Manual de trabajo en taller, de motocicleta CB125 inyectada Honda 2018, de marca honda del peru. describe las especificaciones del fabricante. Este documento es de suma importancia para mecanicos de motos, quienes se identifican que buscan conocimiento profesional y teorico-practico

1. Shop Manual
GLR125WH-F (2015)
GLR125WH
This book is Specific Shop Manual.
Refer to “Basic Shop Manual” for basic and
common maintenance instructions.
1. General Information
2. Fuel & Engine
3. Frame & Chassis
4. Electrical System

2. 1-1
1. GENERAL INFORMATION
A Few Words About Safety ················ 1-2
How To Use This Manual ··················· 1-3
MODEL IDENTIFICATION ··················· 1-5
SPECIFICATIONS······························ 1-6
TORQUE VALUE······························1-11
CABLE & HARNESS ROUTING ··········1-15
TECHNICAL FEATURES ···················1-23
MAINTENANCE SCHEDULE ··············1-24

3. GENERAL INFORMATION
1-2
GENERAL INFORMATION
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your 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
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
Improper service or repairs can create an unsafe
condition that can cause your customer to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.

4. GENERAL INFORMATION
1-3
How To Use This Manual
This manual is "Spec (Specific)" Service Manual. The service and repair information for this model is described in this
manual as specific information. Refer to “Basic" Service Manual for basic/common service information and
instructions.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the
break-in period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
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.
© Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: September, 2014
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided
safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,
or CAUTION. These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS
PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF
APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY
TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,
MOTOR SCOOTERS OR ATVS.

5. GENERAL INFORMATION
1-4
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.
INSTRUCTION SYMBOL
LUBRICATION AND SEAL SYMBOL
Removal or Disassembly procedure.
Disconnect the connector.
Installation or Assembly procedure.
Connect the connector.
Order of removal/disassembly with a point of note.
Order of installation/assembly with a point of
note.
Tighten specified torque. Replace with a new one before assembly.
Check the part for an inspection. Measure the part for an inspection.
Turn ignition switch to OFF. Turn ignition switch to ON.
Start the engine. Measure a resistance or check continuity.
Measure a voltage. Measure an ampere.
Use the Honda special tool.
Refer to “Basic” Service Manual for the instruc-
tion.
Use the recommend engine oil.
Apply molybdenum oil solution (mixture of an
engine oil and molybdenum grease in a ration of
1:1).
Apply a specified grease. Use a multi-purpose
grease unless otherwise specified.
Apply a liquid sealant.
Apply a locking agent. Use a medium strength
one unless otherwise specified.
Use DOT 3 or DOT 4 brake fluid.
Use a specified fork oil or suspension fluid.

6. GENERAL INFORMATION
1-5
MODEL IDENTIFICATION
• Model name: GLR125WH-F
• Destination: China
Model Front drum brake Front disc brake
GLR125 1WH O –
GLR125 2WH/4WH/5WH – O
VEHICLE IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
COLOR LABEL

7. GENERAL INFORMATION
1-6
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
DIMENSIONS Overall length 2,036 mm
Overall width 767 mm
Overall height Front drum brake
type
1,071 mm
Front disc brake type 1,076 mm
Wheelbase 1,292 mm
Seat height 774 mm
Footpeg height 275 mm
Ground clearance 155 mm
Curb weight Front drum brake
type
128 kg
Front disc brake type 129 kg
Maximum weight capacity 158 kg
FRAME Frame type Diamond type
Front suspension Telescopic fork
Front wheel travel 108 mm
Rear suspension Swingarm
Rear wheel travel 90 mm
Front tire size 80/100-18M/C 47P
Rear tire size 90/90-18M/C 51P
Front tire brand C-910 (CST)
Rear tire brand C-6011 (CST)
Front brake Front drum brake
type
Mechanical leading trailing
Front disc brake type Hydraulic single disc
Rear brake Mechanical leading trailing
Caster angle 26° 0’
Trail length 97 mm
Fuel tank capacity 13.0 liter
Fuel tank reserve capacity 4.3 liter
ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical
Bore and stroke 52.4 x 57.8 mm
Displacement 124.7 cm3
Compression ratio 9.2 : 1
Valve train Chain driven OHC with rocker arm
Intake valve opens 5° BTDC at 1 mm lift
closes 30° ABDC at 1 mm lift
Exhaust valve opens 30° BBDC at 1 mm lift
closes 0° TDC at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper filter
Engine dry weight 27.7 kg
Emission control system Crankcase emission control system
Three-way catalytic converter
Evaporative emission control system
FUEL SYSTEM Type PGM-FI (Programmed Fuel Injection)
Throttle bore 26 mm

8. GENERAL INFORMATION
1-7
FUEL & ENGINE SPECIFICATIONS
FUEL SYSTEM
LUBRICATION SYSTEM
Unit: mm
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission 5 speeds
Primary reduction 3.350 (67/20)
Final reduction 3.000 (45/15)
Gear ratio 1st 3.076 (40/13)
2nd 1.875 (30/16)
3rd 1.409 (31/22)
4th 1.120 (28/25)
5th 0.937 (30/32)
Gearshift pattern Left foot operated return system
1 - N - 2 - 3 - 4 - 5
ELECTRICAL Ignition system Full transistorized
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier SCR shorted, triple phase full-wave rectifica-
tion
Lighting system Battery
ITEM SPECIFICATION
ITEM SPECIFICATIONS
Throttle body identification number GQMPA
Engine idle speed 1,500 ± 100 min-1
Throttle grip freeplay 2 – 6 mm
Idle air screw standard opening 2-1/4 turns out from the fully seated position
Fuel pressure at idle 263 – 316 kPa
Fuel pump flow (at 12 V) 82 cm3
minimum/10 seconds
ITEM STANDARD SERVICE
LIMIT
Engine oil capacity After draining 0.8 liter –
After disassembly 1.0 liter –
Recommended engine oil Honda “4-stroke motorcycle oil” or an
equivalent motor oil.
API service classification:
SG or higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
–
Oil pump rotor Tip clearance 0.15 0.20

9. GENERAL INFORMATION
1-8
CYLINDER HEAD
Unit: mm
CYLINDER/PISTON
Unit: mm
CLUTCH/GEARSHIFT LINKAGE/BALANCER GEAR
Unit: mm
ALTERNATOR/STARTER CLUTCH
Unit: mm
ITEM STANDARD SERVICE
LIMIT
Cylinder compression 1,275 kPa at 800 min-1
–
Valve clearance IN 0.08 ± 0.02 –
EX 0.12 ± 0.02 –
Camshaft Cam lobe height IN 32.994 – 33.234 33.01
EX 32.880 – 33.120 32.87
Rocker arm,
rocker arm
shaft
Rocker arm shaft
O.D.
IN/EX 9.972 – 9.987 –
Rocker arm I.D. IN/EX 10.000 – 10.015 10.10
Valve,
valve guide
Valve stem O.D. IN 4.975 – 4.990 4.92
EX 4.955 – 4.970 4.90
Valve guide I.D. IN/EX 5.000 – 5.012 –
Valve guide projec-
tion above cylinder
head
IN/EX 16.8 – 17.0 –
Valve seat width IN/EX 0.9 – 1.1 1.5
Valve spring free length INNER 38.76 –
OUTER 35.95 –
Cylinder head warpage – 0.05
ITEM STANDARD SERVICE
LIMIT
Cylinder I.D. 52.400 – 52.410 52.50
Warpage – 0.10
Piston Piston O.D. 52.370 – 52.390 at 6 mm from bottom
of skirt
52.30
Piston pin bore I.D. 13.002 – 13.008 13.04
Piston pin O.D. 12.994 – 13.000 12.96
Piston rings Piston ring end
gap
Top 0.10 – 0.25 0.40
Second 0.10 – 0.25 0.40
Oil (side
rail)
0.20 – 0.70 0.85
Piston ring-to-ring
groove clearance
Top 0.015 – 0.050 –
Second 0.015 – 0.050 –
ITEM STANDARD SERVICE
LIMIT
Clutch lever freeplay 10 – 20 –
Clutch Disc thickness 2.92 – 3.08 2.7
Plate warpage – 0.20
Spring free length 42.9 41.9
Clutch outer I.D. 23.000 – 23.021 23.08
Clutch outer guide O.D. 22.959 – 22.980 –
I.D. 16.991 – 17.009 –
Mainshaft O.D. at clutch outer guide 16.966 – 16.984 –
ITEM STANDARD SERVICE
LIMIT
Starter driven gear boss O.D. 45.660 – 45.673 –

10. GENERAL INFORMATION
1-9
CRANKSHAFT/TRANSMISSION/BALANCER
Unit: mm
FRAME & CHASSIS SPECIFICATIONS
FRONT WHEEL/SUSPENSION/STEERING
Unit: mm
REAR WHEEL/BRAKE/SUSPENSION
Unit: mm
ITEM STANDARD SERVICE
LIMIT
Connecting
rod
Side clearance 0.10 – 0.35 0.80
Radial clearance 0 – 0.008 0.05
Connecting rod small end I.D. 13.016 – 13.034 13.04
Crankshaft Runout – 0.08
Transmis-
sion
Gear I.D. M4 20.000 – 20.018 –
M5 17.000 – 17.018 –
C1 20.500 – 20.521 –
C2 23.020 – 23.041 –
C3 23.025 – 23.046 –
Gear bushing
O.D.
C1 20.459 – 20.480 –
C2, C3 22.984 – 23.005 –
Gear bushing I.D. C1 17.000 – 17.018 –
C2, C3 20.020 – 20.041 –
Mainshaft O.D. at M4 19.968 – 19.980 –
at M5 16.968 – 16.980 –
Countershaft
O.D.
at C1 16.966 – 16.984 –
at C2 19.978 – 19.989 –
at C3 19.979 – 20.000 –
Shift fork,
fork shaft
Fork I.D. 10.000 – 10.018 –
Fork shaft O.D. 9.986 – 9.995 –
Claw thickness 4.93 – 5.00 –
ITEM STANDARD SERVICE
LIMIT
Cold tire
pressure
Driver only 175 kPa –
Driver and passenger 175 kPa –
Axle runout – 0.2
Wheel rim
runout
Radial – 2.0
Axial – 2.0
Fork Spring free length 476 – 480 468.4
Recommended fork fluid Honda Ultra cushion oil 10W or equiv-
alent
–
Fluid level 187 –
Fluid capacity 145 ± 2.5 cm3
–
ITEM STANDARD SERVICE
LIMIT
Cold tire
pressure
Driver only 200 kPa –
Driver and passenger 225 kPa –
Axle runout – 0.2
Wheel rim
runout
Radial – 2.0
Axial – 2.0
Drive chain slack 20 – 30 –
Drive chain size/link 428DF/122L –
Drive chain
length
41 pins – 518
Rear shock absorber adjuster standard position Second from the softest position –

