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?

YES – Replace the PCM with a known good one
(page 4-43), and recheck. If DTC 32-1 is
MO RIB

indicated again, perform the following

troubleshooting;
– DTC 21-1 (page 13-35)
– DTC 21-2 (page 13-36)
AL ST

– DTC 22-1 (page 13-37)

– DTC 23-1 (page 13-38)
– DTC 24-1 (page 13-39)
BR DI

NO – Intermittent failure
CA SU

DTC 33-2 (EEPROM) (After ’19 model)

• Before starting the inspection, check for loose or
poor contact on the PCM 33P connectors, and
24 O

recheck the DTC.

-20 BID

1. DTC Recheck
Erase the DTC (page 13-28).
Check the DTC with the MCS.
-07 HI

Is DTC 33-2 indicated?

YES – Replace the PCM with a known good one
28 O

(page 4-42), and recheck.

PR

NO – Intermittent failure.

13-42
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DTC 41-1 (SHIFT DRUM POSITION
SWITCH CIRCUIT)
1. Recheck DTC

S. O
Recheck the current DTC with the MCS.

L.
S AD
Is DTC 41-1 indicated?
YES – GO TO STEP 2.

R.
NO – Intermittent failure.

OR RIZ
2. Shift Drum Position Switch Inspection at PCM
Connector
Check the shift drum position switch for short circuit

OT TO
at the PCM 33P (Black) connector (page 13-72).
Are the test results normal?

LM U
YES – GO TO STEP 4.

RA O A
NO – GO TO STEP 3.
3. Shift Drum Position Switch Inspection at Switch
Connector

AB N
Check the shift drum position switch for short circuit
at the shift drum position switch 10P (Gray)

-C O
connector (page 13-72).
Are the test results normal?

L. US
YES – • Short circuit in the Gray wire
• Short circuit in the Light green/red wire
• Short circuit in the White/green wire
S. N O
• Short circuit in the Blue/black wire
• Short circuit in the Yellow wire
• Short circuit in the Blue/red wire
• Short circuit in the Blue/white wire
R.
RS IÓ

• Short circuit in the Blue/green wire

• Short circuit in the Blue wire
• Short circuit in the Light blue wire
TO UC

NO – Faulty shift drum position switch

4. Recheck DTC
MO RIB

Connect the PCM 33P (Black) connector and shift

drum position switch 10P (Gray) connector.
Erase the DTC (page 13-28).
Recheck the DTC with the MCS.
AL ST

Is DTC 41-1 indicated?

YES – Replace the PCM with a new one and
BR DI

recheck.
NO – Intermittent failure
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-43
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DTC 42-1 (GEARSHIFT SWITCH
CIRCUIT)
• Before starting the troubleshooting, check the
handlebar switch 14P (Green) connector for loose

S. O
contacts or corroded terminals, and recheck the

L.
S AD
DTC.
1. Shift Switch Status Inspection

R.
Check the shift switch status and voltage in the Data

OR RIZ
List Menu of MCS as follows:
'14 – '19 models: UP DOWN
"Up" ON 3.64 – 4.08 V 1.76 – 2.09 V

OT TO
"Down" ON 1.76 – 2.09 V 3.64 – 4.08 V
Both ON 4.0 – 4.99 V 4.0 – 4.99 V
Both OFF 0 – 0.99 V 0 – 0.99 V

LM U
After ’19 model: UP DOWN

RA O A
"Up" ON 2.78 – 4.10 V 0.70 – 2.25 V
"Down" ON 0.70 – 2.25 V 2.78 – 4.10 V
Both ON 3.17 – 4.33 V 3.17 – 4.33 V
Both OFF 0 – 0.41 V 0 – 0.41 V

AB N
Is the shift switch status normal?

-C O
YES – Intermittent failure

L. US
NO – GO TO STEP 2.
2. Shift Switch Inspection at PCM connector
Turn the ignition switch OFF.
S. N O
Disconnect the PCM 33P connectors (page 4-42). [1] A6
Check for continuity between the wire harness side B3
33P (Black) connector [1] and (Gray) connector [2]
terminals while pushing each switch.
R.
RS IÓ

TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
TO UC

Connection:
With the upshift switch pushed:
MO RIB

A6 – B3
With the downshift switch pushed:
A16 – B3
A16 [2]
AL ST

Is there continuity?
YES – GO TO STEP 4.
BR DI

NO – GO TO STEP 3.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-44
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

3. Gearshift Switch Inspection at Handlebar Switch
Connector
Remove the left handlebar switch 14P (Green)
connector from the frame and disconnect it (page W/Bu

S. O
23-11). W/Y
Check for continuity between the switch side 14P

L.
S AD
(Green) connector [1] terminals while pushing each
switch.

R.
Connection:

OR RIZ
With the upshift switch pushed [1]
Brown/white – White/blue
With the downshift switch pushed

OT TO
Brown/white – White/yellow
Is there continuity? Br/W

LM U
YES – Open circuit in the following wire between
the PCM and handlebar switch

RA O A
connectors:
• Brown/white wire
• White/blue wire
• White/yellow wire

AB N
NO – Faulty gearshift switch (Replace the
handlebar switch.)

-C O
4. Recheck DTC

L. US
Connect the PCM 33P (Black) connector and
handlebar switch 14P (Green) connector.
Recheck the current DTC with the MCS.
S. N O
Is DTC 42-1 indicated?
YES – Replace the PCM with a known good one
(page 4-43), and recheck.
R.
RS IÓ

NO – Intermittent failure
TO UC

DTC 44-1 (EOT SENSOR LOW

VOLTAGE)
1. EOT Sensor System Inspection
MO RIB

Check the EOT sensor with the MCS.

Is about 0 V indicated?
AL ST

YES – GO TO STEP 2.
NO – Intermittent failure
BR DI

2. EOT Sensor Inspection

Turn the ignition switch OFF.
Disconnect the EOT sensor 2P (Black) connector
CA SU

(page 13-76).
Turn the ignition switch ON.
Check the EOT sensor with the MCS.
24 O

Is about 0 V indicated?
-20 BID

YES – GO TO STEP 4.
NO – GO TO STEP 3.
-07 HI
28 O
PR

13-45
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

3. EOT Sensor Resistance Inspection
Turn the ignition switch OFF.
[1]
Measure the resistance between the sensor side 2P
connector [1] terminals.

S. O
Standard: 2.3 – 2.6 kΩ (20°C/68°F)

L.
S AD
Is the resistance within standard value?

R.
YES – Replace the PCM with a known good one
(page 4-43), and recheck.

OR RIZ
NO – Faulty EOT sensor

OT TO
LM U
4. EOT Sensor Short Circuit Inspection

RA O A
Disconnect the PCM 33P (Gray) connector (page 4-
[1]
42).
Check for continuity between the wire harness side
2P (Black) connector [1] terminal and ground.

AB N
Connection: Blue/yellow – Ground

-C O
Is there continuity?
YES – Short circuit in the Blue/yellow wire

L. US
NO – Replace the PCM with a known good one
(page 4-43), and recheck.
S. N O
Bu/Y

DTC 44-2 (EOT SENSOR HIGH

R.
RS IÓ

VOLTAGE)
TO UC

• Before starting the troubleshooting, check the EOT

switch 2P (Black) connector for loose contacts or
corroded terminals, and recheck the DTC.
MO RIB

1. EOT Sensor System Inspection

Check the EOT sensor with the MCS.
Is about 5 V indicated?
AL ST

YES – GO TO STEP 2.
NO – Intermittent failure
BR DI

2. EOT Sensor Inspection

Turn the ignition switch OFF.
[1]
CA SU

Disconnect the EOT sensor 2P (Black) connector

(page 13-76).
Connect the wire harness side 2P connector [1]
terminals with a jumper wire [2].
24 O

Connection: Blue/yellow – Green/white

-20 BID

Turn the ignition switch ON.

Check the EOT sensor with the MCS.
Is about 0 V indicated?
Bu/Y G/W
-07 HI

YES – Faulty EOT sensor

NO – GO TO STEP 3.
28 O

[2]
PR

13-46
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

3. EOT Sensor Line Open Circuit Inspection
Turn the ignition switch OFF.
[2] [1]
Remove the jumper wire.
Disconnect the PCM 33P (Gray) connector Bu/Y

S. O
(page 4-42).
Check for continuity between the wire harness side

L.
S AD
2P (Black) connector [1] and 33P (Gray) connector
[2] terminals, and between the 2P connector

R.
terminal and ground.

OR RIZ
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110

Connection: B28 – Blue/yellow

OT TO
G/W
Green/white – ground B28

Is there continuity?

LM U
YES – Replace the PCM with a known good one

RA O A
(page 4-43), and recheck.
NO – • Open circuit in the Blue/yellow wire
• Open circuit in the Green/white wire

AB N
DTC 51-1 (TR SENSOR LOW

-C O
VOLTAGE) (After '19 model)

L. US
• Before starting the inspection, check for loose or
poor contact on the sensor harness 8P (Black), PCM
33P (Black) and 33P (Gray) connectors, and
S. N O
recheck the DTC.
1. TR sensor System Inspection
Check the TR sensor with the MCS.
R.
RS IÓ

Is about 0 V indicated?
YES – GO TO STEP 2.
TO UC

NO – Intermittent failure
2. TR sensor Input Voltage Inspection
MO RIB

Turn the ignition switch OFF. [1]

Disconnect the sensor harness 8P (Black)
connector (page 13-74).
AL ST

Turn the ignition switch ON.

Measure the voltage at the wire harness side 8P
(Black) connector [1] terminals.
BR DI

Connection: Brown/white (+) – Green/white (–)

G/W Br/W
Is the voltage within 4.75 – 5.25 V?
CA SU

YES – GO TO STEP 5.
NO – GO TO STEP 3.
24 O
-20 BID
-07 HI
28 O
PR

13-47
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

3. TR Sensor Input Line Open Circuit Inspection
Turn the ignition switch OFF.
[1] [2]
Disconnect the PCM 33P (Gray) connector (page 4-
42).

S. O
Check for continuity between the wire harness side
8P (Black) connector [1] and 33P (Gray) connector

L.
S AD
Br/W B3
[2] terminals.

R.
TOOL:
Test probe, 2 packs 07ZAJ-RDJA110

OR RIZ
Connection: Brown/white – B3
Is there continuity?

OT TO
YES – GO TO STEP 4.
NO – Open circuit in the Brown/white wire

LM U
4. TR Sensor Ground Line Open Circuit Inspection

RA O A
Check for continuity between the wire harness side
[1]
8P (Black) connector [1] and 33P (Gray) connector
[2] terminals.
TOOL:

AB N
Test probe, 2 packs 07ZAJ-RDJA110 G/W B2

-C O
Connection: Green/white – B2

L. US
Is there continuity?
YES – Replace the PCM with a known good one
(page 4-42) and recheck.
S. N O
NO – Open circuit in the Green/white wire
[2]
R.
5. TR Sensor Signal Line Open Circuit Inspection
RS IÓ

Turn the ignition switch OFF.

[1]
Disconnect the PCM 33P (Black) connector (page
TO UC

4-42).
Check for continuity between the wire harness side
8P (Black) connector [1] and 33P (Black) connector Bu A26
MO RIB

[2] terminals.
TOOL:
Test probe, 2 packs 07ZAJ-RDJA110
AL ST

Connection: Blue – A26

Is there continuity?
BR DI

YES – GO TO STEP 6.
NO – Open circuit in the Blue wire [2]
CA SU

6. TR Sensor Output Line Short Circuit Inspection

Check for continuity between the wire harness side
[1]
8P (Black) connector [1] terminal and ground.
24 O

Connection: Blue – Ground

-20 BID

Is there continuity?
YES – Short circuit in the Blue wire Bu
-07 HI

NO – GO TO STEP 7.
28 O
PR

13-48
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

7. TR Sensor Inspection
Replace the TR sensor with a known good one
(page 13-74).
Connect the 8P (Black) connector, 33P (Black)

S. O
connector and 33P (Gray) connector.
Check the TR sensor with the MCS.

L.
S AD
Is about 0 V indicated?

R.
YES – Replace the PCM with a known good one

OR RIZ
(page 4-42) and recheck.
NO – Faulty original TR sensor

OT TO
DTC 51-2 (TR SENSOR HIGH
VOLTAGE) (After '19 model)

LM U
1. TR Sensor System Inspection

RA O A
Check the TR sensor with the MCS.
Is about 5 V indicated?
YES – GO TO STEP 2.

AB N
NO – Intermittent failure
2. TR Sensor Inspection

-C O
Replace the TR sensor with a known good one

L. US
(page 13-74).
Turn the ignition switch ON.
Check the TR sensor with the MCS.
S. N O
Is about 5 V indicated?
YES – Replace the PCM with a known good one
(page 4-42) and recheck.
NO – Faulty original TR sensor
R.
RS IÓ
TO UC

DTC 52-1
(NEUTRAL SWITCH STUCK OFF)
(After '19 model)
MO RIB

• Before starting the inspection, check for loose or

poor contact on the neutral switch 1P connectors
AL ST

and PCM 33P (Black) connector, and recheck the

DTC.
1. DTC Recheck
BR DI

Recheck the DTC with the MCS.

Is DTC 52-1 indicated?
CA SU

YES – GO TO STEP 2.
NO – Intermittent failure
24 O
-20 BID
-07 HI
28 O
PR

13-49
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

2. Neutral Switch Line Open Circuit Inspection
Turn the ignition switch OFF.
[1] [2]
Disconnect the PCM 33P (Black) connector (page
4-42).

S. O
Disconnect the neutral switch 1P connector (page
13-75).

L.
S AD
Check for continuity between the wire harness side
33P (Black) connector [1] and neutral switch 1P

R.
connector [2] terminals.

OR RIZ
Connection: A17 – Light green A17 Lg

TOOL:
Test probe, 2 packs 07ZAJ-RDJA110

OT TO
Is there continuity?
YES – GO TO STEP 3.

LM U
NO – Open circuit in the Light green wire

RA O A
3. Neutral Switch Inspection
Replace the neutral switch with a known good one
(page 13-75).

AB N
Connect the PCM 33P (Black) connector.
Turn the ignition switch ON.

-C O
Recheck the DTC with the MCS.
Is DTC 52-1 indicated?

L. US
YES – Replace the PCM with a known good one
(page 4-42) and recheck.
S. N O
NO – Faulty original neutral switch

DTC 52-2
(NEUTRAL SWITCH STUCK ON)
R.
RS IÓ

(After '19 model)

TO UC

1. Neutral Switch Line Short Circuit Inspection

Disconnect the neutral switch 1P connector (page
13-75).
MO RIB

Check for continuity between the neutral switch 1P

connector and ground.
Connection: Light green – Ground
AL ST

Is there continuity?
YES – Short circuit in the Light green wire
BR DI

NO – GO TO STEP 2.
2. Neutral Switch Inspection
CA SU

Replace the neutral switch with a known good one

(page 13-75).
Check the DTC with the MCS.
Is DTC 52-2 indicated?
24 O

YES – Replace the PCM with a known good one

-20 BID

(page 4-42) and recheck.

