTING ···························· 6-3 STARTER RELAY SWITCH ····················· 6-9

AB N
COMPONENT LOCATION ······················· 6-4 STARTER INHIBITOR RELAY/STARTER
RELAY SWITCH DIODE························ 6-11

-C O
SYSTEM DIAGRAM ······························· 6-5

L. US
IN-GEAR START DIODE (After ’14) ········ 6-12
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

6-1
 dummyhead

ELECTRIC STARTER
SERVICE INFORMATION
ELECTRIC STARTER

GENERAL

S. O
L.
S AD
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be
damaged.

R.
• Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.

OR RIZ
• 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 6-3).
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• '14 – '19 TM1/TE1/FM1/FM2/FE1 models: Refer to each section for the following components information.

OT TO
– Starter clutch (page 14-14)
– Ignition switch (page 23-10)
– Engine stop switch and starter switch (page 23-11)

LM U
– Front brake switch (page 23-12)
– Gear position switch (page 23-11)

RA O A
• '14 – '19 FA1/FA2/FA5/FA6 models: Refer to each section for the following components information.
– Starter clutch (page 14-14)
– Ignition switch (page 23-10)
– Engine stop switch and starter switch (page 23-11)

AB N
– Front brake switch (page 23-12)
– Shift drum position switch (page 13-72)

-C O
• After '19 TM1/FM1/FM2 models: Refer to each section for the following components information.
– Starter clutch (page 14-14)

L. US
– Ignition switch (page 23-10)
– Engine stop switch and starter switch (page 23-11)
– Front brake switch (page 23-12)
– Gear position switch (page 23-11)
S. N O
• After '19 TE1/FE1 models: Refer to each section for the following components information.
– Starter clutch (page 14-14)
– Ignition switch (page 23-10)
– Engine stop switch and starter switch (page 23-11)
R.
RS IÓ

– Front brake switch (page 23-12)

– TR sensor (page 24-30)
– Neutral switch (page 24-31)
TO UC

• After '19 FA2/FA5/FA6 models: Refer to each section for the following components information.
– Starter clutch (page 14-14)
– Ignition switch (page 23-10)
MO RIB

– Engine stop switch and starter switch (page 23-11)

– Front brake switch (page 23-12)
– TR sensor (page 13-74)
– Neutral switch (page 13-75)
AL ST

• The following color codes are used throughout this section.

Bl: Black Bu: Blue Gr: Gray Lg: Light green P: Pink V: Violet Y: Yellow
BR DI

Br: Brown G: Green Lb: Light blue O: Orange R: Red W: White

CA SU
24 O
-20 BID
-07 HI
28 O
PR

6-2
dummyhead

ELECTRIC STARTER
TROUBLESHOOTING
Unusual condition Probable cause (Check in numerical order)
Starter motor Starter motor does not turn 1. Weak battery

S. O
2. Loose connection or open circuit in the battery cable(s)
3. Loose connection or open circuit in the starter motor cable

L.
S AD
4. Faulty starter relay switch (page 6-10)
5. Open circuit in starter relay switch ground circuit (page 6-9)

R.
6. Faulty starter relay switch power input line (page 6-10)

OR RIZ
– Faulty circuit between the battery and IGN fuse (page 4-43)
– Open circuit between the fuse box and engine stop switch
– Faulty handlebar switch (engine stop switch and/or starter switch)
– Open circuit between the starter switch and starter inhibitor relay

OT TO
– Faulty starter inhibitor relay (page 6-11)or its circuits
– Open circuit between the starter inhibitor relay and starter relay
switch

LM U
7. Faulty starter motor
8. Except '14 – '19 FA models and after '19 TM/FM models:

RA O A
Faulty gear position switch or its circuits
9. '14 – '19 FA models: Faulty shift drum position switch or its circuits
10.After '19 TE/FE/FA models: Faulty neutral switch or its circuits
11.After '19 TE/FE/FA models: Faulty TR sensor or its circuits

AB N
12.Faulty front brake switch or its circuits
13.Faulty PCM/ECM

-C O
Starter motor turns slowly 1. Low battery voltage
2. Poorly connected battery cable terminal(s)

L. US
3. Poorly connected starter motor cable
4. Faulty starter motor
5. Poorly connected battery (–) cable ground terminal
Starter motor turns, but engine 1. Faulty starter clutch assembly
S. N O
does not turn 2. Damaged or faulty starter driven gear
3. Damaged or faulty starter reduction gear
4. Damaged or faulty starter motor pinion gear
Starter relay switch "Clicks", 1. Crankshaft does not turn due to engine problems
R.
RS IÓ

but engine does not turn over

TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

6-3
 dummyhead

ELECTRIC STARTER
COMPONENT LOCATION
Except after '19 TE/FE/FA models

S. O
FA2 model shown: STARTER SWITCH
IGNITION SWITCH

L.
S AD
R.
ENGINE STOP SWITCH FRONT BRAKE SWITCH

OR RIZ
FUSE BOX:
– MAIN FUSE 1 (30 A)
– MAIN FUSE 2 (10 A)

OT TO
PCM/ECM
– IGN FUSE (20 A)
– DIODE

LM U
RA O A
AB N
-C O
RELAY BOX

L. US
– STARTER INHIBITOR RELAY
– STARTER RELAY SWITCH DIODE
STARTER RELAY – After ’14: IN-GEAR START DIODE
SWITCH
S. N O
BATTERY
R.
RS IÓ

Except FA models: GEAR POSITION SWITCH

STARTER MOTOR FA models: SHIFT DRUM POSITION SWITCH
TO UC

After '19 TE/FE/FA models

MO RIB

FA6 model shown: STARTER SWITCH

IGNITION SWITCH
ENGINE STOP SWITCH
AL ST

FRONT BRAKE SWITCH

RELAY BOX
PCM
– STARTER INHIBITOR RELAY
BR DI

– IN-GEAR START DIODE

FUSE BOX:
CA SU

– MAIN FUSE 1 (30 A)

– MAIN FUSE 2 (10 A)
– IGN FUSE (20 A)
– DIODE
24 O
-20 BID

STARTER RELAY
-07 HI

BATTERY
28 O

STARTER MOTOR
PR

TR SENSOR

NEUTRAL SWITCH

6-4
dummyhead

ELECTRIC STARTER
SYSTEM DIAGRAM
'14 model

S. O
L.
S AD
R.
BATTERY

OR RIZ
Y/R MAIN FUSE 1 R/Bl
Lg/R (30 A)

OT TO
R/Bl R/Y R
STARTER RELAY
STARTER MAIN FUSE 2 IGNITION
SWITCH DIODE
INHIBITOR (10 A) SWITCH

LM U
RELAY STARTER Bl
ENGINE STOP SWITCH IGN FUSE

RA O A
G Y/R SWITCH
(20 A)
G Bu Bl/W Bl/R
DIODE
Y/R Bl/Br P

AB N
FRONT BRAKE LIGHT
Br/W Bu FUSE
INHIBITOR SWITCH

-C O
STARTER Lg/R (10 A)
MOTOR

L. US
CKP
PCM/ECM
SENSOR
Bu/Y
G
S. N O
Except FA1/FA2: GEAR POSITION SWITCH
FA1/FA2: SHIFT DRUM POSITION SWITCH
R.
RS IÓ

'15 – '19 models

TO UC
MO RIB

BATTERY

Y/R MAIN FUSE 1 R/Bl

Lg/R
AL ST

(30 A)
R/Bl R/Y R
STARTER RELAY STARTER
SWITCH MAIN FUSE 2 IGNITION
BR DI

INHIBITOR DIODE
RELAY STARTER (10 A) SWITCH Bl
SWITCH IGN FUSE
ENGINE STOP SWITCH
G Y/R (20 A)
CA SU

G Bu Bl/W Bl/R
DIODE Y/R
Y/R Bl/Br P
24 O

FRONT BRAKE LIGHT

Br/W INHIBITOR SWITCH FUSE
-20 BID

STARTER Lg/R Lg/R (10 A)

MOTOR CKP
IN-GEAR SENSOR
START DIODE
-07 HI

PCM/ECM
Bu/Y G
28 O

Except FA models: GEAR POSITION SWITCH

PR

FA models: SHIFT DRUM POSITION SWITCH

6-5
 dummyhead

ELECTRIC STARTER
After '19 model
TM/FM models:

S. O
Bl Bl Bl Bl

L.
S AD
STARTER
R BATTERY IGNITION

R.
RELAY
SWITCH
SWITCH

OR RIZ
Y/R MAIN FUSE 1
(30 A) R/Bl

Lg/R R/Bl R/Y R

OT TO
STARTER STARTER MAIN FUSE 2
DIODE
RELAY SWITCH INHIBITOR (10 A) Bl
DIODE RELAY STARTER
ENGINE STOP SWITCH IGN FUSE
SWITCH

LM U
G Y/R Y/R (20 A)
Bu Bu Bl/W Bl/R

RA O A
G
FRONT BRAKE LIGHT
Br/W Br/W Bu SWITCH
IN-GEAR FUSE (10 A)

AB N
START Y/R Bl/Br P
Br/W
DIODE

-C O
GEAR POSITION
Lg/R Lg/R
SWITCH

L. US
CKP
Lg/R
STARTER SENSOR
MOTOR
Bu/Y
G
S. N O
ECM
R.
RS IÓ

Except TM/FM models:

TO UC

Bl Bl Bl Bl

STARTER
R BATTERY IGNITION
RELAY
MO RIB

SWITCH SWITCH
Y/R MAIN FUSE 1
(30 A) R/Bl
AL ST

Lg/R R/Bl R/Y R

STARTER STARTER MAIN FUSE 2
DIODE
RELAY SWITCH INHIBITOR (10 A) Bl
BR DI

DIODE RELAY STARTER

ENGINE STOP SWITCH IGN FUSE
SWITCH
G Y/R Y/R (20 A)
Bu Bu Bl/W Bl/R
CA SU

G
FRONT BRAKE LIGHT
Br/W Br/W Bu SWITCH
IN-GEAR FUSE (10 A)
24 O

START Br/W Y/R Bl/Br P

DIODE
-20 BID

NEUTRAL
Lg Lg
SWITCH
CKP
Lg SENSOR
STARTER
-07 HI

MOTOR
Bu/Y
28 O

PCM G
PR

G/W
Bu TR SENSOR
Br/W Br

6-6
dummyhead

ELECTRIC STARTER
STARTER MOTOR
REMOVAL/INSTALLATION
Remove the air cleaner housing (page 7-17).

S. O
[4] [5]
Disconnect the battery negative (–) cable (page 22-5).

L.
S AD
Remove the following:

R.
– terminal nut [1] (open the rubber cap [2])
– starter motor cable [3]

OR RIZ
– two mounting bolts [4] and ground cable [5]
[3]

OT TO
LM U
[1] [2]

RA O A
Remove the starter motor [1] from the rear crankcase
[3] [2]
cover.
Remove the O-ring [2] from the starter motor.

AB N
Coat a new O-ring with engine oil and install it into the
starter motor groove.

-C O
Apply molybdenum oil solution to the starter motor shaft
splines [3].

L. US
Install the removed parts in the reverse order of
removal.
S. N O
[1]
R.
RS IÓ

DISASSEMBLY/ASSEMBLY
TO UC

The armature coil may be damaged if the magnet in the motor case pulls the armature against the case.
MO RIB

'14 – '19 model shown:

ARMATURE

SEAL RING
AL ST

MOTOR CASE
BR DI

INSULATOR
CA SU

NUT SEAL RING

Align

O-RING
24 O

OIL SEAL
-20 BID

WASHER
BRUSH
SPRINGS
TERMINAL
STOPPER POSITIVE
-07 HI

BRUSH SET
Align
REAR COVER
28 O

BRUSH HOLDER
PR

TERMINAL
BOLT FRONT COVER
NEGATIVE BRUSH SET
3.7 N·m (0.4 kgf·m, 2.7 lbf·ft) 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft)

6-7
 dummyhead

ELECTRIC STARTER
INSPECTION
Check the oil seal [1] and ball bearing [2] in the front
[2]
cover for wear or damage.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

LM U
Check the commutator bars [1] for damage or abnormal

RA O A
[2]
wear.
Check the commutator bars of the armature [2] for
discoloration.

AB N
Clean any metal debris from between commutator bars.

-C O
• Do not use emery or sand paper on the commutator.

L. US
S. N O
[1]

Check for continuity between pairs of commutator bars

CONTINUITY: [1]
[1].
R.
RS IÓ

There should be continuity.

TO UC
MO RIB
AL ST
BR DI

Check for continuity between each commutator bar [1]

NO CONTINUITY: [2]
and the armature shaft [2].
CA SU

There should be no continuity.

24 O
-20 BID
-07 HI
28 O

[1]
PR

6-8
dummyhead

ELECTRIC STARTER
Check for continuity between the starter motor cable
terminal [1] and positive brushes [2].
There should be continuity.

S. O
[2]

L.
S AD
R.
OR RIZ
OT TO
[1]

Check for continuity between the positive brushes [1]

LM U
[3] [2]
and the rear cover [2].

RA O A
There should be no continuity.
Check for continuity between the negative brushes [3]
and the rear cover.

AB N
There should be continuity.
Check for continuity between the positive and negative

-C O
brushes.
There should be no continuity.

L. US [1]
S. N O
STARTER RELAY SWITCH
OPERATION INSPECTION
R.
RS IÓ

Remove the rear fender cover (page 2-12).

’14 model shown:
Turn the ignition switch ON and engine stop switch " ".
TO UC

Shift the transmission into neutral or apply front brake.

Push the starter switch.
MO RIB

The relay coil is normal if the starter relay switch [1]

clicks.
If you don't hear the switch "CLICK", inspect the relay
switch using the procedure below.
AL ST
BR DI

[1]
CA SU

CIRCUIT INSPECTION
Ground Line:
Disconnect the starter relay switch 2P (Green)
24 O

[1]
connector (page 6-10).
-20 BID

Check for continuity between the wire harness side 2P

(Green) connector [1] terminal and ground. G
Connection: Green – Ground
-07 HI

There should be continuity at all times.

28 O
PR

6-9
 dummyhead

ELECTRIC STARTER
Power Input Line:
Disconnect the starter relay switch 2P (Green)
[1]
connector (page 6-10).
Turn the ignition switch ON and engine stop switch " ".

S. O
Y/R
Shift the transmission into neutral or apply front brake.

L.
S AD
Measure the voltage between the wire harness side 2P

R.
(Green) connector [1] terminal and ground.

OR RIZ
Connection: Yellow/red (+) – Ground (–)
There should be battery voltage only when the starter
switch is pushed.

OT TO
LM U
CONTINUITY INSPECTION

RA O A
Remove the starter relay switch [1] (page 6-10).
Connect the fully charged 12 V [2] battery to the starter
relay switch 2P (Green) connector [3] terminals.

AB N
Connection: Battery (+) terminal – Yellow/red
Battery (–) terminal – Light green/red

-C O
There should be continuity between the cable terminals [1]
Lg/R

L. US
while the battery is connected, and no continuity when
the battery is disconnected.
S. N O
Y/R

[3] [2]

REMOVAL/INSTALLATION
R.
RS IÓ

Disconnect the battery negative (–) cable (page 22-5).

’14 model shown: [6]/[7]
TO UC

Disconnect the starter relay switch 2P (Green)

connector [1].
Remove the terminal nuts [2], spring washers [3],
MO RIB

battery positive (+) cable [4] and starter motor cable [5].
Remove the starter relay switch [6] from the rear fender
with the shock rubber [7].
AL ST

Remove the starter relay switch from the shock rubber.

Installation is in the reverse order of removal.
BR DI

[2]/[3]/[4]/[5] [1]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

6-10
dummyhead

ELECTRIC STARTER
STARTER INHIBITOR RELAY/STARTER
RELAY SWITCH DIODE
INSPECTION

S. O
Remove the PCM/ECM from the ECM stay (page 4-43).

L.
S AD
[2]
Remove the screws [1] and relay box lid [2].

R.
OR RIZ
OT TO
LM U
RA O A
[1]

Remove the starter inhibitor relay [1] and starter relay

’14 model shown: [1]

AB N
switch diode [2].

-C O
L. US
S. N O
R.
RS IÓ

[2]

Connect an ohmmeter to the starter inhibitor relay [1]

TO UC

[1]
terminals as shown and check for continuity.
There should be continuity.
Connect a 12 V battery to the relay terminals as shown.
MO RIB

There should be no continuity only when the 12 V

battery is connected.
AL ST
BR DI
CA SU

Check for continuity between the terminals of the diode

[1]
[1].
24 O

When there is continuity, a small resistance value will

register.
-20 BID

If there is continuity in one direction, the diode is

normal.
-07 HI
28 O
PR

6-11
 dummyhead

ELECTRIC STARTER
IN-GEAR START DIODE (After ’14)
INSPECTION
Remove the PCM/ECM from the ECM stay (page 4-43).

S. O
[2]
Remove the screws [1] and relay box lid [2].

L.
S AD
R.
OR RIZ
OT TO
LM U
[1]

RA O A
Remove the in-gear start diode [1].

AB N
-C O
L. US
S. N O
[1]
R.
RS IÓ

Check for continuity between the terminals of the diode

[1]
[1].
TO UC

When there is continuity, a small resistance value will

register.
If there is continuity in one direction, the diode is
MO RIB

normal.
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

6-12
dummytext

7. FUEL SYSTEM

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION························ 7-2 AIR CLEANER HOUSING ····················· 7-17 7

RA O A
SYSTEM COMPONENTS ························ 7-3 THROTTLE BODY ······························· 7-18

AB N
FUEL LINE TROUBLESHOOTING ············ 7-4 IACV·················································· 7-21

-C O
FUEL LINE INSPECTION ························ 7-5 FUEL INJECTOR ································· 7-22

L. US
FUEL PUMP UNIT································ 7-11 EVAP PURGE CONTROL SOLENOID VALVE/
CANISTER (After '19 AC type)··············· 7-23
S. N O
FUEL TANK ········································ 7-16
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

7-1
 dummyhead

FUEL SYSTEM
SERVICE INFORMATION
FUEL SYSTEM

GENERAL
• This section covers service of the mechanical system of the PGM-FI system and the fuel supply system. For electrical system

S. O
service of the PGM-FI system, see PGM-FI System section (page 4-2).
• Before disconnecting the fuel feed hose, relieve pressure from the system (page 7-5).

L.
S AD
• Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bend, resulting in loss of

R.
vehicle control.
• Work in a well ventilated area. Smoking, open flames, or sparks in the work area or where gasoline is stored can cause a fire

OR RIZ
and/or explosion.
• Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle
operation.
• Seal the cylinder head intake port with tape or a clean cloth to keep dirt and debris from entering the intake port after the throttle

OT TO
body has been removed.
• Do not damage the throttle body. It may cause incorrect throttle valve operation.
• Prevent dirt and debris from entering the throttle bore, IACV, sensor hole and fuel feed hose. Clean them using compressed air.

LM U
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• Do not loosen or tighten the white painted screws and nut of the throttle body. Loosening or tightening them can cause throttle

RA O A
body malfunction.
• Tighten the yellow painted screws of the throttle body to the specified torque.
• When disassembling the fuel system parts, note the location of the O-rings. Replace them with new ones upon reassembly.
• When servicing the fuel feed hose, be careful not to bend or kink it.

AB N
TOOLS

-C O
Fuel connector remover Fuel pressure gauge Pressure gauge manifold

L. US
070MF-HP50200 07406-0040004 07ZAJ-S5A0111 (not available in
S. N O U.S.A.)

R.
RS IÓ
TO UC

or 07AMF-001A100 (U.S.A. only) or 07406-004000C or 07406-004000B

(U.S.A. only)
MO RIB

Hose attachment, 9 mm/9 mm Pressure manifold hose Adapter, male

07ZAJ-S5A0120 (not available in 07AMJ-HW3A100 (U.S.A. only) 07AAJ-S6MA200 (U.S.A. only)
U.S.A.)
AL ST
BR DI
CA SU
24 O

Adapter, female
-20 BID

07AAJ-S6MA400 (U.S.A. only)

-07 HI
28 O
PR

7-2
 PR
dummyhead

28 O
-07 HI
-20 BID
'14 – '19 models shown:

24 O
CA SU
BR DI
SYSTEM COMPONENTS

AL ST
MO RIB
TO UC
RS IÓ

1.8 N·m (0.2 kgf·m, 1.3 lbf·ft)

S. N O
R.
L. US
-C O
AB N
RA O A
LM U
OT TO
OR RIZ
S AD
S. O
R.

7-3
FUEL SYSTEM

L.
 dummyhead

FUEL SYSTEM
FUEL LINE TROUBLESHOOTING
• For the following symptoms, always follow the steps in the troubleshooting flow chart.
– engine stalls after warming up the engine

S. O
– rough idling after warming up the engine
– engine lacks power after warming up the engine

L.
S AD
• Before starting the inspection, check for pinched or clogged fuel pump breather hose and fuel feed hose.
1. Fuel pump operation inspection

R.
Turn the ignition switch ON and engine stop switch " ".

OR RIZ
You should hear the fuel pump operation sound for a few seconds.
Do you hear the fuel pump operation sound?

OT TO
YES – GO TO STEP 3.
NO – GO TO STEP 2.
2. Fuel pump Input Voltage inspection

LM U
Inspect the fuel pump input voltage (page 7-12).

RA O A
Is there battery voltage?
YES – Faulty fuel pump

AB N
NO – • Open circuit in the Brown wire and/or Green wire
• Blown IGN fuse (20 A)
• Faulty fuel pump relay (page 7-11)and its circuits

-C O
• Faulty engine stop switch (page 23-11)
• Open circuit in the power/ground lines of the PCM/ECM (page 4-42)

L. US
3. Fuel flow inspection
Inspect the fuel flow (page 7-11).
S. N O
Is the fuel flow specified volume?
YES – GO TO STEP 5.
NO – GO TO STEP 4.
R.
RS IÓ

4. Fuel pump filter inspection

Inspect the fuel pump filter for clogs (page 7-14).
TO UC

Is the fuel pump strainer screen normal?

YES – Replace the fuel pump with a new one (page 7-12), and recheck.
MO RIB

NO – Replace the fuel pump filter (page 7-14), and recheck the fuel flow (page 7-11).
5. Fuel pressure inspection
Inspect the fuel pressure (page 7-10).
AL ST

Is the fuel pressure within specification?

YES – • Inspect the ignition system (page 5-5).
BR DI

• Inspect the cylinder compression (page 10-6).

NO – Replace the fuel pump with a new one (page 7-12), and recheck.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

7-4
dummyhead

FUEL SYSTEM
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING

S. O
• Before disconnecting fuel feed hose, relieve

L.
S AD
pressure from the system as following procedures.
1. Remove the tank cover assembly (page 2-4).

R.
2. Turn the ignition switch OFF.

OR RIZ
3. Disconnect the fuel pump unit 4P connector [1].
[1]
4. Start the engine, and let it idle until the it stalls.

OT TO
5. Turn the ignition switch OFF.
6. Disconnect the battery negative (–) cable
(page 22-5).

LM U
RA O A
AB N
-C O
QUICK CONNECT FITTING REMOVAL

L. US
• Do not bend or twist the fuel feed hose.
S. N O
FUEL PUMP SIDE
1. Relieve the fuel pressure (page 7-5).
2. Check the fuel quick connect fitting [1] for dirt, and
[2]
R.
RS IÓ

clean if necessary.
Place a shop towel [2] over the quick connect fitting.
TO UC
MO RIB
AL ST
BR DI

[1]

3. Pull and release the connector damper [1] from the

[1] [2]
retainer.
CA SU

4. Hold the connector [2] with one hand and squeeze

the retainer tabs [3] with the other hand to release
the locking pawls [4] from the connector, and pull the
24 O

connector off the fuel pipe.

-20 BID

• Absorb the remaining fuel in the fuel feed hose from

flowing out with a shop towel.
[3]
• Be careful not to damage the hose or other parts.
-07 HI

• Do not use any tools to disconnect the connector.

[4]
• If the connector does not move, keep the retainer
28 O

tabs pressed down, and alternately pull and push

the connector until it comes off easily.
PR

7-5
 dummyhead

FUEL SYSTEM
5. Remove the retainer and connector damper from the
[1]
fuel pipe.
To prevent damage and keep foreign matter out,
cover the disconnected connector and fuel pipe end

S. O
with the plastic bags [1].

L.
S AD
R.
OR RIZ
OT TO
INJECTOR SIDE

LM U
1. Relieve the fuel pressure (page 7-5).
[1]

RA O A
Remove the snorkel duct (page 3-13).
Remove the bolt [1], clamp [2] and setting rubber [3].

AB N
-C O
L. US
S. N O
[2] [3]

2. Check the fuel quick connect fitting [1] for dirt, and
[1]
clean if necessary.
R.
RS IÓ

Place a shop towel [2] over the quick connect fitting.

TO UC
MO RIB
AL ST

[2]
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

7-6
dummyhead

FUEL SYSTEM
3. Pull and release the connector damper [1] from the
[1]
retainer.
4. Hold the connector [2] with one hand and squeeze
the retainer tabs [3] with the other hand to release

S. O
the locking pawls [4] from the connector, and pull the [2]
connector off the fuel pipe.

L.
S AD
[3]
If using the special tool:

R.
Pull and release the connector damper from the

OR RIZ
retainer as shown.
Set the special tool to the retainer tabs and push and
release them from the locking pawls.

OT TO
[4]
TOOL:
Fuel connector remover [5] 070MF-HP50200 or
07AMF-001A100

LM U
[1]
(U.S.A. only) [5]

RA O A
Pull the connector off the injector joint.

• Absorb the remaining fuel in the fuel feed hose with

AB N
a shop towel.
• Be careful not to damage the hose or other parts.
• Use the specified special tool only.