11. GENERAL INFORMATION
1-10
BRAKE SYSTEM
Unit: mm
ELECTRICAL SYSTEM SPECIFICATIONS
PGM-FI SYSTEM
IGNITION SYSTEM
BATTERY/CHARGING SYSTEM
ITEM STANDARD SERVICE
LIMIT
Front disc
brake
Specified brake fluid DOT 3 or DOT 4 –
Brake disc thickness 3.8 – 4.2 3.5
Brake disc warpage – 0.3
Master cylinder I.D. 12.700 – 12.743 –
Master piston O.D. 12.657 – 12.684 –
Caliper cylinder I.D. 25.400 – 25.450 –
Caliper piston O.D. 25.318 – 25.368 –
Front drum
brake
Lever freeplay 10 – 20 –
Drum I.D. 130.0 – 130.3 131
Rear drum
brake
Pedal freeplay 20 – 30 –
Drum I.D. 130.0 – 130.3 131
ITEM SPECIFICATIONS
IAT sensor resistance (40°C) 1.0 – 1.2 kΩ
EOT sensor resistance (20°C) 2.5 – 2.8 kΩ
Fuel injector resistance (20°C) 11 – 13 Ω
EVAP purge control solenoid valve resistance
(20°C)
37 – 44 Ω
ITEM SPECIFICATION
Spark plug Standard CPR7EA-9 (NGK)
For extended high speed riding CPR8EA-9 (NGK)
Spark plug gap 0.80 – 0.90 mm
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing ("F" mark) 6° BTDC at idle
ITEM SPECIFICATIONS
Battery Type YTX7L-BS
Capacity 12 V – 6 Ah (10HR)/6.3 Ah (20HR)
Current leakage 0.1 mA max.
Voltage
(20°C)
Fully charged 13.0 – 13.2 V
Needs charging Below 12.3 V
Charging current Normal 0.6 A/5 – 10 h
Quick 3 A/1 h
Alternator Capacity 0.202 kW/5,000 min-1
Charging coil resistance (20°C) 0.1 – 1.0 Ω

12. GENERAL INFORMATION
1-11
LIGHTS/METERS/SWITCHES
TORQUE VALUE
• Each fastener should be tightened to the standard torque value except the fasteners specified torque value.
• Q’TY: Quantity, DIA: Thread diameter (mm), TRQ: Tightening torque (N·m (kgf·m))
STANDARD TIGHTENING TORQUE
FUEL PUMP UNIT
AIR CLEANER
THROTTLE BODY
LUBRICATION SYSTEM
ITEM SPECIFICATION
Bulbs Headlight (Hi/low beam) 12 V - 35/35 W
Brake/tail light 12 V - 21/5 W
Front turn signal light 12 V - 10 W x 2
Rear turn signal light 12 V - 10 W x 2
Position light 12 V - 5 W
License light 12 V - 5 W
Instrument light 12 V - 2 W x 1, 12 V - 3.4 W x 1
Turn signal indicator 12 V - 3.4 W x 2
High beam indicator 12 V - 1.7 W
MIL 12 V - 3.4 W
Gear position indicator LED
Neutral indicator 12 V - 3.4 W
Fuse Main 20 A
Sub 10 A x 3
Fuel level sensor resistance
(20°C)
Full 6 – 10 Ω
Empty 90 – 100 Ω
FASTENER TYPE TRQ (N·m) FASTENER TYPE TRQ (N·m)
5 mm hex bolt and nut 5.2 5 mm screw 4.2
6 mm hex bolt and nut 10 6 mm screw 9.0
6 mm flange bolt 12
8 mm hex bolt and nut 22
10 mm hex bolt and nut 34 8 mm flange bolt and nut 27
12 mm hex bolt and nut 54 10 mm flange bolt and nut 39
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Fuel pump set plate nut 4 6 12 2-4
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Air cleaner cover screw 4 5 1.1
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Throttle cable A adjuster lock nut
(throttle body side)
2 6 4.5
Throttle cable B nut
(throttle body side)
1 6 4.5
Throttle cable holder screw 1 5 3.4
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Engine oil drain bolt 1 12 30
Oil pump cover screw 1 4 3

13. GENERAL INFORMATION
1-12
CYLINDER HEAD
CYLINDER/PISTON
CLUTCH/GEARSHIFT LINKAGE/BALANCER GEAR
ALTERNATOR/STARTER CLUTCH
CRANKCASE/CRANKSHAFT/BALANCER
ENGINE UNIT
BODY PANELS
SIDESTAND
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Timing hole cap 1 14 10
Crankshaft hole cap 1 32 15 Apply grease to the threads.
Valve adjusting lock nut 2 6 14 Apply engine oil.
Cylinder head cover bolt 2 6 10
Cam chain tensioner lifter plug 1 6 4
Camshaft holder nut 4 8 32 Apply engine oil.
Cam sprocket bolt 2 5 9
Rocker arm shaft bolt 2 5 5
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Cylinder stud bolt 4 8 11 2-20
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Clutch center lock nut 1 14 74 Apply engine oil.
Clutch lifter plate bolt 4 6 12
Oil filter rotor lock nut 1 14 64 Apply engine oil.
Oil filter rotor cover screw 3 5 4
Gearshift cam bolt 1 6 12 Apply locking agent.
Shift drum stopper arm bolt 1 6 12 Apply locking agent.
Balancer driven gear lock nut 1 14 64 Apply engine oil.
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Flywheel nut 1 14 74 Apply engine oil.
Starter clutch bolt 6 6 16 Apply locking agent.
Stator mounting bolt 3 6 12
CKP sensor mounting bolt 2 6 12 Apply locking agent.
Alternator wire guide bolt 1 6 12 Apply locking agent.
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Mainshaft bearing setting plate bolt 2 6 12 Apply locking agent.
Push plug bolt 1 6 10 Apply locking agent.
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Front engine hanger nut (Engine side) 2 8 32
Front engine hanger nut (Frame side) 2 10 44
Rear engine hanger nut 2 10 54
Drive sprocket bolt 2 6 12
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Battery box bolt (frame side) 2 6 10
Battery box bolt (air cleaner side) 1 6 7
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Sidestand pivot bolt 1 10 10
Sidestand pivot nut 1 10 29 U-nut

14. GENERAL INFORMATION
1-13
EXHAUST PIPE/MUFFLER
FRONT WHEEL
FORK
HANDLEBAR
STEERING STEM
REAR WHEEL
REAR SUSPENSION
FRONT BRAKE
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Exhaust pipe joint nut 2 8 26
Muffler cover screw 1 6 9
Exhaust pipe stud bolt 2 8 11 3-10
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Front axle nut 1 12 59 U-nut
Front brake disc bolt (Front disc brake
type)
6 8 42 Pre-coated (ALOC) bolt, re-
place with a new one.
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Fork cap 2 26 22
Bottom bridge pinch bolt 2 8 32
Top bridge pinch bolt 2 8 23
Fork socket bolt 2 8 20 Apply locking agent.
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Handlebar holder bolt 4 6 12
Right handlebar switch screw 2 5 2.5
Left handlebar switch screw 2 5 2.5
Rearview mirror lock nut 2 10 34
Rearview mirror adaptor bolt 2 10 34
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Steering bearing adjustment nut 1 26 – 3-16
Steering stem nut 1 24 74 3-16
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Rear axle nut 1 14 88 U-nut
Driven sprocket nut 4 10 64 U-nut
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Shock absorber upper cap nut 2 10 24
Shock absorber lower bolt 2 10 39
Swingarm pivot nut 1 12 59
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Brake hose oil bolt 2 10 34
Master cylinder reservoir cap screw 2 4 1.5
Front brake light switch screw 1 4 1.2
Brake lever pivot bolt 1 6 1
Brake lever pivot nut 1 6 6
Pad pin 2 10 18
Pad pin plug 2 10 2.5
Brake caliper mounting bolt 2 8 26 Pre-coated (ALOC) bolt, re-
place with a new one.
Caliper bleed valve 1 8 8
Front brake arm nut 1 6 10

15. GENERAL INFORMATION
1-14
REAR BRAKE
PGM-FI SYSTEM
IGNITION SYSTEM
BATTERY/CHARGING SYSTEM
LIGHTING SYSTEM
ELECTRICAL COMPONENT
OTHERS
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Rear brake arm nut 1 6 10 U-nut
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
EOT sensor 1 10 14
IAT sensor screw 2 5 1.1
O2 sensor 1 12 25
Bank angle sensor bolt 2 6 10
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Spark plug 1 10 16
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Battery band bolt 1 6 9
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Headlight aim adjusting bolt 1 4 1.5
Tail light unit nut 2 6 7.5
Turn signal light unit nut 4 10 19
License light unit nut 2 5 1.8
Brake/tail light lens screw 2 4.2 0.9
Turn signal light lens screw 4 4 1
License light lens screw 2 4.2 1
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Ignition switch bolt 2 8 22 Pre-coated (ALOC) bolt, re-
place with a new one.
ITEM Q'TY DIA (mm) TRQ (N·m) REMARKS
Throttle cable A adjuster lock nut
(handlebar side)
1 7 3.8
Gearshift spindle return spring pin 1 8 22 Apply locking agent.
Clutch lever pivot bolt 1 6 1
Clutch lever pivot nut 1 6 5.9
Rear reflector nut 1 5 1.7 U-nut
Rear side reflector nut 2 6 1.5 U-nut
Throttle cable A nut (handlebar side) 1 10 3
Throttle cable B nut (handlebar side) 1 12 3
Brake caliper slide pin 2 8 18 Pre-coated (ALOC) bolt, re-
place with a new one.
Air cleaner element holder screw 7 5 1.1

16. GENERAL INFORMATION
1-15
CABLE & HARNESS ROUTING
FRONT DRUM BRAKE TYPE:
FRONT BRAKE CABLE
SPEEDOMETER CABLE
RIGHT HANDLEBAR
SWITCH WIRE
THROTTLE CABLE A
THROTTLE
CABLE B
LEFT HANDLEBAR
SWITCH WIRE
CLUTCH CABLE
CONNECTORS:
– RIGHT HANDLEBAR SWITCH 4P (Black)
– RIGHT HANDLEBAR SWITCH 3P
– LEFT HANDLEBAR SWITCH 9P
– LEFT HANDLEBAR SWITCH 4P
– IGNITION SWITCH 2P
CONNECTORS:
– HEADLIGHT 4P
– FRONT TURN SIGNAL WIRE
CONNECTORS:
– SPEEDOMETER SUB HARNESS 9P (Black)
– SPEEDOMETER SUB HARNESS 9P (Brown)
– SPEEDOMETER SUB HARNESS 6P
– SPEEDOMETER SUB HARNESS WIRE
(Black/yellow and Green)
HEADLIGHT/POSITION LIGHT WIRE
LEFT FRONT TURN
SIGNAL WIRE
RIGHT FRONT TURN
SIGNAL WIRE

17. GENERAL INFORMATION
1-16
FRONT DRUM BRAKE TYPE:
FRONT BRAKE CABLE
SPEEDOMETER CABLE
THROTTLE CABLE A
THROTTLE CABLE B
LEFT HANDLEBAR
SWITCH WIRE
CLUTCH CABLE
MAIN WIRE HARNESS
FRONT BRAKE CABLE
THROTTLE CABLE A
THROTTLE CABLE B
RIGHT HANDLEBAR
SWITCH WIRE
MAIN WIRE HARNESS