NO – Faulty original neutral switch
-07 HI

DTC 57-1 (GEARSHIFT MECHANISM

MALFUNCTION)
28 O

(After '19 model)

PR

Refer to DTC 27-1 (page 13-40).

13-50
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DTC 57-2 (GEAR POSITION
MALFUNCTION) (JUMP OUT OF
GEAR)
(After '19 model)

S. O
Refer to DTC 27-1 (page 13-40).

L.
S AD
R.
DTC 66-1 (REAR VS SENSOR NO

OR RIZ
SIGNAL)
• Before starting the troubleshooting, check the rear
VS sensor 3P (Black) connector and engine sub-

OT TO
wire harness 6P (Black) connector for loose or poor
contacts, and recheck the DTC.
1. Rear VS Sensor System Check

LM U
Erase the DTC (page 13-28).

RA O A
Test-drive the vehicle and stop the engine.
Check the rear VS sensor signal with the MCS.
Is the VS sensor signal indicated normally?
YES – Intermittent failure.

AB N
NO – GO TO STEP 2.

-C O
2. Rear VS Sensor Power Input Voltage Inspection

L. US
Turn the ignition switch OFF.
[1]
Disconnect the rear VS sensor 3P (Black) connector
(page 13-77).
Turn the ignition switch ON.
S. N O
Measure the voltage between the wire harness side
3P (Black) connector [1] terminal and ground.
Connection: Black/white (+) – ground (–)
R.
RS IÓ

Is the voltage more than 10 V?

YES – GO TO STEP 4. Bl/W (+)
TO UC

NO – GO TO STEP 3.
(–)
MO RIB

3. Rear VS Sensor Power Input Line Open Circuit

Inspection
AL ST

Turn the ignition switch OFF.

[1] [2]
Disconnect the PCM 33P (Black) connector (page
4-42). A5
BR DI

Check for continuity between the wire harness side

33P (Black) connector [1] and 3P (Black) connector
[2] terminals
CA SU

TOOL:
Test probe, 2 pack 07ZAJ-RDJA110

Connection: A5 – Black/white
24 O

Is there continuity?
-20 BID

YES – Replace the PCM with a known good one Bl/W

(page 4-43), and recheck.
NO – Open circuit in the Black/red or Black/white
-07 HI

wire
28 O
PR

13-51
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

4. Rear VS Sensor Ground Line Inspection
Measure the voltage between the wire harness side
[1]
3P (Black) connector [1] terminals.
Connection: Black/white (+) – Green (–)

S. O
Is there battery voltage?

L.
S AD
YES – GO TO STEP 5.

R.
NO – Open circuit in the Green wire

OR RIZ
Bl/W (+) G (–)

OT TO
LM U
5. Rear VS Sensor Output Line Inspection

RA O A
Measure the voltage between the wire harness side
[1]
3P (Black) connector [1] terminals.
Connection: Pink (+) – Green (–)

AB N
Is the voltage about 5 V?
YES – GO TO STEP 6.

-C O
NO – Open or short circuit in the Pink or Pink/ G (–)

L. US
P (+)
green wire.
S. N O
R.
6. Rear VS Sensor Inspection
RS IÓ

Turn the ignition switch OFF.

Replace the rear VS sensor with a new one (page
TO UC

13-77).
Erase the DTC (page 13-28).
Test-drive the vehicle and stop the engine.
MO RIB

Check the current DTC with the MCS.

Is DTC 66-1 indicated?
YES – Replace the PCM with a known good one
AL ST

(page 4-43), and recheck.

NO – Faulty original rear VS sensor
BR DI

DTC 67-1 (FRONT VS SENSOR NO

CA SU

SIGNAL)
• Before starting the troubleshooting, check the front
VS sensor 3P (Black) connector for loose or poor
contacts, and recheck the DTC.
24 O

1. Front VS Sensor System Check

-20 BID

Erase the DTC (page 13-28).

Test-drive the vehicle and stop the engine.
Check the front VS sensor signal with the MCS.
-07 HI

Is the VS sensor signal indicated normally?

YES – Intermittent failure.
28 O

NO – GO TO STEP 2.
PR

13-52
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

2. Front VS Sensor Power Input Voltage Inspection
Turn the ignition switch OFF.
[1]
Disconnect the front VS sensor 3P (Black)
connector (page 13-77).

S. O
Turn the ignition switch ON.
Measure the voltage between the wire harness side

L.
S AD
3P (Black) connector [1] terminal and ground.

R.
Connection: Black/red (+) – ground (–)

OR RIZ
Is the voltage more than 10 V?
YES – GO TO STEP 4. Bl/R (+)
NO – GO TO STEP 3.

OT TO
(–)

LM U
3. Front VS Sensor Power Input Line Open Circuit

RA O A
Inspection
Turn the ignition switch OFF.
[1] [2]
Disconnect the PCM 33P (Black) connector (page
4-42).

AB N
A5
Check for continuity between the wire harness side
33P (Black) connector [1] and 3P (Black) connector

-C O
[2] terminals
TOOL:

L. US
Test probe, 2 pack 07ZAJ-RDJA110

Connection: A5 – Black/red
S. N O
Is there continuity?
Bl/R
YES – Replace the PCM with a known good one
(page 4-43), and recheck.
R.
RS IÓ

NO – Open circuit in the Black/red wire

4. Front VS Sensor Ground Line Inspection
TO UC

Measure the voltage between the wire harness side

[1]
3P (Black) connector [1] terminals.
Connection: Black/red (+) – Green (–)
MO RIB

Is there battery voltage?

YES – GO TO STEP 5.
AL ST

NO – Open circuit in the Green wire Bl/R (+) G (–)

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

13-53
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

5. Front VS Sensor Output Line Inspection
Measure the voltage between the wire harness side
[1]
3P (Black) connector [1] terminals.
Connection: Black/yellow (+) – Green (–)

S. O
Is the voltage about 5 V?

L.
S AD
YES – GO TO STEP 6.

R.
NO – Open or short circuit in the Black/yellow
Bl/Y (+) G (–)

OR RIZ
wire

OT TO
LM U
6. Front VS Sensor Inspection

RA O A
Turn the ignition switch OFF.
Replace the front VS sensor with a new one (page
13-77).
Erase the DTC (page 13-28).

AB N
Test-drive the vehicle and stop the engine.
Check the current DTC with the MCS.

-C O
Is DTC 67-1 indicated?

L. US
YES – Replace the PCM with a known good one
(page 4-43), and recheck.
NO – Faulty original front VS sensor
S. N O
FRONT CRANKCASE COVER/SPACER
REMOVAL
R.
RS IÓ

Remove the following:

[2] [3]
TO UC

– engine (page 16-4)

– shift valve body (page 13-79)
– shift control motor/reduction gears (page 13-69)
MO RIB

Loosen the bolt [1] of the front crankcase cover spacer.

Do not allow dust or Remove the following:
dirt to enter the oil
– sixteen bolts [2]
AL ST

passages.
– front crankcase cover [3]
BR DI

[1]
CA SU
24 O
-20 BID

[2]
-07 HI
28 O
PR

13-54
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

– O-ring [1]
[2]/[3] [1] [6]
– oil orifice [2] and O-rings [3]
– joint collar [4] and O-rings [5]
– two dowel pins [6]

S. O
– washer [7]

L.
S AD
R.
OR RIZ
OT TO
[4]/[5] [7]

– dipstick [1]

LM U
[3] [1]
– bolt [2]
– front crankcase cover spacer [3]

RA O A
AB N
-C O
L. US [2]
S. N O
– two dowel pins [1]
[3]/[4] [2]
– O-ring [2]
– joint collar [3] and O-ring [4]
R.
– gasket [5]
RS IÓ
TO UC
MO RIB
AL ST

[1] [5]

– O-ring [1]
BR DI

[2]
– output shaft oil seal [2]
CA SU
24 O
-20 BID
-07 HI

[1]
28 O
PR

13-55
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

– setting cap [1] and O-ring [2]
[1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]
Do not allow the – feed pipe A [1]
[2]

LM U
dust or dirt to enter – setting collar [2] and O-rings [3]
the oil pipe.

RA O A
[1]

AB N
-C O
L. US [3]
S. N O
Do not allow the – feed pipe B [1] and O-ring [2]
[1]
dust or dirt to enter
the oil pipe.
R.
RS IÓ
TO UC
MO RIB
AL ST

[2]

– gearshift spindle oil seal [1]

BR DI

[1]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-56
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

FRONT CRANKCASE COVER
CLEANING/INSPECTION
Remove the oil filter (page 3-21).

S. O
Remove the setting bolt [1], sealing washer [2], spring
and orifice relief valve.

L.
S AD
Wash the crankcase cover with solvent and blow

R.
through the oil passages and orifices with compressed
air to clean them thoroughly. [2]

OR RIZ
OT TO
LM U
[1]

RA O A
Check the orifice relief valve [1] for wear or damage.
Check the spring [2] for fatigue or damage.
Clean the orifice relief valve thoroughly.
Install the orifice relief valve, spring, new sealing

AB N
washer [3] and setting bolt [4] and tighten it.
[2]

-C O
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
Install the oil filter (page 3-21).

L. US
[4]

[1]
S. N O
[3]

Remove the oil strainer [1].

R.
RS IÓ

[1]
Wash the strainer thoroughly in non-flammable or high
flash point solvent until all accumulated dirt has been
TO UC

removed.
Blow dry it with compressed air to clean completely.
Before installing the strainer, the screen mesh should
MO RIB

be examined closely for damage.

Install the oil strainer with the wedge facing the front
side.
Check the feed pipe A and B for abnormal wear or
AL ST

The feed pipes are

used to supply the damage.
engine oil to the
Check the crankshaft and mainshaft bearings for wear
BR DI

dual clutch.
or damage.
CA SU

BEARING REPLACEMENT
CRANKSHAFT BEARING
Remove the bearing [1] with the special tools.
24 O

[1]
TOOLS:
-20 BID

Bearing remover shaft 07936-KC10100

Bearing remover head,
15 mm [2] 07936-KC10200
-07 HI

Remover weight 07741-0010201

U.S.A. TOOLS:
28 O

Bearing remover, 15 mm 07936-KC10500

PR

Remover weight 07936-371020A

[2]

13-57
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Apply engine oil to a new bearing.
[1]
Drive a new bearing squarely with the sealed side
facing down until it is fully seated.
TOOLS:

S. O
Driver [1] 07749-0010000
Attachment, 32 x 35 mm [2] 07746-0010100

L.
S AD
Pilot, 15 mm [3] 07746-0040300

R.
OR RIZ
OT TO
[3] [2]

MAINSHAFT BEARING

LM U
Remove the snap ring [1] and washer [2], and the
[3] [2]

RA O A
bearing [3].
Apply engine oil to a new bearing.
Install the bearing until it is seated.

AB N
Install the washer and snap ring into the cover groove
properly.

-C O
L. US
S. N O
[1]

INSTALLATION
R.
Coat a new O-ring [1] with engine oil and install it onto
RS IÓ

the joint pipe.

TO UC
MO RIB
AL ST
BR DI

[1]

Install the two dowel pins [1] and oil joint pin [2].
CA SU

[2] [3]
Coat new O-rings [3] with the engine oil, and install
them into the front crankcase groove and onto the oil
joint pin.
24 O

Install a new gasket [4].

-20 BID
-07 HI
28 O

[1] [4]
PR

13-58
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Install the front crankcase cover spacer [1] by aligning
the oil pump shaft [2] end with the balancer shaft [3] [3]
groove.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1] [2]

Loosely install the bolt [1].

LM U
[3]
Be careful not to Apply engine oil to a new output shaft oil seal [2] lip and

RA O A
damage the oil seal install it into the crankcase cover spacer until it is fully
lips. seated.
Make sure that the oil seal is installed properly.
Install the dipstick [3].

AB N
Install the centrifugal clutch (page 13-66).

-C O
L. US [2] [1]
S. N O
Apply engine oil to the lips of new gearshift spindle oil
[1]
seal [1] and install it into the front crankcase cover.
R.
RS IÓ
TO UC
MO RIB
AL ST

Coat new O-rings [1] with the engine oil.

BR DI

[2] [1]
Install the O-ring into the groove of the spacer.
Install the O-rings onto the oil orifice [2] and install them
CA SU

into the hole of the spacer.

24 O
-20 BID
-07 HI

[1]
28 O
PR

13-59
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Coat new O-rings [1] with the engine oil and install the
[2]
O-rings onto the joint collar [2].
Install the joint collar into the hole of the spacer.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

Install the washer [1] and two dowel pins [2].

LM U
[2]

RA O A
AB N
-C O
L. US [1]
S. N O
Apply liquid sealant (TB1215 or equivalent) to the
mating surface (shadowed area) of the front crankcase
cover as shown.
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI

Be careful not to Install the front crankcase cover, aligning the water
[1]
damage the oil seal pump shaft [1] end with the pin of the camshaft.
CA SU

lips.
24 O
-20 BID
-07 HI

Align
28 O
PR

13-60
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Install the sixteen bolts [1].
[1]
Tighten the sixteen bolts and spacer bolt [2] in a
crisscross pattern in several steps.

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

LM U
RA O A
AB N
[1]

-C O
L. US
S. N O
Coat a new O-ring [1] with engine oil and install it onto
[2]
the flange of the feed pipe B [2].
Align the flange tabs Carefully insert the pipe B into the crankcase cover.
R.
RS IÓ

with the grooves in

the cover.
TO UC
MO RIB
AL ST

Align
[1]

Coat new O-rings [1] with engine oil and install them
BR DI

[2] Align
into the setting collar [2] grooves.
Install the setting collar until it is seated.
CA SU

Align the flange tabs Carefully insert the pipe A [3] into the setting collar.
with the grooves in
the collar.
24 O
-20 BID
-07 HI

[1] [3]
28 O
PR

13-61
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Coat a new O-ring [1] with engine oil and install it into
[2]
the setting cap [2] groove.
Install the setting cap and tighten it.

S. O
TORQUE: 21 N·m (2.1 kgf·m, 15 lbf·ft)
Install the following:

L.
S AD
– shift control motor/reduction gears (page 13-70)

R.
– shift valve body (page 13-79)

OR RIZ
– engine (page 16-10)

OT TO
[1]

CENTRIFUGAL CLUTCH

LM U
REMOVAL

RA O A
Remove the front crankcase cover (page 13-54).
Unstake [1]
Be careful not to Unstake the clutch lock nut [1].

AB N
damage the
crankshaft threads.

-C O
L. US
S. N O
R.
RS IÓ

Hold the clutch drive plate using the special tool and
[1]
loosen the lock nut.
TO UC

TOOL:
Clutch holder set [1] 07ZMB-HN20001
– holder plate 07ZMB-HN20101
MO RIB

– holder pin 07ZMB-HN20200

U.S.A. TOOL:
AL ST

Clutch holder 07ZMB-HN2A101

Remove the lock nut and washer.
BR DI
CA SU

Remove the centrifugal clutch assembly [1] using the

[1]
special tool.