-C O
• If the connector does not move, keep the retainer

L. US
tabs pressed down, and alternately pull and push
the connector until it comes off easily.
S. N O
5. Remove the retainer and connector damper from the
injector joint.
To prevent damage and keep foreign matter out,
R.
RS IÓ

cover the disconnected connector and injector joint

with plastic bags [1].
TO UC

[1]
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

7-7
 dummyhead

FUEL SYSTEM
QUICK CONNECT FITTING
INSTALLATION

S. O
• Always replace the retainer and connector damper
of the quick connect fitting when the fuel feed hose is

L.
S AD
disconnected.
• If any retainer needs replacing, use the same

R.
manufacturer’s retainer as the ones being removed

OR RIZ
(The various manufactures feature different retainer
specifications).
• Do not bend or twist fuel feed hose.
FUEL PUMP SIDE

OT TO
1. Insert a new retainer [1] into the connector [2].
[2]

LM U
• Align the retainer locking pawls with the connector
grooves.

RA O A
[1]

AB N
-C O
L. US
Align

2. Set a new connector damper [1] onto the fuel pipe

S. N O
[2]
as shown.
Then press the quick connect fitting [2] onto the pipe
until both locking pawls [3] lock with a "CLICK".
R.
RS IÓ

If it is hard to connect, put a small amount of engine

oil on the pipe end.
TO UC

[3]
MO RIB

[1]
AL ST

3. Make sure the connection is secure and that the

[3] [2]
locking pawls [1] are firmly locked into place; check
BR DI

visually and by pulling the connector [2].

4. Make sure the connector damper [3] is positioned [5]
correctly (between the pipe [4] and retainer tabs [5]).
CA SU

5. Install the tank cover assembly (page 2-4).

6. Increase the fuel pressure and check that there is no
leakage in fuel supply system (page 7-10).
24 O
-20 BID

[1]

[4]
-07 HI
28 O
PR

7-8
dummyhead

FUEL SYSTEM
INJECTOR SIDE
1. Insert a new retainer [1] into the connector [2].
[2]

S. O
• Align the retainer locking pawls with the connector
grooves.
[1]

L.
S AD
R.
OR RIZ
OT TO
Align

LM U
2. Set a new connector damper [1] onto the injector
[3]

RA O A
joint as shown.
Then press the quick connect fitting [2] onto the
injector joint until both locking pawls [3] lock with a
"CLICK".

AB N
If it is hard to connect, put a small amount of engine
oil on the injector joint.

-C O
[2]

L. US
S. N O
[1]

3. Make sure the connection is secure and that the

locking pawls [1] are firmly locked into place; check [2]
R.
RS IÓ

visually and by pulling the connector [2].

4. Make sure the connector damper [3] is positioned
TO UC

correctly (between the injector joint [4] and retainer

tabs [5]).
[3]
MO RIB

[1]
AL ST

[5] [4]
BR DI

5. Install the setting rubber [1] and clamp [2].

[2] [3]
CA SU

• Align the clamp end with the groove in the clamp

stay.
Install and tighten the bolt [3].
24 O

6. Install the snorkel duct (page 3-13).

-20 BID

7. Increase the fuel pressure (page 7-10) and check

that there is no leakage in fuel supply system.
-07 HI

Align [1]
28 O
PR

7-9
 dummyhead

FUEL SYSTEM
FUEL PRESSURE INCREASING
1. Connect the fuel pump unit 4P connector [1].
[1]
2. Connect the battery negative (–) cable (page 22-5).

S. O
3. Turn the ignition switch ON and engine stop switch
" ".

L.
S AD
R.
• Do not start the engine.

OR RIZ
4. The fuel pump will run for about 2 seconds, and fuel
pressure will rise.
Turn the ignition switch OFF.

OT TO
Repeat this procedure 2 or 3 times, and check that
there is no leakage in the fuel supply system.

LM U
5. Install the tank cover assembly (page 2-4).

RA O A
FUEL PRESSURE INSPECTION
Disconnect the quick connect fitting from the fuel pump
(page 7-5).

AB N
Attach the special tools between the fuel injector and

-C O
fuel feed hose.
Except U.S.A. TOOLS:

L. US
[1]
Fuel pressure gauge [1] 07406-0040004
Pressure gauge manifold [2] 07ZAJ-S5A0111
Hose attachment, 9 mm/9 mm [3] 07ZAJ-S5A0120
S. N O
U.S.A. TOOLS:
Fuel pressure gauge, 100 psi 07406-004000C or
07406-004000B
R.
RS IÓ

Pressure manifold hose 07AMJ-HW3A100 [3] [2]

Adapter, male 07AAJ-S6MA200
Adapter, female 07AAJ-S6MA400
TO UC

Connect the fuel pump unit 4P (Gray) connector.

Connect the battery negative (–) cable (page 22-5).
MO RIB

Start the engine, let it idle and read the fuel pressure.
Standard:
333 – 363 kPa (3.4 – 3.7 kgf/cm2, 48 – 53 psi)
AL ST

If the fuel pressure is higher than specified pressure,

replace the fuel pump unit (faulty fuel pump or fuel
pressure regulator).
BR DI

If the fuel pressure is lower than specified, inspect the

following:
CA SU

– fuel flow (page 7-11)

– fuel pump (page 7-12)
– clogged fuel pump filter (page 7-14)
24 O

Wrap a shop towel Relieve the fuel pressure (page 7-5) and remove the
around the special tools from the fuel pump and fuel feed hose.
-20 BID

attachment to soak
Connect the quick connect fitting to the fuel pump (page
up any spilled fuel.
7-8).
-07 HI
28 O
PR

7-10
dummyhead

FUEL SYSTEM
FUEL FLOW INSPECTION
Disconnect the quick connect fitting from the fuel pump
(page 7-5).

S. O
Connect the special tools to the fuel feed hose.
Except U.S.A. TOOL:

L.
S AD
Hose attachment, 9 mm/9 mm [1] 07ZAJ-S5A0120

R.
U.S.A. TOOLS:

OR RIZ
Pressure manifold hose 07AMJ-HW3A100
Adapter, male 07AAJ-S6MA200
Fuel pressure gauge, 100 psi 07406-004000C or

OT TO
07406-004000B
Note: The fuel pressure gauge must be installed for
these tests. [1]

LM U
Place the end of the hose attachment into an approved
gasoline container. [2]

RA O A
Remove the fuel pump relay (page 7-11).
Connect the wire harness side fuel pump relay
connector [2] terminals with a jumper wire [3].

AB N
Connection: Brown – Black/red

-C O
Temporarily connect the battery negative (–) cable to
the battery (page 22-5).

L. US
Turn the ignition switch ON.
Turn the engine stop switch " " for 10 seconds and turn
it " " to measure the amount of fuel flow.
S. N O
Amount of fuel flow: [3]
356 cm3 (12.0 US oz, 12.5 Imp oz) minimum/
10 seconds
R.
RS IÓ

If the fuel flow is less than specified, inspect the

following:
TO UC

– fuel pump (page 7-12)

– clogged fuel pump filter (page 7-14)
Turn the ignition switch OFF.
MO RIB

Wrap a shop towel Remove the special tools from the fuel pump.
around the
Connect the quick connect fitting to the fuel pump (page
attachment to soak
7-8).
AL ST

up any spilled fuel.

FUEL PUMP UNIT

BR DI

FUEL PUMP RELAY INSPECTION

CA SU

Remove the relay box lid (page 6-11).

’14 model shown:
Turn the ignition switch OFF.
[1]
Remove the fuel pump relay [1].
24 O
-20 BID
-07 HI
28 O
PR

7-11
 dummyhead

FUEL SYSTEM
Connect an ohmmeter to the terminals of the fuel pump
[1]
relay [1].
Connect a 12 V battery to the fan motor relay terminals
as shown.

S. O
There should be continuity when the 12 V battery is

L.
S AD
connected and no continuity when the battery is
disconnected.

R.
OR RIZ
OT TO
INSPECTION

LM U
Remove the tank cover assembly (page 2-4).
[1]

RA O A
Turn the ignition switch ON and engine stop switch " ",
and confirm that the fuel pump operates for a few
seconds.
If the fuel pump does not operate, inspect as follows:

AB N
Turn the ignition switch OFF.

-C O
Disconnect the fuel pump 4P (Gray) connector [1].

L. US
S. N O
Turn the ignition switch ON and measure the voltage
between the terminals of the wire harness side 4P
R.
RS IÓ

(Gray) connector [1].

Connection: Brown (+) – Green (–)
TO UC

There should be battery voltage for a few seconds after Br

the ignition switch turned ON.
MO RIB

If there is battery voltage, replace the fuel pump unit.

G
If there is no voltage, check the following:
– open circuit in the Brown or Green wires
AL ST

– fuel pump relay (page 7-11)

– open circuit in the Black/white wire between the
engine stop switch and fuel pump relay [1]
BR DI

– open circuit in the Gray/red wire between the fuel

pump relay and PCM/ECM
– power/ground lines of the PCM/ECM (page 4-42)
CA SU

REMOVAL
24 O

Remove the ECM stay (page 3-13).

’14 – ’16 models shown: [2]
Disconnect the quick connect fitting [1] from the fuel
-20 BID

pump (page 7-5).

Disconnect the fuel pump breather hose [2].
’14 – ’16 models only: Remove the fuel pump cover [3].
-07 HI
28 O
PR

[1] [3]

7-12
dummyhead

FUEL SYSTEM
Remove the locking ring [1] by rotating it
[2]
counterclockwise using the fuel tank lock ring wrench
as shown.

TOOL:

S. O
Fuel tank lock ring wrench [2] OTC6599

L.
S AD
R.
OR RIZ
OT TO
[1]

Remove the fuel pump unit [1] and O-ring [2].

LM U
[1]
• Be careful not to damage the fuel level sensor.

RA O A
AB N
-C O
L. US [2]
S. N O
INSTALLATION
Install a new O-ring [1].
[2]
R.
RS IÓ

• Clean the O-ring seating area of the fuel tank, and

be sure that no foreign materials are allowed.
• Always replace the O-ring with a new one.
TO UC

Install the fuel pump unit [2] aligning its tab with the
arrow mark.
MO RIB

• Be careful not to damage the fuel level sensor.

AL ST

Align [1]
BR DI

Install a new locking ring [1].

[3]
• Always replace the locking ring with a new one.
CA SU

Turn the locking ring clockwise using the fuel tank lock
ring wrench until the marks [2] of the fuel tank align with
the grooves of the locking ring.
24 O

TOOL:
-20 BID

Fuel tank lock ring wrench [3] OTC6599

Connect the quick connect fitting to the fuel tank unit
(page 7-8).
-07 HI

Install the removed parts in the reverse order of

removal.
28 O

[1] [2]
PR

7-13
 dummyhead

FUEL SYSTEM
DISASSEMBLY/ASSEMBLY

• Clean the inside of the reservoir, fuel pump and filter

with clean gasoline. Never use commercially

S. O
available carburetor cleaners.

L.
S AD
• Always replace all O-rings with new ones when the
fuel pump has been disassembled.

R.
• Be careful not to damage the fuel pump and fuel
level sensor wires.

OR RIZ
Disconnect the connectors [1] and release the wires
[1]
from the guides [2].

OT TO
LM U
RA O A
AB N
[2]

-C O
Unhook the tab [1] and remove the fuel level sensor [2]

L. US
[2]
upward.
S. N O
[1]
R.
RS IÓ
TO UC
MO RIB

Remove the E-rings [1], reservoir [2] and spring [3].

[2] [1]
AL ST
BR DI
CA SU
24 O

[3]
-20 BID
-07 HI
28 O
PR

7-14
dummyhead

FUEL SYSTEM
Remove the return jet [1] and strainer case [2] from the
[2]
reservoir [3].
• Unhook the hooks as shown.

S. O
L.
S AD
R.
OR RIZ
OT TO
[3] [1]

Remove the fuel pump/filter assembly [1] from the

LM U
[3]
strainer case.

RA O A
Remove the fuel pump wire [2] by disconnecting the
fuel pump 2P connector [3].

AB N
-C O
L. US [1] [2]
S. N O
Remove the O-ring [1] and spacer [2].
[1]
Check the filter [3] for clog or damage.
R.
If the filter is clogged or damaged, replace the fuel
RS IÓ

pump unit assembly.

TO UC
MO RIB
AL ST

[2] [3]

Remove the bracket [1] and pressure regulator [2].

BR DI

[3]
Remove the O-rings [3] and back-up ring [4] from the
pressure regulator.
CA SU
24 O
-20 BID
-07 HI

[2] [1] [4]

28 O
PR

7-15
 dummyhead

FUEL SYSTEM
Remove the bracket [1] from the strainer case [2].
[1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

Assembly is in the reverse order of disassembly.

LM U
• Install the fuel level sensor aligning its groove with

RA O A
the strainer case tab.

AB N
-C O
L. US Align
S. N O
FUEL TANK
REMOVAL/INSTALLATION
R.
RS IÓ

Remove the ECM stay (page 3-13).

[2]
Remove the front fender/carrier (page 2-8).
TO UC

Disconnect the quick connect fitting [1] from the fuel

pump (page 7-5).
Disconnect the fuel pump breather hose [2].
MO RIB
AL ST
BR DI

[1]
CA SU

Remove the bolts [1] and collar [2].

[1]/[2]
24 O
-20 BID
-07 HI
28 O
PR

[1]

7-16
dummyhead

FUEL SYSTEM
Remove the two torx bolts (T30) [1], collars [2] and fuel
[3]
tank [3].
Installation is in the reverse order of removal.

S. O
• Quick connect fitting installation (page 7-8)

L.
S AD
R.
OR RIZ
OT TO
[1]/[2]

AIR CLEANER HOUSING

LM U
REMOVAL/INSTALLATION

RA O A
Remove the snorkel duct (page 3-13).
[5] [6]
Disconnect the following:

AB N
– IAT sensor 2P (Black) connector [1]
– crankcase breather hose [2] [1]

-C O
Remove the following:

L. US
– O2 sensor 4P (Black) connector [3]
– trim clips [4]
Loosen the connecting tube band screw [5], position the
air cleaner tabs to allow clearance from the frame and
S. N O
rear fender tabs, and remove the air cleaner housing
[6].
Installation is in the reverse order of removal.
R.
RS IÓ

[4]
TO UC
MO RIB

[4]
AL ST

[2]
BR DI

[3]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

7-17
 dummyhead

FUEL SYSTEM
THROTTLE BODY
REMOVAL

S. O
• If the sensor unit is removed from the throttle body, After '19 AC type shown: [2]

L.
S AD
the TP sensor reset procedure must be performed
after installing the throttle body (page 4-39). [4]

R.
[1]
Remove the air cleaner housing (page 7-17).

OR RIZ
Disconnect the following:
– quick connect fitting [1] from the injector joint (page [6]
7-5)

OT TO
– After '19 AC type only: EVAP purge control solenoid
valve-to-throttle body hose [2]
– IACV 4P (Black) connector [3]

LM U
– fuel injector 2P (Black) connector [4]
– sensor unit 5P (Black) connector [5]

RA O A
Remove the harness clip [6]. [5] [3]

Remove the screw [1].

[2] [1] [7] [6]

AB N
Remove the throttle drum cover [2] while releasing its
tab [3] from the throttle body slot [4].

-C O
Slide the rubber boot [5] off the adjuster [6]. [5]

L. US
Loosen the throttle cable adjuster lock nut [7], remove
the adjuster from the throttle body and disconnect the
cable end [8] from the throttle drum [9].
S. N O
[9]
R.
RS IÓ

[3]/[4] [8]

Loosen the throttle body side insulator band screw [1].

TO UC

[2]
Remove the throttle body [2] from the insulator.
MO RIB
AL ST
BR DI

[1]
CA SU

Loosen the cylinder head side insulator band screw [1].

[1]
Remove the insulator [2] from the cylinder head.
24 O
-20 BID
-07 HI
28 O
PR

[2]

7-18
dummyhead

FUEL SYSTEM
DISASSEMBLY/CLEANING/
ASSEMBLY

S. O
• The throttle body is factory pre-set. Do not

L.
S AD
disassemble in a way other than shown in this
manual.

R.
• Do not snap the throttle valve from full open to full
close after the throttle cable has been removed. It

OR RIZ
may cause incorrect idle operation.
• Do not damage the throttle body. It may cause
incorrect throttle valve operation.
• Do not loosen or tighten the white painted screws [1]

OT TO
and nut [2] of the throttle body. Loosening or
tightening them can cause throttle valve and idle
control failure.

LM U
• Always clean the throttle body before disassembly to
prevent dirt and debris from entering the passages.

RA O A
• Do not remove the sensor unit unless it is replaced. [1] [2]

Remove the following:

[4] [3] [5]
– screw [1] and wire harness clamp stay [2]

AB N
– screw [3] and fuel feed hose clamp stay [4]
– IACV [5] (page 7-21)

-C O
– fuel injector [6] (page 7-22)
– sensor unit [7] (page 4-39)

L. US
S. N O
R.
[7] [1] [2] [6]
RS IÓ

Cleaning the air Clean the air passage of the throttle body using
TO UC

passages and compressed air.

sensor hole with a Check the air passage for clogs.
piece of wire will
damage the throttle
MO RIB

body. • Do not use high pressure air or bring the nozzle too
close to the throttle body.
Assembly is in the reverse order of disassembly.
AL ST

TORQUE:
Wire harness clamp stay screw:
3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
BR DI

Fuel feed hose clamp stay screw:

3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
CA SU

• Install the wire harness clamp stay and fuel feed

hose clamp stay by aligning each stay hole with the
24 O

pin of the throttle body.

-20 BID
-07 HI
28 O
PR

7-19
 dummyhead

FUEL SYSTEM
INSTALLATION
Face the "HR3" Install the insulator [1] onto the cylinder head by
Align [2]
mark [2] toward the aligning the groove with the lug.
throttle body.
Align the cylinder head side insulator band hole with the

S. O
insulator boss.

L.
S AD
R.
OR RIZ
OT TO
[1]

LM U
Tighten the cylinder head side insulator band screw [1]
[1]

RA O A
so that the distance between the band tabs is as
shown. 11.0 – 13.0 mm
(0.43 – 0.51 in)

AB N
-C O
L. US
S. N O
Install the throttle body [1] into the insulator by aligning
[1]
the lug with the groove.
R.
RS IÓ

Align the throttle body side insulator band hole with the
insulator boss.
TO UC

Tighten the throttle body side insulator band screw [2] in

the same way as the cylinder head side.
Align
MO RIB
AL ST

[2]
BR DI

Connect the throttle cable end [1] to the throttle drum

[4] [3] [6] [9]
[2].
CA SU

Tighten the lock nut Install the throttle cable adjuster [3] to the throttle body
and install the and temporarily tighten the lock nut [4]. [5]
adjuster rubber boot
Install the throttle drum cover [6] by aligning the locating
[5] after adjusting
24 O

tab [7] with the slot [8] in the throttle body.

the throttle lever
Install and tighten the screw [9] to the specified torque.
-20 BID

freeplay.
TORQUE: 1.8 N·m (0.2 kgf·m, 1.3 lbf·ft)
Install the removed parts in the reverse order of
[2]
-07 HI

removal.
• Quick connect fitting installation (page 7-9) [1] [7]/[8]
28 O
PR

7-20
dummyhead

FUEL SYSTEM
IACV
INSPECTION
• The IACV is installed on the throttle body and is

S. O
[1]
operated by the step motor. When the ignition switch
is turned ON, the IACV operates for a few seconds.

L.
S AD
Remove the tank cover assembly (page 2-4).

R.
Turn the ignition switch ON and check the IACV [1].

OR RIZ
If the step motor operating sound is heard, the IACV is
normal.

OT TO
LM U
RA O A
The IACV operation can be checked visually as follows:
[1]
1. Remove the IACV (page 7-21).

AB N
2. Connect the IACV 4P (Black) connector [1].
3. Turn the ignition switch ON and check the IACV

-C O
operation.

L. US
S. N O
R.
RS IÓ

REMOVAL/INSTALLATION
Remove the tank cover assembly (page 2-4).
TO UC

[2]
Clean the throttle body to prevent dirt and debris from
entering the IACV passage.
MO RIB

Turn the ignition switch OFF.

Disconnect the IACV 4P (Black) connector [1].
Remove the two torx screws (T20) [2], retainer plate [3]
AL ST

and IACV [4].

BR DI
CA SU

[3] [1] [4]

Install a new O-ring [1] onto the IACV [2].

[1] [3]
Before installing the IACV, turn the slide valve [3]
24 O

clockwise until lightly seated on IACV.

-20 BID
-07 HI
28 O
PR

[2]

7-21
 dummyhead

FUEL SYSTEM
Install the IACV [1] into the throttle body by aligning the
valve groove with the guide pin in the throttle body.

S. O
L.
S AD
R.
OR RIZ
OT TO
Align [1]

Install the retainer plate [1] by aligning the groove with

LM U
[2]
the valve boss.

RA O A
Install and tighten the two torx screws (T20) [2] to the
specified torque.
TORQUE: 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)

AB N
Connect the IACV 4P (Black) connector [3].
Install the tank cover assembly (page 2-4).

-C O
Align

L. US [1] [3]
S. N O
FUEL INJECTOR
REMOVAL/INSTALLATION
R.
RS IÓ

Remove the tank cover assembly (page 2-4).

[2] [4]
Clean the throttle body to prevent dirt and debris from
TO UC

entering the combustion chamber.

Remove the IACV (page 7-21).
MO RIB

Disconnect the quick connect fitting [1] from the injector

joint (page 7-5).
Disconnect the fuel injector 2P (Black) connector [2].
AL ST

Remove the fuel injector mounting bolts [3] and fuel

injector assembly [4] from the throttle body.
BR DI

[1] [3]
CA SU

Remove the fuel injector [1] from the injector joint [2].
’14 - 21 shown:
Remove the O-ring [3] and seal ring [4]. [2]
[1]
’14－’21 models: Remove the dust seal ring [5].
24 O

Installation is in the reverse order of removal.

-20 BID

• Always replace the O-ring and dust seal ring (’14 –

’21 models) with new ones.
• Apply engine oil to the O-ring and seal ring.
-07 HI

TORQUE:
Fuel injector mounting bolt:
28 O

5.1 N·m (0.5 kgf·m, 3.8 lbf·ft)

PR

[4] [5] [3]

7-22
dummyhead

FUEL SYSTEM
EVAP PURGE CONTROL SOLENOID
VALVE/CANISTER (After '19 AC type)
EVAP PURGE CONTROL SOLENOID

S. O
VALVE

L.
S AD
REMOVAL/INSTALLATION

R.
Remove the right center mudguard (page 2-5).
[1] [4]

OR RIZ
Disconnect the EVAP purge control solenoid valve 2P
(Black) connector [1].
Disconnect the EVAP canister-to-purge control solenoid
valve hose [2].

OT TO
Disconnect the EVAP purge control solenoid valve-to-
throttle body hose [3]. [5]

Remove the bolts [4] and EVAP purge control solenoid

LM U
valve [5].

RA O A
[3] [2]

AB N
INSPECTION

-C O
Remove the EVAP purge control solenoid valve (page
[1]
7-23).

L. US
Check the air flow from hose fitting A (input port) to
hose fitting B (output port) of the EVAP purge control
solenoid valve [1].
Air should not flow.
S. N O
Connect a 12 V battery [2] to the solenoid valve 2P
(Black) connector [3] as shown.
Air should flow out when the battery is connected.
Replace the solenoid valve if it does not operate
R.
RS IÓ

properly. (B) (A)

Install the EVAP purge control solenoid valve (page 7-
TO UC

23).

[3]
MO RIB

[2]
AL ST
BR DI

EVAP CANISTER
CA SU

REMOVAL/INSTALLATION
Remove the right center mudguard (page 2-5).
[6] [1] [2] [9]
24 O

Disconnect the EVAP purge control solenoid valve 2P

[7]/[8]
(Black) connector [1].
-20 BID

Release the wire clip [2].

Remove the clamp [3].
Disconnect the fuel pump breather hose [4] from the [4]
EVAP canister A [5].
-07 HI

Disconnect the EVAP purge control solenoid valve-to- [3]

throttle body hose [6].
28 O

Remove the bolts [7], collars [8].

Release the grommet [9] from the frame boss and
PR

remove the EVAP canister assembly.

[5]

[7]/[8]

7-23
 dummyhead

FUEL SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the EVAP purge control solenoid valve (page 7-23).

S. O
L.
S AD
GROMMETS
CANISTER STAY

R.
HEAT PROTECT RUBBER A

OR RIZ
TRIM CLIPS

OT TO
HEAT PROTECT
RUBBER B

LM U
RA O A
AB N
-C O
L. US
S. N O
EVAP CANISTER-to-PURGE
CLAMPS CONTROL SOLENOID VALVE HOSE
TRIM CLIPS
R.
RS IÓ

EVAP CANISTER A HOSE

CLAMPS
TO UC

CLAMPS
MO RIB

CANISTER JOINT HOSE

AL ST
BR DI
CA SU

AIR VENT HOSE

24 O
-20 BID

CLAMPS

CLAMP
-07 HI

CLAMP
CANISTER CONNECT HOSE
28 O

JOINT CAP
PR

EVAP CANISTER B

7-24
dummytext

8. COOLING SYSTEM

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION························ 8-2 THERMOSTAT ······································ 8-6

RA O A
8
TROUBLESHOOTING ···························· 8-3 RADIATOR/COOLING FAN ····················· 8-7

AB N
SYSTEM FLOW PATTERN······················ 8-4 RADIATOR RESERVE TANK··················· 8-9

-C O
SYSTEM TESTING································· 8-5 WATER PUMP ······································ 8-9

L. US
COOLANT REPLACEMENT ···················· 8-5
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

8-1
 dummyhead

COOLING SYSTEM
SERVICE INFORMATION
COOLING SYSTEM

GENERAL

S. O
L.
S AD
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.

R.
OR RIZ
• If any coolant gets in your eyes, rinse them with water and consult a doctor immediately.
• If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
• If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.

OT TO
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.

LM U
• Add cooling system at the reserve tank. Do not remove the radiator cap except to refill or drain the system.