18. GENERAL INFORMATION
1-17
FRONT DISC BRAKE TYPE:
FRONT BRAKE HOSE
SPEEDOMETER CABLE
RIGHT HANDLEBAR
SWITCH WIRE
THROTTLE CABLE A
THROTTLE
CABLE B
LEFT HANDLEBAR
SWITCH WIRE
CLUTCH CABLE
CONNECTORS:
– RIGHT HANDLEBAR SWITCH 4P (Black)
– RIGHT HANDLEBAR SWITCH 3P
– LEFT HANDLEBAR SWITCH 9P
– LEFT HANDLEBAR SWITCH 4P
– IGNITION SWITCH 2P
CONNECTORS:
– HEADLIGHT 4P
– FRONT TURN SIGNAL WIRE
CONNECTORS:
– SPEEDOMETER SUB HARNESS 9P (Black)
– SPEEDOMETER SUB HARNESS 9P (Brown)
– SPEEDOMETER SUB HARNESS 6P
– SPEEDOMETER SUB HARNESS WIRE
(Black/yellow and Green)
HEADLIGHT/POSITION LIGHT WIRE
LEFT FRONT TURN
SIGNAL WIRE
RIGHT FRONT TURN
SIGNAL WIRE

19. GENERAL INFORMATION
1-18
FRONT DISC BRAKE TYPE:
SPEEDOMETER CABLE
THROTTLE CABLE A
THROTTLE CABLE B
LEFT HANDLEBAR
SWITCH WIRE
CLUTCH CABLE
MAIN WIRE HARNESS
FRONT BRAKE HOSE
THROTTLE CABLE A
THROTTLE CABLE B
RIGHT HANDLEBAR
SWITCH WIRE
MAIN WIRE HARNESS

20. GENERAL INFORMATION
1-19
ALL TYPES:
HORN WIRE
INJECTOR 2P
CONNECTOR
O2 SENSOR
2P CONNECTOR
IAT SENSOR 2P
CONNECTOR
EOT SENSOR
2P CONNECTOR
TP SENSOR
3P CONNECTOR
BANK ANGLE
SENSOR 2P
CONNECTOR
FUSE BOX
REAR BRAKE LIGHT
SWITCH 3P CONNECTOR
STARTER
MOTOR CABLE
BATTERY NEGATIVE
(–) CABLE
BATTERY POSITIVE (+) CABLE
CONNECTORS:
– ALTERNATOR 3P
– CKP SENSOR 2P
– GEAR POSITION SWITCH 6P
EVAP CANISTER
BREATHER DRAIN HOSE
EVAP CANISTER DRAIN HOSE
BATTERY BOX
DRAIN HOSE
FUEL TANK
BREATHER HOSE
EVAP PURGE HOSE B
EVAP PURGE HOSE A

21. GENERAL INFORMATION
1-20
ALL TYPES:
THROTTLE CABLE A
THROTTLE CABLE B
CLUTCH CABLE
REAR BRAKE LIGHT SWITCH WIRE
FUEL TANK BREATHER HOSE
FUEL FEED HOSE
FUEL PUMP 5P CONNECTOR
SPARK PLUG WIRE
CRANKCASE BREATHER HOSE
REGULATOR/RECTIFIER
6P CONNECTOR

22. GENERAL INFORMATION
1-21
ALL TYPES:
FUEL TANK BREATHER HOSE
EVAP PURGE HOSE A
EVAP PURGE CONTROL
SOLENOID VALVE
BATTERY CASE DRAIN HOSE
EVAP CANISTER
BREATHER HOSE
EVAP CANISTER
DRAIN HOSE
AIR VENT HOSE
AIR VENT DRAIN HOSE

23. GENERAL INFORMATION
1-22
ALL TYPES:
DLC
TURN SIGNAL RELAY
2P CONNECTOR
MAIN WIRE HARNESS
GROUND TERMINAL
ECM 33P (Black)
CONNECTOR
LEFT REAR TURN
SIGNAL WIRE
RIGHT REAR TURN
SIGNAL WIRE
BRAKE/TAIL LIGHT WIRE
LICENSE LIGHT WIRE
[1]: BRAKE/TAIL LIGHT WIRE
[2]: LICENSE LIGHT WIRE
[3]: LEFT REAR TURN SIGNAL WIRE
[4]: RIGHT REAR TURN SIGNAL WIRE
CONNECTORS:
– BRAKE/TAIL LIGHT 3P
– LICENSE LIGHT 2P (Black)
– REAR TURN SIGNAL WIRE
– DIODE
[2]
[3]
[1]
[4]
[2]
[3]
[4]
[1]

24. GENERAL INFORMATION
1-23
TECHNICAL FEATURES
FUEL PUMP SYSTEM WITH A FUEL FILTER BLOCKAGE REMINDER
FUNCTION
The fuel pump system of this model consists of the following components:
– Fuel pump chamber
– Fuel filter
– Breather passage
– Breather filter
Under normal condition, the fuel pump chamber sucks fuel through the fuel filter and then supplies it to the injector.
When the fuel filter is clogged, the fuel is sucked into the pump chamber through the breather passage in order to
keep the vehicle running. The breather filter is located in the upper inner side of fuel tank. When the fuel is consumed
to the point where the breather filter is exposed above the fuel level, a certain amount of air will be drawn into the
pump chamber via the breather filter and breather passage. This incoming air produces "a lack of fuel", which impairs
engine performance in order to notify the rider of the fuel filter blockage. This symptom works as a reminder for the
filter replacement.
This system eliminates the need of fuel filter replacement according to a fixed interval, as the rider will experience the
symptom and notice the filter blockage during vehicle usage.
The driveability remains normal as long as the fuel level in tank is maintained above the breather filter because no air
will be drawn into the pump chamber, even when the fuel filter is clogged.
If the fuel in tank is sufficient but such symptom as poor engine performance, lack of fuel, or engine start failure exist,
perform the fuel supply test.
If the fuel filter is replaced, the ECM must be initialized to avoid the rich mixture.
PUMP CHAMBER
FUEL TANK
FUEL FILTER
FUEL PUMP
BREATHER FILTER
BREATHER
PASSAGE
To FUEL INJECTOR
FUEL LEVEL
: Air suction passage under fuel filter blockage
: Air discharge passage under normal fuel filter condition
: Fuel flow under normal fuel filter condition

25. GENERAL INFORMATION
1-24
MAINTENANCE SCHEDULE
• Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
• I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
• The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may
require more technical information and tools. Consult a dealer.
• * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
• ** In the interest of safety, we recommend these items be serviced only by a dealer.
• Honda recommends that a dealer should road test the vehicle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Replacement requires mechanical skill.
• Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this
manual.
ITEMS NOTE
FREQUENCY (NOTE 1) ANNUAL
CHECK
REGULAR
REPLACE
REFER
TO PAGE
X1,000 km 1 4 8 12 16 20 24
* FUEL LINE I I I I I I I
* THROTTLE OPERATION I I I I I I I
* AIR CLEANER NOTE2 R 2-7
CRANKCASE BREATHER NOTE3 C C C C C C C
SPARK PLUG I R I R I R
* VALVE CLEARANCE I I I I I I I 2-14
ENGINE OIL R R R R R R R R 2-12
** ENGINE OIL STRAINER
SCREEN
C C
** ENGINE OIL CENTRIFU-
GAL FILTER
C C
* ENGINE IDLE SPEED I I I I I I I I
* EVAPORATIVE EMISSION
CONTROL SYSTEM
I I
DRIVE CHAIN Every 500 km I, L
BRAKE FLUID (Front disc
brake type)
NOTE4 I I I I I I I 2 years
BRAKE SHOES WEAR
(Front drum brake type)
I I I I I I I
BRAKE SHOES/PADS
WEAR (Front disc brake
type)
I I I I I I I
BRAKE SYSTEM I I I I I I I I
BRAKE LIGHT SWITCH I I I I I I I
HEADLIGHT AIM I I I I I I I 4-26
CLUTCH SYSTEM I I I I I I I I
SIDESTAND I I I I I I I
* SUSPENSION I I I I I I I
* NUTS, BOLTS, FASTEN-
ERS
I I I I I
** WHEELS/TIRES I I I I I I I
** STEERING HEAD BEAR-
INGS
I I I I

26. 2-1
2. FUEL & ENGINE
FUEL LINE ······································· 2-2
FUEL PUMP UNIT······························ 2-4
FUEL TANK······································ 2-6
AIR CLEANER ·································· 2-7
THROTTLE BODY ····························· 2-8
EVAP SYSTEM ································2-10
LUBRICATION SYSTEM ····················2-12
CYLINDER HEAD·····························2-14
CYLINDER/PISTON ··························2-20
CLUTCH/GEARSHIFT LINKAGE/
BALANCER GEAR ···························2-21
ALTERNATOR/STARTER CLUTCH·····2-24
CRANKCASE/CRANKSHAFT/
BALANCER·····································2-26
ENGINE UNIT ··································2-28

27. FUEL & ENGINE
2-2
FUEL & ENGINE
FUEL LINE
• This vehicle uses resin for the part of materials in the fuel
feed hose. Do not bend or twist the fuel feed hose.
• Fuel tank shroud 3-7
• Fuel pump 5P connector
• Let the engine idle until it stops.
• Battery negative (–) cable 4-23
• Do not use tools in removal. If the connector does not
move, alternately pull and push the connector until it comes
off easily.
• Check the fuel quick connect fitting for dirt, and clean if
necessary.
• Place a shop towel over the quick connect fitting.
• Push the retainer tab forward.
• Press down the retainer and disconnect the connector
from the fuel pump joint/injector joint.
• Check the retainer condition and replace it if necessary.
• To prevent damage and keep foreign matter out, cover the
disconnected connector and pipe end with the plastic bags.
• Press the connector onto the fuel pump joint/injector joint
until the retainer locks with a “CLICK”. If it is hard to
connect, put a small amount of engine oil on the pipe end.
• Make sure the connection is secure; check visually and by
pulling the connector.
• After installing the removed parts, turn the ignition switch
ON. (Do not start the engine.)
The fuel pump will run for about 2 seconds, and fuel
pressure will rise. Repeat 2 or 3 times, and check that there
is no leakage in the fuel supply system.