TOOL:
24 O

Clutch puller, 35 x 1.0 mm [2] 07933-HA80000 or

07933-HB3000A
-20 BID

(U.S.A. only)
-07 HI
28 O
PR

[2]

13-62
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Remove the primary drive gear [1] and washer [2].
[1] [2]

S. O
L.
S AD
R.
OR RIZ
OT TO
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

[3] [1]
compressing the clutch spring.
R.
RS IÓ

Remove the following:

– outer plate [2]
TO UC

– clutch spring [3]

– inner plate [4]
MO RIB
AL ST

[4] [2]
BR DI

Remove the clutch weights [1] and springs [2] from the
[1]
drive plate.
CA SU
24 O
-20 BID
-07 HI
28 O

[2]
PR

13-63
 dummyhead

DUAL CLUTCH TRANSMISSION (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 DUAL CLUTCH
TRANSMISSION SPECIFICATIONS (page 1-13).
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
CLUTCH WEIGHTS DRIVE PLATE

AB N
WEIGHT SPRINGS

-C O
CLUTCH SPRING

OUTER PLATE
L. US
S. N O
R.
RS IÓ

CLUTCH DRUM
TO UC
MO RIB

INNER PLATE
AL ST
BR DI

E-CLIPS
CA SU

SPRAG CLUTCH

Install with the Install the clutch weights [1] and springs [2] onto the
24 O

[1]
spring’s open ends drive plate as shown.
facing in.
-20 BID
-07 HI
28 O
PR

[2]

13-64
dummyhead

DUAL CLUTCH TRANSMISSION (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 [2] facing up.

LM U
[1]
Be careful not to Install the E-clips [3] into the spindle grooves with its

RA O A
damage the clutch gap facing towards the pin by using the pliers while
weights while compressing the clutch spring.
compressing.

AB N
-C O
L. US [2] [3]
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

13-65
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

INSTALLATION
Apply engine oil to the primary drive gear sliding
[3] [2]
surface [1].

S. O
Install the washer [2] and primary drive gear [3] onto the
crankshaft.

L.
S AD
R.
OR RIZ
OT TO
[1]

LM U
Set the centrifugal clutch assembly [1] onto the
[1]

RA O A
crankshaft by aligning the splines of the drive plate and
crankshaft, and the splines of the clutch drum and
primary drive gear.
Be careful not to Tap the drive plate to seat the clutch assembly.

AB N
damage the
crankshaft threads.
TOOL:

-C O
Driver, 22 mm I.D. [2] 07746-0020100

L. US
S. N O
[2]

Apply engine oil to the threads and seating surface of a

[1]
new lock nut.
R.
RS IÓ

Install the washer [1] and lock nut [2].

TO UC
MO RIB
AL ST

[2]
BR DI

Hold the drive plate of the centrifugal clutch assembly

[1]
with the special tool and tighten the lock nut.
CA SU

TOOL:
Clutch holder set 07ZMB-HN20001
– holder plate 07ZMB-HN20101
24 O

– holder pin 07ZMB-HN20200

-20 BID

U.S.A. TOOL:
Clutch holder 07ZMB-HN2A101

TORQUE: 118 N·m (12.0 kgf·m, 87 lbf·ft)

-07 HI
28 O
PR

13-66
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Be careful not to Stake the lock nut into the crankshaft groove.
Stake
damage the
Install the front crankcase cover (page 13-58).
crankshaft threads.

S. O
L.
S AD
R.
OR RIZ
OT TO
SHIFT SOLENOID VALVE

LM U
REPLACEMENT

RA O A
Remove the tank cover assembly (page 2-4).
[2] [1]
Clean around the shift solenoid valve [1] with
compressed air to remove dust, dirt and foreign

AB N
material.
Disconnect the 2P (Brown) connector [2].

-C O
Remove the bolt [3] and shift solenoid valve from the
valve body by pulling it.

L. US
S. N O
[3]
R.
RS IÓ

Apply engine oil to the O-rings [1] of a new shift

[2] [1]
solenoid valve [2].
TO UC

Install the solenoid valve into the valve body and tighten
the bolt.
Connect the 2P (Brown) connector.
MO RIB

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

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

13-67
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SHIFT SPINDLE ANGLE SENSOR
REMOVAL/INSTALLATION
Remove the right center mudguard (page 2-5).

S. O
[3]
Remove the engine guard (page 2-8).
[1]

L.
S AD
After '19 model Remove the bolts [1], sensor cover [2], and collars [3].
only:

R.
OR RIZ
OT TO
LM U
[2]

RA O A
[3]

AB N
[2]

-C O
L. US
S. N O
[1]
R.
RS IÓ

Disconnect the 3P (Gray) connector [1] from the shift

'14 – '19 models shown: [3]
spindle angle sensor.
TO UC

Remove the two socket bolts [2] and shift spindle angle
sensor [3] from the rear crankcase cover. [1]
Coat a new O-ring [4] with engine oil and install it into
MO RIB

the shift spindle angle sensor groove.

Install the shift spindle angle sensor by aligning the flat
surface of the sensor hole and gearshift spindle [5] end.
AL ST

Apply locking agent to the socket bolt threads.

Install the socket bolts and tighten them.
TORQUE: 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
BR DI

Install the removed part in the reverse order of removal. [2]

CA SU

'14 – '19 models shown: [5]

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

[4] Align

13-68
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SHIFT CONTROL MOTOR/REDUCTION
GEARS
REMOVAL

S. O
Remove the right center mudguard (page 2-5).

L.
S AD
[1] [2]
Disconnect the 2P (Black) connector [1] from the shift

R.
control motor.

OR RIZ
Remove the three bolts [2], wire clip stay and shift
control motor [3].
Remove the O-ring [4] from the shift control motor.

OT TO
[4]

LM U
RA O A
[3]

Remove the two bolts [1] and reduction gear cover [2].
[2]

AB N
Remove the oil seal [3] from the gear cover.

-C O
L. US
S. N O
R.
RS IÓ

[1] [3]

Remove the two dowel pins [1].

TO UC

[3] [2]
Remove the spindle gear [2] and reduction gears [3].
Remove any grease from the gears, gear cover and
MO RIB

front crankcase cover.

AL ST
BR DI
CA SU

[1]
24 O
-20 BID
-07 HI
28 O
PR

13-69
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

INSTALLATION

O-RING

S. O
SHIFT CONTROL MOTOR REDUCTION GEARS

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

AB N
DOWEL PINS

-C O
L. US
SPINDLE GEAR
S. N O
OIL SEAL REDUCTION
GEAR COVER
R.
RS IÓ

Clean the mating surfaces of the reduction gear cover

[1] [2]
and front crankcase cover thoroughly.
TO UC

Apply 2 – 4 g (0.07 – 0.14 oz) of specified grease to the

reduction gear [1] journals and gear teeth.
SPECIFIED GREASE: UNIREX N3 grease (EXXON)
MO RIB

Install the reduction gears into the front crankcase

cover.
Install the spindle gear [2] onto the gearshift spindle by
AL ST

aligning the punch mark with the wide tooth.

BR DI

Specified grease Align

CA SU

Install the two dowel pins [1].

24 O
-20 BID
-07 HI
28 O
PR

[1]

13-70
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Apply grease to a new oil seal [1] lip and install it into
[2]
the reduction gear cover [2].
Apply sealant to the mating surface of the reduction
gear cover.

S. O
Install the cover with the two bolts [3].

L.
S AD
R.
OR RIZ
OT TO
[3] [1]

Coat a new O-ring [1] with engine oil and install it into

LM U
[1]
the control motor groove.
Install the shift control motor [2] onto the front

RA O A
crankcase cover.

AB N
-C O
L. US [2]
S. N O
Install the wire clip stay [1] and three bolts [2].
[3] [2]
Tighten the five bolts in a crisscross pattern in two or
three steps.
R.
RS IÓ

Connect the 2P (Black) connector [3] to the shift control

motor [4].
TO UC

Install the right center mudguard (page 2-5).

MO RIB
AL ST

[1] [4]
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-71
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SHIFT DRUM POSITION SWITCH ('14 –
'19 models)
SYSTEM INSPECTION

S. O
Turn the ignition switch OFF and disconnect the PCM

L.
S AD
[1] 34 (A2) N2 (A1)
33P (Black) connector (page 4-42).
N (A17) 54 (A13)

R.
Check for continuity between wire harness side 33P
(Black) connector [1] terminals and ground.

OR RIZ
There should be continuity only at the terminal that
corresponds to the shift drum position (open circuit
inspection).

OT TO
There should be no continuity at the other terminals
(short circuit inspection).
You must test at ten terminals in each shift drum

LM U
position. 5N (A12)

RA O A
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110 3N (A29) N4 (A24)
32 (A26)
Shift drum position Connector terminal 12 (A27) 5R (A25)

AB N
5R (5th/Reverse) A25
N (Neutral) A17

-C O
12 (1st/2nd) A27
N2 (Neutral/2nd) A1

L. US
32 (3rd/2nd) A26
3N (3rd/Neutral) A29
34 (3rd/4th) A2
N4 (Neutral/4th) A24
S. N O
54 (5th/4th) A13
5N (5th/Neutral) A12
R.
RS IÓ

SWITCH INSPECTION
TO UC

Remove the right center mudguard (page 2-5)

[1]
Turn the ignition switch OFF and disconnect the gear
position switch 10P (Gray) connector [1].
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-72
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Check for continuity between switch side 10P (Gray)
connector [1] terminals and ground. [1]
W/G
There should be continuity only at the terminal that
corresponds to the shift drum position (open circuit

S. O
inspection). Gr Lg/R
There should be no continuity at the other terminals

L.
S AD
Bu/W
(short circuit inspection).
You must test at ten terminals in each shift drum

R.
Bu/R
position.

OR RIZ
Shift drum position Connector terminal
5R (5th/Reverse) Gray W/Bu
N (Neutral) Light green/red

OT TO
12 (1st/2nd) White/green
N2 (Neutral/2nd) Blue/black Bu/Bl
Bu/G
32 (3rd/2nd) Yellow

LM U
Y Bu
3N (3rd/Neutral) Blue/red
34 (3rd/4th) Blue/white

RA O A
N4 (Neutral/4th) Blue/green
54 (5th/4th) Blue
5N (5th/Neutral) White/blue

AB N
REPLACEMENT

-C O
Remove the rear crankcase cover (page 14-7).

L. US
[2] [4]
Remove the two wire clamp bolts [1].
Remove the wire grommet [2] from the rear crankcase
cover.
S. N O
Remove the retaining bolt [3] and shift drum position
switch [4] from the rear crankcase cover.
Apply locking agent to all bolt threads.
Install the shift drum position switch onto the rear
R.
RS IÓ

crankcase cover and tighten the retaining bolt.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
TO UC

Apply sealant to the grommet seating surface.

Route the wire as shown and install the grommet into
[1] [3]
MO RIB

the crankcase cover groove properly.

Install the two clamp bolts and tighten them.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
AL ST

Install the rear crankcase cover (page 14-11).

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

13-73
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

TR SENSOR (After '19 model)
REMOVAL/INSTALLATION
Remove the left and right center mudguards (page 2-5).

S. O
[1] [2]
Remove the engine guard (page 2-8).
Disconnect the shift spindle angle sensor connector

L.
S AD
(page 13-68).

R.
Disconnect the following connectors:

OR RIZ
– sensor harness 8P (Black) [1]
– neutral switch 1P [2]

OT TO
LM U
RA O A
Remove the following:
[1]

AB N
– wire band [1]
– wire clip [2]

-C O
– neutral switch 1P connector (switch side) [3]
– TR sensor bolt [4]

L. US
– sensor harness/TR sensor [5] and O-ring [6]

[3]
S. N O

[2]
R.
RS IÓ
TO UC

[5]/[6] [4]
Installation is in the reverse order of removal.
MO RIB

[1]
TORQUE:
TR sensor bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
AL ST

• Replace the O-ring with a new one.

BR DI

• Coat a new O-ring with engine oil. [2] [3]

• Align the flat surfaces of the TR sensor [1] hole [2]
and gearshift spindle end [3].
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-74
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

NEUTRAL SWITCH (After '19 model)
REMOVAL/INSTALLATION
Remove the left center mudguard (page 2-5).

S. O
Disconnect the neutral switch 1P connector (switch

L.
S AD
side) [1].
[1]

R.
Remove the neutral switch [2] and sealing washer [3].

OR RIZ
Installation is in the reverse order of removal.
TORQUE:
Neutral switch:

OT TO
13 N·m (1.3 kgf·m, 10 lbf·ft)
[2]/[3]

• Replace the sealing washer with a new one.

LM U
RA O A
REVERSE SWITCH ('14 – '19 models)
SYSTEM INSPECTION

AB N
1. Reverse Switch Inspection at PCM Connector

-C O
Turn the ignition switch OFF.
[1]
Disconnect the PCM 33P (Black) connector (page

L. US
4-42).
Check for continuity between the wire harness side
33P connector [1] terminal and ground in each
reverse selector lever position.
S. N O
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110

Connection: A29 – ground

R.
RS IÓ

There should be continuity with the selector lever

TO UC

depressed and no continuity with the selector lever

released. A29

Are the test results normal?

MO RIB

YES – The system is normal.

NO – GO TO STEP 2.
2. Reverse Switch Inspection at Switch
AL ST

Remove the engine guard (page 2-8).

[2]
Disconnect the Blue/red wire connector [1] from the
BR DI

reverse switch [2].

Check for continuity between the switch terminal
and ground in each reverse selector lever position.
CA SU

There should be continuity with the selector lever

depressed and no continuity with the selector lever
released.
Are the test results normal?
24 O

YES – Open or short circuit in the Blue/red wire.

-20 BID

NO – Faulty reverse switch.

[1]
-07 HI
28 O
PR

13-75
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

REMOVAL/INSTALLATION
Remove the engine guard (page 2-8).
Drain the engine oil (page 3-20).

S. O
Disconnect the Blue/red wire connector [1] from the
reverse switch.

L.
S AD
R.
OR RIZ
OT TO
[1]

LM U
Remove the reverse switch [1] and sealing washer [2].
[1]

RA O A
Install the reverse switch with a new sealing washer
and tighten it.
TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft)

AB N
Connect the Blue/red wire connector to the reverse
switch.

-C O
Fill the crankcase with the recommended engine oil

L. US
(page 3-20).
Install the engine guard (page 2-8).
S. N O
[2]

EOT SENSOR
R.
RS IÓ

REMOVAL/INSTALLATION
Remove the right center mudguard (page 2-5)
TO UC

[3] [1]
Drain the engine oil (page 3-20).
Disconnect the 2P (Black) connector [1] from the EOT
MO RIB

sensor [2].
Remove the EOT sensor and sealing washer [3] from
the front crankcase cover.
Install the EOT sensor with a new sealing washer and
AL ST

tighten it.
TORQUE: 14.5 N·m (1.5 kgf·m, 11 lbf·ft)
BR DI

Connect the 2P (Black) connector.