RA O A
• Avoid spilling coolant on painted surfaces.
• After servicing the system, check for leaks with a cooling system tester.
• For cooling fan system inspection, refer to "Lights/Meters/Switches" section (page 23-14).

AB N
TOOLS

-C O
Remover weight Driver Remover shaft, 15 mm

L. US
07741-0010201 07749-0010000 07936-KC10100 (not available in
S. N O U.S.A.)
R.
RS IÓ
TO UC

or 07936-371020A (U.S.A. only)

Remover head, 15 mm Bearing remover, 15 mm Mechanical seal driver attachment
MO RIB

07936-KC10200 (not available in 07936-KC10500 (U.S.A. only) 07945-4150400 (not available in

U.S.A.) U.S.A.)
AL ST
BR DI
CA SU
24 O

Mechanical seal installer

07965-415000A (U.S.A. only)
-20 BID
-07 HI
28 O
PR

8-2
dummyhead

COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
• Thermostat stuck closed

S. O
• Faulty radiator cap
• Insufficient coolant

L.
S AD
• Passage blocked in radiator, hoses or water jacket
• Air in system

R.
• Faulty cooling fan motor

OR RIZ
• Faulty water pump
Engine temperature too low
• Thermostat stuck open

OT TO
Coolant leaks
• Faulty water pump mechanical seal
• Deteriorated O-rings
• Faulty radiator cap

LM U
• Damaged or deteriorated cylinder head gasket

RA O A
• Loose hose connection or clamp
• Damaged or deteriorated hoses

AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

8-3
8-4
PR
dummyhead

28 O
COOLING SYSTEM

-07 HI
-20 BID

WATER PUMP
24 O
RESERVE TANK

CA SU
SYSTEM FLOW PATTERN

THERMOSTAT
BR DI
AL ST
MO RIB
TO UC
RS IÓ
S. N O
R.
L. US
-C O
AB N
RA O A
LM U
OT TO
RADIATOR

OR RIZ
S AD
S. O
R.
L.
dummyhead

COOLING SYSTEM
SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION

S. O
Remove the radiator cap lid (page 2-3).

L.
S AD
Remove the radiator cap [1].

R.
Wet the sealing surfaces of the cap, then install the cap
onto tester [2].

OR RIZ
TOOLS:
Cooling system pressure tester SVTS4AH
Cooling system adaptor OTCJ33984A

OT TO
Pressurize the radiator cap using the tester.
Replace the radiator cap if it does not hold pressure, or

LM U
if relief pressure is too high or too low. It must hold the
specified pressure for at least 6 seconds.

RA O A
RADIATOR CAP RELIEF PRESSURE: [1]
108 – 137 kPa (1.1 – 1.4 kgf/cm2, 16 – 20 psi) [2]
Pressurize the radiator, engine and hoses using the

AB N
tester, and check for leaks.

-C O
L. US
Excessive pressure can damage the cooling system
components. Do not exceed 137 kPa (1.4 kgf/cm2,
20 psi).
S. N O
Repair or replace components if the system will not hold
the specified pressure for at least 6 seconds. [1]
Remove the tester and install the radiator cap.
Install the lid in the reverse order of removal.
R.
RS IÓ

COOLANT REPLACEMENT
TO UC

REPLACEMENT/AIR BLEEDING
• When filling the system with coolant, place the
MO RIB

[3]
vehicle on a flat, level surface.
The engine must be Remove the following:
cool before
– radiator cap lid (page 2-3)
AL ST

servicing the
– tank cover assembly (page 2-4)
cooling system.
Place a funnel Drain the coolant from the system by removing the
BR DI

under the water drain bolt [1] and sealing washer [2] on the water pump,
pump to catch and the radiator cap [3].
coolant in a
CA SU

Reinstall the drain bolt with a new sealing washer

container.
securely.

[2] [1]
24 O
-20 BID
-07 HI
28 O
PR

8-5
 dummyhead

COOLING SYSTEM
Remove the bolt [1], trim clips [2] and reserve tank [3],
[3] [1] [5]
then open the tank cap to drain the tank.
Disconnect the siphon hose [4] to remove the tank.
Rinse the inside of the reserve tank with water.

S. O
Reconnect the siphon hose and install the reserve tank [6]

L.
S AD
with the bolt and trim clips.
Fill the system with the recommended coolant up to the

R.
filler neck [5].

OR RIZ
Bleed air from the system as follows:
1. Shift the transmission into neutral.
Start the engine and let it idle for 2 – 3 minutes.

OT TO
2. Snap the throttle 3 – 4 times to bleed air from the [2] [4]
system.
3. Stop the engine and add coolant up to the filler neck.

LM U
4. Install the radiator cap.

RA O A
Fill the reserve tank to the upper level line [6] and install
the tank cap.
Install the removed parts in the reverse order of
removal.

AB N
-C O
THERMOSTAT

L. US
REMOVAL/INSTALLATION
Drain the coolant from the system (page 8-5).
[1] [5] [3]
Remove the bolts [1], thermostat cover [2] and
S. N O
thermostat [3].
Make sure the rubber seal [4] on the thermostat is in
good condition.
R.
RS IÓ

Installation is in the reverse order of removal.

• Apply coolant to the rubber seal.
TO UC

• Install the thermostat into the housing with the bleed

hole [5] facing inboard.
Fill and bleed the cooling system (page 8-5).
MO RIB

[2] [4]

INSPECTION
AL ST

Visually inspect the thermostat [1] for damage.

[1] [2]
Replace the thermostat if the valve stays open at room
BR DI

temperature.
Do not let the Heat a container of water with an electric heating
thermostat or element for 5 minutes.
CA SU

thermometer [2] Suspend the thermostat in heated water to check its

touch the pan, or operation.
you will get a false
THERMOSTAT BEGIN TO OPEN:
24 O

reading.
80 – 84°C (176 – 183°F)
-20 BID

VALVE LIFT:
8 mm (0.3 in) minimum at 95°C (203°F)
Replace the thermostat if the valve opens at a
-07 HI

temperature other than those specified.

28 O
PR

8-6
dummyhead

COOLING SYSTEM
RADIATOR/COOLING FAN
RADIATOR REMOVAL/INSTALLATION

S. O
• Take care not to damage the radiator fins while

L.
S AD
servicing the radiator.
Drain the coolant from the system (page 8-5).

R.
[3] [2]
Remove the following:

OR RIZ
– front fender/carrier (page 2-8)
– radiator reserve tank (page 8-9)
– FM2/FA2/FA6 only: EPS ECU (page 25-29)

OT TO
Release the front final gear case breather hose [1].
Remove the following:

LM U
– trim clips [2]

RA O A
– radiator grille cover [3]
– radiator grille center cover [4]

[4] [1]

AB N
Release the fan motor breather hose [1].
[1] [3]

-C O
Remove the following:

L. US
– trim clips [2]
– radiator grille cover [3]
S. N O
R.
RS IÓ
TO UC

[2]

Remove the bolt [1].

[1]
MO RIB

Disconnect the following:

– fan motor 2P connector [2]
– water hose [3]
AL ST
BR DI
CA SU

[2] [3]
24 O

Remove the bolt [1].

[3]
-20 BID

Disconnect the water hose [2].

Remove the radiator assembly [3].
-07 HI
28 O
PR

[2] [1]

8-7
 dummyhead

COOLING SYSTEM
Installation is in the reverse order of removal.
• Install the radiator assembly aligning it bosses with
the grommets.
• Route the fan motor breather hose properly

S. O
(page 1-30).

L.
S AD
Fill and bleed the cooling system (page 8-5).

R.
OR RIZ
OT TO
Align

COOLING FAN REMOVAL/

LM U
INSTALLATION

RA O A
Remove the washer-bolts [1] and motor/stay assembly
[1]
[2].

AB N
-C O
L. US
S. N O
[2]

Remove the nut [1] and cooling fan [2].

R.
RS IÓ

[2]
TO UC
MO RIB
AL ST
BR DI

[1]

Remove the following:

CA SU

[2]
– connector [1]
– three bolts [2]
– fan motor [3]
24 O

Installation is in the reverse order of removal.

-20 BID

• Apply locking agent to the cooling fan nut threads.

TORQUE:
Cooling fan nut: 2.7 N·m (0.3 kgf·m, 2.0 lbf·ft)
-07 HI

Fan motor bolt: 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)

Fan motor stay bolt: 8.4 N·m (0.9 kgf·m, 6.2 lbf·ft)
28 O

[1] [3]
PR

8-8
dummyhead

COOLING SYSTEM
RADIATOR RESERVE TANK
REMOVAL/INSTALLATION
Remove the radiator cap lid (page 2-3).

S. O
[5] [3] [1]
Remove the bolt [1], trim clips [2] and reserve tank [3],

L.
S AD
then open the tank cap to drain the tank.
Disconnect the siphon hose [4] to remove the tank.

R.
Installation is in the reverse order of removal.

OR RIZ
Connect the siphon hose and install the reserve tank
with the two bolts.
Fill the reserve tank to the upper level line [5] and install

OT TO
the tank cap.

LM U
[2] [4]

RA O A
WATER PUMP
MECHANICAL SEAL INSPECTION

AB N
Remove the tank cover assembly (page 2-4).

-C O
Check the bleed hose [1] of the water pump for signs of
coolant leakage.

L. US
If water leaks through the bleed hose, replace the
[1]
mechanical seal (page 8-9).
If oil leaks through the bleed hole, replace the oil seal
S. N O
(page 8-9).
Make sure that there are no continuous coolant leakage
from the bleed hose while operating the engine.
R.
RS IÓ

• A small amount of coolant weeping from the bleed

hose is normal.
TO UC

MECHANICAL SEAL REPLACEMENT

MO RIB

• When replacing the mechanical seal, the impeller

and pump shaft must be replaced with new ones.
AL ST

Remove the front crankcase cover.

[1]
– Except FA models: page 12-5
– FA models: page 13-54
BR DI

[3]
Remove the following:
– five bolts [1] and sealing washer [2]
CA SU

– pump cover [3]

– O-ring [4] (from the cover)
24 O
-20 BID

[2] [4]
-07 HI
28 O
PR

8-9
 dummyhead

COOLING SYSTEM
Remove the impeller assembly from the pump shaft by
[1]
tapping the inside of the impeller [1] through the pump
shaft [2], using a screwdriver or equivalent.
[3]
Remove the following:

S. O
– pump shaft
– thrust washer [3]

L.
S AD
R.
OR RIZ
OT TO
[2]

Remove the mechanical seal [1].

LM U
[1]
TOOLS:

RA O A
Remover Head, 15 mm 07936-KC10200
Remover Shaft, 15 mm 07936-KC10100
Remover Weight 07741-0010201

AB N
U.S.A. TOOLS:
Bearing remover, 15 mm 07936-KC10500

-C O
Remover weight 07936-371020A

L. US
S. N O
Remove the oil seal [1].
Apply molybdenum oil solution to the lips of a new oil
seal. [1]
R.
RS IÓ

Install the oil seal with the flat side facing out until it is
fully seated.
TO UC
MO RIB
AL ST

Be careful not to Drive a new mechanical seal [1] in until it is seated.

BR DI

damage the sliding

surface of the TOOLS:
mechanical seal. Driver [2] 07749-0010000 [2]
CA SU

Mechanical seal driver 07945-4150400

attachment [3]

U.S.A. TOOL:
24 O

[3]
Mechanical seal installer 07965-415000A
-20 BID

(U.S.A. only) [1]

-07 HI
28 O
PR

8-10
dummyhead

COOLING SYSTEM
Be careful not to Apply coolant around a new cup gasket [1] and install it
damage the sliding to a new mating ring [2]. Install the mating ring
[1]
surface of the assembly into a new impeller [3] with the gasket facing
mating ring. the impeller until it is fully seated. [3]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

Do not get oil on the Apply molybdenum oil solution to the journal [1] of a
[2]

LM U
mechanical seal. new pump shaft [2].
Install the washer [3] onto the pump shaft, and insert

RA O A
the shaft into the crankcase cover.

AB N
-C O
L. US [3] [1]
S. N O
Never allow dirt or Degrease [1] the press fitting areas of the impeller [2]
dust to get onto the and shaft [3], and the sliding surfaces of the mechanical
sliding surfaces of seal and mating ring. [2]
the mechanical seal Press the impeller assembly onto the shaft.
R.
RS IÓ

[1]
and mating ring.
Check that the pump shaft turns smoothly without
binding.
TO UC
MO RIB
AL ST

[3]
BR DI
CA SU

Install a new O-ring [1] into the cover groove [2].

24 O

[1]
-20 BID
-07 HI

[2]
28 O
PR

8-11
 dummyhead

COOLING SYSTEM
Install the pump cover [1] and the five bolts [2] with a
new sealing washer [3] in position as shown (triangular [2]
mark [4]). Tighten the bolts in a crisscross pattern in
several steps.

S. O
[1]
Install the front crankcase cover.

L.
S AD
– Except FA models: page 12-7
– FA models: page 13-58

R.
OR RIZ
OT TO
[3] [4]

LM U
RA O A
AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

8-12
dummytext

9. LUBRICATION SYSTEM

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION························ 9-2 OIL PUMP (Except FA models) ··············· 9-6

RA O A
TROUBLESHOOTING ···························· 9-3 RELIEF VALVE (Except FA models) ········ 9-7
9

AB N
LUBRICATION SYSTEM DIAGRAM OIL PRESSURE CHECK (FA models)······· 9-7
(Except FA models) ······························· 9-4

-C O
OIL PUMP/RELIEF VALVE (FA models)···· 9-8

L. US
LUBRICATION SYSTEM DIAGRAM
(FA models) ········································· 9-5
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

9-1
 dummyhead

LUBRICATION SYSTEM
SERVICE INFORMATION
LUBRICATION SYSTEM

GENERAL

S. O
L.
S AD
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

R.
possible after handling used oil.

OR RIZ
• This section covers service of the oil pump and relief valve. The service procedures in this section can be performed 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.

OT TO
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• Oil level check and oil change
– Except FA models: page 3-17

LM U
– FA models: page 3-19
• Oil filter replacement

RA O A
– Except FA models: page 3-20
– FA models: page 3-21

AB N
TOOL
Oil pressure gauge set

-C O
07406-0070002

L. US
S. N O
R.
RS IÓ
TO UC

or 07ZMJ-HN2A100 and 07AMJ-

HN8A100 (U.S.A. Only)
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

9-2
dummyhead

LUBRICATION SYSTEM
TROUBLESHOOTING
Oil level too low – high oil consumption
• Normal oil consumption

S. O
• External oil leak
• Worn piston rings or incorrect piston ring installation

L.
S AD
• Worn cylinder
• Worn valve guides or stem seals

R.
Low oil pressure (only for FA models)

OR RIZ
• Oil level low
• Oil pressure relief valve wear
• Clogged oil strainer or filter
• Faulty oil pump

OT TO
• Internal oil leak
• Incorrect oil being used
No oil pressure (only for FA models)

LM U
• Oil level too low

RA O A
• Oil pressure relief valve stuck open
• Damaged oil pump
• Internal oil leak
High oil pressure (only for FA models)

AB N
• Oil pressure relief valve stuck closed
• Clogged oil gallery or orifice

-C O
• Incorrect oil being used
Oil contamination

L. US
• Oil or filter not changed often enough
• Worn piston rings or incorrect piston ring installation
• Worn valve guides or stem seals
• Clogged oil strainer screen
S. N O
Oil emulsification
• Blown cylinder head gasket
• Leaky coolant passage
R.
RS IÓ

• Water entry
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

9-3
 dummyhead

LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM (Except FA models)

S. O
CYLINDER
HEAD COVER

L.
S AD
R.
OR RIZ
CYLINDER HEAD

OT TO
LM U
CENTRIFUGAL CYLINDER

RA O A
CLUTCH

AB N
CRANKSHAFT

-C O
L. US
S. N O
RELIEF
VALVE
R.
RS IÓ
TO UC
MO RIB

REAR CRANKCASE COVER

OIL FILTER
AL ST

MAINSHAFT
BR DI

FRONT CRANKCASE COVER

OIL PUMP
CA SU

OIL STRAINER
24 O

SCREEN
-20 BID
-07 HI
28 O
PR

COUNTERSHAFT

9-4
dummyhead

LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM (FA models)

S. O
CYLINDER HEAD COVER

L.
S AD
R.
OR RIZ
CYLINDER HEAD

OT TO
CYLINDER

OIL FILTER

LM U
RA O A
AB N
CRANKSHAFT

-C O
CENTRIFUGAL
CLUTCH MAINSHAFT

ORIFICE
L. US
S. N O
RELIEF VALVE
R.
RS IÓ
TO UC
MO RIB
AL ST

RELIEF VALVE
BR DI

1st SHIFT
SHIFT VALVE 2nd SHIFT COUNTERSHAFT
CLUTCH
BODY CLUTCH
CA SU
24 O
-20 BID

OIL PUMP
-07 HI

OIL TANK
28 O
PR

OIL STRAINER SCREEN

9-5
 dummyhead

LUBRICATION SYSTEM
OIL PUMP (Except FA models)
REMOVAL/INSTALLATION
Remove the front crankcase cover (page 12-5).

S. O
[2]
Remove the three bolts [1] and oil pump [2].

L.
S AD
R.
OR RIZ
OT TO
LM U
[1]

RA O A
Install the oil pump [1] onto the crankcase by aligning
[3]
the pump shaft end [2] with the balancer shaft groove
[3].

AB N
Install the removed parts in the reverse order of
removal.

-C O
L. US
S. N O
[1] [2]
R.
RS IÓ

DISASSEMBLY/ASSEMBLY
Remove the bolt [1] and rotor side plate [2].
TO UC

[1] [2]
MO RIB
AL ST
BR DI
CA SU

Remove the pump shaft [1] and drive pin [2]

[3] [1] [5]
Remove the inner rotor [3] and outer rotor [4] from the
24 O

pump body [5].

-20 BID

Dip all parts in clean engine oil.

Assemble the oil pump in the reverse order of
disassembly.
-07 HI
28 O
PR

[2] [4]

9-6
dummyhead

LUBRICATION SYSTEM
INSPECTION
Inspect the following parts for abnormal wear or
damage. Replace or clean if necessary.

S. O
– oil pump shaft
– drive pin

L.
S AD
– inner and outer rotors
– oil pump body

R.
Measure the oil pump clearances according to

OR RIZ
LUBRICATION SYSTEM SPECIFICATIONS
(page 1-11).
If any of the measurement is out of the service limit,

OT TO
replace the oil pump as an assembly.

RELIEF VALVE (Except FA models)

LM U
RA O A
REMOVAL/INSTALLATION
Remove the front crankcase cover (page 12-5).
[1]
Remove the relief valve assembly [1] from the front

AB N
crankcase cover.
Remove the O-ring from the relief valve body.

-C O
Check the operation of the relief valve by pushing on
the piston.

L. US
Replace the relief valve assembly if necessary.
S. N O
R.
RS IÓ

Coat a new O-ring [1] with engine oil and install it into
[2]
the relief valve body groove.
TO UC

Install the relief valve assembly [2] into the front

crankcase cover.
Install the front crankcase cover (page 12-7).
MO RIB
AL ST
BR DI

[1]
CA SU

OIL PRESSURE CHECK (FA models)

Failure to warm the Check the oil level and add the recommended oil if
[1]
necessary (page 3-19).
24 O

engine will cause

very high oil Also, warm the engine to normal operating temperature
-20 BID

pressure readings. and check for external leaks.

External leaks will
Remove the tank cover assembly (page 2-4).
cause low oil
pressure readings. Remove the oil gallery sealing bolt [1] and washer [2]
-07 HI

on the right side of the front crankcase cover.

28 O

• Clean around the sealing bolt with compressed air

before removing the bolt, and be sure that no dirt
PR

enters the oil gallery.

[2]

9-7
 dummyhead

LUBRICATION SYSTEM
Connect an oil pressure gauge and adapter to the oil
[1]
gallery hole.

TOOLS:
Oil pressure gauge set [1] 07406-0070002

S. O
U.S.A. TOOLS:

L.
S AD
Oil pressure gauge 0–160 psi 07ZMJ-HN2A100
and

R.
Adapter, banjo 8 x 1.25 mm 07AMJ-HN8A100

OR RIZ
Start the engine and check the oil pressure.
OIL PRESSURE (80°C/176°F):
510 kPa (5.2 kgf/cm2, 74 psi) at 5,000 rpm

OT TO
Stop the engine and remove the oil pressure gauge and
hose.

LM U
Install the sealing bolt [1] with a new sealing washer [2]
[1]
and tighten the bolt securely.

RA O A
Start the engine and make sure there are no oil leaks.

AB N
-C O
L. US
S. N O
[2]

OIL PUMP/RELIEF VALVE (FA models)

R.
RS IÓ

DISASSEMBLY
Remove the front crankcase cover and spacer (page
TO UC

[2]
13-54).
Remove the following:
MO RIB

– five bolts [1]

– oil pump body A [2]
AL ST
BR DI

[1]
CA SU

– outer rotor C [1]

[2] [1]
– inner rotor C [2]
– drive pin [3]
24 O
-20 BID
-07 HI
28 O
PR

[3]

9-8
dummyhead

LUBRICATION SYSTEM
– oil pump body B [1]
[1]
– pressure relief valve [2]
– O-ring [3] (from the relief valve)
– two dowel pins [4]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]/[3] [4]

– oil pump shaft [1]

LM U
[3] [1]
– drive pin [2]
– outer rotor A [3]

RA O A
– inner rotor A [4]
Clean all the disassembled parts thoroughly.

AB N
-C O
L. US [4] [2]
S. N O
INSPECTION
Inspect the following parts for abnormal wear or
damage. Replace or clean if necessary.
R.
RS IÓ

– oil pump shaft

– drive pins
TO UC

– inner rotors A and C

– outer rotors A and C
– oil pump body B
MO RIB

– front crankcase cover spacer (oil pump body)

Check the operation of the relief valve by pushing on
the piston.
Replace the relief valve assembly if necessary.
AL ST

Measure the oil pump clearances according to

LUBRICATION SYSTEM SPECIFICATIONS
BR DI

(page 1-11).
If any of the measurement is out of the service limit,
replace the oil pump as an assembly.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

9-9
 dummyhead

LUBRICATION SYSTEM
ASSEMBLY
Assembly is essentially in the reverse order of
disassembly.

S. O
• Dip the inner rotors, outer rotors and pump shaft in
clean engine oil.

L.
S AD
• Replace the O-ring with a new one.
• Coat O-ring with engine oil.

R.
OR RIZ
FRONT CRANKCASE COVER SPACER
PRESSURE RELIEF VALVE

OT TO
O-RING

LM U
RA O A
PUMP BODY B

AB N
DOWEL PIN
OUTER ROTOR A

-C O
INNER ROTOR C

L. US
INNER ROTOR A
S. N O
DRIVE PINS

DOWEL PIN
R.
RS IÓ

OUTER ROTOR C
TO UC
MO RIB

PUMP SHAFT
PUMP BODY A
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

9-10
dummytext

10. CYLINDER HEAD/VALVE

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 10-2 CYLINDER HEAD COVER····················· 10-6

RA O A
TROUBLESHOOTING ·························· 10-3 CYLINDER HEAD ······························· 10-10

AB N
SYSTEM COMPONENTS ······················ 10-4 CAMSHAFT ······································· 10-16
10

-C O
CYLINDER COMPRESSION ·················· 10-6

L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

10-1
 dummyhead

CYLINDER HEAD/VALVE
SERVICE INFORMATION
CYLINDER HEAD/VALVE

GENERAL
• This section covers service of the rocker arms, cylinder head, valves and camshaft. These services can be done with the engine

S. O
installed in the frame.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.

L.
S AD
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.

R.
• Rocker arm and valve lubricating oil is fed through oil passages in the cylinder head and head cover. Clean the oil passages
before assembling cylinder head.

OR RIZ
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike the
cylinder head too hard during removal.

OT TO
TOOLS
Valve spring compressor Valve guide driver, 6 mm Valve guide reamer, 6 mm

LM U
07757-0010000 07942-6570100 07VMH-MBB0200

RA O A
AB N
-C O
L. US
or 07VMH-MBB020A (U.S.A. only)
S. N O
Seat cutter, 40 mm (IN 45°) Seat cutter, 33 mm (EX 45°) Flat cutter, 38.5 mm (IN 32°)
07780-0010500 07780-0010800 07780-0012400
R.
RS IÓ
TO UC
MO RIB

or equivalent commercially available in or equivalent commercially available in or equivalent commercially available in

AL ST

U.S.A. U.S.A. U.S.A.

Flat cutter, 33 mm (EX 32°) Interior cutter, 37.5 mm (IN 60°) Interior cutter, 34 mm (EX 60°)
07780-0012900 07780-0014100 07780-0014700
BR DI
CA SU
24 O
-20 BID

or equivalent commercially available in or equivalent commercially available in or equivalent commercially available in

-07 HI

U.S.A. U.S.A. U.S.A.

28 O
PR

10-2
dummyhead

CYLINDER HEAD/VALVE
Cutter holder, 6 mm
07VMH-MBB0100

S. O
L.
S AD
R.
OR RIZ
OT TO
or equivalent commercially available in
U.S.A.

LM U
TROUBLESHOOTING

RA O A
• Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by
tracing top-end noise with a sounding rod or stethoscope.

AB N
• If the performance is poor at low speeds, check for a white smoke in the crankcase breather hose. If the hose is smoky, check
for seized piston ring (page 11-4).