28. FUEL & ENGINE
2-3
FUEL SUPPLY TEST
FUEL PRESSURE TEST
FUEL FLOW INSPECTION
• If the fuel in tank is sufficient but such symptom as poor en-
gine performance, lack of fuel, or engine start failure exist,
perform the following.
• Perform the fuel pressure test. 2-3
• If the fuel pressure is within specification, perform the fuel
flow inspection. 2-3
• Perform the fuel flow inspection in the specified fuel quanti-
ty. 2-3
• Quick connect fitting (fuel pump side) 2-2
• Attach the fuel pressure gauge, attachments and manifold.
[A] Fuel pressure gauge: 07406-0040004
[B] Pressure gauge manifold: 07ZAJ-S5A0111
[C] Hose attachment, 9 mm/9 mm: 07ZAJ-S5A0120
[D] Hose attachment, 6 mm/9 mm: 07ZAJ-S5A0130
[E] Attachment joint, 6 mm/9 mm: 07ZAJ-S5A0150
• Temporarily connect the negative cable to the battery and
fuel pump 5P connector.
Start the engine and let it idle, and read the fuel pressure.
Standard: 263 - 316 kPa
• If the fuel pressure is higher than specified, replace the fuel
pump assembly. 2-4
• If the fuel pressure is lower than specified, inspect the
following.
– Fuel line leaking
– Any erratic swing or vibration of the gauge needle in the
pressure gauge reading.
• If the needle swings or vibrates, replace the fuel filter. 2-5
• If the needle is stable, replace the fuel pump unit. 2-4
[A]
[E]
[B]
[C]
[D]
to INJECTOR (fuel feed hose)
from FUEL PUMP
• Quick connect fitting (injector side) 2-2
• Place the end of the hose into an approved gasoline
container. Wipe off spilled out gasoline.
• The fuel pump operates for 2 seconds. Repeat 5 times
to meet the total measuring time.
Standard: 82 cm3
minimum/ 10 seconds
• If fuel flow is less than specified, inspect the following:
– Clogged fuel hose
– Fuel pump unit
• Adjust the fuel in the tank so that the fuel gauge nee-
dle is positioned between the specified range [A], and
inspect the fuel flow.
• If the fuel flow is above specification, check for other
malfunctioning parts.
• If the fuel flow is under specification, replace the fuel fil-
ter. 2-5
from FUEL PUMP
[A]

29. FUEL & ENGINE
2-4
FUEL PUMP UNIT
12 N·m
• Quick connect fitting (fuel pump side) 2-2
• Fuel tank 2-6
• Loosen the nuts in a crisscross pattern in several steps.
• Carefully remove the fuel pump unit from the fuel tank to prevent damaging the fuel level sensor.
• Install a new outer packing onto the fuel pump unit groove by aligning the tab with the boss of the fuel pump
unit.
• Place the setting plate onto the fuel pump by aligning the hole and boss.
• Install fuel pump into the fuel tank by aligning the triangle marks of the setting plate and fuel tank.
• Tighten the fuel pump set plate nuts in the specified sequence as shown.
• Fuel pump malfunction and inspection

30. FUEL & ENGINE
2-5
FUEL FILTER
G
Y
R Y G
G
Y
Y G
Bl
• Fuel filter clog or excessive damage
• To prevent dirt and debris from entering the fuel pump unit, always clean it before disassembly.
• Clean the fuel pump unit and fuel pump filter with clean gasoline. Never use commercially available
carburetor cleaners.
• Release the hooks from the stoppers by slightly spreading the hooks using the special tool.
Fuel pump case remover: 070MF-KVS0300
• Release the hooks from the stoppers by slightly spreading the hooks, and then turn it clockwise.
• Before installing the fuel pump filter, check the fuel pump unit for dirt. If necessary, clean the fuel pump unit
with compressed air. Do not blow into the fuel pump unit.
• If the R or Bl wire connector is disconnected, replace the fuel level sensor with a new one.
• Make sure the "CLICK" when the fuel pump unit is assembled.
• Connect the fuel pump motor wires to the specified position.
• Route the fuel pump motor wires and fuel level sensor wires to the guide and terminals properly.

31. FUEL & ENGINE
2-6
FUEL TANK
• Quick connect fitting (fuel pump side) 2-2

32. FUEL & ENGINE
2-7
AIR CLEANER
1.1 N·m
1.1 N·m
• Seat 3-4
• Discard the air cleaner element in accordance with the maintenance schedule. 1-24
• Replace the element any time if it is excessively dirty or damaged.
• Rear fender 3-6
• Battery box 3-7

33. FUEL & ENGINE
2-8
THROTTLE BODY
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• Do not remove the white painted screw and TP sensor. Removing them can cause throttle body malfunction.
• Do not loosen or tighten the white painted nut of the throttle drum. Loosening or tightening it can cause throttle body
malfunction.
4.5 N·m
4.5 N·m
• Quick connect fitting (injector side) 2-2
• TP sensor reset procedure 2-9
• Throttle body cleaning and inspection
3.4 N·m
• TP sensor reset procedure 2-9

34. FUEL & ENGINE
2-9
TP SENSOR RESET PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, TP sensor reset mode won’t start.
• If the TP sensor (throttle body) is replaced, perform the
procedure below.
• Seat 3-4
• Disconnect the DLC [A] from the dummy connector.
• Connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
• Disconnect the EOT sensor 2P connector [B].
• Short the EOT sensor terminals with jumper wire.
Connection: Yellow/blue – Green/yellow
• Turn the ignition switch ON, and then disconnect the
jumper wire from the EOT sensor 2P connector within 10
seconds while the MIL is blinking (reset receiving pattern).
• Check for the MIL blinks.
After disconnecting the jumper wire, the MIL should start
blinking. (reset completed pattern)
If the jumper wire is connected for more than 10 seconds,
the MIL will stay ON (unsuccessful pattern). Try again from
the first.
• Check the engine idle speed.
[A]
Yellow/
blue
Green/
yellow
[B]
within 10 sec.
[B]
within 10 sec.
0.1 sec.
Reset receiving Reset completed
1.2 sec.
0.3 sec.
0.3 sec.
Reset procedure and MIL blinking pattern

35. FUEL & ENGINE
2-10
INJECTOR
EVAP SYSTEM
• Quick connect fitting (injector side) 2-2
• Battery box 3-7

36. FUEL & ENGINE
2-11
• Lift up the fuel tank 2-2

37. FUEL & ENGINE
2-12
LUBRICATION SYSTEM
SYSTEM DIAGRAM
ENGINE OIL LEVEL CHECK
OIL PUMP
OIL STRAINER SCREEN
OIL FILTER ROTOR
• Support the vehicle with its centerstand on a level surface.
• Let the engine idle for 3 - 5 minutes.
• Wait for 2 - 3 minutes.
• Remove the oil filler cap/dipstick and wipe it clean.
• Insert the oil filler cap/dipstick without screwing it in,
and then remove it and check the oil level.
• If the oil level is below or near the lower level line on the
dipstick, add the recommended oil to the upper level.
• RECOMMENDED ENGINE OIL:
Honda “4-stroke motorcycle oil” or an equivalent mo-
tor oil.
API service classification: SG or higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
UPPER
LOWER

38. FUEL & ENGINE
2-13
ENGINE OIL CHANGE
OIL PUMP
• Remove the drain bolt and sealing washer.
• Drain oil completely.
• Install the oil drain bolt with a new sealing washer and
tighten it.
• Fill the crankcase with the recommended engine oil.
• Check that the O-ring on the oil filler cap is in good
condition, and replace it if necessary.
• ENGINE OIL CAPACITY:
0.8 liter after draining
1.0 liter after disassembly
30 N·m
3 N·m
• Engine oil 2-13
• Right crankcase cover 2-21
• Oil pump inspection

39. FUEL & ENGINE
2-14
CYLINDER HEAD
VALVE CLEARANCE
CYLINDER HEAD COVER
• Inspect while the engine is cold (below 35 °C).
• After the valve clearance inspection, check the engine
idle speed.
• Cylinder head cover 2-14
• Timing hole cap/O-ring, crankshaft hole cap/O-ring
• Turn the crankshaft in rotating direction slowly.
• Confirm the TDC (Top Dead Center) on the compression
stroke position by checking the slack in the rocker arm. If
there is no slack, rotate the crankshaft one full turn slowly
and recheck.
• Valve clearance (Insert a feeler gauge between the valve
adjusting screw and valve stem).
IN: 0.08 ± 0.02 mm, EX: 0.12 ± 0.02 mm
Valve adjusting wrench: 07908-KE90000
• Loosen the lock nut and turn the adjusting screw until
there is a slight drag on the feeler gauge.
• Hold the adjusting screw and tighten the lock nut.
• Recheck after tightening.
10 N·m
15 N·m
14 N·m
10 N·m
• Left side cover 3-3

40. FUEL & ENGINE
2-15
CYLINDER HEAD
• The cylinder head can be serviced with the engine in-
stalled in the frame.
• Cylinder head cover 2-14
• Spark plug cap 4-16
• O2 sensor clip/connector 4-13
• EOT sensor connector 4-12
• Fuel tank shrouds 3-7
• Exhaust pipe/muffler 3-10
• Intake pipe mounting bolts/insulator/O-rings 2-8
• Set the piston to the TDC on the
compression stroke. 2-14
• Make sure that the index lines [A] on the cam sprocket are
flush with the top surface of cylinder head and that the
mark [B] on the cam sprocket is in position shown (TDC).
If the cam sprocket mark is not in position shown, rotate
the crankshaft one full turn.
• Install the special tool into the tensioner body and turn the
tool clockwise until it stops turning. Hold the tensioner lifter
by pushing the tool while aligning the tabs of the tool with
the grooves of the tensioner lifter.
Tensioner stopper: 070MG-0010100
[A]
[B]
4 N·m

41. FUEL & ENGINE
2-16
32 N·m
9 N·m
• Remove the cylinder head bolts.
• Loosen the camshaft holder nuts in a crisscross pattern in several steps.
• Install the cam chain guide while aligning its pins with the grooves on the cylinder and its end with the
groove on the left crankcase.

42. FUEL & ENGINE
2-17
5 N·m
• Camshaft inspection.
• Install the camshaft with its flange tab facing up.

43. FUEL & ENGINE
2-18
• Remove the valve cotters.
Valve spring compressor: 07757-0010000
• Ream the valve guide to remove any carbon build up before measuring the guide. Insert the reamer from
the combustion chamber side of the cylinder head and always rotate the reamer clockwise.
Valve guide reamer, 5.0 mm: 07984-MA60001
• Support the cylinder head and drive the valve guides out of the cylinder head from the combustion
chamber side.
Valve guide driver: 07942-8920000
• Drive new valve guides into the cylinder head to the specified height from the cylinder head.
VALVE GUIDE PROJECTION: 16.8 – 17.0 mm
Valve guide adjusting driver: 07743-0020000
• Valve and valve spring inspection.
• Valve guide inspection.
• Valve seat inspection.

44. FUEL & ENGINE
2-19
CAM CHAIN TENSIONER
• Install the special tool into the tensioner body and turn the
tool clockwise until it stops. Hold the tensioner lifter by
pushing the tool while aligning the tabs of the tool with the
grooves of the tensioner lifter.
Tensioner stopper: 070MG-0010100
• Check the cam chain tensioner lifter operation:
– The tensioner shaft should not go into the body when it
is pushed.
– When it is turned clockwise with the tensioner stopper,
the tensioner shaft should be pulled into the body. The
shaft should protrude from the body as soon as the
tensioner stopper is released.
4 N·m

45. FUEL & ENGINE
2-20
CYLINDER/PISTON
113.4 - 115.4 mm
11 N·m
• The cylinder/piston can be serviced with the engine installed in the frame.
• Cylinder head 2-14
• Spread each piston ring and remove it by lifting up at a point opposite the gap.
• Carefully install the piston rings into the piston ring grooves with the markings facing up.
• Install the piston with the “IN” mark facing the intake side.
• Do not align the piston pin clip end gap with the piston cut-out.
• Piston and piston rings inspection.
• Cylinder inspection.

46. FUEL & ENGINE
2-21
CLUTCH/GEARSHIFT LINKAGE/BALANCER GEAR
12 N·m
12 N·m
74 N·m
64 N·m
Coating width:
6.5 ± 1 mm from tip
12 N·m
64 N·m
4 N·m
• The clutch/gearshift linkage/balancer gear can be serviced with the engine installed in the frame.
• Loosen the balancer driven gear lock nut.
Gear holder: 07724-0010200
• Loosen the oil filter rotor lock nut.
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar/handle: 07716-0020500
Gear holder: 07724-0010200
• Loosen the clutch center lock nut.
Clutch center holder: 07GMB-KT70101
• Align the balancer driven gear punch mark with the drive gear mark.