Fill the crankcase with the recommended engine oil
CA SU

(page 3-20). [2]

Install the right center mudguard (page 2-5).

24 O
-20 BID
-07 HI
28 O
PR

13-76
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

REAR VS SENSOR
REMOVAL/INSTALLATION
Remove the tank cover assembly (page 2-4).

S. O
[3] [1]
Disconnect the 3P (Black) connector [1] from the rear

L.
S AD
VS sensor [2].
Remove the bolt [3] and rear VS sensor from the rear

R.
crankcase cover.

OR RIZ
OT TO
LM U
[2]

RA O A
Remove the O-ring [1] from the rear VS sensor [2].
[1]
Coat a new O-ring with engine oil and install it onto the
rear VS sensor.

AB N
Install the rear VS sensor into the rear crankcase cover
and tighten the bolt.

-C O
Connect the 3P (Black) connector to the rear VS
sensor.

L. US
Install the tank cover assembly (page 2-4).
S. N O
[2]
R.
RS IÓ

FRONT VS SENSOR
TO UC

REMOVAL/INSTALLATION
Remove the bolt [1] and guard plate [2].
[2] [4]
MO RIB

Disconnect the 3P (Black) connector [3] from the front

VS sensor [4].
Remove the front VS sensor from the front final gear
case.
AL ST
BR DI
CA SU

[3] [1]
24 O

Remove the O-ring [1] from the front VS sensor [2].

[2]
-20 BID

Coat a new O-ring with engine oil and install it onto the
front VS sensor.
Install the front VS sensor into the front final gear case.
-07 HI

Connect the 3P (Black) connector to the front VS

sensor.
28 O

Install the guard plate and bolt, and tighten the bolt.
PR

[1]

13-77
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DRIVE MODE SELECT SWITCH
SYSTEM INSPECTION
1. Drive Mode Select Switch Inspection

S. O
Raise the front fender (page 23-10).

L.
S AD
[1]
Disconnect the drive mode select switch 2P (Black)
connector [1].

R.
Check for continuity between the switch side

OR RIZ
connector terminals in each switch position.
There should be continuity with the switch turned to
AUTO, and no continuity with the switch turned to
ESP.

OT TO
Is the switch normal?
YES – GO TO STEP 2.

LM U
NO – Faulty drive mode select switch

RA O A
2. Power Input Line Open Circuit Inspection

AB N
Turn the ignition switch ON.
[1]
Measure the voltage between the wire harness side

-C O
2P (Black) connector [1] terminal and ground.
Connection: Black/red (+) – ground (–)

L. US
Is there battery voltage?
YES – GO TO STEP 3.
(–)
S. N O
NO – Open circuit in the Black/red wire
R.
RS IÓ

Bl/R (+)
TO UC

3. Output Line Open Circuit Inspection

Turn the ignition switch OFF.
[1]
MO RIB

Connect the drive mode select switch 2P (Black)

connector.
Disconnect the PCM 33P (Black) connector (page
4-42).
AL ST

Turn the drive mode select switch to AUTO and the

ignition witch ON.
Measure the voltage between the wire harness side
BR DI

33P connector [1] terminal and ground.

TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
CA SU

(–)
A18 (+)
Connection: A18 (+) – ground (–)
Is there battery voltage?
24 O

YES – The system is normal.

-20 BID

NO – Open circuit in the Brown/black wire

-07 HI
28 O
PR

13-78
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SHIFT VALVE BODY

S. O
Do not drop or strike the solenoid valves when
servicing. Excessive shock may damage the solenoid

L.
S AD
valve.

R.
EMERGENCY VALVE FUNCTION

OR RIZ
• The emergency valve is used when the hydraulic
pressure is shut off by the faulty dual clutch PC
solenoid (stuck; mechanical lock), and the vehicle is

OT TO
prevented from running. Open the bypass oil circuit
manually to supply hydraulic pressure.
’14 – ’19

LM U
The stopper bolt [1] that operates the emergency valve

RA O A
[3]
is secured with the lock plate [2].
When trouble occurs, loosen the lock plate screw [3]
and turn the stopper bolt all the way in to activate the
emergency valve.

AB N
-C O
L. US
S. N O
[1] [2]

After ’19
R.
RS IÓ

The stopper bolt [1] that operates the emergency valve

[3] [1] [3]
is secured with the lock plate [2].
When trouble occurs, loosen the lock plate bolt [3].
TO UC

Remove the oil check lid (page 2-3).

Release the lock plate bolt fixing the lock plate with the
MO RIB

gear change lever tool [4].

Turn the stopper bolt all the way in to activate the
emergency valve.
AL ST
BR DI

[4] [2]

REMOVAL/INSTALLATION
CA SU

Remove the left center mudguard (page 2-5).

[2]
Clean around the valve body with compressed air to
24 O

remove dust, dirt and foreign material.

Remove the wire clip [1] from the stay.
-20 BID

Disconnect the shift solenoid valve 2P (Brown)

connector [2] and dual clutch PC solenoid valve 2P
(Black) connector [3].
-07 HI
28 O
PR

[3] [1]

13-79
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Place a shop towel under the valve body [1].
[2]
Remove the following:
– six bolts [2]
– valve body assembly

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

– gasket [1]

LM U
[1]
– three oil guide pin [2]
– six O-rings [3] from the guide pins

RA O A
Cover the shift valve body housing of the front
crankcase cover with tape or clean cloth.

AB N
-C O
L. US [2]/[3]
S. N O
Installation is essentially in the reverse order of
removal.
• Replace the O-rings and gasket with new ones.
R.
RS IÓ

• Coat the O-rings with engine oil.

TO UC

O-RINGS

VALVE BODY ASSEMBLY

MO RIB

OIL GUIDE PINS

AL ST

2P (Brown)
CONNECTOR
BR DI
CA SU

GASKET
24 O

2P (Black)
-20 BID

CONNECTOR
-07 HI
28 O
PR

13-80
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

DISASSEMBLY/ASSEMBLY

• Keep dust and dirt away from all the parts.

• Take care not to damage the mating surfaces of the

S. O
valve body components.

L.
S AD
• Before assembly, clean all the parts with
compressed air. Make sure that there is no dust or

R.
lint on any parts.

OR RIZ
Remove the following:
[3] [4]
– bolt [1] and shift solenoid valve [2]
– three bolts [3], wire clip stay [4] and dual clutch PC

OT TO
solenoid valve assembly [5]

LM U
RA O A
AB N
[1] [2] [5]

-C O
– rubber seal [1]

L. US
S. N O
R.
RS IÓ
TO UC

[1]
MO RIB

– screw [1] and lock plate [2]

– valve stopper bolt [3]
– emergency valve [4]
– valve spring [5]
AL ST

[2]
BR DI

[1]
CA SU

[5]
24 O

[4] [3]
-20 BID
-07 HI
28 O
PR

13-81
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

– four bolts [1]
[2]
– valve body [2]

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

– separator plate [1]

LM U
[2] [3]/[4]
– two dowel pins [2]
– three sealing bolts [3] and washers [4]

RA O A
AB N
-C O
L. US [1]
S. N O
– spring seat [1]
[3] [2]
– valve spring [2]
– shift valve [3]
R.
RS IÓ

Wash all the parts with a high flash point or non-

flammable solvent and blow through all oil passages
with compressed air to clean completely.
TO UC
MO RIB
AL ST

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

13-82
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Assembly is essentially in the reverse order of
disassembly.
• Replace the O-rings, rubber seal and sealing
washers with new ones.

S. O
• Coat O-rings and rubber seal with engine oil.
• Apply engine oil to the shift valve outer surface.

L.
S AD
R.
OR RIZ
VALVE SPRING WIRE CLIP STAY

EMERGENCY VALVE DUAL CLUTCH PC

SOLENOID VALVE

OT TO
O-RING

LM U
RA O A
STOPPER BOLT
RUBBER SEAL

AB N
LOCK PLATE

-C O
SEALING WASHER

L. US
SEALING WASHERS O-RINGS

SHIFT SOLENOID VALVE

S. N O
VALVE BODY BASE

SEPARATOR PLATE
R.
RS IÓ

SPRING SEAT
TO UC

DOWEL PINS
MO RIB

VALVE BODY
AL ST

VALVE SPRING
BR DI
CA SU

SHIFT VALVE
24 O
-20 BID
-07 HI
28 O
PR

13-83
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

INSPECTION
SHIFT SOLENOID VALVE
Use a hand- Connect a pressure pump to the input port (filter side) of
operated air pump the shift solenoid valve.

S. O
only. Do not use a
Connect a 12 V battery [1] to the shift solenoid valve

L.
S AD
high pressure air
connector [2] terminals as shown and check for air flow
source.
conditions.

R.
OR RIZ
OT TO
LM U
[2] [1]

RA O A
Air should not flow (the pressure should be maintained)
while the battery is connected, and should flow out of
the output ports [1] that go to the shift valve when the
battery is disconnected.

AB N
[1]

-C O
L. US
S. N O

DUAL CLUTCH PC SOLENOID VALVE

R.
RS IÓ

Connect the 12 V battery [1] positive terminal to the

dual clutch PC solenoid valve connector [2] terminals
TO UC

and check the spool valve through the oil passages for
operation.
MO RIB
AL ST
BR DI

[2] [1]
CA SU

The valve [1] should move to away from the solenoid

side when the battery is connected, and should return
by spring force when the battery is disconnected.
24 O
-20 BID
-07 HI
28 O
PR

[1]

13-84
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

SHIFT VALVE AND VALVE BODY
Check the shift valve [1] and valve body [2] bore for
[2]
scoring scratches or abnormal wear.
Check the valve spring [3] for fatigue or damage.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1] [3]

LM U
DUAL CLUTCH/PRIMARY DRIVEN

RA O A
GEAR
REMOVAL

AB N
Remove the centrifugal clutch (page 13-62).
[1] Unstake
Be careful not to Unstake the lock nut [1].

-C O
damage the
mainshaft threads.

L. US
S. N O
R.
RS IÓ
TO UC

Loosen the lock nut [1] while holding the gear guide
[1]
boss with the special tool.
MO RIB

TOOL:
Lock nut wrench, 32.5 mm [2] 07AMA-HP7A100
Remove the following
AL ST

– lock nut
BR DI
CA SU

[2]

– washer [1]
24 O

[1] [2] [3]

– 1st clutch gear guide [2]
– thrust washer [3]
-20 BID
-07 HI
28 O
PR

13-85
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

– shift clutch/primary driven gear assembly [1]
[1]
– four seal rings [2] from the mainshaft grooves

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

1ST SHIFT CLUTCH DISASSEMBLY

LM U
Remove the following:
[2]

RA O A
– 1st shift clutch assembly [1]
– needle bearing [2]

AB N
-C O
L. US
S. N O
[1]

– seal rings [1]

R.
RS IÓ
TO UC
MO RIB
AL ST

[1]
BR DI

– snap ring [1]

[1] [2]
– clutch end plate A [2]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

13-86
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

– three clutch discs [1] and plates [2]
[3] [1]
– wave spring [3]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]
If either support Install the special tools onto the shift clutch.
[3] [4]

LM U
block [1] is set over
an area of the TOOLS:

RA O A
spring seat [2] that Clutch compressor set 07LAE-PX40000
is unsupported by or
the return spring, Clutch compressor 07LAE-PX40100
the spring seat may attachment [3] (2 required) and Support area

AB N
be damaged. Compressor bolt assembly [4] 07GAE-PG40200 or
07GAE-PG4020A

-C O
(U.S.A. only)

L. US
• Be sure the special tool is adjusted to have full
contact the stepped areas with the spring seat.
[2] [1]
S. N O
To prevent loss of Compress the return spring [1] by tightening the nut.
[1]
spring tension, do Remove the snap ring [2] from the boss.
not compress the
Loosen the nut and remove the special tools, snap ring,
R.
spring more than
RS IÓ

spring seat [3] and return spring.

necessary.
TO UC
MO RIB
AL ST

[3] [2]

Wrap a shop towel around the clutch drum.

BR DI

Apply air pressure to the oil hole while closing the other
holes with your finger to remove the clutch piston.
CA SU

Remove the O-rings from the piston.

Clean all the parts of the shift clutch in solvent
thoroughly and blow dry them with compressed air.
24 O
-20 BID
-07 HI
28 O
PR

13-87
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

2ND SHIFT CLUTCH DISASSEMBLY
Remove the following:
– 2nd shift clutch assembly [1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

LM U
– needle bearing [1]
[1]

RA O A
– seal rings [2]

AB N
-C O
L. US
S. N O
[2]

– snap ring [1]

[1] [2]
– clutch end plate B [2]
R.
RS IÓ

– clutch guide plate A [3]

TO UC
MO RIB
AL ST

[3]
BR DI

– 2nd clutch gear guide [1]

[2] [1]
– thrust washer [2]
CA SU

Remove the following in the same procedures as the

1st shift clutch (page 13-87):
– three clutch discs and plates
24 O

– wave spring
– snap ring
-20 BID

– spring seat
– return spring
– clutch piston
-07 HI
28 O
PR

13-88
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation. Replace if necessary.

S. O
– clutch drum and piston
– clutch spring

L.
S AD
– clutch discs/plates
– primary driven gear

R.
Measure each part according to DUAL CLUTCH

OR RIZ
TRANSMISSION SPECIFICATIONS (page 1-13).
Replace any part if it is out of service limit.
• Replace the clutch discs and plates as a set.

OT TO
CLUTCH DRUM AND PISTON
Check the clutch drum [1] for nicks, indentations or
[3] [2]
abnormal wear made by the clutch plates.

LM U
Check the oil holes in the drum boss and check valve

RA O A
[2] in the piston [3] for clogs.

AB N
-C O
L. US
[1]
S. N O
1ST SHIFT CLUTCH ASSEMBLY
CLUTCH PLATES (3 pcs)
R.
RS IÓ

CLUTCH DISCS (3 pcs)

TO UC

PRIMARY DRIVEN GEAR

MO RIB

NEEDLE
BEARING
AL ST

CLUTCH PISTON
BR DI
CA SU

END PLATE

SNAP RING
24 O

SEAL RINGS
-20 BID
-07 HI

O-RINGS
CLUTCH DRUM
28 O

WAVE SPRING
PR

SNAP RING RETURN SPRING

SPRING SEAT

13-89
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Clean the inner surface of the clutch drum [1]
[1] [2]
thoroughly and blow through the oil holes in the drum
boss and check valve in the piston [2].
Apply engine oil to new O-rings [3] and install them into

S. O
the piston groove.

L.
S AD
Place the clutch piston into the clutch drum with the flat
side facing in.

R.
OR RIZ
OT TO
[3]
Be careful not to Install the piston [1] while turning it to ensure proper
[1]

LM U
pinch the O-rings seating.
with too much

RA O A
force.