-C O
Compression too low, hard starting or poor performance at low speed
• Valves

L. US
– Incorrect valve adjustment
– Burned or bent valves
– Incorrect valve timing
– Broken valve spring
S. N O
– Uneven valve seating
– Valve stuck open
• Cylinder head
– Leaking or damaged cylinder head gasket
R.
RS IÓ

– Warped or cracked cylinder head

– Loose spark plug
• Cylinder/piston problem (page 11-2)
TO UC

Compression too high

• Excessive carbon build-up on piston head or combustion chamber
• Worn or damaged decompressor system
MO RIB

Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
AL ST

• Cylinder/piston problem (page 11-2)

Excessive noise
BR DI

• Incorrect valve clearance

• Sticking valve or broken valve spring
• Excessively worn valve seat
• Worn or damaged camshaft
CA SU

• Worn rocker arm and/or shaft

• Worn rocker arm follower or valve stem end
• Worn or damaged push rod and/or cam follower
24 O

• Worn cam chain

• Worn or damaged cam chain tensioner
-20 BID

• Worn cam sprocket teeth

• Cylinder/piston problem (page 11-2)
Rough idle
• Low cylinder compression
-07 HI
28 O
PR

10-3
 dummyhead

CYLINDER HEAD/VALVE
SYSTEM COMPONENTS

S. O
L.
S AD
R.
OR RIZ
OT TO
12 N·m (1.2 kgf·m, 9 lbf·ft)

LM U
RA O A
39 N·m (4.0 kgf·m, 29 lbf·ft)

AB N
-C O
22 N·m (2.2 kgf·m, 16 lbf·ft)

L. US
39 N·m (4.0 kgf·m, 29 lbf·ft)
S. N O
63 N·m (6.4 kgf·m, 46 lbf·ft)
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID

32 N·m (3.3 kgf·m, 24 lbf·ft)

-07 HI
28 O
PR

10-4
dummyhead

CYLINDER HEAD/VALVE

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
27 N·m (2.8 kgf·m, 20 lbf·ft)

-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID

12 N·m (1.2 kgf·m, 9 lbf·ft)

-07 HI
28 O
PR

12 N·m (1.2 kgf·m, 9 lbf·ft)

10-5
 dummyhead

CYLINDER HEAD/VALVE
CYLINDER COMPRESSION
Warm up the engine to normal operating temperature.
[1]
Stop the engine and remove the spark plug (page 3-

S. O
12).
Install the compression gauge [1] into the spark plug

L.
S AD
hole.

R.
Shift the transmission into neutral.
Open the throttle all the way and crank the engine with

OR RIZ
the starter motor until the gauge reading stops rising.
The maximum reading is usually reached within 4 – 7
seconds.

OT TO
The cylinder COMPRESSION PRESSURE:
compression 500 kPa (5.1 kgf/cm2, 73 psi) at 400 rpm
specification is

LM U
comparatively low Check that there is no leakage at the gauge connection.
because the

RA O A
Low compression can be caused by:
camshaft has a
decompression – blown cylinder head gasket
device installed. – improper valve adjustment
– valve leakage

AB N
– worn piston ring or cylinder
High compression can be caused by:

-C O
– carbon deposits in combustion chamber or on piston

L. US
head

CYLINDER HEAD COVER

S. N O
REMOVAL
Raise the left side of the heat protector and set the
[2] [3]
R.
RS IÓ

piston position to Top Dead Center on the compression

stroke (page 3-13).
TO UC

If you plan to remove the rocker arms, loosen the two

rocker arm shaft retaining bolts [1].
Remove the following:
MO RIB

– eight cylinder head cover bolts [2]

– cylinder head cover [3]
AL ST
BR DI

[1]
Mark the push rods – push rods [1]
[1] [2]
so they can be – gasket [2]
CA SU

placed back in their – two dowel pins [3]

original locations.
24 O
-20 BID
-07 HI
28 O

[3]
PR

10-6
dummyhead

CYLINDER HEAD/VALVE
DISASSEMBLY
Remove the two rocker arm shaft retaining bolts [1] and
[1]
sealing washers [2].

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

LM U
Push each rocker arm shaft [1] with a small screwdriver
[4]

RA O A
through the bolt hole until the O-ring [2] on the shaft is
removed out of the head cover.
Remove the following:

AB N
– rocker arm shafts
– rocker arms [3]
– setting plates [4]

-C O
– O-rings

L. US
S. N O
[3] [1] [2]

INSPECTION
R.
Inspect the following parts for damage, abnormal wear,
RS IÓ

deformation, burning or clogs in oil passages. Replace

or clean if necessary.
TO UC

– Rocker arm
– Rocker arm shaft
– Push rod
MO RIB

Measure each part and clearance according to

CYLINDER HEAD/VALVES SPECIFICATIONS (page
1-12).
AL ST

Replace any part if it is out of service limit.

If the push rod is worn or damaged, check the cam
BR DI

follower and camshaft (page 10-16).

CA SU
24 O
-20 BID
-07 HI
28 O
PR

10-7
 dummyhead

CYLINDER HEAD/VALVE
ASSEMBLY

S. O
EXHAUST ROCKER ARM

L.
S AD
R.
OR RIZ
SETTING PLATE

OT TO
LM U
RA O A
INTAKE ROCKER ARM

AB N
-C O
SEALING WASHER

L. US
RETAINING BOLT
S. N O
ROCKER ARM SHAFT
O-RING
R.
RS IÓ

Blow through the oil passages in the cylinder head

[2]
cover with compressed air.
TO UC

Coat new O-rings [1] with engine oil and install them
into the grooves in the rocker arm shafts [2].
Apply molybdenum oil solution to the sliding surfaces of
MO RIB

the rocker arm shafts.

AL ST
BR DI

[1]
CA SU

Place the setting plates [1] on the cylinder head cover

[1]
as shown.
24 O
-20 BID
-07 HI
28 O
PR

10-8
dummyhead

CYLINDER HEAD/VALVE
Intake rocker arm Install the intake rocker arm [3] and exhaust rocker arm
[4] [2]
has "IN" mark [1] [4] properly, and insert the rocker arm shafts.
and exhaust rocker
arm has "EX" mark

S. O
[2].

L.
S AD
R.
OR RIZ
OT TO
[3] [1]

Align the bolt holes in the cylinder head cover and

[2]

LM U
rocker arm shaft by turning the shaft with a screwdriver.

RA O A
Install the rocker arm shaft retaining bolts [1] with new
sealing washers [2].

AB N
-C O
L. US [1]
S. N O
INSTALLATION
Clean the mating surfaces of the head cover and
[1]
cylinder head, being careful not to damage them.
R.
RS IÓ

Install the push rods [1] onto the cam followers.

Make sure the piston is TDC (Top Dead Center) on the
TO UC

compression stroke by checking the push rod height.

If the exhaust side push rod height is high, rotate the
crankshaft clockwise one full turn and align the "T" mark
MO RIB

with the index notch again.

AL ST
BR DI

Install the two dowel pins [1] and a new gasket [2].
[1]
Rest the push rods onto the gasket grooves as shown.
CA SU
24 O
-20 BID
-07 HI
28 O

[2]
PR

10-9
 dummyhead

CYLINDER HEAD/VALVE
Apply engine oil to the rocker arm followers and
[2] [1]
adjusting screw, and install the cylinder head cover [1].
Make sure there is no clearance at the mating surface
of the cylinder head and cover.

S. O
Install the eight bolts [2] and tighten them in a
crisscross pattern in several steps.

L.
S AD
Tighten the rocker arm shaft retaining bolts [3].

R.
Adjust the valve clearance (page 3-13).

OR RIZ
OT TO
[3]

CYLINDER HEAD

LM U
REMOVAL

RA O A
Remove the following:
[2] [3]
– throttle body (page 7-18)
– exhaust system (page 2-14)

AB N
– thermostat (page 8-6)
– cylinder head cover (page 10-6)

-C O
– Spark plug [1]
– ECT sensor [2] and O-ring [3]

L. US
Loosen the water hose band screw [4] and disconnect
the hose from the cylinder head.
S. N O
[4] [1]
R.
RS IÓ

Remove the following:

[1]
– upper engine hanger nut [1] and bolt (frame side) [2]
TO UC

– upper engine hanger bolts (engine side) [3]

– engine hanger bracket [4] and mounting rubbers [5]
MO RIB

[2]
AL ST
BR DI

[5] [4] [3]

CA SU

Loosen the two cylinder bolts [1].

[3] [1] [2]
Be careful not to let Loosen the cylinder head bolt [2] and nuts [3] in a
the nuts and crisscross pattern in several steps, and remove the bolt,
24 O

washers fall into the nuts and washers.

crankcase.
Remove the cylinder head [4], being careful not to
-20 BID

damage the mating surfaces.

-07 HI
28 O
PR

[4]

10-10
dummyhead

CYLINDER HEAD/VALVE
Remove the gasket [1] and two dowel pins [2].
[1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

DISASSEMBLY

LM U
Remove the cylinder head (page 10-10).

RA O A
To prevent loss of Remove the valve spring cotters using the valve spring
tension, do not compressor [1].
compress the valve
springs more than
TOOL:

AB N
necessary. Valve spring compressor 07757-0010000

-C O
L. US
S. N O
[1]

Mark all the parts Remove the following:

so they can be
R.
– spring retainer [1]
RS IÓ

placed back in their [5]

– outer and inner valve springs [2]
original locations.
– valve [3]
TO UC

[2]
– stem seal [4]
– spring seat [5]
MO RIB

[1]
AL ST

[3]

[4]
BR DI

INSPECTION
Inspect the following parts for damage, abnormal wear,
CA SU

deformation, burning or clogs in oil passage. Replace or

clean if necessary.
– cylinder head
24 O

– valve springs
– valves
-20 BID

Measure each part according to CYLINDER HEAD/

VALVE SPECIFICATIONS (page 1-12).
Replace any part if it is out of service limit.
-07 HI
28 O
PR

10-11
 dummyhead

CYLINDER HEAD/VALVE
VALVE GUIDE REPLACEMENT
Mark new valve guide at the specified height indicated
[1]
below, using a maker.
Chill the new valve guides in a freezer for about an

S. O
hour.

L.
S AD
Be sure to wear Heat the cylinder head to 130 – 140 °C (275 – 290 °F)
heavy gloves to with a hot plate or oven. Do not heat the cylinder head

R.
avoid burns when beyond 150°C (300°F). Use temperature indicator

OR RIZ
handling the heated sticks, available from welding supply stores, to be sure
cylinder head. the cylinder head is heated to the proper temperature.
Using a torch to
Support the cylinder head and drive the valve guides
heat the cylinder
out of the cylinder head from the combustion chamber

OT TO
head may cause
side.
warpage.
TOOL:

LM U
Valve guide driver, 6 mm [1] 07942-6570100

RA O A
Remove the new valve guides from the freezer.
[1]
While the cylinder head is still heated, drive each valve
guide in the cylinder head from the rocker arm side until
the exposed height is at the specified value (at the

AB N
mark).
TOOL:

-C O
Valve guide driver, 6 mm [1] 07942-6570100

L. US
VALVE GUIDE PROJECTION:
IN/EX: 14.8 – 15.0 mm (0.58 – 0.59 in)
Let the cylinder head cool to room temperature.
S. N O
Use cutting oil on Ream the new valve guides.
R.
RS IÓ

the reamer during Insert the reamer from the combustion chamber side of
this operation. Take the cylinder head and always rotate the reamer clock-
care not to tilt or wise.
TO UC

lean the reamer in

the guide while
TOOL:
reaming. Valve guide reamer, 6 mm [1] 07VMH-MBB0200 or
MO RIB

07VMH-MBB020A
(U.S.A. only)
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve seat
AL ST

(page 10-13).
BR DI

[1]

VALVE SEAT INSPECTION/REFACING

CA SU

INSPECTION
Clean all intake and exhaust valves thoroughly to
remove carbon deposits.
24 O

Apply a light coating of Prussian Blue to each valve

seat.
-20 BID

Tap the valve against the valve seat several times

without rotating the valve, to check for proper valve seat
contact.
-07 HI
28 O
PR

10-12
dummyhead

CYLINDER HEAD/VALVE
REFACING
Reface the valve seat using the following tools.

TOOLS:

S. O
Seat cutter, 40 mm (IN 45°) 07780-0010500
Seat cutter, 33 mm (EX 45°) 07780-0010800

L.
S AD
Flat cutter, 38.5 mm (IN 32°) 07780-0012400

R.
Flat cutter, 33 mm (EX 32°) 07780-0012900
Interior cutter, 37.5 mm (IN 60°) 07780-0014100

OR RIZ
Interior cutter, 34 mm (EX 60°) 07780-0014700
Cutter holder, 6 mm 07VMH-MBB0100
or equivalent commercially available in U.S.A.

OT TO
VALVE SEAT WIDTH: 1.2 mm (0.05 in)

LM U
• Follow the refacer manufacturer’s operating OLD SEAT
WIDTH

RA O A
instructions.
• Be careful not to grind the seat more than
necessary. 32°
1. Use a 45° seat cutter, remove any roughness or

AB N
irregularities from the seat.
2. Use a 32° flat cutter, remove the top 1/4 of the OLD SEAT

-C O
existing valve seat material. WIDTH
3. Use a 60° interior cutter, remove the bottom 1/4 of

L. US
the existing valve seat material.
4. Using a 45° seat cutter, cut the seat to the proper
width.
5. After cutting the seat, apply lapping compound to the 60°
S. N O
valve face, and lap the valve using light pressure.

• Excessive lapping pressure may deform or damage

R.
the seat.
RS IÓ

• Change the angle of hand lapping tool [1] frequently [1]

to prevent uneven seat wear.
TO UC

• Do not allow lapping compound to enter the guides.

After lapping, wash any residual compound off the
cylinder head and valve and recheck the seat contact.
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

10-13
 dummyhead

CYLINDER HEAD/VALVE
ASSEMBLY

VALVE COTTERS INNER VALVE SPRING

S. O
L.
S AD
SPRING RETAINER

R.
OUTER VALVE SPRING

OR RIZ
OT TO
STEM SEAL

LM U
SPRING SEAT

RA O A
VALVE GUIDE

AB N
-C O
L. US EXHAUST VALVE
S. N O
INTAKE VALVE
R.
RS IÓ

Blow through the oil passage in the cylinder head with

[2]
compressed air.
TO UC

Install the spring seats [1] and new stem seals [2].
Lubricate the valve stem sliding surface with
molybdenum oil solution.
MO RIB

Insert the valve [3] into the guide while turning it slowly
to avoid damaging the stem seal.
AL ST
BR DI

[3] [1]
CA SU

Install the inner and outer valve springs with the tightly
wound coils facing the combustion chamber [1].
Install the spring retainer.
24 O
-20 BID
-07 HI
28 O

[1]
PR

10-14
dummyhead

CYLINDER HEAD/VALVE
Grease the cotters Install the valve spring cotters using the valve spring
to ease installation. compressor [1].
To prevent loss of
tension, do not TOOL:
Valve spring compressor 07757-0010000

S. O
compress the valve
springs more than

L.
S AD
necessary.

R.
OR RIZ
OT TO
[1]

Support the cylinder Tap the valve stems gently with a plastic hammer and

LM U
head so the valve shaft as shown to seat the cotters firmly.
heads will not

RA O A
Install the cylinder head (page 10-15).
contact anything
that cause damage.

AB N
-C O
L. US
S. N O
INSTALLATION
Clean the mating surfaces of the cylinder and cylinder
[2]
head, being careful not to damage them.
R.
RS IÓ

Install the two dowel pins [1] and a new gasket [2] with
the mark facing up.
TO UC
MO RIB
AL ST

[1]
BR DI

Install the cylinder head on the cylinder.

[5]
Be careful not to let Apply engine oil to the threads and seating surface of
CA SU

the nuts and the cap nuts [1] and flange nuts [2], and install the [4]
washers fall into the washers [3] and nuts.
crankcase. Tighten the nuts in a crisscross pattern in several steps.
[1]/[3]
24 O

TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft)

-20 BID

Install the cylinder head bolt [4] and tighten it.

Tighten the two cylinder bolts [5].
-07 HI
28 O

[2]/[3]
PR

10-15
 dummyhead

CYLINDER HEAD/VALVE
Install the mounting rubbers [1] onto the hanger bracket
[1]
bushing [2] with the large I.D. side facing in.

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]
Insert the 10 mm Install the engine hanger bracket with the 8 mm bolts
[3]

LM U
(frame side) bolt [1], 10 mm bolt [2] and nut [3].
from the front side.

RA O A
Tighten the engine hanger bolts and nut.
TORQUE:
10 mm nut: 63 N·m (6.4 kgf·m, 46 lbf·ft) [2]
8 mm bolt: 32 N·m (3.3 kgf·m, 24 lbf·ft)

AB N
-C O
L. US [1]
S. N O
Connect the water hose to the cylinder head and tighten
[3] [2]
the hose band screw [1].
Coat a new O-ring [2] with engine oil and install it onto
R.
RS IÓ

the ECT sensor [3].

Install the ECT sensor and tighten it.
TO UC

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Install the spark plug [4] and tighten it.
MO RIB

TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)

Install the following:
– cylinder head cover (page 10-9)
AL ST

– throttle body (page 7-20) [1] [4]

– exhaust system (page 2-14)
– thermostat (page 8-6)
BR DI

CAMSHAFT
CA SU

REMOVAL
Remove the following:
24 O

[1]
– cylinder (page 11-4)
-20 BID

– Except FA models: change clutch/primary drive gear

(page 12-12)
– FA models: dual clutch/primary driven gear (page
13-85)
-07 HI

Mark the followers Remove the cam followers [1] from the crankcase.
so they can be
28 O

placed back in their

original locations.
PR

10-16
dummyhead

CYLINDER HEAD/VALVE
Push in the tensioner lifter shaft [1] while pressing the
[5] [3]
ratchet pawl [2] and insert a pin into the hole [3] to hold
the tensioner lifter shaft.
Remove the two bolts [4] and cam chain tensioner lifter

S. O
[5].

L.
S AD
R.
OR RIZ
OT TO
[1] [2] [4]

Remove the following:

LM U
[2] [3]
– tensioner pivot bolt [1]

RA O A
– cam chain tensioner [2]
– washer [3]

AB N
-C O
L. US [1]
S. N O
– bolt [1] and bearing setting plate [2]
[2]
R.
RS IÓ
TO UC
MO RIB
AL ST

[1]

Remove the bearing of the camshaft [1] from the

BR DI

[1] [3]
crankcase, derail the cam chain [2] from the timing
sprocket [3] of the crankshaft, and remove the camshaft
and cam chain.
CA SU
24 O
-20 BID
-07 HI

[2]
28 O
PR

10-17
 dummyhead

CYLINDER HEAD/VALVE
INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning or clogs in oil passages. Replace
or clean if necessary.

S. O
– Camshaft

L.
S AD
– Cam sprocket
– Cam chain tensioner

R.
– Cam follower

OR RIZ
Measure each part according to CYLINDER HEAD/
VALVES SPECIFICATIONS (page 1-12).
Replace any part if it is out of service limit.

OT TO
DECOMPRESSOR OPERATION
Check the decompressor cam [1] operation.
Press on the decompressor cam as shown.

LM U
As you press on one side, the decompressor cam

RA O A
should lock above the base circle of the exhaust cam Push
lobe.
As you press on the other side, the decompressor lobe
will drop below the base circle of the exhaust cam lobe.

AB N
Push

-C O
L. US
[1]
S. N O
CAM CHAIN TENSIONER LIFTER
Check the tensioner lifter operation:
– The tensioner lifter shaft should not go into the body
R.
RS IÓ

when it is pushed.
– When the ratchet pawl is pressed in, the tensioner
shaft should be pushed into the lifter body and the
TO UC

shaft springs out of the body.

MO RIB
AL ST
BR DI

INSTALLATION
Cover the piston Rotate the crankshaft to align the "T" mark [1] on the
[2]
flywheel with the index notch [2] on the crankcase
CA SU

with a shop towel or

equivalent to cover.
protect it from
damage.
24 O
-20 BID

[1]
-07 HI
28 O
PR

10-18
dummyhead

CYLINDER HEAD/VALVE
Lubricate the camshaft bearing and journal with engine
oil.
Apply molybdenum oil solution to the cam lobes.
Install the camshaft into the crankcase.

S. O
L.
S AD
R.
OR RIZ
OT TO
Lubricate the cam chain [1] whole surface with engine

LM U
[3] [1]
oil and install it on the cam sprocket [2].

RA O A
Loosely install the camshaft [3] into the crankcase.

AB N
-C O
L. US [2]
S. N O
Do not turn the Line up the camshaft pin [1] and index mark ( ) [2] on
[2]
crankshaft during the crankcase and install the cam chain over the timing
installation. sprocket on the crankshaft
Install the camshaft into the crankcase completely and
R.
RS IÓ

make sure that the camshaft pin and index mark ( )

line up. Line up
TO UC
MO RIB
AL ST

[1]

Apply locking agent to the setting plate bolt [1] threads

BR DI

[2]
(page 1-18).
Install the bearing setting plate [2] onto the crankcase
and tighten the bolt to the specified torque.
CA SU

TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)

24 O
-20 BID
-07 HI

[1]
28 O
PR

10-19
 dummyhead

CYLINDER HEAD/VALVE
Apply locking agent to the tensioner pivot bolt [1]
[3] [2]
threads (page 1-18).
Install the washer [2], cam chain tensioner [3] and pivot
bolt, and tighten the bolt to the specified torque.

S. O
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

L.
S AD
R.
OR RIZ
OT TO
[1]

Push in the tensioner lifter shaft [1] while pressing the

LM U
[2]
ratchet pawl [2] and insert a pin [3] into the hole to hold
the tensioner lifter shaft.

RA O A
AB N
-C O
[1]

L. US [3]
S. N O
Apply locking agent to the tensioner lifter bolt [1]
[2]
threads (page 1-18).
Install the tensioner lifter [2] and tighten the bolts to the
R.
RS IÓ

specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
TO UC

Remove the pin from the tensioner lifter.

Make sure that the camshaft pin and index mark ( )
MO RIB

line up when the "T" mark on the flywheel is aligned

with the index notch on the crankcase cover.
AL ST

[1]
Be careful not to Apply engine oil to the whole surfaces of the cam
BR DI

[1]
scratch the sliding followers [1] and install them into the crankcase with the
surfaces of the opening facing up.
followers and
CA SU

Install the following:

bores.
– Except FA models: primary drive gear/change clutch
(page 12-15)
– FA models: primary driven gear/dual clutch (page
24 O

13-94)
– cylinder (page 11-7)
-20 BID
-07 HI
28 O
PR

10-20
dummytext

11. CYLINDER/PISTON

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 11-2 SYSTEM COMPONENTS ······················ 11-3

RA O A
TROUBLESHOOTING ·························· 11-2 CYLINDER/PISTON ····························· 11-4

AB N
-C O
11

L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

11-1
 dummyhead

CYLINDER/PISTON
SERVICE INFORMATION
CYLINDER/PISTON

GENERAL
• The cylinder and piston can be serviced with the engine installed in the frame.

S. O
• Take care not to damage the cylinder wall and piston.
• Be careful not to damage the mating surfaces when removing the cylinder.

L.
S AD
• Rocker arm and valve lubricating oil is fed through the oil passage in the cylinder. Clean the oil passage before installing the

R.
cylinder.

OR RIZ
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed

OT TO
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston

LM U
Compression too high, overheating or knocking

RA O A
• Excessive carbon build-up on piston head or combustion chamber
Excessive smoke
• Worn cylinder, piston or piston rings
• Improper installation of piston rings

AB N
• Scored or scratched piston or cylinder wall

-C O
Abnormal noise
• Worn piston pin or piston pin hole

L. US
• Worn connecting rod small end
• Worn cylinder, piston or piston rings S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

11-2
 PR
dummyhead

28 O
-07 HI
-20 BID
24 O
CA SU
BR DI
SYSTEM COMPONENTS

AL ST
MO RIB
TO UC
RS IÓ
S. N O
R.
L. US
-C O
AB N
RA O A
LM U
OT TO
OR RIZ
12 N·m (1.2 kgf·m, 9 lbf·ft)

S AD
S. O
R.
CYLINDER/PISTON

11-3
L.
 dummyhead

CYLINDER/PISTON
CYLINDER/PISTON
CYLINDER REMOVAL
Remove the cylinder head (page 10-10)

S. O
[2]
Remove the two bolts [1].

L.
S AD
Do not damage the Lift the cylinder [2] and remove it, being careful not to

R.
mating surface with damage the piston and piston rings with the stud bolts.
a screwdriver.

OR RIZ
OT TO
LM U
[1]

RA O A
Remove the gasket [1] and the two dowel pins [2].

AB N
-C O
L. US
S. N O
[2] [1]
R.
RS IÓ

PISTON REMOVAL
Place a clean shop towel over the crankcase to prevent
TO UC

[2] [3]
the piston pin clip [1] from falling into the crankcase.
Remove the piston pin clips with the pliers.
MO RIB

Push the piston pin [2] out of the piston [3] and
connecting rod, and remove the piston.
AL ST
BR DI
CA SU

[1]
Do not damage the Spread each piston ring and remove it by lifting up at a
piston ring by point opposite the gap.
24 O

spreading the ends

too far.
-20 BID
-07 HI
28 O
PR

11-4
dummyhead

CYLINDER/PISTON
Never use a wire Clean carbon deposits from the ring grooves with a ring
brush; it will scratch that will be discarded.
the grooves.

S. O
L.
S AD
R.
OR RIZ
OT TO
INSPECTION

LM U
Inspect the following parts for scratch, damage,

RA O A
abnormal wear, deformation, burning or clogs in oil
passage. Replace or clean if necessary.
– cylinder
– piston

AB N
– piston rings
– piston pin

-C O
– connecting rod small end
Measure each part and clearance according to

L. US
CYLINDER/PISTON SPECIFICATIONS (page 1-12).
Replace any part if it is out of service limit.
S. N O
CYLINDER STUD BOLT
REPLACEMENT
R.
Thread two nuts onto the stud and tighten them
RS IÓ

together, and use a wrench on them to turn the stud bolt

out. m
7.8 m
TO UC

Install new stud bolts and tighten them. 6 .2 – 16 in)

16 1
– 6.6
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) (6.54
m
MO RIB

m
41.8
Be sure to verify the stud height from the cylinder 2 – 1 8 in)
139. 5
mating surface of the crankcase. – 5.
(5.58
Adjust the height if necessary.
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

11-5
 dummyhead

CYLINDER/PISTON
PISTON RING INSTALLATION
Carefully install the piston rings into the piston ring
grooves with the markings [1] facing up. [1] [1]

S. O
• Do not confuse the top ring [2] and second ring [3].

L.
S AD
• To install the oil ring [4], install the spacer [5] first,
then install the side rails [6].

R.
Stagger the piston ring end gaps 120° degrees apart

OR RIZ
from each other.
Stagger the side rail end gaps as shown.