47. FUEL & ENGINE
2-22
3 - 4 mm
• Drive the spring pin into the clutch lifter arm until the pin end is flush with the lifter arm surface.
Pin driver: 07744-0010100
• Drive the spring pin until it projects as specified above.
Pin driver: 07744-0010100
Hook the return spring ends to the right crankcase cover and spring pin.
• Assemble clutch discs, clutch plates and pressure plate onto clutch center, while aligning " " marks of
clutch center and pressure plate.
• Install the tabs of the clutch disc (outside) into the shallow slots in the clutch outer.
• Clutch inspection

48. FUEL & ENGINE
2-23

49. FUEL & ENGINE
2-24
ALTERNATOR/STARTER CLUTCH
74 N·m
16 N·m
Coating width:
6.5 ± 1 mm from tip
• The alternator/starter clutch can be serviced with the engine installed in the frame.
• Left side cover 3-3
• Drive sprocket cover 3-8
• Hold the flywheel with the special tool for the nut removal.
Flywheel holder: 07725-0040001
• Flywheel
Flywheel puller: 07933-KM10000
• Clean any oil and grease from crankshaft and flywheel contact area. Install the flywheel onto the crank-
shaft by aligning the key way on the flywheel with the woodruff key.

50. FUEL & ENGINE
2-25
12 N·m
12 N·m
Coating width:
6.5 ± 1 mm from tip
(ThreeBond 1141 or
1215 or 1207G)
12 N·m

51. FUEL & ENGINE
2-26
CRANKCASE/CRANKSHAFT/BALANCER
CRANKSHAFT RUNOUT INSPECTION
10 N·m
12 N·m
Coating width:
6.5 ± 1 mm from tip
1 – 2 cc
(ThreeBond
1215 or 1207G)
[A]
• Engine unit 2-28
• Cylinder/piston 2-20
• Clutch/gearshift linkage/balancer gear 2-21
• Alternator/starter clutch 2-24
• Oil pump 2-13
• Remove the crankcase bolts in a crisscross pattern in 2 - 3 steps.
• Place the crankcase with the right crankcase facing down and separate.
• Apply sealant to the left crankcase mating surface except the oil passage area [A].
• Hook the retainer plate tab into the left crankshaft bearing groove.
• Install the push plug by aligning its flat surface with the crankshaft bearing outer race.
• Crankshaft inspection
• Connecting rod inspection
• Set the crankshaft on V-blocks and measure the runout
using a dial indicator.
43.0 mm
47.5 mm

52. FUEL & ENGINE
2-27
TRANSMISSION
MAINSHAFT
COUNTERSHAFT
• Transmission inspection

53. FUEL & ENGINE
2-28
ENGINE UNIT
32 N·m
44 N·m
32 N·m
12 N·m
54 N·m
• Rear brake pedal 3-22
• Exhaust pipe/muffler 3-10
• Drive sprocket cover 3-8

54. 3-1
3. FRAME & CHASSIS
BODY PANELS ································· 3-2
CENTERSTAND ································ 3-9
SIDESTAND ····································3-10
EXHAUST PIPE/MUFFLER·················3-10
FRONT WHEEL································3-11
FORK ·············································3-13
HANDLEBAR ··································3-15
STEERING STEM ·····························3-16
REAR WHEEL ·································3-17
REAR SUSPENSION ························3-18
FRONT BRAKE································3-19
REAR BRAKE ·································3-22

55. FRAME & CHASSIS
3-2
FRAME & CHASSIS
BODY PANELS
FRONT VISOR
(4)
(5)
(6)
(10)
(9)
(14)
(12)
(1)
(3)
(2)
(7)
(8)
(13)
(11)
[1] Front visor 3-2 [8] License light cover 3-6
[2] Headlight rear cover 3-3 [9] Rear fender 3-6
[3] Side cover 3-3 [10] Fuel tank shroud 3-7
[4] Seat 3-4 [11] Battery box 3-7
[5] Rear grip 3-4 [12] Front fender 3-8
[6] Tail cover 3-5 [13] Drive sprocket cover 3-8
[7] Body cover 3-5 [14] Drive chain cover 3-9

56. FRAME & CHASSIS
3-3
HEADLIGHT REAR COVER
SIDE COVER
• Front visor 3-2
• Seat 3-4

57. FRAME & CHASSIS
3-4
SEAT
REAR GRIP
• Seat 3-4

58. FRAME & CHASSIS
3-5
TAIL COVER
BODY COVER
• Seat 3-4
• Tail cover 3-5
• Side cover 3-3

59. FRAME & CHASSIS
3-6
LICENSE LIGHT COVER
REAR FENDER
[A]
• Seat 3-4
• Release the snap fit clips [A].
• Taillight unit 4-23
• License light cover 3-6

60. FRAME & CHASSIS
3-7
FUEL TANK SHROUD
BATTERY BOX
• Side cover 3-3
7 N·m
10 N·m
• Lift up the fuel tank. 2-2
• Drive sprocket cover 3-8
• Battery 4-23

61. FRAME & CHASSIS
3-8
FRONT FENDER
DRIVE SPROCKET COVER

62. FRAME & CHASSIS
3-9
DRIVE CHAIN COVER
CENTERSTAND
• Brake pedal freeplay adjustment

63. FRAME & CHASSIS
3-10
SIDESTAND
EXHAUST PIPE/MUFFLER
29 N·m
10 N·m
26 N·m
9 N·m
20.5 - 22.5 mm
11 N·m

64. FRAME & CHASSIS
3-11
FRONT WHEEL
DISC BRAKE TYPE
59 N·m
3 g
• Align the cable slot with the gear tab.
• Align the gear slots with the retainer tabs.
• Align the gearbox slot with the left fork leg boss.
42 N·m
• Wheel disassembly and inspection

65. FRAME & CHASSIS
3-12
DRUM BRAKE TYPE
59 N·m
• Align the brake panel slot with the left fork leg boss.
• Brake lever freeplay adjustment
• Wheel disassembly and inspection

66. FRAME & CHASSIS
3-13
FORK
32 N·m
23 N·m
22 N·m
• Headlight rear cover 3-3
• Front fender 3-8
• Front wheel 3-11
• Disc brake type: Brake caliper mounting bolts/brake caliper 3-20
• Align the top surface of the fork pipe with the top bridge upper surface.

67. FRAME & CHASSIS
3-14
20 N·m
187 mm
• Remove the oil seal.
Oil seal remover: 07748-0010001
• Drive in a new oil seal squarely with its marked side facing up until it is fully seated.
Fork seal driver body: 07747-0010100
Attachment, 31 mm: 07747-0010400
• Pour the specified amount of recommended fork fluid into the fork pipe.
RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W
FORK FLUID CAPACITY: 145 ± 2.5 cm3
• Compress the fork pipe fully and measure the fluid level from the top of the fork pipe.
FORK FLUID LEVEL: 187 mm
• Pull the fork pipe up and install the fork spring with its tightly wound coil side facing down.
• Fork disassembly and inspection

68. FRAME & CHASSIS
3-15
HANDLEBAR
2.5 N·m
2.5 N·m
34 N·m
12 N·m
34 N·m
• Align the punch mark on the handlebar with the handlebar lower holder top surface. Install the handlebar
upper holders with their punch marks facing forward.
• Install the brake lever bracket/master cylinder holder with the "UP" mark facing up. Align the edge of the
master cylinder with the punch mark on the handlebar.
• Align the slit of the clutch lever holder with the punch mark on the handlebar.
• Brake lever freeplay adjustment

69. FRAME & CHASSIS
3-16
STEERING STEM
74 N·m
[A]
[C]
[B] [D] [E]
Multi-purpose extreme pressure
grease NLGI #2 (ALVANIA EP2
manufactured by Shell,EXCELITE
EP2 manufactured by KYODO
YUSHI CO., LTD. or equivalent)
[B] [D] [E]
[A]
3 – 5 g
3 – 5 g
3 – 5 g
3 – 5 g
3 – 5 g
• Handlebar 3-15
• Fork 3-13
• STEERING STEM:
[A] Socket wrench: 07916-3710101
• STEERING STEM BEARINGS:
[B] Ball race remover shaft: 07GMD-KS40100
• STEERING STEM:
[A] Socket wrench: 07916-3710101
• STEERING STEM BEARINGS:
[C] Steering stem driver: 07946-4300101, [D] Driver: 07749-0010000
[E] Attachment, 42 x 47 mm: 07746-0010300
• Install the top thread. Hold the steering stem and tighten the stem top thread to the initial torque.
TORQUE: 25 N·m
• Turn the steering stem lock-to-lock several times to seat the bearing. Completely loosen the top thread.
• Retighten the stem top thread to the specified torque.
TORQUE: 2.5 N·m
• Steering disassembly/assembly and inspection

70. FRAME & CHASSIS
3-17
REAR WHEEL
88 N·m
• Wheel inspection
• Brake pedal freeplay adjustment
• Drive chain slack adjustment
64 N·m
• Wheel disassembly and inspection

71. FRAME & CHASSIS
3-18
REAR SUSPENSION
59 N·m
39 N·m
24 N·m
• Side covers 3-3
• Drive chain cover 3-9
• Rear wheel 3-17
• Exhaust pipe/muffler 3-10

72. FRAME & CHASSIS
3-19
FRONT BRAKE
BRAKE MASTER CYLINDER
34 N·m
• Install the brake master cylinder holder with the "UP" mark facing up. Align the edge of the master cylin-
der with the punch mark on the handlebar.
6 N·m
1 N·m
Silicone grease
Silicone
grease
1.2 N·m
1.5 N·m
Silicone grease
• Remove the snap ring.
Snap ring pliers: 07914-SA50001
• Master cylinder inspection

73. FRAME & CHASSIS
3-20
BRAKE CALIPER
BRAKE PAD REPLACEMENT
18 N·m
2.5 N·m
• Install brake pads so that they are set on the brake caliper bracket and bracket pin.
34 N·m
26 N·m
• Caliper cylinder inspection

74. FRAME & CHASSIS
3-21
DRUM BRAKE
8 N·m
Silicone grease
Silicone
grease
Silicone grease
18 N·m
2.5 N·m
Silicone grease
Silicone grease
10 N·m
Gear oil
1.0 – 1.4 g
• Front wheel 3-11
• Drum brake service

75. FRAME & CHASSIS
3-22
REAR BRAKE
10 N·m
Gear oil
• Rear wheel 3-17
• Drum brake service

76. FRAME & CHASSIS
3-23
59 N·m
3 g
• Right side cover 3-3
• Brake pedal freeplay adjustment

77. MEMO

78. 4-1
4. ELECTRICAL SYSTEM
PGM-FI SYSTEM ······························· 4-2
IGNITION SYSTEM ···························4-15
ELECTRICAL STARTER····················4-18
BATTERY/CHARGING SYSTEM ·········4-22
LIGHTING SYSTEM ··························4-23
SPEEDOMETER ······························4-27
ELECTRICAL COMPONENT ··············4-30