AB N
-C O
L. US
S. N O
Place the return spring [1], spring seat [2] and snap ring
[4]
[3] into the clutch drum.
Install the special tools [4] while adjusting their position
R.
RS IÓ

carefully (page 13-87).

To prevent loss of Compress the return spring by tightening the nut.
TO UC

spring tension, do
not compress the
spring more than
MO RIB

necessary.
AL ST

[2] [1] [3]

Align the end gap Install the snap ring [1] into the groove in the drum boss
BR DI

with the groove (3 properly.

places) in the
Loosen the nut and remove the special tools.
spring seat.
CA SU
24 O
-20 BID
-07 HI

[1]
28 O
PR

13-90
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Install the wave spring [1] into the piston groove.
[1] [2]
Coat the clutch discs [2] with engine oil.
Install the three clutch plates [3] and discs alternately,
starting with the plate.

S. O
L.
S AD
R.
OR RIZ
OT TO
[3]

Install end plate A [1] with the stepped side facing out.

LM U
[2] [1]
Install the snap ring [2] into the drum grooves properly.

RA O A
Check the clutch initial clearance (page 13-93).

AB N
-C O
L. US
S. N O
Coat new seal rings [1] with engine oil and install them
into the primary driven gear grooves.
R.
RS IÓ
TO UC
MO RIB
AL ST

[1]

Apply engine oil to the needle bearing [1] and install it

BR DI

[1]
into the primary driven gear.
Install the 1st shift clutch assembly [2] onto the primary
driven gear by aligning the splines.
CA SU
24 O
-20 BID
-07 HI

[2]
28 O
PR

13-91
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

2ND SHIFT CLUTCH ASSEMBLY
RETURN SPRING
SNAP RING
CLUTCH PISTON
WAVE SPRING

S. O
CLUTCH DRUM

L.
S AD
O-RINGS

R.
PRIMARY DRIVEN GEAR

OR RIZ
SEAL
RINGS

OT TO
SPRING SEAT

LM U
RA O A
NEEDLE

AB N
BEARING

-C O
L. US
SNAP RING

END PLATE
S. N O
WASHER GUIDE PLATE
GEAR GUIDE
R.
RS IÓ

CLUTCH PLATES (3 pcs) CLUTCH DISCS (3 pcs)

TO UC

Install the following in the same procedures as the 1st

[2]
shift clutch (page 13-89):
– clutch piston
MO RIB

– return spring
– spring seat
– snap ring
AL ST

– wave spring
– three clutch plates and discs
Install the thrust washer [1] onto the clutch drum.
BR DI

Install the 2nd clutch gear guide [2] by aligning the gear
guide teeth with the clutch discs tabs.
CA SU

[1]

Install clutch guide plate A [1] and clutch end plate B [2].
[3] [2]
24 O

Install the snap ring [3] into the drum grooves properly.
Check the clutch initial clearance (page 13-93).
-20 BID
-07 HI
28 O
PR

[1]

13-92
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Coat new seal rings [1] with engine oil and install them
[2]
into the primary driven gear grooves.
Apply engine oil to the needle bearing [2] and install it
into the primary driven gear.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

Install the 2nd shift clutch assembly [1] onto the primary

LM U
driven gear by aligning the splines.

RA O A
AB N
-C O
L. US [1]
S. N O
CLUTCH INITIAL CLEARANCE CHECK
Set a dial indicator on the end plate [1] with the plate
lowered.
R.
RS IÓ

Lift the end plate up against the snap ring and read the
clearance, and record it.
TO UC

Perform this inspection at the three points in 120° apart.

STANDARD:
1st clutch: 0.70 – 0.90 mm (0.028 – 0.035 in)
MO RIB

2nd clutch: 0.65 – 0.95 mm (0.026 – 0.037 in) 120°

120°
If the clearance is not within the standard value, select 120°
the replacement end plate as follows:
AL ST

[1]
BR DI

Remove the snap ring and end plate.

Measure the flange thickness of the end plate at several
CA SU

points and record it.

Calculate the new plate thickness using the equation
below. Choose a new plate as close to this dimension
24 O

as possible.
A = (B – 0.8) + C
-20 BID

A: New plate thickness

B: Recorded clearance
C: Old plate thickness
-07 HI
28 O
PR

13-93
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

If the calculated Select the end plate from the table below.
dimension is over
the thickest plate
1ST CLUTCH 2ND CLUTCH
thickness, replace Mark Thickness Mark Thickness
the clutch discs and 1 1.9 mm 1.9 1.9 mm

S. O
plates as a set. 2 2.0 mm 2.0 2.0 mm

L.
S AD
3 2.1 mm 2.1 2.1 mm
4 2.2 mm 2.2 2.2 mm

R.
5 2.3 mm 2.3 2.3 mm

OR RIZ
6 2.4 mm 2.4 2.4 mm
7 2.5 mm 2.5 2.5 mm
8 2.6 mm 2.6 2.6 mm
9 2.7 mm 2.7 2.7 mm

OT TO
Install the end plate into the drum.
Install the snap ring into the drum grooves properly.

LM U
RA O A
INSTALLATION
Blow through the oil passages in the mainshaft with
compressed air.

AB N
Coat new seal rings [1] with engine oil and install them
into the mainshaft grooves.

-C O
L. US
S. N O
[1]
R.
RS IÓ

Apply engine oil to the needle bearings in the primary

[1]
driven gear.
TO UC

Install the shift clutch/primary driven gear assembly [1]

by aligning the splines of the 2nd clutch gear guide and
mainshaft.
MO RIB
AL ST
BR DI
CA SU

Install the thrust washer [1] onto the mainshaft.

[1]
24 O
-20 BID
-07 HI
28 O
PR

13-94
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Install the 1st clutch gear guide [1] by aligning the gear
[2] [1]
guide teeth with the clutch disc tabs, and also aligning
the splines of the gear guide and mainshaft, until it is
fully seated.

S. O
Install the washer [2].

L.
S AD
R.
OR RIZ
OT TO
Apply engine oil to new lock nut [1] threads and install it

LM U
[1]
onto the mainshaft.
Tighten the lock nut while holding the gear guide boss

RA O A
with the special tool.
TOOL:
Lock nut wrench, 32.5 mm [2] 07AMA-HP7A100

AB N
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)

-C O
L. US [2]
S. N O
Be careful not to Stake the lock nut into [1] the mainshaft groove.
[1] Stake
damage the
Install the centrifugal clutch (page 13-66).
mainshaft threads.
R.
RS IÓ
TO UC
MO RIB
AL ST

GEARSHIFT LINKAGE
BR DI

REMOVAL
CA SU

Remove the following:

[2]
– shift spindle angle sensor (page 13-68)
– front crankcase cover/spacer (page 13-54)
24 O

– dual clutch/primary driven gear assembly

(page 13-85)
-20 BID

– gearshift spindle assembly [1] and washer [2]

-07 HI
28 O
PR

[1]

13-95
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

– two bolts [1]
[1]
– guide plate [2] and drum shifter assembly [3]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2] [3]
Shift the – two dowel pins [1]
[5] [2] [3]

LM U
transmission into – shift drum center bolt [2]
reverse when – shift drum center [3]

RA O A
loosening the – pivot bolt [4], stopper arm [5], return spring [6] and
center bolt. washer [7]
Check all parts for wear or damage.

AB N
[7]

-C O
L. US [4] [6] [1]
S. N O
INSTALLATION
Apply locking agent to the stopper arm pivot bolt [1]
[3] [2]
threads.
R.
RS IÓ

Install the stopper arm [2], return spring [3], washer [4]
(between the arm and crankcase) and pivot bolt as
shown.
TO UC

Tighten the pivot bolt.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
MO RIB
AL ST

[4] [1]
BR DI

Hold the stopper arm with a screwdriver and install the

[3] [1]
shift drum center [1] by aligning the pin groove [2] with
CA SU

the dowel pin [3].

24 O
-20 BID
-07 HI
28 O

[2]
PR

13-96
dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

Apply locking agent to the shift drum center bolt [1]
[1]
threads.
Install the bolt and tighten it.
TORQUE:

S. O
’14 – ’19: 23 N·m (2.3 kgf·m, 17 lbf·ft)
After ’19: 31 N·m (3.2 kgf·m, 23 lbf·ft)

L.
S AD
Install the two dowel pins [2].

R.
OR RIZ
OT TO
[2]

Apply engine oil to the drum shifter [1], springs [2],

LM U
[5] [1]
plungers [3] and ratchet pawls [4], and assemble them
with the guide plate [5].

RA O A
[4]
[4]

AB N
-C O
L. US [3] [2] [2] [3]
S. N O
Install the guide plate [1] and drum shifter assembly [2]
[3]
into the shift drum center and onto the dowel pins as
shown.
R.
Apply locking agent to the guide plate bolt [3] threads.
RS IÓ

Install the bolts and tighten them.

TO UC

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

MO RIB
AL ST

[1] [2]

Install the washer [1] onto the gearshift spindle and

BR DI

[5] [4]
insert the spindle into the crankcase while aligning the
return spring ends [2] with the spring pin [3], and the
shifter collar [4] with the drum shifter pin [5].
CA SU

Install the following:

– dual clutch/primary driven gear assembly
(page 13-94)
24 O

– front crankcase cover/spacer (page 13-58)

-20 BID

– shift spindle angle sensor (page 13-68)

-07 HI

[3] [1] [2]

28 O
PR

13-97
 dummyhead

DUAL CLUTCH TRANSMISSION (FA models)

REVERSE STOPPER SHAFT ('14 – '19
models)
REMOVAL

S. O
Remove the rear crankcase cover (page 14-7).

L.
S AD
[1]
Release the reverse stopper arm [1] from the shift drum

R.
groove and remove the stopper shaft assembly [2] from
the crankcase.

OR RIZ
OT TO
LM U
RA O A
[2]

INSPECTION

AB N
Check the reverse stopper shaft [1] for wear or damage.
[1]
Check the return spring [2] for fatigue or damage.

-C O
L. US
S. N O
R.
RS IÓ

[2]
TO UC

INSTALLATION
Apply engine oil to the reverse stopper shaft journal
MO RIB

surface.
Install the reverse stopper shaft assembly [1] into the
crankcase as shown.
AL ST

Install the rear crankcase cover (page 14-11).

BR DI
CA SU

[1]
24 O
-20 BID
-07 HI
28 O
PR

13-98
dummytext

14. ALTERNATOR/STARTER CLUTCH

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 14-2 RECOIL STARTER (CM type only) ········· 14-6

RA O A
TROUBLESHOOTING ·························· 14-3 ALTERNATOR STATOR ······················· 14-7

AB N
SYSTEM COMPONENTS ······················ 14-4 FLYWHEEL/STARTER CLUTCH ··········· 14-14

-C O
L. US
S. N O
14
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

14-1
 dummyhead

ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
ALTERNATOR/STARTER CLUTCH

GENERAL
• This section covers service of the alternator stator, flywheel and starter clutch.

S. O
• Transmission lubricating oil is fed through the oil passages in the rear crankcase cover. Clean the oil passages before installing
the cover.

L.
S AD
• Alternator stator inspection (page 22-7).

R.
• Starter motor servicing (page 6-7).

OR RIZ
TOOLS
Flywheel holder Rotor puller Remover weight

OT TO
07725-0040001 07733-0020001 07741-0010201

LM U
RA O A
AB N
-C O
or equivalent commercially available in or 07933-3950000 (U.S.A. only) or 07936-371020A (U.S.A. only)

L. US
U.S.A.
Attachment, 52 x 55 mm Attachment, 24 x 26 mm Pilot, 10 mm
07746-0010400 07746-0010700 07746-0040100
S. N O
R.
RS IÓ
TO UC
MO RIB

Pilot, 25 mm Driver Bearing remover shaft, 10 mm

07746-0040600 07749-0010000 07936-GE00100 (not available in
U.S.A.)
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

14-2
dummyhead

ALTERNATOR/STARTER CLUTCH
Bearing remover head, 10 mm Bearing remover, 10 mm Remover handle
07936-GE00200 (not available in 07936-GE0A000 (U.S.A. only) 07936-3710100 (U.S.A. only)
U.S.A.)

S. O
L.
S AD
R.
OR RIZ
OT TO
Recoil pulley holder
07SMB-HM70100

LM U
RA O A
AB N
-C O
L. US
S. N O
TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
R.
RS IÓ

• Damaged starter reduction gear and/or driven gear

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

14-3
 dummyhead

ALTERNATOR/STARTER CLUTCH
SYSTEM COMPONENTS
Without Recoil Starter Models:

S. O
’19 - ’21 TE1/FE1 shown:

L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
L. US
108 N·m (11.0 kgf·m, 80 lbf·ft)
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

14-4
dummyhead

ALTERNATOR/STARTER CLUTCH
With Recoil Starter Models:

’19 - ’21 FE1 shown:

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

108 N·m (11.0 kgf·m, 80 lbf·ft)

14-5
 dummyhead

ALTERNATOR/STARTER CLUTCH
RECOIL STARTER (CM type only)
REMOVAL/INSTALLATION
Remove the center mudguards (page 2-5).

S. O
[1] [3]
Remove the following:

L.
S AD
– four bolts [1] and clamp [2]

R.
– recoil starter assembly [3]
[2]

OR RIZ
Apply locking agent to the bolt threads.
Install the recoil starter assembly with the four bolts and
clamp, and tighten the bolts in a crisscross pattern in
several steps.

OT TO
Secure the wire with the clamp properly.
Install the center mudguards (page 2-5).

LM U
RA O A
STARTER ROPE REPLACEMENT
When the rope has Pull the starter rope [1] fully to align the rope holes in
[4] [1] [3] [2]
broken or the pulley the drive pulley [2] and housing [3], and secure the

AB N
has rewound, align pulley with a vise pliers or equivalent tool to prevent the
the rope holes by pulley from rewinding.

-C O
turning the pulley
Untie the starter rope and remove the rope.
6-1/2 turns

L. US
counterclockwise Insert a new starter rope through the pulley, housing
and hold it. and grip [4], and tie the rope ends in a square knot. Set
the pulley side rope end into the cavity as shown.
S. N O
Carefully release the pulley and check the recoil starter
for smooth operation by pulling the grip.

Rope ends:
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

14-6
dummyhead

ALTERNATOR/STARTER CLUTCH
ALTERNATOR STATOR
REAR CRANKCASE COVER
REMOVAL

S. O
Remove the following:
FA5/FA6 only: [2]

L.
S AD
– air cleaner housing (page 7-17)
– center mudguards (page 2-5)

R.
[3]
– engine guard (page 2-8)

OR RIZ
– rear wheels (page 18-6)
– skid plate (page 2-11)
– swingarm (except FA5/FA6) (page 18-9)
– starter motor (page 6-7)

OT TO
– shift spindle angle sensor
FA: page 13-68
TE/FE: page 24-28

LM U
– TR sensor (after '19)
FA: page 13-74

RA O A
TE/FE: page 24-30
– recoil starter (page 14-6) [1]

FA5/FA6 only: Disconnect the rear final gear case breather hose [1]. [2] [5]

AB N
Remove the bolts [2] and rear brake hose clamps [3].
Remove the brake adjusting nut [4]. Disconnect the

-C O
brake cable [5] from the brake arm [6] and remove the
joint pin [7].