120°

OT TO
[2]
120° 120°
[3]

LM U
[4]

RA O A
AB N
[6]

-C O
20 mm or more

L. US
S. N O [5]

R.
RS IÓ

PISTON INSTALLATION
Place a clean shop towel over the crankcase to prevent
TO UC

[2] [4] [3]

the piston pin clip [1] from falling into the crankcase.
Apply engine oil to the piston pin hole and connecting
rod inner surface.
MO RIB

Apply molybdenum oil solution to the piston pin [2] outer

surface.
Install the piston [3] with the "IN" mark [4] toward the
AL ST

intake side and insert the piston pin through the piston
and connecting rod.
Install new piston pin clips into the grooves in the piston
BR DI

pin hole.

[1]
CA SU

• Make sure that the piston pin clips [1] are seated
[2]
securely.
• Do not align the piston pin clip end gap [2] with the
24 O

piston cutout [3].

-20 BID
-07 HI
28 O
PR

[1] [3]

11-6
dummyhead

CYLINDER/PISTON
CYLINDER INSTALLATION
Clean the mating surfaces of the cylinder and
crankcase thoroughly, being careful not to damage
them, and being careful not to allow gasket material to

S. O
enter the crankcase.

L.
S AD
Blow through the oil passage in the cylinder with
compressed air.

R.
Install the two dowel pins [1] and a new gasket [2].

OR RIZ
OT TO
[1] [2]

LM U
Apply engine oil to the cylinder [1] wall, piston [2] outer
[1]

RA O A
surface and piston rings [3].
Install the cylinder over the piston while compressing
the piston rings with your fingers.

AB N
-C O
L. US
S. N O
[3] [2]

Make sure that the cylinder touches the crankcase

evenly.
R.
RS IÓ

Install the two bolts [1].

Install the cylinder head (page 10-15).
TO UC
MO RIB
AL ST

[1]
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

11-7
 PR
dummyhead

28 O
-07 HI
-20 BID
24 O
CA SU
BR DI
AL ST
MO RIB
MEMO

TO UC
RS IÓ
S. N O
R.
L. US
-C O
AB N
RA O A
LM U
OT TO
OR RIZ
S AD
S. O
R.
L.
dummytext

12. CLUTCH/GEARSHIFT LINKAGE (Except FA models)

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 12-2 CENTRIFUGAL CLUTCH ······················ 12-8

RA O A
TROUBLESHOOTING ·························· 12-3 CHANGE CLUTCH······························ 12-12

AB N
SYSTEM COMPONENTS ······················ 12-4 GEARSHIFT LINKAGE ························ 12-17

-C O
FRONT CRANKCASE COVER ··············· 12-5

L. US
S. N O 12
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

12-1
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

SERVICE INFORMATION
CLUTCH/GEARSHIFT LINKAGE (Except FA models)

GENERAL
• This section covers service of the clutch (centrifugal clutch and change clutch) and gearshift linkage. To service the reverse

S. O
stopper shaft and gearshift spindles, the engine must be removed from the frame.
• The crankcase must be separated when the transmission, shift drum and shift forks require service (page 15-6).

L.
S AD
• Engine oil viscosity and level and the use of oil additives have an effect on clutch operation. Oil additives of any kind are

R.
specifically not recommended. When the clutch does not disengage or the vehicle creeps, inspect the engine oil and oil level
before servicing the clutch system.

OR RIZ
• Engine lubricating oil is fed through the oil passages in the front crankcase cover. Clean the oil passages before installing the
crankcase cover.
• The TE1/FE1 models are equipped with the electric shift program (ESP). ESP service (page 24-2)

OT TO
TOOLS

LM U
Driver Attachment, 32 x 35 mm Pilot, 15 mm

RA O A
07749-0010000 07746-0010100 07746-0040300

AB N
-C O
L. US
S. N O
Driver, 22 mm I.D. Puller, 35 x 1.0 mm Clutch center holder
07746-0020100 07933-HA80000 07JMB-MN50302
R.
RS IÓ
TO UC
MO RIB

or
AL ST

07HGB-001010B and
or 07933-HB3000A (U.S.A. only) 07HGB-001020B (U.S.A. only)
BR DI

Clutch holder set Clutch holder plate Clutch holder pin

07ZMB-HN20001 07ZMB-HN20101 (not available in 07ZMB-HN20200 (not available in
U.S.A.) U.S.A.)
CA SU
24 O
-20 BID
-07 HI

or 07ZMB-HN2A101 (U.S.A. only)

28 O
PR

12-2
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

Remover weight Bearing remover shaft Bearing remover head, 15 mm
07741-0010201 07936-KC10100 (not available in 07936-KC10200 (not available in
U.S.A.) U.S.A.)

S. O
L.
S AD
R.
OR RIZ
OT TO
or 07936-371020A (U.S.A. only)
Bearing remover, 15 mm
07936-KC10500 (U.S.A. only)

LM U
RA O A
AB N
-C O
L. US
S. N O
TROUBLESHOOTING
Clutch slips when accelerating
• Incorrect clutch adjustment (page 3-35)
R.
RS IÓ

• Worn clutch discs

• Weak clutch springs
TO UC

• Faulty clutch lifter

• Improper oil viscosity or oil additive used
Clutch will not disengage
MO RIB

• Faulty clutch lifter

• Warped clutch plates
The vehicle creeps
• Faulty centrifugal clutch
AL ST

Clutch operating feels rough

• Worn clutch outer and center grooves
BR DI

• Warped clutch plates

• Loose clutch lock nut
• Faulty clutch lifter
CA SU

• Improper oil viscosity or oil level

Hard to shift
• Incorrect clutch adjustment (page 3-35)
• Worn or damaged gearshift linkage components
24 O

• Faulty clutch lifter

• Improper engine oil viscosity
-20 BID

• Faulty gearshift spindle

• Faulty shift forks/shaft or shift drum (page 15-4)
Transmission jumps out of gear
-07 HI

• Broken shift drum stopper arm

• Weak or broken shift linkage return springs
28 O

• Worn or damaged gearshift cam

• Faulty gearshift spindle
PR

• Faulty shift forks/shaft or shift drum (page 15-4)

• Faulty transmission gears (page 15-4)

12-3
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

SYSTEM COMPONENTS
TE1/FE1 models shown:

S. O
118 N·m (12.0 kgf·m, 87 lbf·ft)

L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
L. US
S. N O
108 N·m
(11.0 kgf·m,
80 lbf·ft) 12 N·m (1.2 kgf·m,
R.
RS IÓ

9 lbf·ft)
TO UC
MO RIB
AL ST
BR DI

12 N·m (1.2 kgf·m,

9 lbf·ft)
CA SU
24 O

16 N·m (1.6 kgf·m,

12 lbf·ft)
-20 BID
-07 HI
28 O
PR

12-4
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

FRONT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-18).

S. O
[1]
Drain the coolant (page 8-5).

L.
S AD
Remove the following:

R.
– center mudguards (page 2-5)
– FM1/FM2/FE1 models only: front propeller shaft

OR RIZ
(without removing the left drive shaft) (page 20-13)
– TE1/FE1 models only: shift control motor and
reduction gears (page 24-31)

OT TO
Disconnect the water hoses [1] from the front crankcase
cover.

LM U
RA O A
Remove the following:
[2]
– fifteen bolts [1]
– front crankcase cover [2]

AB N
-C O
L. US
S. N O
[1]
R.
RS IÓ

– lifter cam plate [1]

[3]/[4] [4] [2]
– two dowel pins [2]
TO UC

– joint collars [3]

– O-rings [4]
MO RIB
AL ST
BR DI

[3]/[4] [1]
CA SU

– output shaft oil seal [1]

[1]
– gearshift spindle oil seal [2] (TE1/FE1 models only)
24 O
-20 BID
-07 HI
28 O
PR

[2]

12-5
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

CRANKSHAFT BEARING
REPLACEMENT
Check the crankshaft bearing [1].
[3] [1]
If the inner race does not turn smoothly, quietly, or if the

S. O
outer race fits loosely in the cover, replace the bearing
as follows:

L.
S AD
Remove the crankshaft bearing with the special tools.

R.
TOOLS:

OR RIZ
Bearing remover shaft [2] 07936-KC10100
Bearing remover head, 15 mm [3] 07936-KC10200
Remover weight [4] 07741-0010201

OT TO
U.S.A. TOOLS:
Bearing remover, 15 mm 07936-KC10500

LM U
Remover weight 07936-371020A [4] [2]

RA O A
Apply engine oil to a new bearing.
[1]
Drive a new bearing squarely with the sealed side
facing down until it is fully seated.

AB N
TOOLS:
Driver [1] 07749-0010000
Attachment, 32 x 35 mm [2] 07746-0010100

-C O
Pilot, 15 mm [3] 07746-0040300

L. US
S. N O
[3] [2]

CLUTCH LIFTER REMOVAL/

R.
RS IÓ

INSTALLATION
TO UC

Check the clutch lifter plate assembly and cam plate for
[1]
wear or damage, replace them if necessary.
Remove the lock nut [1] and washer [2].
MO RIB
AL ST
BR DI
CA SU

[2]

Remove the adjusting bolt/lifter plate assembly [1] and

Align
O-ring [2].
24 O

Remove the adjusting bolt from the lifter plate

assembly.
-20 BID

Install the adjusting bolt into the lifter plate assembly.

Coat a new O-ring with engine oil and install it onto the
adjusting bolt.
-07 HI

Install the adjusting bolt/lifter plate assembly by aligning

the groove with the stopper pin.
Temporarily install the washer and lock nut.
28 O
PR

[1] [2]

12-6
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

INSTALLATION
Clean the mating surfaces of the front crankcase cover
and crankcase thoroughly, being careful not to damage
them.

S. O
Blow through the oil passages in the front crankcase

L.
S AD
cover with compressed air.
Apply engine oil to the boss of the adjusting plate.

R.
OR RIZ
OT TO
LM U
Install a new output shaft oil seal [1] into the front
[1]

RA O A
crankcase cover.
TE1/FE1 models only: Install a new gearshift spindle oil
seal [2] into the front crankcase cover.

AB N
-C O
L. US
S. N O
[2]

Install the joint collars [1] and dowel pins [2].

[1]/[3] [3] [2]
Coat new O-rings [3] with engine oil and install them.
R.
RS IÓ
TO UC
MO RIB
AL ST

[1]/[3]
BR DI

Apply liquid sealant (TB1215 or equivalent) to the

mating surface (shadowed area) of the front crankcase
CA SU

cover as shown.
24 O
-20 BID
-07 HI
28 O
PR

12-7
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

Apply engine oil to the oil seal [1] lips.
[2]
Be careful not to Install the crankcase cover [2], being careful not to
drop the lifter cam damage the oil seal lips.
plate.

S. O
Install the fifteen bolts [3] and tighten them in a
crisscross pattern in several steps.

L.
S AD
R.
OR RIZ
OT TO
[3] [1]

Connect the water hoses [1] to the crankcase cover.

LM U
[1]
Install the following:

RA O A
– TE1/FE1 models only: reduction gears and shift
control motor (page 24-32)
– FM1/FM2/FE1 models only: front propeller shaft
(page 20-37)

AB N
– center mudguards (page 2-5)
Adjust the clutch system (page 3-35).

-C O
Fill the engine with recommended oil (page 3-18).

L. US
Fill and bleed the cooling system (page 8-5).
Check the engine oil level (page 3-17).
S. N O
CENTRIFUGAL CLUTCH
REMOVAL
R.
RS IÓ

Remove the front crankcase cover (page 12-5).

Unstake [1]
Unstake the clutch lock nut [1].
TO UC

Be careful not to
damage the
crankshaft threads.
MO RIB
AL ST
BR DI
CA SU

Hold the clutch drive plate using the special tool and
[3] [1]
loosen the lock nut.
TOOL:
24 O

Clutch holder set [1] 07ZMB-HN20001

– holder plate 07ZMB-HN20101
-20 BID

– holder pin 07ZMB-HN20200

U.S.A. TOOL:
-07 HI

Clutch holder 07ZMB-HN2A101

Remove the lock nut [2] and washer [3].
28 O
PR

[2]

12-8
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

Remove the centrifugal clutch assembly [1] using the
[1]
special tool.
TOOL:
Puller, 35 x 1.0 mm [2] 07933-HA80000 or

S. O
07933-HB3000A

L.
S AD
(U.S.A. only)

R.
OR RIZ
OT TO
[2]

DISASSEMBLY

LM U
You should be able to turn the clutch weight assembly
[1]

RA O A
[1] counterclockwise smoothly, but the assembly should
not turn clockwise.
Remove the clutch weight assembly from the clutch
drum [2] while turning it counterclockwise.

AB N
-C O
L. US
S. N O
[2]

Remove the E-clips [1] using a screwdriver while

[2] [1]
compressing the clutch spring.
R.
RS IÓ

Remove the following:

TO UC

– outer plate [2]

– clutch spring [3]
– inner plate [4]
MO RIB
AL ST

[4] [3]
BR DI

Remove the clutch weights [1] and springs [2] from the
[1] [2]
drive plate.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

12-9
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation. Replace if necessary.

S. O
– clutch drum
– sprag clutch

L.
S AD
– drive plate
– clutch weights

R.
– clutch weight springs

OR RIZ
Measure each part according to CLUTCH/GEARSHIFT
LINKAGE SPECIFICATIONS (page 1-12).
Replace any part if it is out of service limit.

OT TO
• Replace the clutch weight springs as a set.
• Replace the clutch weights as a set.

LM U
ASSEMBLY

RA O A
DRIVE PLATE
CLUTCH WEIGHTS

AB N
WEIGHT SPRINGS

-C O
CLUTCH SPRING

L. US
OUTER PLATE
S. N O
R.
RS IÓ

CLUTCH DRUM
TO UC
MO RIB
AL ST

INNER PLATE
BR DI

E-CLIPS
CA SU

SPRAG CLUTCH

Install with the Install the clutch weights [1] and springs [2] onto the
24 O

[1] [2]
spring’s open ends drive plate as shown.
facing in.
-20 BID
-07 HI
28 O
PR

12-10
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

Install the inner plate [1] with flange side facing up.
[2]
Install the clutch spring [2] with concavity side facing
down.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

Install the outer plate [1] with the pins facing up.

LM U
Be careful not to Install the E-clips [2] into the spindle grooves with their

RA O A
damage the clutch gaps facing towards the pins [3] by using the pliers
weights while while compressing the clutch spring.
compressing.

AB N
-C O
L. US [3] [2] [1]
S. N O
Apply engine oil to the sprag clutch [1] whole surface
[2]
and the sprag clutch contacting surface of the clutch
drum.
R.
RS IÓ

Install the sprag clutch into the clutch drum with the
"OUT SIDE" mark [2] facing up.
TO UC
MO RIB
AL ST

[1]

Apply engine oil to the sprag clutch contacting surface

BR DI

[1]
of the drive plate boss.
Install the clutch weight assembly [1] while turning it
CA SU

counterclockwise.
24 O
-20 BID
-07 HI
28 O
PR

12-11
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

INSTALLATION
Set the centrifugal clutch assembly [1] onto the
[1]
crankshaft by aligning the splines of the drive plate and
crankshaft, and the splines of the clutch drum and

S. O
primary drive gear.

L.
S AD
Be careful not to Tap the drive plate to seat it.
damage the

R.
crankshaft threads.
TOOL:
Driver, 22 mm I.D. [2] 07746-0020100

OR RIZ
OT TO
[2]

LM U
Apply engine oil to the threads and seating surface of a
[2] [3]

RA O A
new lock nut [1].
Install the washer [2] and lock nut.
Hold the drive plate of the centrifugal clutch assembly
with the special tool and tighten the lock nut.

AB N
TOOL:

-C O
Clutch holder set [3] 07ZMB-HN20001
– holder plate 07ZMB-HN20101

L. US
– holder pin 07ZMB-HN20200

U.S.A. TOOL:
Clutch holder 07ZMB-HN2A101
S. N O
[1]
TORQUE: 118 N·m (12.0 kgf·m, 87 lbf·ft)
Be careful not to Stake the lock nut into the crankshaft groove.
Stake
R.
RS IÓ

damage the
Install the front crankcase cover (page 12-7).
crankshaft threads.
TO UC
MO RIB
AL ST
BR DI

CHANGE CLUTCH
CA SU

DISASSEMBLY
Remove the following:
[2]
24 O

– centrifugal clutch assembly (page 12-8)

– TE1/FE1 models: shift arm spring, gearshift spindle
-20 BID

and washer (page 12-17)

– TM1/FM1/FM2 models: clutch lifter lever (page 12-
17)
– lifter bearing [1] and collar [2]
-07 HI
28 O
PR

[1]

12-12
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

Loosen the clutch spring bolts [1] in a crisscross pattern
[1] [3]
in several steps, and remove the bolts, lifter plate [2]
and clutch springs [3].

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]
Be careful not to Unstake the clutch center lock nut [1].
Unstake

LM U
damage the
mainshaft threads.

RA O A
AB N
-C O
L. US [1]
S. N O
Install the clutch center holder [1] onto the pressure
[1]
plate bosses with the four clutch spring bolts.
TOOL:
R.
RS IÓ

Clutch center holder 07JMB-MN50302

TO UC

U.S.A. TOOLS:
Holder plate 07HGB-001010B
Holder collar A 07HGB-001020B
MO RIB

Hold the clutch center and loosen the clutch center lock
nut.
Remove the lock nut and washer.
AL ST

Remove the following:

BR DI

[1] [2]/[3]
– clutch center [1]
– TE1/FE1 models: six discs [2] and five plates [3]
CA SU

– TM1/FM1/FM2 models: seven discs [2] and six

plates [3]
– pressure plate [4]
24 O
-20 BID
-07 HI

[4]
28 O
PR

12-13
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

– thrust washer [1]
[2]
– clutch outer [2]

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

– clutch outer guide [1]

LM U
[1]

RA O A
AB N
-C O
L. US
S. N O
Remove the primary drive gear [1] and washer [2] from
[1] [2]
the crankshaft.
R.
RS IÓ
TO UC
MO RIB
AL ST

INSPECTION
BR DI

Inspect the following parts for scratch, damage,

abnormal wear and deformation. Replace if necessary.
CA SU

– clutch lifter bearing/cam plate/plate/collar

– clutch springs
– clutch discs/plates
– clutch center
24 O

– clutch outer
– clutch outer guide
-20 BID

– primary drive gear

– mainshaft/crankshaft
Measure each part according to CLUTCH/GEARSHIFT
-07 HI

LINKAGE SPECIFICATIONS (page 1-12).

Replace any part if it is out of service limit.
28 O

• Replace the clutch springs as a set.

• Replace the clutch discs and plates as a set.
PR

12-14
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

ASSEMBLY
Apply engine oil to the primary drive gear [1] sliding
[2] [1]
surfaces of the crankshaft.
Install the thrust washer [2] and the drive gear onto the

S. O
crankshaft.

L.
S AD
R.
OR RIZ
OT TO
LM U
Apply molybdenum oil solution to the inner and outer
[1]

RA O A
surfaces of the clutch outer guide [1].
Install the outer guide onto the mainshaft.

AB N
-C O
L. US
S. N O
Install the clutch outer [1] and thrust washer [2].
[1]
R.
RS IÓ
TO UC
MO RIB
AL ST

[2]
BR DI

Coat the clutch discs with clean engine oil.

[1] [3]/[4]
Install the discs and Install the following:
CA SU

plate alternately,
– pressure plate [2]
starting with the
– TE1/FE1 models: six discs [3] and five plates [4]
disc.
– TM1/FM1/FM2 models: seven discs [3] and six
24 O

Set the outside

plates [4]
clutch disc tabs into
– clutch center [5]
-20 BID

the shallow slots [1]

in the clutch outer.
-07 HI
28 O

[5] [2]
PR

12-15
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

Install the washer [1].
[1]

S. O
L.
S AD
R.
OR RIZ
OT TO
Apply engine oil to the threads and seating surface of a

LM U
[1]
new lock nut [1], and install it.

RA O A
Install the clutch center holder [2] onto the pressure
plate bosses with the four clutch spring bolts.
TOOL:
Clutch center holder 07JMB-MN50302

AB N
U.S.A. TOOLS:

-C O
Holder plate 07HGB-001010B
Holder collar A 07HGB-001020B

L. US
Hold the clutch center holder and tighten the lock nut.
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft) [2]
S. N O
Be careful not to Stake the lock nut into the mainshaft groove.
Stake
damage the
mainshaft threads.
R.
RS IÓ
TO UC
MO RIB
AL ST

Install the clutch springs [1] and the lifter plate [2] with
BR DI

[4] [1] [3]

the "OUT" mark [3] facing out.
Install the clutch spring bolts [4] and tighten them in a
crisscross pattern in several steps.
CA SU

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

24 O
-20 BID
-07 HI

[2]
28 O
PR

12-16
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

Apply engine oil to the lifter bearing [1], and install the
[2]
lifter collar [2] and bearing.
Install the following:

S. O
– TE1/FE1 models: washer, gearshift spindle and shift
arm spring (page 12-18)

L.
S AD
– TM1/FM1/FM2 models: lifter lever (page 12-18)
– lifter bearing and collar

R.
– centrifugal clutch assembly (page 12-12)

OR RIZ
OT TO
[1]

GEARSHIFT LINKAGE

LM U
REMOVAL

RA O A
Remove the centrifugal clutch (page 12-8).
[1]
Remove the following:

AB N
TE1/FE1 models: – shift spindle angle sensor (page 24-28)
– shift arm spring [1]

-C O
– gearshift spindle assembly [2] and washer [3]

L. US
S. N O
[2] [3]
R.
RS IÓ

TM1/FM1/FM2 – clutch lifter lever [1]

[4]
models: – shift arm spring [2]
TO UC

– return spring [3] and gearshift arm [4]

• For gearshift spindle service (page 15-7)

MO RIB
AL ST
BR DI

[2] [3]
CA SU

[1]

– bolt [1]
24 O

[1]
– guide plate [2]
-20 BID
-07 HI
28 O
PR

[2]

12-17
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

– gearshift plate [1]
– TM1/FM1/FM2 models only: washer from the
gearshift spindle
– gearshift cam [2] (while holding stopper arm with a

S. O
screwdriver)

L.
S AD
R.
OR RIZ
OT TO
[1] [2]

– bolt [1]

LM U
[4] [2]
– stopper arm [2]
– washer [3]

RA O A
– return spring [4]
Check all parts for wear or damage. Replace if
necessary.

AB N
-C O
L. US [1] [3]
S. N O
INSTALLATION
Apply locking agent to the stopper arm bolt [1] threads
[2] [4]
(page 1-19).
R.
RS IÓ

Install the return spring [2], washer [3] (between the arm
and crankcase), stopper arm [4] and bolt, and tighten
the bolt to the specified torque.
TO UC

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

MO RIB
AL ST

[1] [3]
BR DI

Hold the stopper arm with a screwdriver and install the

[3]
gearshift cam [1] by aligning the pin hole [2] with the
CA SU

dowel pin [3].

24 O
-20 BID
-07 HI
28 O

[1] [2]
PR

12-18
dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

TM1/FM1/FM2 models only: Install the washer onto the
[1]
gearshift spindle.
Install the gearshift plate [1] onto the cam as shown.

S. O
Install the guide plate [2] by aligning the tab with the
groove in the cam.

L.
S AD
R.
Align

OR RIZ
OT TO
[2]

Apply locking agent to the gearshift cam bolt [1] threads

LM U
(page 1-19).
Install the cam bolt and tighten it to the specified torque.

RA O A
TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft)

AB N
-C O
L. US [1]
S. N O
TE1/FE1 models: Install the washer [1] and insert the gearshift spindle
[2] [4]
assembly [2] into the crankcase.
Align the return spring ends with the stopper pin [3].
R.
RS IÓ

Hook the shift arm spring [4] to the gearshift arm and
plate.
TO UC

Install the angle sensor (page 24-28).

MO RIB
AL ST

[1] [3]
TM1/FM1/FM2 Install the gearshift arm [1] and return spring [2],
BR DI

[1]
models: aligning the spring ends with the stopper pin.
Hook the shift arm spring [3] to the gearshift arm and
CA SU

plate.
Install the lifter lever [4] by aligning the wide groove with
the wide tooth of the splines.
24 O

All models: Install the centrifugal clutch (page 12-12).