79. ELECTRICAL SYSTEM
4-2
ELECTRICAL SYSTEM
PGM-FI SYSTEM
MIL CODE INDEX
PGM-FI SYSTEM LOCATION
• Refer to "Basic Shop manual" for the following information.
– PGM-FI technical feature and each sensor function.
– Symptom troubleshooting for the PGM-FI system.
MIL Function Failure Symptom/Fail-safe function Page
7
EOT sensor malfunction
• Loose or poor contact of the EOT sensor connector
• EOT sensor or its circuit malfunction
• Hard start at a low temperature
4-4
8
TP sensor malfunction
• Loose or poor contact of the TP sensor connector
• TP sensor or its circuit malfunction
• Poor engine acceleration
4-5
9
IAT sensor malfunction
• Loose or poor contact of the IAT sensor connector
• IAT sensor or its circuit malfunction
• Engine operates normally
4-6
12
Injector malfunction
• Loose or poor contact of the injector connector
• Injector or its circuit malfunction
• Engine does not start
• Injector, fuel pump and ignition coil shut
down
4-7
21
O2 sensor malfunction
• Loose or poor contact of the O2 sensor connector
• O2 sensor or its circuit malfunction
• Engine operates normally
4-8
54
Bank angle sensor malfunction
• Loose or poor contact of the Bank angle sensor con-
nector
• Bank angle sensor or its circuit malfunction
• Engine operates normally
• Engine stop function does not operate
4-9
EOT SENSOR
TP SENSOR
O2 SENSOR
CKP SENSOR
DLC
ECM
INJECTOR
IAT SENSOR
BANK ANGLE
SENSOR

80. ELECTRICAL SYSTEM
4-3
PGM-FI SYSTEM DIAGRAM
CKP
SENSOR
15
SCS
30
K-LINE
DLC SCS
CONNECTOR
O/W
Bu/W
G/Bl
12 PCP
23 PCM
Bu/Y
W/Y 1
IGP
16
INJ
INJECTOR
P/G
8
FFP
FUEL PUMP
Bl/O
IGNITION
SWITCH
BATTERY
MAIN
FUSE
20A
R
R/W
MIL
18
FI IND W/Bu
(8)
(7)
EOT SENSOR
5 THL
24 TO
26 BA
6 VCC
3 O2
4 SG1
9 PG1 10 PG2 2 LG
TP SENSOR
Y/Bu
Y/Bl
Bu Bl/Bu
G/Bu
W/R
G
G G/Bl
(12)
ECM
: Engine does not start when detecting MIL
: MIL
( )
31 SG2
G/Y
FUEL PUMP
IGN INJ
FUSE 10A
(54)
BANK ANGLE
SENSOR
O2 SENSOR
(21)
(9)
IAT SENSOR
14 TA
Gr/Bu
32 SG3
G/O
P/Bl
: Short terminals for reading MIL
R/Bl
HORN TURN
METER FUSE 10A
Bl/R
R/Bl
Br/Y
R/Bl
Br/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Y
G
Bl
Bl : Black
Y : Yellow
Bu : Blue
G : Green
R : Red
W : White
Br : Brown
O : Orange
P : Pink
Gr : Gray
Bl
G
33P (Black) CONNECTOR
(ECM side / male terminal)
A11
A1
A23 A33
A22
A12

81. ELECTRICAL SYSTEM
4-4
MIL TROUBLESHOOTING
MIL 7 BLINKS (EOT SENSOR)
EOT Sensor Diagram
• Seat 3-4
EOT sensor
TO
5 V
SG2
ECM
G/Y Y/Bu
ECM 33P (Black) connector
EOT sensor 2P
connector
G/Y
Y/Bu
G/Y Y/Bu
A B
EOT sensor 2P
connector
1. EOT Sensor System Inspection
• Is the MIL blinks 7 times? No
►
• Intermittent failure
• Loose or poor contact at the connector
Yes ▼
2. EOT Sensor Input Voltage Inspection
• Connection: Y/Bu (+) – G/Y (–)
• Is the voltage within 4.75 – 5.25 V? No
►
• Open or short circuit in Y/Bu wire
• Open circuit in G/Y wire
• If there is no open or short circuit, replace the ECM
with a new one 4-12, and recheck.
Yes ▼
3. EOT Sensor Resistance inspection
• Connection: A – B
• Is the resistance within 2.5 – 2.8 kΩ (20°C)?
No
►
• Faulty EOT sensor
Yes ▼
• Replace the ECM with a new one 4-12, and
recheck.

82. ELECTRICAL SYSTEM
4-5
MIL 8 BLINKS (TP SENSOR)
TP Sensor Diagram
• Seat 3-4
• Left side cover 3-3
THL
5 V
SG1
ECM
TP sensor
VCC
G/Bu Y/Bl W/R
TP sensor 3P connector ECM 33P (Black) connector
G/Bu
Y/Bl
W/R
G/Bu
Y/Bl
W/R
B C
TP sensor 3P
connector
A
1. TP Sensor System Inspection
• Is the MIL blinks 8 times? No
►
• Intermittent failure
• Loose or poor contact at the connector
Yes ▼
2. TP sensor Power Input Voltage Inspection
• Connection: W/R (+) – G/Bu (–)
• Is the voltage within 4.75 – 5.25 V?
No
►
• Open or short circuit in W/R wire
• Open circuit in G/Bu wire
• If there is no open or short circuit, replace the ECM
with a new one 4-12, and recheck.
Yes ▼
3. TP Sensor Output Line Inspection
• Check a open or short circuit in Y/BI wire.
• Is there open or short circuit?
Yes
►
• Faulty Y/Bl wire
No ▼
4. TP Sensor Resistance inspection
• Connection: A – B, B – C
• Does the resistance of the TP sensor changes
according to the throttle operation?
No
►
• Faulty TP sensor (throttle body)
Yes ▼
• Replace the ECM with a new one 4-12, and
recheck.

83. ELECTRICAL SYSTEM
4-6
MIL 9 BLINKS (IAT SENSOR)
IAT Sensor Diagram
• Seat 3-4
• Left side cover 3-3
5 V
SG3
ECM
IAT sensor
TA
Gr/Bu
G/O
Gr/Bu
G/O
IAT sensor 2P
connector
ECM 33P (Black) connector
G/O
Gr/Bu
A B
IAT sensor 2P
connector
1. IAT Sensor System Inspection
• Is the MIL blinks 9 times? No
►
• Intermittent failure
• Loose or poor contact at the connector
Yes ▼
2. IAT Sensor Input Voltage Inspection
• Connection: Gr/Bu (+) – G/O (–)
• Is the voltage within 4.75 – 5.25 V? No
►
• Open or short circuit in Gr/Bu wire
• Open circuit in G/O wire
• If there is no open or short circuit, replace the ECM
with a new one 4-12, and recheck.
Yes ▼
3. IAT Sensor Resistance inspection
• Connection: A – B
• Is the resistance within 1.0 – 1.2 kΩ (40°C)?
No
►
• Faulty IAT sensor
Yes ▼
• Replace the ECM with a new one 4-12, and
recheck.

84. ELECTRICAL SYSTEM
4-7
MIL 12 BLINKS (INJECTOR)
Injector Diagram
• Seat 3-4
• Right side cover 3-3
INJ
ECM
Injector
From Battery
Bl/R
P/G
Bl/R P/G
P/G
Injector 2P connector
(Wire side) ECM 33P (Black) connector
Injector 2P connector
(Injector side)
A B
1. Fuel Injector System Inspection
• Is the MIL blinks 12 times? No
►
• Intermittent failure
• Loose or poor contact at the connector
Yes ▼
2. Fuel Injector Input Voltage Inspection
• Connection: Bl/R (+) – Ground (–)
• Does the battery voltage exist?
No
►
• Open circuit in Bl/R wire
Yes ▼
3. Fuel Injector Signal Line Inspection
• Check an open or short circuit in P/G wire.
• Is there open or short circuit?
Yes
►
• Faulty P/G wire
No ▼
4. Fuel Injector Resistance inspection
• Connection: A – B
• Is the resistance within 11 – 13 Ω (20 °C)?
No
►
• Faulty fuel injector
Yes ▼
• Replace the ECM with a new one 4-12, and
recheck.

85. ELECTRICAL SYSTEM
4-8
MIL 21 BLINKS (O2 SENSOR)
O2 Sensor Diagram
• Seat 3-4
O2
ECM
O2 sensor
Bu
Bl/Bu
O2 sensor 2P connector ECM 33P (Black) connector
Bl/Bu
Bl/Bu
1. O2 Sensor System Inspection
• Test-ride the vehicle and check the MIL.
• Is the MIL blinks 21 times?
No
►
• Intermittent failure
• Loose or poor contact at the connector
Yes ▼
2. O2 Sensor Circuit Inspection
• Check an open or short circuit in Bl/Bu wire.
• Is there open or short circuit?
Yes
►
• Faulty Bl/Bu wire
No ▼
3. O2 Sensor Inspection
• Replace the O2 sensor with a new one 4-13
• Erase the DTC’s.
• Test-ride the vehicle and check the MIL.
• If the MIL blinks 21 times, replace the ECM with
a new one 4-12, and recheck.

86. ELECTRICAL SYSTEM
4-9
MIL 54 BLINKS (BANK ANGLE SENSOR)
Bank Angle Sensor Diagram
• Seat 3-4
• Bank angle sensor system inspection
BA
ECM
Bank angle sensor
From Battery
P/Bl Bl/R
Bank angle sensor 2P connector ECM 33P (Black) connector
P/Bl
Bl/R
P/Bl
1. Bank Angle Sensor System Inspection
• Is the MIL blinks 54 times? No
►
• Intermittent failure
• Loose or poor contact at the connector
Yes ▼
2. Bank Angle Sensor Power Input Voltage In-
spection
• Connection: Bl/R (+) – Ground (–)
• Does the battery voltage exist?
No
►
• Open circuit in Bl/R wire
Yes ▼
3. Bank Angle Sensor Output Line Inspection
• Check a open or short circuit in P/Bl wire.
• Is there open or short circuit?
Yes
►
• Faulty P/Bl wire
No ▼
4. Bank Angle Sensor Inspection
• Inspect the bank angle sensor (specified incline
angle: 70 ± 5 °).
• Is the above inspection normal?
No
►
• Faulty bank angle sensor
Yes ▼
• Replace the ECM with a new one 4-12, and
recheck.