L. US
Remove the brake cable from the caliper body.

[6]
S. N O

[3] [7]
R.
RS IÓ

[4]
FA5/FA6 only: Remove the rear shock absorber upper mounting nuts FA5/FA6 only: [2]
TO UC

[1] and bolts [2]. [1]

Left side shown:
Remove the frame side upper arm pivot nuts [3] and
bolts [4].
MO RIB
AL ST
BR DI

[3] [4]
CA SU

FA5/FA6 only: Loosen the rear sub-frame rear mounting nut [1] while
holding the bolt [2]. FA5/FA6 only:
24 O
-20 BID
-07 HI
28 O
PR

[1]/[2]

14-7
 dummyhead

ALTERNATOR/STARTER CLUTCH
FA5/FA6 only: Support the rear sub-frame [1] with a jack or an FA5/FA6 only:
adjustable support. [2]/[3]
Right side shown:
Remove the rear sub-frame lower mounting nuts [2]
and bolts [3].

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

FA5/FA6 only: Slightly lower the rear sub-frame, then disconnect the
FA5/FA6 only: [2]

LM U
universal joint [1] from the engine output shaft [2] while
adjusting the sub-frame height.

RA O A
Remove the O-ring [3] from the engine output shaft.

AB N
-C O
L. US
[3]
[1]
S. N O
Remove the following:
[1]
Recoil starter Hold the recoil starter driven pulley using the special
equipment model tool and loosen the bolt.
R.
RS IÓ

only:
TOOL:
Recoil pulley holder [1] 07SMB-HM70100
TO UC
MO RIB
AL ST

Recoil starter Remove the following:

BR DI

[4] [3]
equipment model
– bolt [1] and O-ring [2]
only:
– driven pulley [3]
CA SU

– oil seal [4]

24 O
-20 BID
-07 HI

[2] [1]
28 O
PR

14-8
dummyhead

ALTERNATOR/STARTER CLUTCH
The cover (stator) is – Except FA: thirteen bolts [1]
FA shown: [2]
magnetically – FA: fourteen bolts [1]
attracted to the – rear crankcase cover [2]
flywheel, be careful

S. O
during removal.

L.
S AD
R.
OR RIZ
OT TO
[1]

– two dowel pins [1]

FA shown: [2]/[3]

LM U
– oil joint pipe [2] and O-ring [3]
– thrust washer [4] from the countershaft [4]

RA O A
– Except FA and after '19 TE/FE: thrust washer from
the reverse stopper shaft [5]

AB N
-C O
L. US [5] [1]
S. N O
– output shaft oil seal [1]
[1] [2]
– reverse lever oil seal [2]
– TE/FE/FA only: gearshift spindle oil seal [3]
R.
RS IÓ
TO UC
MO RIB
AL ST

[3]

STATOR AND CKP SENSOR

BR DI

REMOVAL
Remove the following:
[5] [3]
CA SU

– two CKP sensor bolts [1]

– four stator bolts [2]
– grommet [3]
– stator [4]/CKP sensor [5] assembly
24 O
-20 BID

[4]
-07 HI
28 O

[1] [2]
PR

14-9
 dummyhead

ALTERNATOR/STARTER CLUTCH
STATOR AND CKP SENSOR
INSTALLATION
Set the stator [1]/CKP sensor [2] assembly onto the
[2] [3]
alternator cover.

S. O
Apply sealant to the grommet [3] seating surface and

L.
S AD
install the grommet into the cover groove securely.

R.
Apply locking agent to the threads of the stator bolts [4]
and CKP sensor bolts [5] (page 1-21).

OR RIZ
Install the stator and CKP sensor bolts, and tighten [1]
them to the specified torque.
TORQUE:

OT TO
Stator bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)
CKP sensor bolt: 6 N·m (0.6 kgf·m, 4.4 lbf·ft)

LM U
[5] [4]

RA O A
BEARING REPLACEMENT
OUTPUT SHAFT BEARING
Drive the bearing out of the cover.

AB N
Apply engine oil to a new bearing.
Drive the bearing into the cover with the marked side

-C O
facing up.

L. US
TOOLS:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 25 mm 07746-0040600
S. N O
R.
RS IÓ

[1]
TO UC

CRANKSHAFT BEARING
Remove the crankshaft hole cap.
[1] [2]
Remove the snap ring [1] and bearing [2].
MO RIB

Apply engine oil to a new bearing.

Install the bearing and snap ring.
• Make sure the snap ring is firmly seated in the
AL ST

groove.
Install the crankshaft hole cap.
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

14-10
dummyhead

ALTERNATOR/STARTER CLUTCH
REAR CRANKCASE COVER
INSTALLATION
Clean the mating surfaces of the crankcase and rear
[3] [2]
crankcase cover thoroughly, being careful not to

S. O
damage them.

L.
S AD
Blow through the oil passage in the rear crankcase
cover with compressed air.

R.
Install new gearshift spindle oil seal (TE/FE/FA only) [1]

OR RIZ
and reverse lever oil seal [2] until they are fully seated.
Install a new output shaft oil seal [3] until the depth from
the crankcase cover is 1.5 ± 0.2 mm (0.06 ± 0.01 in).

OT TO
Apply engine oil to the oil seal lips.

LM U
[1]

RA O A
[3]
1.5 ± 0.2 mm
(0.06 ± 0.01 in)

AB N
-C O
L. US
S. N O

Apply liquid sealant (TB1215 or equivalent) to the

R.
RS IÓ

mating surface (shadowed area) of the rear crankcase Except after '19 TE/FE/FA (FA shown):
cover as shown.
TO UC
MO RIB
AL ST
BR DI
CA SU

After '19 TE/FE/FA (FA model shown):

24 O
-20 BID
-07 HI
28 O
PR

14-11
 dummyhead

ALTERNATOR/STARTER CLUTCH
Install the two dowel pins [1] and oil joint pipe [2].
FA shown: [2]/[3]
Coat a new O-ring [3] with engine oil and install it onto
the oil joint pipe. [4]
Install the thrust washer [4] onto the countershaft.

S. O
Except FA and after '19 TE/FE: Install the thrust washer
onto the reverse stopper shaft [5].

L.
S AD
R.
OR RIZ
OT TO
[5] [1]

Shift the transmission into neutral to align the groove in

LM U
LUG [2]
the shift drum [1] with the lug on the crankcase.

RA O A
Align the long end [2] of the gear position switch pin
with the "N" mark (lug) on the rear crankcase cover.
The cover (stator) is Install the rear crankcase cover aligning the switch pin
magnetically with the shift drum groove, being careful not to damage

AB N
attracted to the the oil seal lips.
flywheel, be careful

-C O
not to get anything
caught between • TM/FM only: Align the arm of gearshift spindle A

L. US
these parts when with the arm hole in the gearshift spindle when
installing. installing the cover.

[1] "N" MARK LUG

S. N O
Except FA: Install the thirteen bolts [1].
FA: Install the fourteen bolts [1]. FA shown:
Tighten the bolts in a crisscross pattern in 2 or 3 steps.
R.
RS IÓ
TO UC
MO RIB
AL ST

[1]
Recoil starter Apply specified grease to the lips of a new oil seal [1]
BR DI

equipment model and install it into the crankcase cover until it is fully Mobilith SHC 100 grease [1] [4]
only: seated.
CA SU

SPECIFIED GREASE: Mobilith SHC 100 (EXXON)

Coat a new O-ring [2] with engine oil and install it onto
the pulley bolt flange.
24 O

Apply engine oil to the threads and seating surface of

the pulley bolt [3].
-20 BID

Install the driven pulley [4] with the bolt, aligning the
bosses with the grooves in the crankshaft.
-07 HI

[2] [3]
28 O
PR

14-12
dummyhead

ALTERNATOR/STARTER CLUTCH
Recoil starter Hold the driven pulley using the special tool and tighten
[1]
equipment model the bolt.
only:
TOOL:
Recoil pulley holder [1] 07SMB-HM70100

S. O
L.
S AD
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)

R.
OR RIZ
OT TO
FA5/FA6 only: Apply molybdenum disulfide grease to inner splines of [3]

LM U
universal joint [1] and a new O-ring [2], then install it to FA5/FA6 only:
the engine output shaft [3].

RA O A
Connect the universal joint to the engine output shaft
while lifting up the front side of rear sub-frame.

AB N
-C O
L. US [1] [2]
S. N O
FA5/FA6 only: Install the rear sub-frame lower mounting bolts [1] and
Install the bolts new nuts [2]. FA5/FA6 only:
from the outboard Right side shown:
R.
side.
RS IÓ

’15 – ’19: Tighten the nuts to the specified torque.

TO UC

TORQUE: 130 N·m (13.3 kgf·m, 96 lbf·ft)

After ’19: Tighten the bolts to the specified torque.

MO RIB

TORQUE: 120 N·m (12.2 kgf·m, 89 lbf·ft)

[1]/[2]
AL ST

FA5/FA6 only: Remove the rear sub-frame rear mounting nut [1] and
BR DI

FA5/FA6 only:
replace it with a new one, then install and tighten it to
the specified torque while holding the bolt [2].
CA SU

TORQUE:
’15 – ’19: 130 N·m (13.3 kgf·m, 96 lbf·ft)
After ’19: 75 N·m (7.6 kgf·m, 55 lbf·ft)
24 O
-20 BID
-07 HI

[1]/[2]
28 O
PR

14-13
 dummyhead

ALTERNATOR/STARTER CLUTCH
FA5/FA6 only: Install the frame side upper arm pivot bolts [1] and new
FA5/FA6 only: [3]
Install the upper nuts [2] and loosely tighten them.
arm pivot bolts from Left side shown:
• Tighten the pivot nuts to the specified torque after
the rear side.
placing the vehicle on level ground.

S. O
Install the upper Install the rear shock absorber upper mounting bolts [3]

L.
S AD
mounting bolts from and new nuts [4] and tighten them to the specified [4]
the front side. torque.

R.
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

OR RIZ
OT TO
[2] [1]

FA5/FA6 only: Connect the rear final gear case breather hose [1].
FA5/FA6 only:

LM U
[3]
Set the rear brake hose clamps [2] to the frame, then

RA O A
install and tighten new bolts [3]. [2]
Install the joint pin [4] into the brake arm [5], then install
the brake cable [6] into the brake caliper and joint pin.
Install the adjusting nut [7].

AB N
Install the following:

-C O
– TR sensor (after '19)
FA: page 13-74

L. US
TE/FE: page 24-30
– shift spindle angle sensor
FA: page 13-68
TE/FE: page 24-28 [1]
S. N O
– recoil starter (page 14-6)
– starter motor (page 6-7) [6]
– swingarm (except FA5/FA6) (page 18-9)
– rear wheels (page 18-6) [3]
R.
RS IÓ

– skid plate (page 2-11)

– air cleaner housing (page 7-17)
– center mudguards (page 2-5)
TO UC

– engine guard (page 2-8)

FA5/FA6 only: Adjust the parking brake cable (page 3-32). [5]
MO RIB

FA5/FA6 only: Place the vehicle on level ground and tighten the frame
side upper arm pivot bolts to the specified torque.
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)
AL ST

[2] [7] [4]

FLYWHEEL/STARTER CLUTCH
BR DI

REMOVAL
CA SU

Remove the rear crankcase cover (page 14-7).

[2]
Remove the starter reduction gear shaft [1] and gear
[2].
24 O
-20 BID
-07 HI
28 O
PR

[1]

14-14
dummyhead

ALTERNATOR/STARTER CLUTCH
Except recoil starter Hold the flywheel using the special tool, and remove the
[2] [3]
equipment model: flywheel bolt [1] and collar [2].

• Do not hold the CKP sensor magnet portion on the

S. O
flywheel.

L.
S AD
TOOL:

R.
Flywheel holder [3] 07725-0040001 or
equivalent

OR RIZ
commercially
available in U.S.A.

OT TO
[1]

Hold the flywheel [1] and remove it from the crankshaft

LM U
[1]
using the special tools.

RA O A
TOOL:
Rotor puller [2] 07733-0020001 or
07933-3950000
(U.S.A. only)

AB N
-C O
L. US [2]
S. N O
Be careful not to Remove the woodruff key [1] from the crankshaft.
[1]
damage the
crankshaft and key
R.
RS IÓ

groove.
TO UC
MO RIB
AL ST

STARTER CLUTCH DISASSEMBLY

BR DI

Make sure that the starter driven gear [1] turns

[1]
clockwise smoothly and does not turn
CA SU

counterclockwise.
Remove the driven gear while turning it clockwise.
24 O
-20 BID
-07 HI
28 O
PR

14-15
 dummyhead

ALTERNATOR/STARTER CLUTCH
Hold the flywheel with the special tool and remove the
[2]
starter clutch bolts (T40) [1].

• Do not hold the CKP sensor magnet portion on the

S. O
flywheel.

L.
S AD
TOOL:

R.
Flywheel holder [2] 07725-0040001 or
equivalent

OR RIZ
commercially
available in U.S.A.
Remove the starter clutch assembly from the flywheel.

OT TO
[1]

INSPECTION

LM U
Inspect the following parts for scratch, damage,

RA O A
abnormal wear and deformation. Replace if necessary.
– starter driven gear
– starter clutch outer
– sprag clutch

AB N
– starter reduction gear shaft
– starter reduction gear

-C O
Measure each part according to ALTERNATOR/
STARTER CLUTCH SPECIFICATIONS (page 1-13).

L. US
Replace any part if it is out of service limit.
S. N O
STARTER CLUTCH ASSEMBLY
Lubricate the sprag clutch [1] with engine oil and install
[1]
it into the clutch outer [2] with the flange facing the
flywheel side.
R.
RS IÓ

Install the starter clutch onto the flywheel.

TO UC
MO RIB
AL ST

[2]
BR DI

Apply locking agent to the starter clutch bolt [1] threads

’14 - ’21 shown: [2]
(page 1-21).
Align the bolt holes in the flywheel and starter clutch,
CA SU

and install the bolts.

Hold the flywheel with the special tool and tighten the
bolts.
24 O

• Do not hold the CKP sensor magnet portion on the

-20 BID

flywheel.

TOOL:
Flywheel holder [2] 07725-0040001 or
-07 HI

equivalent
commercially [1]
28 O

available in U.S.A.
PR

TORQUE:
’14 – ’21: 37 N·m (3.8 kgf·m, 27 lbf·ft)
After ’21: 23 N·m (2.3 kgf·m, 17 lbf·ft)

14-16
dummyhead

ALTERNATOR/STARTER CLUTCH
Install the starter driven gear [1] while turning it clock-
[1]
wise.