-20 BID

[3] [2]
-07 HI
28 O

[4]
PR

12-19
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (Except FA models)

GEARSHIFT SPINDLE A (TM1/FM1/
FM2 models only)
Remove the rear crankcase cover (page 14-7).
[2] [1]

S. O
Remove the stopper bolt [1], washer [2] and gearshift
spindle A [3] from the rear crankcase cover [4].

L.
S AD
Remove the oil seal [5] from the rear crankcase cover. [4]

R.
Install a new oil seal.
Apply engine oil to the oil seal lip and install the

OR RIZ
gearshift spindle A.
Apply locking agent to the stopper bolt threads
(page 1-19).
Install the washer and stopper bolt, and tighten the bolt

OT TO
to the specified torque.
[5]
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)

LM U
Install the rear crankcase cover (page 14-11). [3]

RA O A
AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

12-20
dummytext

13. DUAL CLUTCH TRANSMISSION (FA models)

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 13-2 SHIFT DRUM POSITION SWITCH
('14 –'19 models) ································ 13-72

RA O A
SYSTEM COMPONENTS ······················ 13-4
TR SENSOR (After '19 model) ·············· 13-74

AB N
DCT SYSTEM OVERVIEW ···················· 13-6
NEUTRAL SWITCH (After '19 model) ···· 13-75

-C O
SYMPTOM TROUBLESHOOTING ·········13-18

L. US
REVERSE SWITCH ('14 – '19 models)···· 13-75
COMPONENT LOCATION ····················13-23
EOT SENSOR ···································· 13-76
13
S. N O
SYSTEM DIAGRAM ····························13-25
REAR VS SENSOR ····························· 13-77
TROUBLESHOOTING INFORMATION ····13-27
R.
RS IÓ

FRONT VS SENSOR ··························· 13-77

DTC INDEX········································13-29
TO UC

DRIVE MODE SELECT SWITCH ··········· 13-78

DTC TROUBLESHOOTING ··················13-32
MO RIB

SHIFT VALVE BODY··························· 13-79

FRONT CRANKCASE COVER/SPACER ···13-54
DUAL CLUTCH/PRIMARY DRIVEN
AL ST

CENTRIFUGAL CLUTCH ·····················13-62 GEAR ··············································· 13-85

GEARSHIFT LINKAGE ························ 13-95

BR DI

SHIFT SOLENOID VALVE ····················13-67

REVERSE STOPPER SHAFT

CA SU

SHIFT SPINDLE ANGLE SENSOR ········13-68

('14 – '19 models) ······························· 13-98
SHIFT CONTROL MOTOR/REDUCTION
24 O

GEARS ·············································13-69
-20 BID
-07 HI
28 O
PR

13-1
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SERVICE INFORMATION
DUAL CLUTCH TRANSMISSION (FA models)

GENERAL
• This section covers service of the electrical and mechanical systems of the Dual Clutch Transmission (DCT).

S. O
• A faulty DCT system is often related to poorly connected or corroded connectors. Check those connections before proceeding.
• Read the "DCT Troubleshooting Information" carefully, and inspect and troubleshoot the DCT system according to the DTC.

L.
S AD
Observe each step of the procedures one by one. Note the DTC and probable faulty part before starting diagnosis and

R.
troubleshooting.
• The PCM may be damaged if dropped. Also, if a connector is disconnected when current is flowing, the excessive voltage may

OR RIZ
damage the PCM. Always turn off the ignition switch before servicing.
• The drive mode (Automatic or ESP) is changed electrically with the drive mode select switch.
• Oil pump service (page 9-8).
• The following color codes are used throughout this section.

OT TO
Bl: Black Bu: Blue Gr: Gray Lg: Light green P: Pink V: Violet Y: Yellow
Br: Brown G: Green Lb: Light blue O: Orange R: Red W: White

LM U
RA O A
For DCT system Troubleshooting
The DCT system is controlled by the PCM. Therefore some detection items that are shared in the PGM-FI and DCT systems, and
they may affect the operation of both systems.
Before starting any troubleshooting, check the following items and refer to the appropriate troubleshooting.

AB N
1. MIL blinks DTC for the PGM-FI system (page 4-10).
2. Gear position indicator blinks DTC for the DCT system (page 13-27).

-C O
3. Symptom of the DCT system operation (page 13-18).

L. US
Refer to "PGM-FI Troubleshooting Information" for the general troubleshooting information (page 4-9).

TOOLS
S. N O
Pressure gauge set Clutch compressor set SCS Short Connector
07406-0020005 07LAE-PX40000 070PZ-ZY30100
R.
RS IÓ
TO UC
MO RIB
AL ST

or 07ZMJ-HN2A100 and 07AMJ- or 07GAE-PG40200 or

HN8A100 (U.S.A. only) (2 required) 07GAE-PG4020A (U.S.A. only)
and
BR DI

07LAE-PX40100 (2 required)
Test probe, 2 pack Lock nut wrench, 32.5 mm Driver
CA SU

07ZAJ-RDJA110 07AMA-HP7A100 07749-0010000

24 O
-20 BID
-07 HI
28 O
PR

13-2
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Attachment, 32 x 35 mm Pilot, 15 mm Driver, 22 mm I.D.
07746-0010100 07746-0040300 07746-0020100

S. O
L.
S AD
R.
OR RIZ
OT TO
Clutch puller, 35 x 1.0 mm Remover weight Bearing remover shaft
07933-HA80000 07741-0010201 07936-KC10100 (not available in
U.S.A.)

LM U
RA O A
AB N
-C O
L. US
or 07933-HB3000A (U.S.A. only) or 07936-371020A (U.S.A. only)
Bearing remover head, 15 mm Bearing remover, 15 mm Clutch holder set
07936-KC10200 (not available in 07936-KC10500 (U.S.A. only) 07ZMB-HN20001
S. N O
U.S.A.)
R.
RS IÓ
TO UC
MO RIB

or 07ZMB-HN2A101 (U.S.A. only)

Clutch holder plate Clutch holder pin Adapter, 25L x 8 x 1.25 mm
07ZMB-HN20101 (not available in
AL ST

07ZMB-HN20200 (not available in 07AMJ-HP7A100

U.S.A.) U.S.A.)
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-3
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SYSTEM COMPONENTS

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
L. US
S. N O
R.
RS IÓ

118 N·m (12.0 kgf·m, 87 lbf·ft)

TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21 N·m (2.1 kgf·m, 15 lbf·ft)

13-4
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
108 N·m (11.0 kgf·m, 80 lbf·ft)

AB N
-C O
’14 – ’19:

L. US
23 N·m (2.3 kgf·m, 17 lbf·ft)
After ’19:
31 N·m (3.2 kgf·m, 23 lbf·ft)
S. N O
12 N·m (1.2 kgf·m,
9 lbf·ft)
R.
RS IÓ

12 N·m (1.2 kgf·m,

TO UC

9 lbf·ft)
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-5
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DCT SYSTEM OVERVIEW
DESCRIPTION
The dual clutch transmission is a combination of the hydraulic shift clutch system and ESP controlled by the PCM. The system

S. O
provides high transmission efficiency to match the riding conditions and ATV usage.

L.
S AD
The system consists of the centrifugal clutch, valve body assembly, primary driven gear assembly, constant mesh transmission and
ESP.

R.
CENTRIFUGAL CLUTCH

OR RIZ
The centrifugal clutch transmits engine power to the primary driven gear in the same way as a conventional clutch.
PRIMARY DRIVEN GEAR ASSEMBLY

OT TO
The primary driven gear assembly has two hydraulic shift clutches. The 1st shift clutch transmits the driving power to the 1st
mainshaft, and the 2nd shift clutch transmits the power to the 2nd mainshaft. Their operation is controlled by the PCM.
CONSTANT MESH TRANSMISSION

LM U
The 1st, 3rd and 5th gears are located on the 1st mainshaft, with 2nd, 4th and reverse gears located on the 2nd mainshaft. The 2nd

RA O A
mainshaft is located on the 1st mainshaft. The shifting pattern in each gear position is different from a conventional transmission.
ESP
The ESP consists of the shift control motor, gearshift linkage, shift drum position switch/TR sensor and shift spindle angle sensor.
The ESP on this mode is the conventional type used previously.

AB N
VALVE BODY ASSEMBLY

-C O
The valve body assembly consists of the dual clutch PC solenoid valve, emergency valve, shift solenoid valve, valve body plate,
valve body, shift valve and two orifice control valves,

L. US
CENTRIFUGAL CLUTCH
CRANKSHAFT
S. N O
2ND MAINSHAFT
R.
RS IÓ
TO UC
MO RIB

1ST MAINSHAFT
AL ST

1ST SHIFT CLUTCH COUNTERSHAFT

PRIMARY DRIVEN GEAR

BR DI

OUTPUT SHAFT
2ND SHIFT CLUTCH
CA SU

SHIFT CONTROL MOTOR

SHIFT FORK SHAFT
24 O

SHIFT FORKS
-20 BID

SHIFT DRUM
SHIFT DRUM
POSITION SWITCH/
-07 HI
28 O
PR

REDUCTION GEARS SHIFT SPINDLE ANGLE SENSOR

GEARSHIFT SPINDLE

13-6
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

HYDRAULIC SYSTEM
The oil pump supplies pressure regulated oil to the dual clutch PC solenoid valve for clutch operation and to the shift solenoid valve
for shift valve operation.

S. O
DUAL CLUTCH PC SOLENOID VALVE
Dual clutch PC solenoid valve is controlled by the PCM. The spool valve supplies the clutch operating oil to the shift valve when the

L.
S AD
solenoid is off, and it shuts off the oil when the solenoid is on.

R.
SHIFT SOLENOID VALVE

OR RIZ
The shift solenoid valve is controlled by the PCM. The valve supplies the operating oil to the shift valve when the solenoid is off and
it shuts off the oil when the solenoid is on.
SHIFT VALVE

OT TO
The shift valve is controlled by the shift solenoid valve. The valve supplies the clutch operating oil to the 2nd clutch when the shift
solenoid valve is off, and it supplies the clutch operating oil to the 1st clutch when the shift solenoid valve is on.
1ST ORIFICE CONTROL VALVE

LM U
The 1st orifice control valve operates to absorb the 2nd clutch engagement shock and to drain the 1st clutch operating oil.

RA O A
2ND ORIFICE CONTROL VALVE
The 2nd orifice control valve operates to absorb the 1st clutch engagement shock and to drain the 2nd clutch operating oil.
EMERGENCY VALVE

AB N
The emergency valve is used if a problem with the dual clutch PC solenoid valve (mechanical lock) prevents oil from being supplied
to the clutch. The operator must manually open the bypass oil circuit to supply the clutch with oil.

-C O
L. US
1ST SHIFT 2ND SHIFT
CLUTCH CLUTCH
SHIFT SOLENOID
2ND ORIFICE VALVE
S. N O
CONTROL VALVE
R.
1ST ORIFICE
RS IÓ

CONTROL VALVE
TO UC

SHIFT VALVE
MO RIB

EMERGENCY
To crankshaft VALVE
AL ST

To cylinder head
VARIABLE OIL
BR DI

ORIFICE

To transmission
CA SU

OIL PRESSURE
REGULATOR VALVE OIL FILTER
DUAL CLUTCH PC
SOLENOID VALVE
24 O
-20 BID

SCAVENGE
PUMP
-07 HI

FEED PUMP
28 O
PR

OIL PAN OIL TANK

13-7
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

OIL FLOW
When the transmission is in the neutral position:

Part name: Dual clutch PC solenoid valve Shift solenoid valve 1st shift clutch 2nd shift clutch

S. O
Condition: ON (controlling) OFF Disengaged Engaged

L.
S AD
The 2nd clutch oil supply circuit is open and the 1st clutch oil drain circuit is open.

R.
2ND SHIFT CLUTCH 2ND ORIFICE

OR RIZ
CONTROL VALVE
1ST SHIFT CLUTCH

SHIFT SOLENOID

OT TO
VALVE
1ST ORIFICE
CONTROL VALVE

LM U
RA O A
Oil drain
SHIFT VALVE

EMERGENCY

AB N
VALVE

-C O
L. US
DUAL CLUTCH PC
SOLENOID VALVE
S. N O
From oil pump
R.
RS IÓ

When the transmission is in the 1st, 3rd or 5th gear position:

TO UC

Part name: Dual clutch PC solenoid valve Shift solenoid valve 1st shift clutch 2nd shift clutch
Condition: OFF ON Engaged Disengaged
The 1st clutch oil supply circuit is open and the 2nd clutch oil drain circuit is open.
MO RIB

2ND SHIFT CLUTCH 2ND ORIFICE

CONTROL VALVE
1ST SHIFT CLUTCH
AL ST

Oil drain
SHIFT SOLENOID
VALVE
BR DI

1ST ORIFICE
CONTROL VALVE
CA SU

SHIFT VALVE
24 O

EMERGENCY
VALVE
-20 BID
-07 HI

DUAL CLUTCH PC
28 O

SOLENOID VALVE
PR

From oil pump

13-8
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

When the transmission is in the 2nd, 4th or reverse gear position:

Part name: Dual clutch PC solenoid valve Shift solenoid valve 1st shift clutch 2nd shift clutch
Condition: OFF OFF Disengaged Engaged

S. O
The 2nd clutch oil supply circuit is open and the 1st clutch oil drain circuit is open.

L.
S AD
2ND SHIFT CLUTCH 2ND ORIFICE

R.
CONTROL VALVE
1ST SHIFT CLUTCH

OR RIZ
SHIFT SOLENOID
VALVE
1ST ORIFICE

OT TO
CONTROL VALVE

LM U
Oil drain
SHIFT VALVE

RA O A
EMERGENCY
VALVE

AB N
-C O
L. US
DUAL CLUTCH PC
S. N OSOLENOID VALVE

From oil pump

When the emergency valve stopper bolt is turned in (In case of the dual clutch PC solenoid valve stuck at closed
R.
RS IÓ

position):
The clutch oil supply circuit is open and shift clutches are engaged or disengaged normally. (The figure is shown when the 2nd
TO UC

clutch is engaged.)

2ND SHIFT CLUTCH 2ND ORIFICE

MO RIB

CONTROL VALVE
1ST SHIFT CLUTCH

SHIFT SOLENOID
AL ST

VALVE
1ST ORIFICE
CONTROL VALVE
BR DI

Oil drain
SHIFT VALVE
CA SU

EMERGENCY
VALVE
24 O
-20 BID

DUAL CLUTCH PC
-07 HI

SOLENOID VALVE
28 O

From oil pump

PR

13-9
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

TRANSMISSION OPERATION
The engine power is transmitted to the primary driven gear via the centrifugal clutch when the engine speed rises. The 1st and 2nd
clutch drums are connected to the primary driven gear. The 1st clutch gear guide is connected to the 1st mainshaft and the 2nd
clutch gear guide is connected to the 2nd mainshaft. Therefor, depending upon the shift drum position, the 1st, 3rd or 5th gear is

S. O
driven when the 1st clutch is engaged, and 2nd, 4th or reverse gear is driven when the 2nd clutch is engaged.

L.
S AD
CENTRIFUGAL CLUTCH

R.
OR RIZ
CRANKSHAFT

OT TO
2ND MAINSHAFT
(2nd, 4th and reverse gear)

LM U
RA O A
AB N
1ST MAINSHAFT

-C O
L. US
COUNTERSHAFT
S. N O
R.
RS IÓ
TO UC

1ST CLUTCH
GEAR GUIDE
MO RIB

1ST CLUTCH DRUM

AL ST

PRIMARY DRIVEN GEAR 2ND CLUTCH GEAR GUIDE

BR DI

2ND CLUTCH DRUM

CA SU

OUTPUT SHAFT
24 O
-20 BID
-07 HI
28 O
PR

13-10
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

POWER FLOW
When the transmission is shifted into 1st gear
Shift from neutral

S. O
1. Front gear shifter is shifted to 2nd position from neutral position (pre-shifting).
2. Rear gear shifter is shifted to 1st position from neutral position (pre-shifting).

L.
S AD
3. 1st shift clutch is engaged.
Shift down from 2nd gear

R.
1. Rear gear shifter is shifted to 1st position from 3rd position (pre-shifting).

OR RIZ
2. 2nd shift clutch is disengaged and 1st shift clutch is engaged.
The engine power is transmitted as follows:
– crankshaft

OT TO
– centrifugal clutch
– primary driven gear
– 1st shift clutch
– 1st mainshaft

LM U
– rear gear shifter

RA O A
– M1 gear
– C1 gear
– countershaft
– output drive and driven gears

AB N
– output shaft

-C O
CENTRIFUGAL CLUTCH
CRANKSHAFT

L. US 1ST MAINSHAFT
S. N O
REAR GEAR SHIFTER
R.
RS IÓ
TO UC

M1 GEAR
MO RIB

OUTPUT DRIVE GEAR

AL ST
BR DI
CA SU

OUTPUT SHAFT
24 O
-20 BID

1ST SHIFT CLUTCH

-07 HI

PRIMARY DRIVEN GEAR COUNTERSHAFT

28 O

FRONT GEAR SHIFTER C1 GEAR

PR

OUTPUT DRIVEN GEAR

13-11
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

When the transmission is shifted into 2nd gear
Shift up from 1st gear
1. 1st shift clutch is disengaged and 2nd shift clutch is engaged.
2. Rear gear shifter is shifted to 3rd position from 1st position (pre-shifting).

S. O
Shift down from 3rd gear

L.
S AD
1. Front gear shifter is shifted to 2nd position from 4th position (pre-shifting).
2. 1st shift clutch is disengaged and 2nd shift clutch is engaged.

R.
The engine power is transmitted as follows:

OR RIZ
– crankshaft
– centrifugal clutch
– primary driven gear
– 2nd shift clutch

OT TO
– 2nd mainshaft (M2 gear)
– C2 gear
– front gear shifter

LM U
– countershaft
– output drive and driven gears

RA O A
– output shaft

CENTRIFUGAL CLUTCH

AB N
CRANKSHAFT

-C O
2ND MAINSHAFT
(M2 GEAR)

L. US
REAR GEAR SHIFTER
S. N O
R.
RS IÓ
TO UC

OUTPUT DRIVE GEAR

MO RIB
AL ST
BR DI

OUTPUT SHAFT
CA SU
24 O
-20 BID

2ND SHIFT CLUTCH

C2 GEAR
PRIMARY DRIVEN GEAR
FRONT GEAR SHIFTER
-07 HI

COUNTERSHAFT
28 O

OUTPUT DRIVEN GEAR

PR

13-12
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

When the transmission is shifted into 3rd gear
Shift up from 2nd gear
1. 2nd shift clutch is disengaged and 1st shift clutch is engaged.
2. Front gear shifter is shifted to 4th position from 2nd position (pre-shifting).

S. O
Shift down from 4th gear

L.
S AD
1. Center gear shifter is shifted to neutral from 5th position (pre-shifting).
2. Rear gear shifter is shifted to 3rd position from neutral position (pre-shifting).

R.
3. 2nd shift clutch is disengaged and 1st shift clutch is engaged.

OR RIZ
The engine power is transmitted as follows:
– crankshaft
– centrifugal clutch
– primary driven gear

OT TO
– 1st shift clutch
– 1st mainshaft
– rear gear shifter

LM U
– M3 gear
– center gear shifter (C3 gear)

RA O A
– countershaft
– output drive and driven gears
– output shaft

AB N
CENTRIFUGAL CLUTCH
CRANKSHAFT

-C O
M3 GEAR

L. US
1ST MAINSHAFT
REAR GEAR SHIFTER
S. N O
R.
RS IÓ
TO UC

COUNTERSHAFT
MO RIB

OUTPUT DRIVE GEAR

AL ST
BR DI
CA SU

OUTPUT SHAFT
24 O

1ST SHIFT CLUTCH

-20 BID

PRIMARY DRIVEN GEAR

-07 HI

FRONT GEAR SHIFTER

28 O

CENTER GEAR SHIFTER

(C3 GEAR)
PR

OUTPUT DRIVEN GEAR

13-13
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

When the transmission is shifted into 4th gear
Shift up from 3rd gear
1. 1st shift clutch is disengaged and 2nd shift clutch is engaged.
2. Rear gear shifter is shifted to neutral position from 3rd position (pre-shifting).

S. O
3. Center gear shifter is shifted to 5th position from neutral position (pre-shifting).

L.
S AD
Shift down from 5th gear
1. Front gear shifter is shifted to 4th position from neutral position (pre-shifting).

R.
2. 1st shift clutch is disengaged and 2nd shift clutch is engaged.

OR RIZ
The engine power is transmitted as follows:
– crankshaft
– centrifugal clutch
– primary driven gear

OT TO
– 2nd shift clutch
– 2nd mainshaft (M4 gear)
– C4 gear

LM U
– front gear shifter
– countershaft

RA O A
– output drive and driven gears
– output shaft

CENTRIFUGAL CLUTCH

AB N
CRANKSHAFT

-C O
L. US
2ND MAINSHAFT
(M4 GEAR)
REAR GEAR SHIFTER
S. N O
R.
RS IÓ

COUNTERSHAFT
TO UC
MO RIB

OUTPUT DRIVE GEAR

AL ST
BR DI

OUTPUT SHAFT
CA SU
24 O
-20 BID

2ND SHIFT CLUTCH

PRIMARY DRIVEN GEAR
-07 HI

C4 GEAR
CENTER GEAR SHIFTER
28 O

FRONT GEAR SHIFTER

PR

OUTPUT DRIVEN GEAR

13-14
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

When the transmission is shifted into 5th gear
Shift up from 4th gear
1. 2nd shift clutch is disengaged and 1st shift clutch is engaged.
2. Front gear shifter is shifted to neutral position from 4th position.

S. O
The engine power is transmitted as follows:

L.
S AD
– crankshaft
– centrifugal clutch

R.
– primary driven gear
– 1st shift clutch

OR RIZ
– 1st mainshaft
– rear gear shifter (M5 gear)
– C5 gear
– center gear shifter

OT TO
– countershaft
– output drive and driven gears
– output shaft

LM U
RA O A
CENTRIFUGAL CLUTCH
CRANKSHAFT

AB N
1ST MAINSHAFT REAR GEAR SHIFTER

-C O
(M5 GEAR)

L. US
S. N O

COUNTERSHAFT
R.
RS IÓ
TO UC

OUTPUT DRIVE GEAR

MO RIB
AL ST

OUTPUT SHAFT
BR DI

1ST SHIFT CLUTCH

CA SU
24 O

PRIMARY DRIVEN GEAR

C5 GEAR
-20 BID

FRONT GEAR SHIFTER

CENTER GEAR SHIFTER

-07 HI

OUTPUT DRIVEN GEAR

28 O
PR

13-15
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

When the transmission is shifted into reverse gear
Shift from neutral
1. Center gear shifter is shifted to reverse position from neutral position.
2. 2nd shift clutch is engaged.

S. O
The engine power is transmitted as follows:

L.
S AD
– crankshaft
– centrifugal clutch

R.
– primary driven gear
– 2nd shift clutch

OR RIZ
– 2nd mainshaft (M2/MR gear)
– reverse idle gear
– CR gear
– center gear shifter

OT TO
– countershaft
– output drive and driven gears
– output shaft

LM U
RA O A
CENTRIFUGAL CLUTCH
CRANKSHAFT

AB N
2ND MAINSHAFT

-C O
(M2/MR GEAR)

L. US
S. N O
R.
RS IÓ

REVERSE IDLE GEAR

TO UC
MO RIB

OUTPUT DRIVE GEAR

AL ST
BR DI
CA SU

OUTPUT SHAFT
24 O

2ND SHIFT CLUTCH

-20 BID

PRIMARY DRIVEN GEAR

-07 HI

CENTER GEAR SHIFTER

28 O

COUNTERSHAFT CR GEAR
PR

OUTPUT DRIVEN GEAR

13-16
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DRIVE MODE
The system provides two type of driving modes, AUTO (Automatic) and ESP (Electric Shift Program). These modes can be
changed with the drive mode select switch.

S. O
AUTOMATIC MODE (R – N – D)
The dual clutch transmission will enter Automatic mode when the drive mode select switch is turned to AUTO.

L.
S AD
The transmission is shifted to the Drive range from Neutral by pushing the UPSHIFT switch; the gear position indicator will display

R.
"D". When the vehicle is driven, the transmission will automatically shift in accordance with the throttle opening and vehicle speed.

OR RIZ
The transmission is shifted to the Reverse from neutral by pulling the reverse select lever, squeezing the rear brake lever and
pushing the DOWNSHIFT switch; the gear position indicator will display "R".
ESP MODE (R – N – 1 – 2 – 3 – 4 – 5)

OT TO
The dual clutch transmission will enter ESP mode when the drive mode select switch is turned to ESP.
The transmission is shifted to the 1st gear from Neutral by pushing the UPSHIFT switch; the gear position indicator will display "1".
Up-shifting or down-shifting to next gear is completed by pushing the UPSHIFT or DOWNSHIFT switch.

LM U
’14 – ’19 models:

RA O A
The transmission is shifted to the Reverse from neutral by pulling the reverse selector lever, squeezing the rear brake lever and
pushing the DOWNSHIFT switch; the gear position indicator will display "R".
After ’19 model:
Press and hold the reverse switch, then press the downshift switch within 10 seconds to shift into "R" reverse gear.

AB N
You can also shift into "R" reverse gear by pressing and holding the downshift switch, then pressing the reverse switch within 0.5
seconds.

-C O
Make sure that the reverse indicator comes on and the gear position indicator shows "R".
Shift out of reverse and into “N” (neutral) or “D or 1” (forward gear)

L. US
• To shift into “N” (neutral), press the upshift switch once.
• To shift into “D or 1” (forward gear), press and hold the reverse switch, then press the upshift switch within 10 seconds.
You can also shift into “D or 1” (forward gear) by pressing and holding the upshift switch, then pressing the reverse switch within
S. N O
0.5 seconds.

AUTO MODE ESP MODE UPSHIFT SWITCH

R.
RS IÓ

REVERSE SWITCH
(After ’19 model)
TO UC
MO RIB
AL ST
BR DI

DRIVE MODE SELECT SWITCH DOWNSHIFT SWITCH

CA SU

REVERSE SELECTOR LEVER (except after '19 model)

24 O
-20 BID
-07 HI
28 O
PR

GEAR POSITION INDICATOR

REAR BRAKE LEVER

13-17
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SYMPTOM TROUBLESHOOTING
GENERAL INFORMATION
If the ATV has any DCT trouble, check the DTC or gear position indicator blinking, refer to the DTC index and

S. O
begin the appropriate troubleshooting procedure (page 13-29).

L.
S AD
If there are no DTC stored in the PCM memory, do the troubleshooting as following symptom and then inspect
the oil pressure and diagnose according to the troubleshooting chart (page 13-22).