87. ELECTRICAL SYSTEM
4-10
ECM INITIALIZING PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, ECM initializing mode won’t start.
• Perform this procedure when any of the following fuel
related part is replaced with a new one.
– Idle air screw
– Fuel pump/fuel filter
– Injector
– O2 sensor
• Perform this procedure when any of the following engine
part is replaced or is overhauled.
– Cylinder head
– Valves/valve guides/valve seat
– Cylinder/piston/piston ring
• Seat 3-4
• Turn the idle air screw to specified opening.
Standard opening: 2-1/4 turns out
• Disconnect the DLC [A] from the dummy connector and
connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
• Open the throttle grip fully and hold.
• The MIL should come on and then start blinking rapidly.
Within 5 seconds after rapid blinking starts, close the
throttle grip and hold for more than 3 seconds.
• If the MIL does not start blinking rapidly, turn the ignition
switch OFF and try again.
• If you can not restart the procedure, recheck if the DTC is
not stored in ECM.
• If the DTC is not stored but you still can not restart the
procedure, replace the ECM with a known-good one and
try again.
• When the ECM initializing is successful, the MIL will repeat
one short blink.
• If the successful pattern is indicated, turn the ignition
switch OFF.
• If altitude is higher than 2,000 m, perform the altitude
setting 4-11
• Check the engine idle speed.
[A]
[A]
Open and hold.
MIL ON
Within 5 seconds after
rapid blink starts, close
and hold for more than
3 seconds.
Successful pattern
(One short blink repeats)
Rapid blink

88. ELECTRICAL SYSTEM
4-11
ALTITUDE SETTING
• Make sure that DTC is not stored in ECM. If stored, the
ECM cannot enter the setting mode.
• The setting will fail if the engine is started during the
procedure.
• Select the appropriate MODE which meets the situation
described below.
MODE1: 0 – 2,000 m above sea level
MODE2: 2,000 – 2,500 m above sea level
MODE3: 2,500 – 3,500 m above sea level
MODE4: 3,500 m or higher above sea level
• Seat 3-4
• Turn the idle air screw to specified opening.
Standard opening: 2-1/4 turns out
• Disconnect the DLC [A] from the dummy connector and
connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
• Open the throttle grip fully and hold.
• The MIL should come on and then start blinking rapidly.
MODE1: Within 5 seconds after rapid blinking starts, close
the throttle grip and hold for more than 3 seconds.
MODE2, 3, 4: Within 5 seconds after rapid blinking starts,
snap the throttle grip (close for 0.5 second/open for 0.5
second) as specified times, then close and hold for more
than 3 seconds.
MODE2: Snap 1 time
MODE3: Snap 2 times
MODE4: Snap 3 times
• If the MIL does not start blinking rapidly, turn the ignition
switch OFF and try again.
• If you can not restart the procedure, recheck if the DTC is
not stored in the ECM.
• If the DTC is not stored but you still can not restart the
procedure, replace the ECM with a known-good one and
try again.
• The MIL will repeat the short blinks as the number of the
selected MODE.
• If the desired successful pattern is indicated, turn the
ignition switch OFF.
• If the MIL starts blinking slowly during this step before
successful pattern is indicated, turn the ignition switch OFF
and try again.
• If the number of MIL blink and the number of desired
MODE is different, turn the ignition switch OFF and try
again.
• Turn the idle air screw to the specified opening and check
the engine idle speed.
[A]
[A]
Open and
hold.
MIL ON
MODE 2: Snap 1 time
MODE 3: Snap 2 times
MODE 4: Snap 3 times
Rapid blink
Successful patterns (Short blinks repeat):
MODE 2:
MODE 3:
MODE 4:
Within 5 seconds after rapid
blink starts, snap (close 0.5
sec./open 0.5 sec.), close and
hold for more than 3 seconds.
Close 0.5 sec.
Open 0.5 sec.
Close and hold.
MODE 1:
MODE 1: MODE 2, 3, 4:
Within 5 seconds
after rapid blink
starts, close and
hold for more than
3 seconds.

89. ELECTRICAL SYSTEM
4-12
ECM
EOT SENSOR
• Seat 3-4
• ECM power circuit and ground circuit inspection
14 N·m
• EOT sensor inspection

90. ELECTRICAL SYSTEM
4-13
IAT SENSOR
O2 SENSOR
1.1 N·m
• Left side cover 3-3
• IAT sensor inspection
25 N·m
[A]
• Remove the O2 sensor using the special tool.
Flare nut socket [A]: FRXM17 (Snap on) or equivalent

91. ELECTRICAL SYSTEM
4-14
BANK ANGLE SENSOR
10 N·m
• Bank angle sensor inspection

92. ELECTRICAL SYSTEM
4-15
IGNITION SYSTEM
IGNITION SYSTEM LOCATION
IGNITION SYSTEM DIAGRAM
IGNITION SWITCH
IGNITION COIL
ECM
CKP SENSOR
SPARK PLUG
BATTERY
MAIN FUSE 20 A
FUEL PUMP IGN
INJ FUSE 10 A
IGNITION
SWITCH
SPARK
PLUG
CKP
SENSOR
ECM
BATTERY
MAINFUSE
20 A
P/Bu
G
Bl
IGNITION
COIL
G G/Bl
G G
G/Bl
Bl
FUEL PUMP IGN
INJ FUSE 10 A
R/W
R/Bl
Bl/R
Bl/R
Bl/R
G
P/Bu
W/Y
Bu/Y
Bu/Y
R
Bl: Black
Y: Yellow
Bu: Blue
G: Green
R: Red
W: White
P: Pink

93. ELECTRICAL SYSTEM
4-16
SPARK PLUG REPLACEMENT
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Refer to "Basic Shop Manual" for the detail information of
ignition coil primary peak voltage inspection.
• Support the vehicle with its centerstand on a level
surface.
• Lift up the fuel tank 2-2
• Disconnect the spark plug cap from the spark plug.
• Connect a known-good spark plug to the spark plug
cap and ground it to the cylinder head as done in a spark
test.
• With the ignition coil primary wires connected, connect
the peak voltage adaptor probes to the ignition coil
primary terminal and ground.
CONNECTION: Pink/blue (+) – Ground (–)
• Check the initial voltage at this time.
STANDARD VOLTAGE: Battery voltage
• Shift the transmission in neutral, and then crank the en-
gine with the starter and measure the ignition coil primary
peak voltage.
PEAK VOLTAGE: 100 V minimum
16 N·m

94. ELECTRICAL SYSTEM
4-17
CKP SENSOR PEAK VOLTAGE
IGNITION TIMING
• Support the vehicle with its centerstand on a level
surface.
• Seat 3-4
• Disconnect the ECM 33P (Black) connector.
• Connect the peak voltage adaptor probes to the following
terminals.
CONNECTION: Blue/yellow (+) – White/yellow (–)
• Shift the transmission in neutral, and then crank the en-
gine with the starter and measure the CKP sensor peak
voltage.
PEAK VOLTAGE: 0.7 V minimum
If the value is abnormal, measure the peak voltage at the
CKP sensor 2P connector.
• Left side cover 3-3
• Disconnect the CKP sensor 2P connector.
• Connect the peak voltage adaptor probes to the following
terminals.
CONNECTION: Blue/yellow (+) – Green (–)
• Shift the transmission in neutral, and then crank the en-
gine with the starter and measure the CKP sensor peak
voltage.
PEAK VOLTAGE: 0.7 V minimum
– If the value is abnormal, replace the CKP sensor with a
known-good one and recheck.
– If the value is normal, check for open circuit or loose
connection between the CKP sensor 2P connector and
ECM 33P (Black) connector.
• Warm the engine up to normal operating temperature.
• Connect the timing light to the spark plug wire.
• Start the engine and let it idle
IDLE SPEED: 1,500 ± 100 min-1
• The ignition timing is correct if the "F" mark on the fly-
wheel aligns with the index mark on the left crankcase
cover.
Bu/Y
W/Y
Bu/Y G

95. ELECTRICAL SYSTEM
4-18
ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION
ELECTRICAL STARTER SYSTEM DIAGRAM
IGNITION SWITCH
GEAR POSITION SWITCH
STARTER SWITCH
STARTER RELAY SWITCH
CLUTCH SWITCH
DIODE
BATTERY
STARTER MOTOR
FUEL PUMP IGN INJ FUSE 10 A
MAIN FUSE 20A
Y/R
MAIN FUSE 20A
IGNITION
SWITCH
FUEL PUMP IGN
INJ FUSE 10 A
GEAR
POSITION
SWITCH
CLUTCH
SWITCH
STARTER
MOTOR
BATTERY
DIODE
STARTER
RELAY
SWITCH
G/R
G
N
Lg/R
Bl
STARTER SWITCH
Bl
G/R
G/R
Bl Bl
Bl
Bl
Bl
Bl
Bl
R/W R/Bl
R/Bl
Bl/R
Bl/R
R
Bl: Black
Y: Yellow
G: Green
R: Red
W: White
Lg: Light green

96. ELECTRICAL SYSTEM
4-19
ELECTRICAL STARTER TROUBLESHOOTING
STARTER MOTOR DOES NOT TURN
Connector Diagram
Left side cover 3-3
• Loose or poor contacts of related terminal/connector.
• Battery condition
• Burned fuse
Starter relay switch 4P (Red) connector
G/R Y/R
1. Starter Relay Coil Input Circuit inspection
• Connection: Y/R (+) – Ground (–)
• Depress the starter button.
• Does the battery voltage exist?
No
►
• Inspect the following.
– Ignition switch
– Starter switch
– Starter relay coil input related circuit
Yes ▼
2. Starter Relay Coil Ground Circuit inspection
• Connection: G/R – Ground
• Squeeze the clutch lever or shift the transmis-
sion in neutral position.
• Is there continuity?
No
►
• Inspect the following.
– Diode
– Clutch switch
– Gear position switch
– Starter relay coil ground related circuit
Yes ▼
3. Starter Relay inspection
• Replace the starter relay with a new one, and
recheck.
• Does the starter motor turn?
Yes
►
• Faulty original starter relay
No ▼
• Check a short or open circuit in starter motor
cable.
• If there is no faulty circuit, replace the starter
motor with a new one, and recheck.

97. ELECTRICAL SYSTEM
4-20
STARTER MOTOR
Battery negative (-) terminal 4-23
• Starter motor service

98. ELECTRICAL SYSTEM
4-21
GEAR POSITION SWITCH
• Left side cover 3-3
• Drive sprocket cover 3-8
• Drain the engine oil. 2-13

99. ELECTRICAL SYSTEM
4-22
BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEM LOCATION
BATTERY/CHARGING SYSTEM DIAGRAM
ALTERNATOR
REGULATOR/RECTIFIER
BATTERY
MAIN FUSE 20 A
R/W
G
Bl Y Y Y Y Y
BATTERY REGULATOR/RECTIFIER
ALTERNATOR
Y
Bl
Bl
MAIN FUSE 20 A
Bl: Black
Y: Yellow
G: Green
R: Red
W: White
• Battery/charging system information, troubleshooting and inspection

100. ELECTRICAL SYSTEM
4-23
BATTERY
LIGHTING SYSTEM
9 N·m
• Left side cover 3-3
1.5 N·m
• Front visor 3-2

101. ELECTRICAL SYSTEM
4-24
7.5 N·m
• Body covers 3-5
19 N·m
• Front
– Front visor 3-2
• Rear
– License light cover 3-6
1.8 N·m
• License light cover 3-6

102. ELECTRICAL SYSTEM
4-25
BULB REPLACEMENT
• Front visor 3-2
0.9 N·m

103. ELECTRICAL SYSTEM
4-26
HEADLIGHT AIM
1 N·m
1 N·m
Beam
up
Beam
down
1.5 N·m

104. ELECTRICAL SYSTEM
4-27
SPEEDOMETER
Br/W, G
(2.0 W)
Br/W, G
(3.4 W)
Y/W
G/Bl
Br/Y
Lb, G O, G
Bu, G
W/Bu,
Br/Y
Lg/R,
Br/Y
Headlight unit 4-23

105. ELECTRICAL SYSTEM
4-28
FUEL LEVEL SENSOR
R
R
Bl Y G
Bl
• Fuel pump unit 2-4
• Route the fuel level sensor wires to the guide and terminals properly.