S. O
L.
S AD
R.
OR RIZ
OT TO
INSTALLATION

LM U
Be careful not to Install the woodruff key [1] into the key groove.
[1]

RA O A
damage the
Apply molybdenum oil solution to the starter driven gear
crankshaft and key
sliding surface of the crankshaft.
groove.
Clean any oil from the tapered portions of the
crankshaft and flywheel.

AB N
-C O
L. US
S. N O
Degrease

Install the flywheel [1] aligning the key way with the key
[1]
on the crankshaft.
R.
RS IÓ
TO UC
MO RIB
AL ST

Align
BR DI

Except recoil starter Apply engine oil to the flywheel bolt [1] threads and
[2] [3]
equipment model: seating surface.
CA SU

Install the collar [2] by aligning the lugs with the grooves
in the flywheel properly, and install the flywheel bolt.
Hold the flywheel using the special tool and tighten the
flywheel bolt.
24 O
-20 BID

• Do not hold the CKP sensor magnet portion on the

flywheel.

TOOL:
-07 HI

Flywheel holder [3] 07725-0040001 or

equivalent
commercially [1]
28 O

available in U.S.A.
PR

TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)

14-17
 dummyhead

ALTERNATOR/STARTER CLUTCH
Apply molybdenum oil solution to the starter reduction
[2]
gear shaft [1], and install the gear [2] and shaft.
Install the rear crankcase cover (page 14-11).

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

STARTER MOTOR BEARING

LM U
REPLACEMENT

RA O A
Remove the rear crankcase cover (page 14-7).
[2]
Remove the starter reduction gear shaft [1] and gear
[2].

AB N
Turn the inner race of the bearing [3] with your finger.
The bearing should turn smoothly and quietly.

-C O
Also check that the bearing outer race fits tightly in the
rear crankcase cover.

L. US
Replace the bearing if the inner race does not turn
smoothly, quietly or if the outer race fits loosely in the
cover.
Remove the bearing using the special tools.
S. N O
TOOLS:
Bearing remover shaft, 10 mm 07936-GE00100 [1]
Bearing remover head, 10 mm 07936-GE00200
R.
RS IÓ

Remover weight 07741-0010201 [3]

U.S.A. TOOLS:
TO UC

Bearing remover, 10 mm 07936-GE0A000

Remover handle 07936-3710100
Remover weight 07936-371020A
MO RIB

Apply engine oil to a new bearing.

Drive a new bearing into the crankcase with the marked
side facing out, using the special tools.
AL ST

TOOLS:
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
BR DI

Pilot, 10 mm 07746-0040100
Apply molybdenum oil solution to the starter reduction
CA SU

gear shaft, and install the gear and shaft.

Install the rear crankcase cover (page 14-11).
24 O
-20 BID
-07 HI
28 O
PR

14-18
dummytext

15. CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 15-2 TRANSMISSION·································· 15-7

RA O A
TROUBLESHOOTING ·························· 15-4 CRANKSHAFT/BALANCER ················· 15-13

AB N
SYSTEM COMPONENTS ······················ 15-5 CRANKCASE BEARING
REPLACEMENT ································· 15-15

-C O
CRANKCASE SEPARATION ················· 15-6

L. US
CRANKCASE ASSEMBLY ··················· 15-19
S. N O
R.
RS IÓ

15
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

15-1
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
SERVICE INFORMATION
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER

GENERAL
• The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the engine must be

S. O
removed from the frame (page 16-4).
• Be careful not to damage the crankcase mating surfaces when servicing.

L.
S AD
• Engine lubricating oil is fed through the oil passages in the crankcase. Clean the oil passages before assembling the crankcase

R.
halves.
• Figures in this section are mainly those of TM1/TE1/FM1/FM2/FE1 models.

OR RIZ
TOOLS

OT TO
Driver Attachment, 24 x 26 mm Attachment, 32 x 35 mm
07749-0010000 07746-0010700 07746-0010100

LM U
RA O A
AB N
-C O
L. US
Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm
07746-0010200 07746-0010300 07746-0010400
S. N O
R.
RS IÓ
TO UC
MO RIB

Attachment, 62 x 68 mm Attachment, 72 x 75 mm Attachment, 78 x 90 mm

07746-0010500 07746-0010600 07GAD-SD40101
AL ST
BR DI
CA SU
24 O

Pilot, 15 mm Pilot, 17 mm Pilot, 20 mm

07746-0040300 07746-0040400 07746-0040500
-20 BID
-07 HI
28 O
PR

15-2
dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Pilot, 22 mm Pilot, 25 mm Pilot, 32 mm
07746-0041000 07746-0040600 07MAD-PR90200

S. O
L.
S AD
R.
OR RIZ
OT TO
Pilot, 35 mm Pilot, 40 mm Bearing remover shaft, 15 mm
07746-0040800 07746-0040900 07936-KC10100 (not available in
U.S.A.)

LM U
RA O A
AB N
-C O
L. US
Bearing remover head, 15 mm Bearing remover, 15 mm Bearing remover, 17 mm
07936-KC10200 (not available in 07936-KC10500 (U.S.A. only) 07936-3710300
S. N O
U.S.A.)
R.
RS IÓ
TO UC
MO RIB

Bearing remover, 20 mm Remover handle Remover weight

07936-3710600
AL ST

07936-3710100 07741-0010201
BR DI
CA SU
24 O
-20 BID

or 07936-371020A (U.S.A. only)

-07 HI
28 O
PR

15-3
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Assembly collar Assembly shaft Special nut
07965-VM00100 07965-VM00200 (not available in 07931-HB3020A (U.S.A. only)
U.S.A.)

S. O
L.
S AD
R.
OR RIZ
OT TO
Puller shaft Universal bearing puller Threaded adapter
07931-ME4010B (U.S.A. only) 07631-0010000 07965-VM00300

LM U
RA O A
AB N
-C O
L. US
or equivalent commercially available in or 07931-KF00200 (U.S.A. only)
U.S.A.
S. N O
TROUBLESHOOTING
R.
RS IÓ

Excessive engine noise

• Worn, seized or chipped transmission gears
TO UC

• Worn transmission bearings

• Worn connecting rod big end bearing
• Worn crankshaft main journal bearing
• Worn balancer bearing
MO RIB

• Improper balancer installation

Transmission jumps out of gear
• Worn gear dogs or dog holes
AL ST

• Worn shift drum guide groove

• Worn shift fork guide pin
• Worn gear shifter groove
BR DI

• Worn shift fork

• Bent shift fork shaft
• Faulty gearshift linkage (page 12-3)
CA SU

Hard to shift
• Damaged shift fork
• Bent shift fork shaft
• Damaged shift fork guide pin
24 O

• Damaged shift drum guide groove

• Bent gearshift spindle
-20 BID

• Faulty gearshift linkage (page 12-3)

Abnormal vibration
• Improper balancer timing
-07 HI
28 O
PR

15-4
 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
S AD
S. O
R.
CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER

15-5
L.
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
CRANKCASE SEPARATION
Remove the following:
[2]/[3]
– engine (page 16-4)

S. O
– cylinder head (page 10-10)
– cylinder and piston (page 11-4)

L.
S AD
– camshaft (page 10-16)
– Except FA models: gearshift linkage (page 12-17)

R.
– Except FA models: change clutch (page 12-12)

OR RIZ
– FA models: gearshift linkage (page 13-95)
– Except FA models: oil pump (page 9-6)
– flywheel and starter clutch (page 14-14)
– reverse stopper shaft assembly [1]

OT TO
FA models: See page 13-98
– output shaft drive gear [2], driven gear [3] and output
shaft [4] [1] [4]

LM U
– two front crankcase bolts [1]

RA O A
[1]

AB N
-C O
L. US
S. N O
Loosen the – fifteen rear crankcase bolts [1]
[1]
R.
RS IÓ

crankcase bolts in a
Place the crankcase assembly with the rear crankcase
crisscross pattern in
down.
several steps.
TO UC
MO RIB
AL ST
BR DI

Do not pry the Remove the front crankcase while tapping it at several
[1]
crankcase apart locations with a soft hammer.
CA SU

with a screwdriver.
Remove the three dowel pins [1].
Remove any sealant material from the crankcase
mating surfaces.
24 O
-20 BID
-07 HI
28 O
PR

15-6
dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
OIL STRAINER CLEANING
Remove the oil strainer [1] and strainer plate [2].
[1]
Wash the strainer thoroughly in non-flammable or high

S. O
flash point solvent until all accumulated dirt has been
removed.

L.
S AD
Blow dry the strainer with compressed air completely.
Before installing the strainer, the screen mesh should

R.
be examined closely for damage.

OR RIZ
Install the strainer and plate with the wedge facing the
crankcase.

OT TO
[2]

LM U
TRANSMISSION

RA O A
DISASSEMBLY
Separate the crankcase (page 15-6).
[3] [1]

AB N
Remove the following:
– TM1/FM1/FM2 models only: gearshift spindle

-C O
– shift fork shaft [1]
– shift forks [2]

L. US
– shift drum [3]
S. N O
R.
RS IÓ

[2]

– reverse idle shaft [1] and idle gear [2]

TO UC

[1]
MO RIB
AL ST
BR DI
CA SU

[2]
Position the crank – mainshaft [1] and countershaft [2] as an assembly
[1] [2]
weights so that they
24 O

do not interfere with

the mainshaft
-20 BID

gears.
-07 HI
28 O
PR

15-7
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Do not expand the Disassemble the mainshaft [1] and countershaft [2].
[2]
snap ring more than
Clean all disassembled parts in solvent thoroughly.
necessary for
removal.

S. O
• Keep track of the disassembled parts (gears,
bushings, washers and snap ring) by sliding them

L.
S AD
onto a tool or slipping them onto a piece of wire.

R.
OR RIZ
OT TO
[1]

INSPECTION

LM U
Inspect the following parts for scratch, damage,

RA O A
abnormal wear and deformation. Replace if necessary.
– transmission gears
– transmission bushings
– transmission bearings

AB N
– shift drum
– shift forks

-C O
– shift fork shaft
Measure each part according to CRANKCASE/

L. US
TRANSMISSION/CRANKSHAFT/BALANCER
SPECIFICATIONS (page 1-13).
Replace any part if it is out of service limit.
S. N O
ASSEMBLY
R.
RS IÓ

• Always install the thrust washers and snap ring [1]

with the chamfered (rolled) edge facing away from Ends aligned Ends aligned
TO UC

the thrust load. with grooves with splines

• Install the snap ring so its ends aligns with the
grooves in the splines.
Incorrect Correct
MO RIB

• Make sure the snap ring is fully seated in the shaft

groove after installing it.
Clean all parts in solvent and dry them thoroughly.
AL ST

Apply molybdenum oil solution to the gear and bushing

sliding surfaces.
Assemble the mainshaft and countershaft.
BR DI

[1]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

15-8
dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
MAINSHAFT (Except FA models)

M3 BUSHING
THRUST WASHER

S. O
M5 GEAR (33T)

L.
S AD
M2/MR GEAR (17T)
SPECIAL WASHER

R.
M1 GEAR (14T)

OR RIZ
MAINSHAFT

OT TO
LM U
RA O A
AB N
M5 BUSHING

-C O
L. US
S. N O THRUST WASHER

M4 GEAR (28T)
SNAP RING
M5 GEAR (33T)
R.
SPLINE WASHER
RS IÓ

M4 GEAR (28T)

M3 GEAR (21T)
TO UC

M3 GEAR (21T)
MO RIB
AL ST
BR DI

: Gear and bushing sliding surfaces

CA SU
24 O
-20 BID
-07 HI
28 O
PR

SPLINE WASHER SNAP RING THRUST WASHERS

Washer and snap ring direction:

15-9
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
COUNTERSHAFT (Except FA models)

C1 GEAR (54T)
CR GEAR (46T)

S. O
C1/CR BUSHING

L.
S AD
R.
C2/CR GEAR SHIFTER

OR RIZ
SPLINE COLLAR

OT TO
C2 GEAR (38T)
C2 BUSHING

LM U
RA O A
AB N
-C O
L. US
C5 GEAR (28T)

COUNTERSHAFT
S. N O
THRUST WASHER C4 BUSHING
R.
C4 GEAR (33T)
RS IÓ

C3 GEAR (33T)
SPLINE COLLAR
TO UC

C1 GEAR (54T)
C4 GEAR (33T)
CR GEAR (46T)
MO RIB

C3 GEAR (33T)
C5 GEAR (28T)
C2 GEAR (38T)
AL ST
BR DI
CA SU

: Gear and bushing sliding surfaces

24 O
-20 BID
-07 HI
28 O
PR

THRUST WASHER

Washer direction:

15-10
dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
MAINSHAFT (FA models)
M1 GEAR (17T) M5 GEAR (33T)
SPECIAL WASHER THRUST WASHER

S. O
M3 GEAR (24T)

L.
S AD
R.
SNAP RING

OR RIZ
M1 BUSHING

M3 BUSHING

OT TO
SPLINE WASHER

LM U
MAINSHAFT

RA O A
THRUST WASHER THRUST WASHERS

AB N
NEEDLE BEARING

-C O
L. US
M2/M4 GEAR (19T/28T)

NEEDLE BEARINGS
S. N O
Washer and snap ring direction: : Gear and bushing sliding surfaces
R.
RS IÓ

COUNTERSHAFT (FA models)

CR GEAR (45T)
TO UC

C2/CR BUSHING

THRUST WASHER C2 GEAR (41T)

MO RIB

SPLINE COLLAR
C1 GEAR (52T)
C2/CR GEAR SHIFTER
AL ST

C5 GEAR (28T)

C4 GEAR (33T)
BR DI

THRUST WASHER
CA SU

THRUST WASHER

C5 BUSHING C4 BUSHING
24 O

THRUST WASHER
-20 BID

C3 GEAR (37T)
-07 HI
28 O

COUNTERSHAFT
PR

Washer direction: : Gear and bushing sliding surfaces

15-11
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Check the gears for freedom of movement or rotation
[2]
on the shaft.
Apply engine oil to the mainshaft [1] and countershaft
[2] journals.

S. O
Engage the mainshaft and countershaft gears.

L.
S AD
R.
OR RIZ
OT TO
[1]

Position the crank weights so that they do not interfere

LM U
[1] [2]
with the mainshaft [1].

RA O A
Install the mainshaft and countershaft [2] assemblies as
a set into the rear crankcase.

AB N
-C O
L. US
S. N O
Apply molybdenum oil solution to the reverse idle gear
[2]
[1] sliding surface.
Install the reverse idle gear and shaft [2].
R.
RS IÓ
TO UC
MO RIB
AL ST

[1]

Each shift fork has an identification mark; "FR" [1] for

BR DI

[1] [2] [3]

the front fork, "C" [2] for the center fork and "RR" [3] for
the rear fork.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

15-12
dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Apply engine oil to the shift drum guide pin grooves and
[1] [5] [4]
install the shift drum [1].
Install each shift fork into the gear shifter grooves and
shift drum groove with their identification marks facing

S. O
up (front crankcase side).

L.
S AD
• Except FA models:
– rear shift fork [2] into the M4 gear

R.
– center shift fork [3] into the C3 gear
– front shift fork [4] into the C2/CR gear shifter

OR RIZ
• FA models:
– rear shift fork [2] into the M5 gear
– center shift fork [3] into the C3 gear

OT TO
– front shift fork [4] into the C2/C4 gear shifter
[3] [2]
Apply engine oil to the fork shaft [5].
Install the fork shaft through the shift forks and into the

LM U
crankcase.
TM1/FM1/FM2 models only: Install the gearshift

RA O A
spindle.
Assemble the crankcase halves (page 15-19).