R.
Symptom Diagnosis procedure Also check for

OR RIZ
Starting control failure Check the centrifugal clutch system (page 13-62). • Engine oil level
Refer to the following symptom troubleshooting: (page 3-19)
• Vehicle does not accelerate (page 13-18) • Oil pressure

OT TO
• Excessive starting shock (page 13-19) (page 13-20)
Shift control failure Refer to the following symptom troubleshooting: • Engine oil level
• DCT does not shift (page 13-19) (page 3-19)
• When shifting in the AUTO (automatic) mode, • Oil pressure

LM U
excessive shift shock, engine rpm rises or driving (page 13-20)

RA O A
power falls off (page 13-20)
Gear position indicator Check the shift drum position switch/TR sensor and • Serial
shows "–" but no DTC its circuit (for open circuit) communication
set line (page 23-8)

AB N
Gear position indicator Check the DLC circuit (Brown/red wire) for short • Short circuit in
shows nothing and MIL circuit. the DLC related

-C O
stays on at all times (No wire
DTC set)

L. US
STARTING CONTROL FAILURE
S. N O
Vehicle Does Not Accelerate
1. Dual Clutch PC Solenoid Valve Operation Sound
Check
Remove the tank cover assembly (page 2-4).
R.
RS IÓ

[1]
Check for a "click" sound from the dual clutch PC
solenoid valve [1] when the ignition switch is turned
TO UC

ON.
Is there sound?
YES – GO TO STEP 3.
MO RIB

NO – GO TO STEP 2.
AL ST
BR DI

2. Dual Clutch PC Solenoid Valve Operation Check

CA SU

Turn the ignition switch OFF.

Disconnect the dual clutch PC solenoid 2P (Black)
connector.
24 O

Connect a 12 V battery [1] to the solenoid valve

connector [2] terminals as shown.
-20 BID

The solenoid valve should operate (sounds) when

the battery is connected.
Does the solenoid operate?
-07 HI

YES – GO TO STEP 3.
NO – Faulty dual clutch PC solenoid valve.
28 O
PR

[2] [1]

13-18
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

3. Vehicle Test-riding
Turn the mode select switch to ESP.
Accelerate the vehicle with the transmission in 2nd
gear.

S. O
Does the vehicle accelerate?

L.
S AD
YES – Faulty 1st shift clutch system (page 13-85).

R.
NO – Hydraulic circuit malfunction is the likely
cause. Check the oil pressure (page 13-

OR RIZ
20).

OT TO
Excessive Jerking when Accelerating
1. Vehicle Test-riding
Turn the drive mode select switch to ESP.

LM U
Check for acceleration jerking with the transmission

RA O A
in the 2nd gear.
Is there acceleration jerking with the
transmission in 2nd gear?
YES – Hydraulic circuit malfunction is the likely

AB N
cause. Check the oil pressure (page 13-
20).

-C O
NO – Faulty 1st shift clutch system (page 13-85).

L. US
SHIFT CONTROL FAILURE
DCT Does Not Shift
S. N O
1. Vehicle Test-riding
Test-ride the vehicle with the drive mode select
switch at ESP and shift the transmission with the
R.
RS IÓ

gearshift switch.
Is the transmission shifted?
TO UC

YES – • Faulty TP sensor system. Check the

installation condition (page 4-39).
• Faulty VS sensor system. Check the
MO RIB

installation condition (page 13-77).

NO – GO TO STEP 2.
2. Shift Solenoid Valve Operation Check
AL ST

Turn the ignition switch OFF.

[1]
Remove the tank cover assembly (page 2-4).
BR DI

Disconnect the shift solenoid valve 2P (Brown)

connector [1].
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-19
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Connect a 12 V battery [1] to the solenoid valve
connector [2] terminals as shown.
The shift solenoid valve should operate (sound)
when the battery is connected.

S. O
Does the solenoid valve operate?

L.
S AD
YES – Hydraulic circuit malfunction is likely
cause. Check the oil pressure (page 13-

R.
20).

OR RIZ
NO – Faulty shift solenoid valve.

OT TO
[2] [1]

When Shifting in the AUTO (automatic) Mode,

LM U
Excessive Shift Shock, Engine rpm Rises or Driving
Power Falls Off

RA O A
1. Vehicle Test-riding
Test-ride the vehicle with the drive mode select
switch at ESP. Check above symptoms when

AB N
shifting with the gearshift switch.
Are there repeated symptoms?

-C O
YES – Hydraulic circuit malfunction is likely

L. US
cause. Check the oil pressure (page 13-
20).
NO – • Faulty TP sensor system; Check the
installation condition (page 4-39).
S. N O
• Faulty VS sensor system. Check the
installation condition (page 13-77).
R.
RS IÓ

OIL PRESSURE CHECK

TO UC

• If the oil pressure is abnormal, inspect and clean the

parts according to the hydraulic circuit
troubleshooting chart (page 13-22).
MO RIB

• Failure to warm the engine will cause very high oil

pressure readings.
External leaks will cause low oil pressure readings.
Check the oil level and add the recommended engine
AL ST

oil if necessary (page 3-19).

Warm the engine to normal operating temperature and
BR DI

check for external oil leaks.

LINE OIL PRESSURE
CA SU

Remove the tank cover assembly (page 2-4).

[2]
Clean around the sealing bolt [1] with compressed air.
Be sure that no dirt Remove the sealing bolt and sealing washer [2] from
24 O

is allowed to enter the right side of the shift valve body.

the oil gallery.
-20 BID
-07 HI
28 O
PR

[1]

13-20
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Connect the oil pressure gauge and adapter to the
[1]
sealing bolt hole (hole threads: M8 x 1.25).
Except U.S.A. TOOL:
Pressure gauge set [1] 07406-0020005

S. O
L.
S AD
U.S.A. TOOLS:
Oil pressure gauge 0–160 psi 07ZMJ-HN2A100 and

R.
Adaptor, banjo 8 x 1.25 mm 07AMJ-HN8A100

OR RIZ
(2 required)
Adapter, 25L x 8 x 1.25 mm 07AMJ-HP7A100
(Use for first clutch
testing)

OT TO
Shift the transmission into neutral.
Start the engine and measure the oil pressure.

LM U
LINE OIL PRESSURE (80°C/176°F):
510 kPa (5.2 kgf/cm2, 74 psi) at 5,000 rpm

RA O A
Stop the engine.
Remove the pressure gauge and adaptor.
Install the sealing bolt [1] with a new sealing washer [2]

AB N
[2]
and tighten it.
Install the tank cover assembly (page 2-4).

-C O
L. US
S. N O
R.
RS IÓ

[1]
TO UC

SHIFT CLUTCH OIL PRESSURE

Remove the tank cover assembly (page 2-4).
[2] [1]
MO RIB

Be careful not touch Support the vehicle using a hoist or equivalent and
the rotating wheels raise all the wheels off the ground.
during inspection.
Clean around the sealing bolts with compressed air.
AL ST

Be sure that no dirt Remove the sealing bolt (for 1st clutch) [1], sealing bolt
is allowed to enter (for 2nd clutch) [2] and sealing washers [3] from the left
the oil gallery. side of the front crankcase cover.
BR DI
CA SU

[3]
24 O
-20 BID
-07 HI
28 O
PR

13-21
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Connect the oil pressure gauges and adaptors to the
[1]
sealing bolt holes (hole threads: M8 x 1.25).
Except U.S.A. TOOL:
Pressure gauge set [1] 07406-0020005

S. O
L.
S AD
U.S.A. TOOLS:
Oil pressure gauge 0–160 psi 07ZMJ-HN2A100 and

R.
Adapter, banjo 8 x 1.25 mm 07AMJ-HN8A100
(2 required)

OR RIZ
Adapter, 25L x 8 x 1.25 mm 07AMJ-HP7A100
(Use for first clutch
testing)

OT TO
Turn the drive mode select switch to ESP.
Start the engine and measure the oil pressure at 1st
gear and 2nd gear.

LM U
SHIFT CLUTCH OIL PRESSURE (80°C/176°F):

RA O A
510 kPa (5.2 kgf/cm2, 74 psi) at 5,000 rpm
Stop the engine.
[1]
Remove the pressure gauges and adaptors.

AB N
Install the sealing bolts [1] with new sealing washers [2]
and tighten them.

-C O
Install the tank cover assembly (page 2-4).

L. US
S. N O

[2]
R.
RS IÓ

TROUBLESHOOTING CHART OF
TO UC

HYDRAULIC CIRCUIT
PRESSURE CHECK SECTION MEASUREMENT RESULT (■: Abnormal, Blank: Normal)
Line pressure ■ Refer to
MO RIB

1st clutch pressure ■ ■ ■ page

2nd clutch pressure ■ ■ ■
Dual clutch PC solenoid valve O
AL ST

Emergency valve O
Probable Faulty Part (applied to O)

Shift valve O O
13-79
Shift solenoid valve O
BR DI

Valve body base O

Valve body O
1st shift clutch O
CA SU

13-85
2nd shift clutch O
Feed pipe A O
Feed pipe B O 13-54
24 O

Oil guide pin O O O

Oil pump O 9-8
-20 BID

Oil filter O 3-21

Oil strainer O 15-7
Oil level O 3-19
-07 HI
28 O
PR

13-22
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

COMPONENT LOCATION
’14 – ’19 models

S. O
FA2 model shown:

L.
S AD
R.
COMBINATION METER

OR RIZ
– GEAR POSITION INDICATOR

UPSHIFT SWITCH IGNITION SWITCH

OT TO
DOWNSHIFT SWITCH DRIVE MODE
SELECT SWITCH

LM U
RA O A
PCM
DLC
RELAY BOX

AB N
– MAIN POWER RELAY
FUSE BOX FRONT VS

-C O
– MAIN FUSE 1 (30 A) SENSOR
– MAIN FUSE 2 (10 A)

L. US
– IGN FUSE (20 A) SHIFT SOLENOID VALVE
– ACC FUSE (20 A)
– DIODE
S. N O
SHIFT CONTROL
MOTOR
R.
RS IÓ
TO UC
MO RIB

EOT SENSOR
AL ST

BATTERY
BR DI

DUAL CLUTCH PC
SENSOR UNIT
SOLENOID VALVE
(TP SENSOR)
CA SU

REAR VS SENSOR
24 O

CKP SENSOR
-20 BID

SHIFT SPINDLE SHIFT DRUM

ANGLE SENSOR POSITION SWITCH

REVERSE SWITCH
-07 HI
28 O
PR

13-23
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

After '19 models
FA6 model shown:

S. O
REVERSE SWITCH

L.
S AD
DOWNSHIFT SWITCH

R.
COMBINATION METER

OR RIZ
UPSHIFT SWITCH – GEAR POSITION INDICATOR

IGNITION SWITCH
PCM

OT TO
DRIVE MODE
RELAY BOX
SELECT SWITCH
– MAIN POWER RELAY

LM U
DLC

RA O A
SHIFT SOLENOID VALVE

FUSE BOX

AB N
– MAIN FUSE 1 (30 A)
– MAIN FUSE 2 (10 A) FRONT VS SENSOR

-C O
– IGN FUSE (20 A)
– ACC FUSE (20 A)

L. US
– DIODE

DUAL CLUTCH PC
SOLENOID VALVE
S. N O
BATTERY

SENSOR UNIT
REAR VS SENSOR (TP SENSOR)
R.
RS IÓ

TR SENSOR
EOT SENSOR
TO UC
MO RIB

SHIFT CONTROL MOTOR

SHIFT SPINDLE
ANGLE SENSOR CKP SENSOR
AL ST

NEUTRAL SWITCH
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-24
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SYSTEM DIAGRAM
'14 – '19 models

S. O
ES FUSE (30 A)
R R/W

L.
S AD
REGULATOR/
MAIN POWER

R.
RECTIFIER
IGNITION RELAY
SWITCH IGN FUSE

OR RIZ
(20A) R/Bl R R

R Bl Bl/R Bl/R V/W

BATTERY MAIN FUSE 1 (30 A)
R R/Bl R/Bl P W/Bl

ACC FUSE

OT TO
(20A)
Bl/Br Bl/Br

LIGHT FUSE
FRONT BRAKE (10A)

LM U
Bl/Br Y/R
SWITCH
R/Bl R/Y R
REAR BRAKE

RA O A
MAIN FUSE 2 (10A) DIODE
SWITCH Bl/Br G/Y
(LEVER)
REAR BRAKE PRC B31 V/W
SWITCH Bl G/Y A14 STOP LAMP SW
(PEDAL) MAIN B1 Bl/R Bl/R
UP

AB N
W/Bu A6 SFT UP
SHIFT ES
SWITCH DOWN W/Y A16 SFT DOWN
AT-ES SW A18 Br/Bl Bl/G
AT
(42)

-C O
Br/W
DRIVE MODE
SELECT SWITCH

L. US
CKP Bu/Y B23 PCP
SENSOR G
MIL
IGN Bl/R
M-TXD/RXD A21 P UART
GEAR POSITION GND G
SENSOR UNIT INDICATOR
S. N O
TP Br/W Br/W B3 VCC COMBINATION METER
SENSOR Bu/Bl B14 TH
(8) G/W G/W B2 SG

G/W W/Bl
R.
RS IÓ

Bu/Y B28 TOIL K - LINE B17 O/W

SCS B29 Br/R
G
EOT
TO UC

DLC SCS SERVICE CONNECTOR

SENSOR PCM
(44)
PVB C4 R/W

SHIFT SHIFT CONTROL

Br/W MOP C1 R
M MOTOR
MO RIB

SPINDLE G/Y G/Bu A23 ANGLE MOM C2 Bl

ANGLE (24)
G/R G/W
SENSOR
(21, 22, 23)
Bl/W Bl/R A5 SEN VB1 PG3 C5 G
P P/G B16 RR VSP
AL ST

REAR VS
SENSOR G FAIL-SAFE
RELAY SFT SOL A B7 Br/W SHIFT SOLENOID
(66)
(32) VALVE
BR DI

G (15)
Bl/R
Bl/Y B15 FR VSP

LIN P A8 Bl/W DUAL CLUTCH PC

CA SU

FRONT VS
SENSOR G SOLENOID VALVE
(67) LIN M A9 W/Y (4)

Gr A25 DP 5R
24 O

Lg/R A17 DP N REVERSE SW A7 R/Y Bu/R

5R N
12 W/G A27 DP 12
N2 Bu/Bl A1 DP N2 REVERSE
SWITCH
-20 BID

32 Y A26 DP 32
3N Bu/R A29 DP 3N LG B13 G
34 Bu/W A2 DP34
N4 Bu/G A24 DP N4 PG1 B21 G
5N 54 Bu A13 DP 54
W/Bu Lb A12 DP 5N PG2 B10 G
-07 HI

SHIFT DRUM
POSITION SWITCH
(41)
C-1 C-3
28 O

PCM A-1 A-11 B-1 B-11

A-12 A-22 B-12 B-22
PR

( ): Gear position
indicator blink
( ): MIL Blink

: Short terminals for

reading DTC

C-4 C-5 A-23 A-33 B-23 B-33

13-25
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

After '19 model
ES FUSE (30 A)
Bl R R R/W

S. O
REGULATOR/
MAIN POWER RECTIFIER

L.
S AD
IGNITION RELAY
SWITCH IGN FUSE
BATTERY (20A) R/Bl R R

R.
R Bl Bl/R Bl/R V/W
MAIN FUSE 1 (30 A)

OR RIZ
R R/Bl R/Bl P W/Bl

ACC FUSE
(20A)
Bl/Br

OT TO
LIGHT FUSE
FRONT BRAKE (10A)
Bl/Br Y/R
SWITCH
STOP SIGNAL R/Bl R/Y R
REAR BRAKE DIODE MAIN FUSE 2 (10A) DIODE

LM U
SWITCH (LEVER) Bl/Br G/Y

PRC B31 V/W

RA O A
REAR BRAKE
SWITCH (PEDAL) Bl G/Y A14 STOP LAMP SW
MAIN B1 Bl/R Bl/R
UP
W/Bu A6 SFT UP
SHIFT ES
SWITCH DOWN AT-ES SW A18 Br/Bl Bl/G
W/Y A16 SFT DOWN AT

AB N
Br/W
DRIVE MODE
SELECT SWITCH
REVERSE
Br/W
SWITCH

-C O
W/R B19 RVS HOLE SW
IGN Bl/R

L. US
M-TXD A21 P UART

SENSOR UNIT GEAR POSITION GND G

INDICATOR
TP Br/W Br/W B3 VCC COMBINATION METER
SENSOR Bu/Bl B14 TH
S. N O
G/W G/W B2 SG

W/Bl
EOT G/W K - LINE B17 O/W
SENSOR Bu/Y B28 TOIL SCS B29 Br/R
G
R.
RS IÓ

SHIFT Br/W
PCM DLC
SPINDLE G/Y G/Y A23 ANGLE
ANGLE
G/R G/W
TO UC

SENSOR
PVB+SUB VB C4 R/W
Br Br/W MOP C1 R
TR
SENSOR
Bu Bu A26 DP MOM C2 Bl M
G/W
MO RIB

SHIFT CONTROL
MOTOR
NEUTRAL Lg Lg A17 DP N
SWITCH

SFT SOL A B7 Br/W SHIFT SOLENOID

AL ST

G VALVE
CKP Bu/Y B23 PCP
SENSOR G
BR DI

LIN P A8 Bl/W DUAL CLUTCH PC

LIN M A9 W/Y SOLENOID VALVE
Bl/W Bl/R A5 SEN VB1
REAR VS P P/G B16 RR VSP
CA SU

SENSOR

Bl/R G
FRONT VS
Bl/Y B15 FR VSP
SENSOR
24 O

G LG B13 G
-20 BID

PG1 B21 G
PG2 B10 G
PG3 C5 G
-07 HI
28 O

Bl .... Black O .... Orange

1 2 3 Br .... Brown P .... Pink
PR

Bu .... Blue R .... Red

4 5 G .... Green V .... Violet
Gr .... Gray W .... White
Lg .... Light green Y .... Yellow

PCM 5P (Black) PCM 33P (Black) CONNECTOR A PCM 33P (Gray) CONNECTOR B
CONNECTOR C (PCM SIDE) (PCM SIDE)
(PCM side)

13-26
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Refer to the "GENERAL TROUBLESHOOTING" in "PGM-FI system" (page 4-9)

S. O
L.
S AD
SYSTEM DESCRIPTION

R.
SELF-DIAGNOSIS SYSTEM

OR RIZ
The DCT system is equipped with the self-diagnostic system. When any
abnormality occurs in the DCT system, the PCM have the gear position FA1 model shown:
indicator [1] blinking "–" and stores a DTC in its erasable memory for the
relevant system failure.

OT TO
FAIL-SAFE FUNCTION
The DCT system is provided with a fail-safe function to secure a minimum

LM U
running capability even when there is trouble in the system.

RA O A
When the PCM detects a problem in the DCT system, the PCM stops the
automatic shift and ESP functions, and defaults the transmission into the
2nd/4th/reverse gear position. Also, the gear position indicator blinks "–" to
indicate the DTC.

AB N
INDICATOR BLINK PATTERN
• The number of indicator blinks is the equivalent the main code of the [1]

-C O
DTC (the sub code cannot be displayed by the indicator blinking).
• The indicator has two types of blinks, a long blink and short blink. The long blink lasts for 1.2 seconds, the short blink lasts for

L. US
0.4 seconds. One long blink is the equivalent of ten short blinks. For example, when one long blink is followed by five short
blinks, the DTC is 15 (one long blink = 10 blinks, plus five short blinks).
• When the PCM stores more than one DTC, the indicator displays in the order from the lowest number to highest number.
S. N O
CURRENT DTC/STORED DTC
The DTC is indicated in two ways according to the failure status.
• If the PCM detects the problem at present, the gear position indicator will blink at all time. It is possible to readout the indicator
R.
RS IÓ

blink pattern as the current DTC.

• If the PCM does not detect any problem at present but has a problem stored in its memory, the indicator will not blink. If it is
necessary to retrieve the past problem, readout the stored DTC by following the DTC readout procedure.
TO UC

MCS INFORMATION
MO RIB

Refer to the "MCS INFORMATION" in "PGM-FI system" (page 4-10).

DTC READOUT
AL ST

• If the MIL blinks, readout the DTC (page 4-10)and troubleshoot the
BR DI

PGM-FI system first. Then recheck the DCT system after erasing the FA1 model shown:
PGM-FI DTC.
• After performing diagnostic troubleshooting, erase the problem code(s)
CA SU

(page 13-28)and test-drive the vehicle to be sure that the problem(s)

have been removed.
If the gear position indicator [1] blinks "–", connect the MCS to the DLC
24 O

(page 4-10).
Read the DTC and stored data, and follow the troubleshooting index (page
-20 BID

13-29).
To read the DTC with the gear position indicator, use the following
procedure.
-07 HI

[1]
28 O
PR

13-27
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Reading DTC with the gear position indicator
Turn the ignition switch ON and read "–" blinks on the gear position
[1]
indicator. The number of blinks indicates the current DTC.
Refer to the troubleshooting index (page 13-29).

S. O
When retrieving the stored DTC, refer to the following procedures.

L.
S AD
Remove the dummy connector (page 4-10).

R.
Short the DLC [1] terminals using the special tool.

OR RIZ
TOOL:
SCS Short Connector [2] 070PZ-ZY30100
CONNECTION: Brown/red – Green

OT TO
Turn the ignition switch ON and read "–" blinks on the gear position
indicator. The number of blinks indicates the stored DTC. [2]

LM U
Refer to the troubleshooting index (page 13-29).

RA O A
ERASING DTC
Connect the MCS to the DLC (page 4-10).

AB N
Erase the DTC with the MCS while the engine is stopped.
To erase the DTC without MCS, refer to the following procedure.

-C O
How to erase the DTC without MCS

L. US
• When the DCT DTC is erased, the PGM-FI DTC would also be erased at the same time. Check the MIL blinks and troubleshoot
the PGM-FI system before erasing the DCT DTC.
S. N O
1. Turn the ignition switch OFF.
2. Remove the dummy connector (page 4-10).
3. Short the DLC [1] terminals using the special tool
[1]
R.
RS IÓ

TOOL:
SCS Short Connector [2] 070PZ-ZY30100
TO UC

Connection: Brown/red – Green

4. Turn the ignition switch ON.
MO RIB

5. Remove the special tool from the DLC.

AL ST
BR DI

[2]

6. The gear position indicator [1] will show "–" for approximately 5 seconds.
FA1 model shown:
CA SU

While the indicator shows "–", short the DLC terminals again with the
special tool. The self-diagnostic memory is erased if the indicator starts
blinking "–".
24 O

• The DLC must be jumped while the indicator shows "–". If not, the
-20 BID

indicator will not start blinking.

• Note that the self-diagnostic memory cannot be erased if the ignition
switch is turned OFF before the indicator starts blinking.
-07 HI
28 O

[1]
PR

CIRCUIT INSPECTION
Refer to the "INSPECTION AT PCM/ECM CONNECTOR" information in "PGM-FI system" (page 4-11).

13-28
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DTC INDEX
• When the gear position indicator shows "–" constantly, but no problem code is indicated and retrievable, refer to the symptom
troubleshooting (page 13-18).

S. O
'14 – '19 models

L.
S AD
DTC Refer to MIL
Function Failure Symptom/Fail-safe Function

R.
("–" blinks) page blinks
Dual clutch PC solenoid valve Low input • Gearshift function does not

OR RIZ
• Loose or poor contact of the dual clutch work (2nd, 4th or reverse
4-1 (4) PC solenoid valve connector gear only) 13-32
• Dual clutch PC solenoid valve or its
circuit malfunction

OT TO
Dual clutch PC solenoid valve High input • Gearshift function does not –
4-2 (4) • Dual clutch PC solenoid valve or its work (2nd, 4th or reverse 13-33
circuit malfunction gear only)

LM U
Dual clutch PC solenoid valve drive circuit • Gearshift function does not

RA O A
4-3 (4) • Dual clutch PC solenoid valve or its work (2nd, 4th or reverse 13-32
circuit malfunction gear only)
TP sensor circuit Low voltage • Poor engine acceleration
• TP sensor or its circuit malfunction • Fail-safe value: 0°

AB N
8-1 (8) • Loose or poor contact of the TP sensor • Gearshift function does not 4-21
connector work (2nd, 4th or reverse
gear only)

-C O
8
TP sensor circuit High voltage • Poor engine acceleration
• TP sensor or its circuit malfunction • Fail-safe value: 0°

L. US
8-2 (8) • Gearshift function does not 4-23
work (2nd, 4th or reverse
gear only)
S. N O
Shift solenoid valve circuit • Gearshift function does not
• Loose or poor contact of the shift work (2nd, 4th or reverse
15-1 (15) solenoid valve connector gear only) 13-34 –
• Shift solenoid valve or its circuit
R.
malfunction
RS IÓ

Shift spindle angle sensor circuit Low • Gearshift function does not
voltage work (2nd, 4th or reverse
TO UC

• Loose or poor contact of the shift spindle gear only)

21-1 (21) 13-35 –
angle sensor connector
• Shift spindle angle sensor or its circuit
MO RIB

malfunction
Shift spindle angle sensor circuit High • Gearshift function does not
voltage work (2nd, 4th or reverse
21-2 (21) 13-36 –
• Shift spindle angle sensor or its circuit gear only)
AL ST

malfunction
Shift spindle operation malfunction (while • Gearshift function does not
operating gearshift mechanism) work (2nd, 4th or reverse
BR DI

22-1 (22) • Control motor or its circuit malfunction gear only) 13-37 –
• Shift spindle angle sensor or its circuit
malfunction
CA SU

Shift spindle operation malfunction (after • Gearshift function does not

operating gearshift mechanism) work (2nd, 4th or reverse
• Shift spindle angle sensor installation gear only)
23-1 (23) 13-38 –
problem
24 O

• Shift spindle angle sensor or its circuit

malfunction
-20 BID

Shift control motor drive circuit • Gearshift function does not

• Loose or poor contact of the shift control work (2nd, 4th or reverse
24-1 (24) motor connector gear only) 13-39 –
• Control motor or its circuit malfunction
-07 HI

• Control motor drive circuit malfunction

Fail-safe relay circuit • Gearshift function does not
28 O

32-1 (32) • Fail-safe relay circuit malfunction work (2nd, 4th or reverse 13-42 –
gear only)
PR

Shift drum position switch circuit • Gearshift function does not

41-1 (41) • Shift drum position switch or its circuit work (2nd, 4th or reverse 13-43 41
malfunction (Short) gear only)

13-29
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DTC Refer to MIL
Function Failure Symptom/Fail-safe Function
("–" blinks) page blinks
Gearshift switch circuit • Gearshift function does not
42-1 (42) • Gearshift switch or its circuit malfunction work (2nd, 4th or reverse 13-44 –

S. O
gear only)
EOT sensor circuit low voltage (less than • Gearshift function does not

L.
S AD
0.08 V) work (2nd, 4th or reverse
44-1 (44) 13-45
• EOT sensor or its circuit malfunction gear only)

R.
• Cooling fan turns on

OR RIZ
EOT sensor circuit high voltage (more than • Gearshift function does not 44
4.92 V) work (2nd, 4th or reverse
44-2 (44) • Loose or poor contact of the EOT sensor gear only) 13-46
connector • Cooling fan turns on

OT TO
• EOT sensor or its circuit malfunction
Rear VS sensor no signal • Gearshift function does not
• Loose or poor contact of the Rear VS work (2nd, 4th or reverse
66-1 (66) 13-51 66

LM U
sensor connector gear only)
• Rear VS sensor or its circuit malfunction

RA O A
Front VS sensor no signal • Gearshift function does not
• Loose or poor contact of the Front VS work (2nd, 4th or reverse
67-1 (67) 13-52 67
sensor connector gear only)
• Front VS sensor or its circuit malfunction

AB N
After '19 model

-C O
• If the MCS is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the DTC.