106. ELECTRICAL SYSTEM
4-29
FUEL METER TROUBLESHOOTING
FUEL METER NEEDLE DOES NOT MOVE
• Fuel pump unit 2-4
• Loose or poor contacts of related terminal/connector.
FUEL UNIT 5P CONNECTOR
FULL
EMPTY
A B
1. Fuel Level Sensor Circuit Inspection
• Check the Y/W and G/Bl wire.
• Is there open or short circuit?
Yes
►
• Faulty Y/W or G/Bl wire
No ▼
2. Fuel Level Sensor Inspection
• Connection: A – B
• Standard: FULL 6 – 10 Ω, EMPTY 90 – 100 Ω.
• Does the standard resistance exist?
No
►
• Replace the fuel level sensor with a new one 4-28,
and recheck.
Yes ▼
Replace the speedometer with a new one 4-27,
and recheck.

107. ELECTRICAL SYSTEM
4-30
ELECTRICAL COMPONENT
IGNITION SWITCH
HORN
22 N·m
• Headlight rear cover 3-3

108. 5-1
dummytext
INDEX
A
A Few Words About Safety······································1-2
AIR CLEANER······················································2-7
ALTERNATOR/STARTER CLUTCH························2-24
ALTITUDE SETTING ···········································4-11
B
BATTERY/CHARGING SYSTEM····························4-22
BODY PANELS ····················································3-2
BULB REPLACEMENT ········································4-25
C
CABLE & HARNESS ROUTING ·····························1-15
CENTERSTAND ···················································3-9
CLUTCH/GEARSHIFT LINKAGE/BALANCER
GEAR ·······························································2-21
CRANKCASE/CRANKSHAFT/BALANCER···············2-26
CYLINDER HEAD ···············································2-14
CYLINDER/PISTON ············································2-20
E
ECM INITIALIZING PROCEDURE ··························4-10
ELECTRICAL COMPONENT·································4-30
ELECTRICAL STARTER ······································4-18
ENGINE OIL CHANGE·········································2-13
ENGINE OIL LEVEL CHECK ·································2-12
ENGINE UNIT ····················································2-28
EVAP SYSTEM ··················································2-10
EXHAUST PIPE/MUFFLER···································3-10
F
FORK ·······························································3-13
FRONT BRAKE ··················································3-19
FRONT WHEEL··················································3-11
FUEL LEVEL SENSOR ········································4-28
FUEL LINE ··························································2-2
FUEL PUMP UNIT·················································2-4
FUEL TANK ·························································2-6
H
HANDLEBAR ····················································· 3-15
HORN······························································· 4-30
How To Use This Manual········································1-3
I
IGNITION SYSTEM ············································· 4-15
INJECTOR························································· 2-10
L
LIGHTING SYSTEM ············································ 4-23
LUBRICATION SYSTEM ······································ 2-12
M
MAINTENANCE SCHEDULE································· 1-24
MODEL IDENTIFICATION ······································1-5
P
PGM-FI SYSTEM··················································4-2
R
REAR BRAKE ···················································· 3-22
REAR SUSPENSION··········································· 3-18
REAR WHEEL···················································· 3-17
S
SIDESTAND ······················································ 3-10
SPARK PLUG REPLACEMENT ····························· 4-16
SPECIFICATIONS·················································1-6
SPEEDOMETER················································· 4-27
STEERING STEM ··············································· 3-16
T
TECHNICAL FEATURES······································ 1-23
THROTTLE BODY ················································2-8
TORQUE VALUE ················································ 1-11
TP SENSOR RESET PROCEDURE ·························2-9
V
VALVE CLEARANCE··········································· 2-14
INDEX

109. 1
N
2
3
4
5
(N)
R R/Bl Bu/W W Bu
ON
BAT1 HL LO HI
BAT2
OFF
LOCK
COLOR COLOR COLOR
PUSH
FREE
HO BAT
Bl/W Br/Y COLOR
PUSH
FREE
ST BAT
Y/R Bl/R COLOR
PUSH
FREE
BAT HI
Br Bu
IGNITION SWITCH
(N)
Gr Lb O
WR R L
COLOR
TURN SIGNAL SWITCH
DIMMER SWITCH
Br Br/W Bu/W
BAT TL HL
COLOR
LIGHTING SWITCH
HORN SWITCH STARTER SWITCH PASSING SWITCH
33P
(Bl)
1
2
3
5
6
7
8
9
10
11
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
-
12
PCP
TA
INJ
15
SCS
-
FI
IND
-
-
-
PCS
PCM
TO
-
BA
-
-
NLSW
K-LINE
SG2
SG3
-
IGP
LG
O2
THL
4
SG1
VCC
TACHO
FFP
PG1
PG2
IGPLS
2P
10A
10A
10A
10A
SPARE
FUSE
12V 6AH
F/P
TL
HL
BAT
ST
BAT
L
R
LO
HI
HO
BAT
BAT
HI
WR
HL
3P
4P
(R)
3P
6P
2P
FUEL
PUMP
IGN
INJ
HORN
TURN
METER
HEADLIGHT
TAIL
POSITION
MAIN FUSE
20A
2P
BAT1
BAT2
4P (Bl)
4P
9P
4P
6P
9P (Br)
9P (Bl)
3P
2P (Bl)
3P
2P
2P
2P
2P
2P
2P
3P
2P
5P
4P
(R)
VCC
SG
SG
TO
THL
6P
IN
OUT
Lg/Br
Lg/G
Lg/Y
Lg/Bl
Lg/P
Lg/R
Lg/Br
Lg/G
Lg/Y
Lg/Bl
P/Bl
Bl/R
Bl/R
P/G
Y/Bu
G/Y
G/O
Gr/Bu
Bl/R
P/Bu
W/Bl
Bl/R
G/Bl
Y/W
Bl/O
Bl/R
Bl
R
G
Y
G
G/Bl
G/Bl
G
G
G
G
G
Bl/W
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Y
Y
Y
Y
Y
Y
G
G
Bu/Y
Bu/Y
W/Y
Bu/Y
Bl/Bu
Bu
Bu
Lg/P
Lg/R
Lg/Br
Lg/G
Lg/Y
Lg/Bl
Lg/P
Lg/R
Br/Y
Gr
Lg/R
Lg/R
G/R
G/R
Y/R
R/W
R/W
G/R
G/R
R/Bl
Br/Y
Br/Y
Br
Br
Bl/R
R/W
R/Bl
Bl/R
R
R/Bl
Bl
Bl
W/R
G/Bu
Y/Bl
Bl/R
G/Bl
Bl/Bu
G/Bu
Y/Bl
W/R
Bl/Y
Bl/O
W/Bl
W/Y
Y/Bu
P/Bl
G/R
O/W
G/Y
G/O
G
G
P/Bu
Bu/Y
Gr/Bu
Bu/W
P/G
W/Bu
G
R/W
Y
Y
Y
Y
Y
Y
Bl
Bl
Bu/W
O/W
G/Bl
Bl/R
Br/Y
G/Y
Br/Y
G/Y
Lb
Lb
G
G/Y
G
Br
G/Y
G
Br
G/Y
G
Br/W
G
O
G
G
O
Lb
Br/W
G
Br/W
G
Br/W
G
G
O
Bu
Gr
Br/Y
Br
Bu/W
O
Lb
Bl/W
W
Bl
Bl
Bu
Gr
Br/Y
Br
Bu/W
O
Lb
Bl/W
W
G
G/R
O
Gr
Lb
Br/Y
Bl/W
Bu
W
Bu/W
Br
Bu
Bl
Bl
W
Bu
G
Br/W
W
Bu
G
Br/W
Lb
O
W
Bu
Br/W
Lb
O
W
Bu
Br/W
Lb
G
W
Bu
G
Br/W
G
G
Lb
O
O
G
G
O
Lg/R
G/Bl
G
Lg/Bl
Lg/Y
Lg/G
Lg/Br
Lg/P
Lg/R
G/Bl
G
Lg/Bl
Lg/Y
Lg/G
Lg/Br
Lg/P
Y/R
Bl/R
Bl
Bl
Bu/W
Br
Br/W
Bu/W
Br/W
Y/R
G/Y
Br
Br/Y
Bl/R
Bu/W
Br/W
Y/R
Bl
Br
Bl
Bl/R
Y/W
Bu
W/Bu
Br/Y
Br/W
Bl/Y
G
Y/W
Bu
W/Bu
Br/Y
Br/W
Bl/Y
G
Bl/Y
Br/Y
G
Y/W
Br/Y
G/Bl
Bl/Y
Bl
G
G
Bu
G
Lb
O
G
W/Bu
Br/Y
G
Br/W
G
Br/W
Lg/R
Br/Y
Br/Y
Lg/Bl
Br/Y
Lg/Y
Br/Y
Lg/G
Br/Y
Lg/Br
Br/Y
Lg/P
Bl Bl
GEAR POSITION
SWITCH
BANK
ANGLE
SENSOR
INJECTOR
EOT
SENSOR
IAT
SENSOR
ALTERNATOR
CKP
SENSOR
IGNITION
COIL
EVAP
PURGE
CONTROL
SOLENOID
VALVE
FUEL
LEVEL
SENSOR
FRAME GROUND
HORN
O2
SENSOR ENGINE
GROUND
RIGHT REAR TURN
SIGNAL LIGHT
12V10W
LEFT REAR TURN
SIGNAL LIGHT
12V10W
BRAKE/TAIL LIGHT
12V21W/5W
LICENSE LIGHT
12V5W
TURN
SIGNAL
SWITCH
HORN
SWITCH
DIMMER
SWITCH
PASSING
SWITCH
CLUTCH
SWITCH
POSITION LIGHT
12V5W
HEADLIGHT
12V35/35W
RIGHT FRONT TURN
SIGNAL LIGHT
12V10W
LEFT FRONT TURN
SIGNAL LIGHT
12V10W
HIGH BEAM
INDICATOR
12V1.7W
TACHO
METER
FUEL
METER
RIGHT TURN
SIGNAL
INDICATOR
12V3.4W
LEFT TURN
SIGNAL
INDICATOR
12V3.4W
MIL
12V3.4W
METER LIGHT
12V2.0W
METER LIGHT
12V3.4W
NEUTRAL
INDICATOR
12V3.4W
GEAR
POSITION
INDICATORS
1
2
3
4
5
SPEEDOMETER
LIGHTING
SWITCH
STARTER
SWITCH
FRONT
BRAKE
LIGHT
SWITCH
REGULATOR/
RECTIFIER
DIODE
ENGINE
GROUND
STARTER
MOTOR
FUSE BOX
IGNITION
SWITCH
BATTERY
TURN
SIGNAL
RELAY
TP
SENSOR
ECM
REAR
BRAKE
LIGHT
SWITCH
DLC
FUEL
PUMP
STARTER
RELAY
SWITCH
Bl BLACK
Y YELLOW
Bu BLUE
G GREEN
R RED
W WHITE
TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
Br BROWN
O ORANGE
Lb LIGHT BLUE
Lg LIGHT GREEN
P PINK
Gr GRAY
GLR125-F (1WH/2WH/4WH/5WH, CH)

110. © Honda Motor Co.,Ltd. 2014
Published by Honda Motor Co.,Ltd.
Printed in Japan
Book#: 82KPNY50
A. 2014.9