L. US
Refer to
DTC Function Failure Symptom/Fail-safe Function
page
Dual clutch PC solenoid valve Low input • Gearshift function does not work
• Loose or poor contact of the dual clutch
S. N O
4-1 PC solenoid valve connector 13-32
• Dual clutch PC solenoid valve or its
circuit malfunction
Dual clutch PC solenoid valve High input • Gearshift function does not work
R.
RS IÓ

4-2 • Dual clutch PC solenoid valve or its 13-33

circuit malfunction
TO UC

Dual clutch PC solenoid valve drive circuit • Gearshift function does not work
4-3 • Dual clutch PC solenoid valve or its 13-32
circuit malfunction
MO RIB

TP sensor circuit Low voltage (less than • Poor engine acceleration

0.225 V) • Gearshift function does not work
8-1 • TP sensor or its circuit malfunction 4-21
• Loose or poor contact of the TP sensor
AL ST

connector
TP sensor circuit High voltage (more than • Poor engine acceleration
8-2 4.922 V) • Gearshift function does not work 4-23
BR DI

• TP sensor or its circuit malfunction

Shift solenoid valve circuit • Gearshift function does not work
• Loose or poor contact of the shift
CA SU

15-1 solenoid valve connector 13-34

• Shift solenoid valve or its circuit
malfunction
Shift spindle angle sensor circuit Low • Gearshift function does not work
24 O

voltage (less than 0.215 V)

• Loose or poor contact of the shift spindle
-20 BID

21-1 13-35
angle sensor connector
• Shift spindle angle sensor or its circuit
malfunction
Shift spindle angle sensor circuit High • Gearshift function does not work
-07 HI

voltage (more than 4.619 V)

21-2 13-36
• Shift spindle angle sensor or its circuit
28 O

malfunction
Shift spindle operation malfunction (while • Gearshift function does not work
PR

operating gearshift mechanism)

22-1 • Control motor or its circuit malfunction 13-37
• Shift spindle angle sensor or its circuit
malfunction

13-30
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Refer to
DTC Function Failure Symptom/Fail-safe Function
page
Shift spindle operation malfunction (after • Gearshift function does not work
operating gearshift mechanism)

S. O
• Shift spindle angle sensor installation
23-1 13-38
problem

L.
S AD
• Shift spindle angle sensor or its circuit
malfunction

R.
Shift control motor drive circuit • Gearshift function does not work

OR RIZ
• Loose or poor contact of the shift control
24-1 motor connector 13-39
• Control motor or its circuit malfunction
• Control motor drive circuit malfunction

OT TO
Shift drum position malfunction • Gearshift function does not work
27-1 • TR sensor or its circuit malfunction 13-40
• Faulty gearshift mechanism

LM U
Shift control input power low voltage (less • Gearshift function does not work (2nd
than 8.992 V) gear only)

RA O A
• Faulty fail safe relay in the PCM
31-1 13-42
• Blown ES fuse (30 A)
• Loose or poor contact of the PCM 5P
(Black) connector

AB N
Fail-safe relay circuit • Gearshift function does not work
32-1 13-42
• Fail-safe relay circuit malfunction

-C O
33-2* PCM EEPROM malfunction • Does not hold the self-diagnosis data 13-42
Gearshift switch circuit • Gearshift function does not work

L. US
42-1 13-44
• Gearshift switch or its circuit malfunction
EOT sensor circuit low voltage (less than • Gearshift function does not work
44-1 0.059 V) • Cooling fan turns on 13-45
• EOT sensor or its circuit malfunction
S. N O
EOT sensor circuit high voltage (more than • Gearshift function does not work
4.922 V) • Cooling fan turns on
44-2 • Loose or poor contact of the EOT sensor 13-46
connector
R.
RS IÓ

• EOT sensor or its circuit malfunction

TR sensor Low voltage (less than 0.410 V) • Gearshift function does not work
TO UC

• Loose or poor contact of the TR sensor

51-1 13-47
connector
• TR sensor or its circuit malfunction
MO RIB

TR sensor High voltage (more than 4.702 V) • Gearshift function does not work
51-2 13-49
• TR sensor or its circuit malfunction
Neutral switch stuck OFF • Gearshift function does not work
• Loose or poor contact of the neutral
52-1 13-49
AL ST

switch connector
• Neutral switch or its circuit malfunction
Neutral switch stuck ON • Gearshift function does not work
52-2 13-50
BR DI

• Neutral switch or its circuit malfunction

Gearshift mechanism malfunction • Gearshift function does not work
57-1 • TR sensor malfunction 13-50
CA SU

• Faulty shifter mechanism

Gear position malfunction (jumps out of • Gearshift function does not work
gear)
57-2 13-51
• TR sensor malfunction
24 O

• Faulty shifter mechanism

Rear VS sensor no signal • Gearshift function does not work
-20 BID

• Loose or poor contact of the Rear VS

66-1 13-51
sensor connector
• Rear VS sensor or its circuit malfunction
-07 HI

Front VS sensor no signal • Gearshift function does not work

• Loose or poor contact of the Front VS
67-1 13-52
sensor connector
28 O

• Front VS sensor or its circuit malfunction

PR

* DTC can be readout/erased only by MCS.

13-31
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DTC TROUBLESHOOTING
• Perform inspection with the ignition switch turned OFF, unless otherwise

S. O
specified.
• After troubleshooting, erase the DTC (page 13-28) and test-ride the

L.
S AD
vehicle to be sure that the system is normal.

R.
DTC 4-1 (DUAL CLUTCH PC SOLENOID LOW INPUT),

OR RIZ
DTC 4-3 (DUAL CLUTCH PC SOLENOID DRIVE
CIRCUIT)

OT TO
• Before starting the troubleshooting, check the dual clutch PC solenoid
valve 2P (Black) connector for loose or poor contacts, and recheck the
DTC.

LM U
1. Recheck DTC

RA O A
Recheck the current DTC with the MCS.
Is DTC 4-1 or 4-3 indicated?
YES – GO TO STEP 2.

AB N
NO – Intermittent failure
2. Dual Clutch PC Solenoid Inspection

-C O
Turn the ignition switch OFF.

L. US
[1]
Disconnect the dual clutch PC solenoid valve 2P (Black) connector
(page 13-18).
Measure the resistance between the solenoid valve side 2P connector
[1] terminals.
S. N O
Standard: 5.1 – 5.7 Ω (20°C/68°F)
Is the resistance within standard value?
R.
YES – GO TO STEP 3.
RS IÓ

NO – Faulty dual clutch PC solenoid valve

TO UC
MO RIB

3. Dual Clutch PC Solenoid Valve Line Open

Circuit Inspection
Disconnect the PCM 33P (Black) connector (page 4-42).
AL ST

[2]
Check for continuity between the wire harness side 33P (Black)
connector [1] and 2P (Black) connector [2] terminals. A9
BR DI

TOOL:
Test probe, 2 pack 07ZAJ-RDJA110 W/Y
CA SU

Connection: A8 – Black/white
A9 – White/yellow
Is there continuity?
24 O

YES – GO TO STEP 4.
-20 BID

NO – • Open circuit in the Black/white wire A8 Bl/W

• Open circuit in the White/yellow wire
[1]
-07 HI
28 O
PR

13-32
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

4. Recheck DTC
Connect the dual clutch PC solenoid valve 2P
(Black) connector and PCM 33P (Black) connector.
Recheck the current DTC with the MCS.

S. O
Is DTC 4-1 or 4-3 indicated?

L.
S AD
YES – Replace the PCM with a known good one
(page 4-43), and recheck.

R.
NO – Intermittent failure

OR RIZ
DTC 4-2 (DUAL CLUTCH PC
SOLENOID HIGH INPUT)

OT TO
1. Recheck DTC
Recheck the current DTC with the MCS.

LM U
Is DTC 4-2 indicated?

RA O A
YES – GO TO STEP 2.
NO – Intermittent failure

AB N
2. Dual Clutch PC Solenoid Valve Inspection
Turn the ignition switch OFF.
[1]

-C O
Disconnect the dual clutch PC solenoid valve 2P
(Black) connector (page 13-18).

L. US
Measure the resistance between the solenoid valve
side 2P connector [1] terminals.
Standard: 5.1 – 5.7 Ω (20°C/68°F)
S. N O
Is the resistance within 4.5 – 10.0 Ω?
YES – GO TO STEP 3.
NO – Faulty dual clutch PC solenoid valve
R.
RS IÓ
TO UC

3. Dual Clutch PC Solenoid Valve Line Short

MO RIB

Circuit Inspection
Disconnect the PCM 33P (Black) connector (page
[1]
4-42).
Check the for continuity between the wire harness
AL ST

side 2P (Black) connector [1] terminal and ground.

Connection: Black/white – ground W/Y Bl/W
BR DI

White/yellow – ground
Is there continuity?
CA SU

YES – • Short circuit in the Black/white wire

• Short circuit in White/yellow wire
NO – GO TO STEP 4.
24 O
-20 BID
-07 HI
28 O
PR

13-33
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

4. Recheck DTC
Connect the dual clutch PC solenoid valve 2P
(Black) connector and PCM 33P (Black) connector.
Recheck the current DTC with the MCS.

S. O
Is DTC 4-2 indicated?

L.
S AD
YES – Replace the PCM with a known good one
(page 4-43), and recheck.

R.
NO – Intermittent failure

OR RIZ
DTC 15-1 (SHIFT SOLENOID VALVE
CIRCUIT)

OT TO
• Before starting the troubleshooting, check the shift
solenoid valve 2P (Brown) connector for loose or

LM U
poor contacts, and recheck the DTC.

RA O A
1. Recheck DTC
Recheck the current DTC with the MCS.
Is DTC 15-1 indicated?

AB N
YES – GO TO STEP 2.
NO – Intermittent failure

-C O
2. Shift Solenoid Valve Inspection

L. US
Turn the ignition switch OFF.
[1]
Disconnect the shift solenoid valve 2P (Brown)
connector (page 13-67).
S. N O
Measure the resistance between the solenoid valve
side 2P connector [1] terminals.
Is the resistance within 14.6 – 16.2 Ω (20°C/
68°F)?
R.
RS IÓ

YES – GO TO STEP 3.
NO – Faulty shift solenoid valve
TO UC
MO RIB

3. Shift Solenoid Valve Line Open Circuit

Inspection
AL ST

Disconnect the PCM 33P (Gray) connector (page 4-

[1] [2]
42).
BR DI

Check for continuity between the wire harness side

33P (Black) connector [1] and 2P (Brown) connector
[2] terminals, and between the 2P (Brown) G
CA SU

connector terminal and ground.

TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
24 O

Connection: B7 – Brown/white
Green – ground
-20 BID

Is there continuity? B7 Br/W

YES – GO TO STEP 4.
-07 HI

NO – • Open circuit in the Brown/white wire

• Open circuit in the Green wire
28 O
PR

13-34
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

4. Shift Solenoid Valve Line Short Circuit
Inspection
Check for continuity between the wire harness side
[1]
2P (Brown) connector [1] terminal and ground.

S. O
Connection: Brown/white – ground

L.
S AD
Is there continuity?

R.
YES – Short circuit in the Brown/white wire

OR RIZ
NO – GO TO STEP 5.

OT TO
Br/W

LM U
RA O A
5. Recheck DTC
Connect the shift solenoid valve 2P (Brown)
connector and PCM 33P (Gray) connector.
Recheck the current DTC with the MCS.

AB N
Is DTC 15-1 indicated?

-C O
YES – Replace the PCM with a known good one
(page 4-43), and recheck.

L. US
NO – Intermittent failure

DTC 21-1 (SHIFT SPINDLE ANGLE

S. N O
SENSOR LOW VOLTAGE)
• Before starting the troubleshooting, check the shift
spindle angle sensor 3P (Gray) connector and
R.
RS IÓ

engine sub-wire harness 6P (Black) connector for

loose contacts or corroded terminals, and recheck
TO UC

the DTC.
1. Shift Spindle Angle Sensor System Inspection
Check the shift spindle angle sensor with the MCS.
MO RIB

Is about 0 V indicated?
YES – GO TO STEP 2.
AL ST

NO – Intermittent failure
2. Shift Spindle Angle Sensor Input Voltage
Inspection
BR DI

Turn the ignition switch OFF.

[1]
Disconnect the shift spindle angle sensor 3P (Gray)
CA SU

connector (page 13-68).

Turn the ignition switch ON.
Measure the voltage between the wire harness side
3P (Gray) connector [1] terminals.
24 O

Connection: Brown/white (+) – Green/red (–)

-20 BID

Is the voltage within 4.75 – 5.25 V?

YES – GO TO STEP 3.
NO – Replace the PCM with a known good one
-07 HI

(page 4-43), and recheck.

Br/W (+) G/R (–)
28 O
PR

13-35
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

3. Shift Spindle Angle Sensor Output Line Short
Circuit Inspection
Check for continuity between the wire harness side
[1]
3P (Gray) connector [1] terminal and ground.

S. O
Connection: Green/yellow – ground

L.
S AD
Is there continuity?

R.
YES – Short circuit in the Green/yellow or Green/
blue wire

OR RIZ
NO – GO TO STEP 4.

OT TO
G/Y

LM U
RA O A
4. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a known
good one (page 13-68).
Connect the shift spindle angle sensor 3P (Gray)

AB N
connector and PCM 33P (Black) connector.
Turn the ignition switch ON.

-C O
Check the shift spindle angle sensor with the MCS.
Is about 0 V indicated?

L. US
YES – Replace the PCM with a known good one
(page 4-43), and recheck.
S. N O
NO – Faulty original shift spindle angle sensor

DTC 21-2 (SHIFT SPINDLE ANGLE

SENSOR HIGH VOLTAGE)
R.
RS IÓ

1. Shift Spindle Angle Sensor System Inspection

TO UC

Check the shift spindle angle sensor with the MCS.

Is about 5 V indicated?
MO RIB

YES – GO TO STEP 2.
NO – Intermittent failure
2. Shift Spindle Angle Sensor Input Voltage
AL ST

Inspection
Turn the ignition switch OFF.
[1]
Disconnect the shift spindle angle sensor 3P (Gray)
BR DI

connector (page 13-68).

Turn the ignition switch ON.
Measure the voltage between the wire harness side
CA SU

3P (Gray) connector [1] terminals.

Connection: Brown/white (+) – Green/red (–)
Is the voltage within 4.75 – 5.25 V?
24 O

YES – GO TO STEP 3.
-20 BID

NO – • Open circuit in the Brown/white wire

• Open circuit in the Green/red or Green/
white wire Br/W (+) G/R (–)
-07 HI
28 O
PR

13-36
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

3. Shift Spindle Angle Sensor Output Line Open
Circuit Inspection
Turn the ignition switch OFF.
[1] [2]
Disconnect the PCM 33P (Black) connector (page

S. O
4-42).
Check for continuity between the wire harness side

L.
S AD
33P (Black) connector [1] and 3P (Gray) connector
[2] terminals.

R.
TOOL:

OR RIZ
Test probe, 2 pack 07ZAJ-RDJA110

Connection: A23 – Green/yellow

OT TO
Is there continuity?
YES – GO TO STEP 4. A23 G/Y

LM U
NO – Open circuit in the Green/yellow or Green/
blue wire

RA O A
4. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a known
good one (page 13-68).

AB N
Connect the shift spindle angle sensor 3P (Gray)
connector and PCM 33P (Black) connector.

-C O
Turn the ignition switch ON.
Check the shift spindle angle sensor with the MCS.

L. US
Is about 5 V indicated?
YES – Replace the PCM with a known good one
(page 4-43), and recheck.
S. N O
NO – Faulty original shift spindle angle sensor

DTC 22-1 (SHIFT SPINDLE ANGLE

R.
RS IÓ

SENSOR MALFUNCTION: While

operating gearshift mechanism)
TO UC

1. Shift Spindle Angle Sensor System Inspection

Check the shift spindle angle sensor with the MCS.
MO RIB

Is Low voltage (about 0 V) or High voltage (about

5 V) indicated?
YES – • About 0 V: See DTC 21-1 (page 13-35)
AL ST

• About 5 V: See DTC 21-2 (page 13-36)

NO – GO TO STEP 2.
BR DI

2. Shift Control Motor/Reduction Gear Condition

Inspection
Turn the ignition switch OFF.
CA SU

Check that the shift control motor and reduction

gears are installed properly and are not damaged
(page 13-69).
24 O

Are the shift control motor and reduction gears

in normal condition?
-20 BID

YES – GO TO STEP 3.
NO – Install the shift control motor and reduction
gears properly or replace faulty parts.
-07 HI
28 O
PR

13-37
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

3. Shift Control Motor Inspection
Remove the shift control motor (page 13-69).
Connect a fully charged 12 V battery [1] to the
control motor 2P connector [2] terminals to check

S. O
the motor operation.
Change the battery connection to check the reverse

L.
S AD
operation.

R.
Does the shift control motor turn in both
direction?

OR RIZ
YES – GO TO STEP 4.
NO – Faulty shift control motor

OT TO
[2] [1]

LM U
4. Shift Spindle Angle Sensor System Inspection

RA O A
Remove the shift spindle angle sensor with the
connector connected.
Turn the ignition switch ON.
While turning the shift spindle angle sensor shaft,

AB N
check the shift spindle angle sensor voltage with the
MCS.

-C O
When turning the sensor shaft clockwise:
Voltage increase

L. US
When turning the sensor shaft
counterclockwise:
Voltage decrease
S. N O
Does the voltage vary properly?
YES – GO TO STEP 5.
NO – Faulty shift spindle angle sensor
R.
RS IÓ

5. Shift Spindle Angle Sensor Condition Inspection

TO UC

Check that the shift spindle angle sensor is installed

properly.
Is the shift spindle angle sensor in normal
MO RIB

condition?
YES – GO TO STEP 6.
NO – Install the shift spindle angle sensor
AL ST

properly.
6. DTC Recheck
BR DI

Recheck the DTC with the MCS.

Is DTC 22-1 indicated?
CA SU

YES – Replace the PCM with a known good one

(page 4-43), and recheck.
NO – Intermittent failure
24 O

DTC 23-1 (SHIFT SPINDLE ANGLE

-20 BID

SENSOR MALFUNCTION: After

operating gearshift mechanism)
Refer to DTC 22-1 (page 13-37).
-07 HI
28 O
PR

13-38
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DTC 24-1 (SHIFT CONTROL MOTOR
DRIVE CIRCUIT)
• Before starting the troubleshooting, check the shift
control motor 2P (Black) connector for loose

S. O
contacts or corroded terminals, and recheck the

L.
S AD
DTC.
1. PCM Motor Power Input Line Open Circuit

R.
Inspection

OR RIZ
Disconnect the PCM 5P (Black) connector
[1]
(page 4-42).
Measure the voltage between the wire harness side
5P (Black) connector [1] terminal and ground.

OT TO
Connection: C4 (+) – ground (–)
Is there battery voltage?

LM U
YES – GO TO STEP 2.

RA O A
NO – • Brown ES fuse (30 A)
• Open circuit in the Red or Red/white
wire (–)

AB N
C4 (+)

-C O
2. PCM Motor Power Ground Line Open Circuit

L. US
Inspection
Check for continuity between the wire harness side
[1]
5P (Black) connector [1] terminal and ground.
S. N O
Connection: C5 – ground
Is there continuity?
YES – GO TO STEP 3.
R.
RS IÓ

NO – Open circuit in the Green wire

TO UC

C5
MO RIB

3. Shift Control Motor Line Open Circuit Inspection

AL ST

Disconnect the shift control motor 2P (Black)

[1] [2]
connector (page 13-69).
Check for continuity between the wire harness side
BR DI

5P (Black) connector [1] and 2P (Black) connector

[2] terminals.
CA SU

Connection: C1 – Red
C2 – Black
Is there continuity?
24 O

YES – GO TO STEP 4.
C2
-20 BID

NO – • Open circuit in the Red wire

R Bl
• Open circuit in the Black wire C1
-07 HI
28 O
PR

13-39
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

4. Shift Control Motor Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
5P (Black) connector [1] terminals and ground.
Connection: C1 – ground

S. O
C2 – ground

L.
S AD
Is there continuity?

R.
YES – • Short circuit in the Red wire

OR RIZ
• Short circuit in the Black wire
NO – GO TO STEP 5.

OT TO
C2 C1

LM U
5. Shift Control Motor Inspection

RA O A
Remove the shift control motor (page 13-69).
Connect a fully charged 12 V battery [1] to the
control motor side 2P connector [2] terminals to
check the motor operation.

AB N
Change the battery connection to check the reverse
operation.

-C O
Does the shift control motor turn in both
directions?

L. US
YES – GO TO STEP 6.
NO – Faulty shift control motor
S. N O
[2] [1]
R.
6. Recheck DTC
RS IÓ

Connect the PCM 5P (Black) connector and shift

control motor 2P (Black) connector.
TO UC

Recheck the current DTC with the MCS.

Is DTC 24-1 indicated?
MO RIB

YES – Replace the PCM with a known good one

(page 4-43), and recheck. If DTC 24-1 is
indicated again, replace the control motor.
AL ST

NO – Intermittent failure

DTC 27-1
BR DI

(SHIFT DRUM POSITION

MALFUNCTION)
CA SU

(After '19 model)

1. TR Sensor System Inspection
Check the TR sensor with the MCS.
24 O

Is Low voltage (about 0 V) or High voltage (about

-20 BID

5 V) indicated?
YES – • About 0 V: See DTC 51-1 (page 13-47).
• About 5 V: See DTC 51-2 (page 13-49).
-07 HI

NO – GO TO STEP 2.
28 O
PR

13-40
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

2. Reduction Gear condition
Check the reduction gears are installed properly and
are not damaged.
Are the reduction gears in normal condition?

S. O
YES – GO TO STEP 3.

L.
S AD
NO – Install the reduction gears or replace faulty

R.
parts.

OR RIZ
3. Shift Control Motor Inspection
Remove the shift control motor (page 13-69).
[2]
Connect a fully charged 12 V battery [1] to the shift

OT TO
control motor 2P connector [2] to check the motor
operation.
Reverse the battery connection to check the reverse
operation.

LM U
Does the shift control motor turn in both

RA O A
directions?
YES – GO TO STEP 4.
NO – Faulty shift control motor

AB N
-C O
[1]

L. US
4. TR Sensor System Inspection
Remove the TR sensor with the connector
connected (page 13-74).
Turn the ignition switch ON.
S. N O
While turning the TR sensor shaft, check the TR
sensor voltage with the MCS.
When turning the shaft clockwise:
R.
RS IÓ

Voltage increase
When turning the shaft counterclockwise:
Voltage decrease
TO UC

Does the voltage vary properly?

YES – GO TO STEP 5.
MO RIB

NO – Faulty TR sensor
5. TR Sensor Condition Inspection
AL ST

Check that the TR sensor is installed properly and is

not damaged.
Is the TR sensor in normal condition?
BR DI

YES – GO TO STEP 6.
NO – Install the TR sensor properly or replace it
CA SU

(page 13-74).
6. DTC Recheck
Recheck the DTC with the MCS.
24 O

Is DTC 27-1 indicated?

-20 BID

YES – Replace the PCM with a known good one

(page 4-42), and recheck.
NO – Intermittent failure
-07 HI
28 O
PR

13-41
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DTC 31-1 (SHIFT CONTROL MOTOR
LOW VOLTAGE) (After '19 model)
• Before starting the inspection, check for loose or
poor contact of the shift control motor 2P (Black) and

S. O
PCM 5P (Black) connectors, and recheck the DTC.

L.
S AD
1. Recheck The DTC

R.
Erase the DTC (page 13-28).
Check the DTC with the MCS.

OR RIZ
Is DTC 32-1 indicated?
YES – See DTC 32-1 (page 13-42).

OT TO
NO – GO TO STEP 2.
2. Shift Control Motor Line Open Circuit Inspection

LM U
Disconnect the shift control motor 2P (Black)
[1] [2]
connector (page 13-69).

RA O A
Check for continuity between the wire harness side
5P (Black) connector [1] and 2P (Black) connector
[2] terminals.
Connection: C1 – Red

AB N
C2 – Black

-C O
Is there continuity?
YES – Replace the PCM with a known good one

L. US
(page 4-42)and recheck. C2
NO – • Open circuit in the Red wire C1 R Bl
• Open circuit in the Black wire
S. N O
DTC 32-1 (FAIL SAFE RELAY CIRCUIT)
1. Recheck DTC
R.
RS IÓ

Erase the DTC (page 13-28).

Recheck the current DTC with the MCS.
TO UC

Is DTC 32-1 indicated?