AB N
CRANKSHAFT/BALANCER

-C O
REMOVAL

L. US
Separate the crankcase halves (page 15-6).
[1]
Remove the transmission (page 15-7).
Be careful not to Remove the crankshaft [1] and balancer [2] from the
S. N O
damage the crank- rear crankcase using a hydraulic press. Be sure to hold
case mating surface the crankshaft and balancer while pressing them out of
and crankshaft the crankcase.
assembly.
R.
RS IÓ
TO UC
MO RIB

[2]

Remove the rear crankshaft bearing [1] using the

[1] [3]
bearing puller with a suitable protector [2]. Discard the
AL ST

bearing.

TOOL:
BR DI

Universal bearing puller [3] 07631-0010000 or

equivalent
commercially
CA SU

available in U.S.A.

• Always replace the rear crankshaft bearing with a

24 O

new one when the crankshaft is removed.

-20 BID

[2]
INSPECTION
Inspect the following parts for scratch, damage,
-07 HI

abnormal wear and deformation. Replace if necessary.

– balancer drive gear
28 O

– balancer driven gear

– crankshaft
PR

Measure each part according to CRANKCASE/

TRANSMISSION/CRANKSHAFT/BALANCER
SPECIFICATIONS (page 1-13).
Replace any part if it is out of service limit.

15-13
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
CRANKSHAFT RUNOUT
Set the crankshaft in a stand or V-blocks and measure
the runout using a dial indicator.

S. O
SERVICE LIMIT: 0.15 mm (0.006 in) GAUGE GAUGE

L.
S AD
R.
OR RIZ
OT TO
4 mm Hold Hold 6 mm

LM U
INSTALLATION

RA O A
Apply engine oil to a new rear crankshaft bearing.
[1]
Drive the crankshaft bearing into the rear crankcase
with the marking side facing up.

AB N
TOOLS:
Driver [1] 07749-0010000

-C O
Attachment, 72 x 75 mm [2] 07746-0010600
Pilot, 32 mm [3] 07MAD-PR90200

L. US
Other bearing replacement in the crankcase halves
(page 15-15)
S. N O
[3] [2]
Engage the balancer and crankshaft by aligning the
R.
Be careful not to
RS IÓ

[2]
disengage the index lines [1] on the crank weight [2] and balancer
gears. driven gear [3], and install them together into the rear
TO UC

crankcase.
MO RIB
AL ST
BR DI

[1] [3]
Take care that the Install the special tool onto the rear crankshaft end.
CA SU

crankshaft and
balancer do not fall TOOL:
out of the Threaded adapter [1] 07965-VM00300 or
crankcase when 07931-KF00200
24 O

installing the (U.S.A. only)

special tools.
-20 BID
-07 HI
28 O

[1]
PR

15-14
dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Install the special tools onto the crankshaft and
[1]
crankshaft bearing.

TOOLS:
Assembly collar [1] 07965-VM00100

S. O
Assembly shaft [2] 07965-VM00200

L.
S AD
U.S.A. TOOLS:
Assembly collar 07965-VM00100

R.
Assembly shaft 07931-ME4010B

OR RIZ
Special nut 07931-HB3020A

Be careful not to let Draw the crankshaft into the bearing inner race.
the connecting rod

OT TO
press against the
crankcase mating [2]
surface.
After installing the crankshaft, make sure the index lines

LM U
[2]
[1] on the crank weight [2] and balancer driven gear [3]
are aligned.

RA O A
Install the transmission (page 15-8).
Assemble the crankcase halves (page 15-19).

AB N
-C O
L. US [1] [3]
S. N O
CRANKCASE BEARING
REPLACEMENT
R.
RS IÓ

FRONT CRANKCASE (Except FA

models)
TO UC

Remove the countershaft bearing [1] and balancer

[4] [1]
bearing [2] with the special tools.
MO RIB

TOOLS:
Countershaft bearing:
Remover handle 07936-3710100
Remover shaft, 20 mm [3] 07936-3710600
AL ST

Remover weight [4] 07741-0010201 or

07936-371020A
(U.S.A. only)
BR DI

Balancer bearing:
Remover handle 07936-3710100
CA SU

Bearing remover, 17 mm 07936-3710300

Remover weight 07741-0010201 or [3]
07936-371020A
(U.S.A. only)
24 O

[5] [2]
Drive the crankshaft bearing [5], output shaft bearing [6]
-20 BID

and shift drum bearing [7] out of the front crankcase.

-07 HI
28 O
PR

[6] [7]

15-15
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Remove the two setting bolts [1] and drive the
[1]
mainshaft bearing [2] out of the front crankcase.

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

Apply engine oil to new bearings.

LM U
[1]
Drive the bearings in with the marked side facing up.

RA O A
TOOLS:
Crankshaft bearing:
Driver [1] 07749-0010000

AB N
Attachment, 78 x 90 mm [2] 07GAD-SD40101
Pilot, 40 mm [3] 07746-0040900
Balancer bearing:

-C O
Driver [1] 07749-0010000

L. US
Attachment, 37 x 40 mm [2] 07746-0010200
Pilot, 17 mm [3] 07746-0040400
Mainshaft bearing:
Driver [1] 07749-0010000 [3] [2]
S. N O
Attachment, 52 x 55 mm [2] 07746-0010400
Pilot, 22 mm [3] 07746-0041000
Countershaft bearing:
Driver [1] 07749-0010000
R.
RS IÓ

Attachment, 42 x 47 mm [2] 07746-0010300

Pilot, 20 mm [3] 07746-0040500
TO UC

Output shaft bearing:

Driver [1] 07749-0010000
Attachment, 42 x 47 mm [2] 07746-0010300
MO RIB

Pilot, 22 mm [3] 07746-0041000

Shift drum bearing:
Driver [1] 07749-0010000
Attachment, 52 x 55 mm [2] 07746-0010400
AL ST

Pilot, 35 mm [3] 07746-0040800

Apply locking agent to the mainshaft bearing setting
BR DI

[1]
bolt [1] threads (page 1-21).
Install the setting bolts and tighten them to the specified
torque.
CA SU

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

24 O
-20 BID
-07 HI
28 O
PR

15-16
dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
FRONT CRANKCASE (FA models)
Remove the countershaft bearing [1] with the special
[3] [1]
tools.

S. O
TOOLS:
Remover handle 07936-3710100

L.
S AD
Remover shaft, 20 mm [2] 07936-3710600

R.
Remover weight [3] 07741-0010201 or
07936-371020A

OR RIZ
(U.S.A. only)
Drive the crankshaft bearing [4], mainshaft bearing [5],
balancer bearing [6] and output shaft bearing [7] out of

OT TO
the front crankcase.
Remove the two setting bolts [8] and drive the shift
drum bearing [9] out of the front crankcase. [2]

LM U
[9] [5] [4]

RA O A
AB N
-C O
L. US
S. N O
[7] [8] [6]

Apply engine oil to new bearings.

[1]
R.
Drive the bearings in with the marked side facing up.
RS IÓ

TOOLS:
TO UC

Crankshaft bearing:
Driver 07749-0010000
Attachment, 78 x 90 mm 07GAD-SD40101
MO RIB

Pilot, 40 mm 07746-0040900
Balancer bearing:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
AL ST

Pilot, 17 mm 07746-0040400
Mainshaft bearing:
Driver 07749-0010000 [3] [2]
BR DI

Attachment, 62 x 68 mm 07746-0010500
Pilot, 35 mm 07746-0040800
Countershaft bearing:
CA SU

Driver [1] 07749-0010000

Attachment, 42 x 47 mm [2] 07746-0010300
Pilot, 20 mm [3] 07746-0040500
24 O

Output shaft bearing:

Driver 07749-0010000
-20 BID

Attachment, 52 x 55 mm 07746-0010400
Pilot, 25 mm 07746-0040600
Shift drum bearing:
-07 HI

Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 25 mm 07746-0040600
28 O
PR

15-17
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Apply locking agent to the shift drum bearing setting
bolt [1] threads (page 1-21).
Install the setting bolts and tighten them 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]

REAR CRANKCASE

LM U
Remove the mainshaft bearing [1] and camshaft
[4] [3] [1]

RA O A
bearing [2] with the special tools.

TOOLS:
Mainshaft bearing:

AB N
Bearing remover, 17 mm [3] 07936-3710300
Remover handle 07936-3710100

-C O
Remover weight [4] 07741-0010201 or
07936-371020A

L. US
(U.S.A. only)
Camshaft bearing:
Bearing remover shaft, 15 mm 07936-KC10100
Bearing remover head, 15 mm 07936-KC10200
S. N O
Bearing remover, 15 mm 07936-KC10500
(U.S.A. only)
Remover weight 07741-0010201 or [2] [5]
07936-371020A
R.
RS IÓ

(U.S.A. only)
Drive the countershaft bearing [5] and balancer bearing
TO UC

[6] out of the rear crankcase.

FA models only: Heat the crankcase around the shift
drum bearing [7] to 80°C (176°F) and remove the shift
MO RIB

drum bearing.
AL ST

[6] [7]
BR DI

Apply engine oil to new bearings.

[1]
Drive the bearings in with the marked side facing up.
CA SU

TOOLS:
Balancer and mainshaft bearings:
Driver [1] 07749-0010000
24 O

Attachment, 37 x 40 mm [2] 07746-0010200

-20 BID

Pilot, 17 mm [3] 07746-0040400

Countershaft bearing:
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
-07 HI

Pilot, 25 mm 07746-0040600
Camshaft bearing:
28 O

Driver 07749-0010000 [3] [2]

Attachment, 32 x 35 mm 07746-0010100
PR

Pilot, 15 mm 07746-0040300

15-18
dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
FA models only: Freeze the shift drum bearing.
[1]
Press the shift drum bearing [1] in with the marking
facing up until the depth from the crankcase mating
surface is 70.8 – 71.4 mm (2.79 – 2.81 in).

S. O
70.8 – 71.4 mm
TOOLS:
(2.79 – 2.81 in)

L.
S AD
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700

R.
Pilot, 20 mm 07746-0040500

OR RIZ
OT TO
CRANKCASE ASSEMBLY

LM U
Clean the front and rear crankcase mating surfaces

RA O A
thoroughly, being careful not to damage them.
Blow through the oil passages in the crankcases with
compressed air.

AB N
Apply liquid sealant (TB1215 or equivalent) to the
mating surface (shadowed area) of the front crankcase

-C O
as shown.

L. US
S. N O
Install the three dowel pins [1].
[1]
R.
RS IÓ

Make sure all the parts are installed in the rear

crankcase.
TO UC

Install the front crankcase over the rear crankcase.

MO RIB
AL ST
BR DI

Install the fifteen rear crankcase bolts [1].

[1]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

15-19
 dummyhead

CRANKCASE/TRANSMISSION/CRANKSHAFT/BALANCER
Install the two front crankcase bolts [1].
[1]
Tighten all the bolts in a crisscross pattern in several
steps.

S. O
L.
S AD
R.
OR RIZ
OT TO
Insert the output shaft [1] into the crankcase until it

LM U
[2]/[3] [4]
seats against the bearing in the front crankcase.
Install the output shaft drive gear [2] and output shaft

RA O A
driven gear [3].
Except FA models: Apply engine oil to the reverse
stopper shaft journal surface and install the reverse

AB N
stopper shaft assembly [4] into the crankcase as
shown.

-C O
Install the following:
– FA models: reverse stopper shaft assembly (page

L. US
13-98)
– flywheel and starter clutch (page 14-17)
– Except FA models: oil pump (page 9-6) [1]
S. N O
– FA models: gearshift linkage (page 13-96)
– Except FA models: change clutch (page 12-15)
– Except FA models: gearshift linkage (page 12-18)
– camshaft (page 10-18)
– piston and cylinder (page 11-4)
R.
RS IÓ

– cylinder head (page 10-15)

– engine (page 16-10)
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

15-20
dummytext

16. ENGINE REMOVAL/INSTALLATION

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 16-2 ENGINE REMOVAL ····························· 16-4

RA O A
SYSTEM COMPONENTS ······················ 16-3 ENGINE INSTALLATION ····················· 16-10

AB N
-C O
L. US
S. N O
R.
RS IÓ
TO UC

16
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

16-1
 dummyhead

ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
ENGINE REMOVAL/INSTALLATION

GENERAL
• When removing and installing the engine, tape the frame around the engine and front gear case beforehand for frame

S. O
protection.
• The transmission/crankshaft/balancer require engine removal for service (page 15-6).

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

16-2
dummyhead

ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
44 N·m (4.5 kgf·m, 32 lbf·ft)
44 N·m (4.5 kgf·m, 32 lbf·ft)

AB N
63 N·m (6.4 kgf·m, 46 lbf·ft)

-C O
L. US
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

32 N·m (3.3 kgf·m, 24

24 O
-20 BID
-07 HI
28 O
PR

16-3
 dummyhead

ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Remove the following:
– center mudguards (page 2-5)

S. O
– engine guard (page 2-8)
– exhaust system (page 2-14)

L.
S AD
– battery (–) cable (page 22-5)
– throttle body (page 7-18)

R.
– fuel tank (page 7-16)

OR RIZ
Drain the engine oil
– Except FA models: page 3-18
– FA models: page 3-20

OT TO
Drain the coolant (page 8-5).
TM/FM models only: Remove the pinch bolt [1] and the [2] [1]

LM U
gearshift pedal [2].

RA O A
’14 model: Disconnect the alternator 3P (Gray) connector [1] from
’14 model: [1]
the regulator/rectifier and release the alternator wire
from the wire clamps [2].

AB N
-C O
L. US
S. N O
[2]
After ’14: Disconnect the alternator 3P (Gray) connector [1] from
After ’14:
R.
RS IÓ

the regulator/rectifier.
Release the wire clamp [2], and remove the wire band [3]
TO UC

[3], wires, and cables.

MO RIB

[1]
AL ST
BR DI

[2]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

16-4
dummyhead

ENGINE REMOVAL/INSTALLATION
Remove the trim clips [1].
[1] [3]
Remove the heat protector [2] from the left frame pipe,
slide it rearward to release the retaining tabs [3] as
shown.

S. O
Remove the heat protector while releasing the water
hose [4] from the guides [5].

L.
S AD
R.
[5]

OR RIZ
OT TO
LM U
RA O A
[2]

AB N
-C O
L. US
[4]
S. N O
Disconnect the CKP sensor 2P (Gray) connector [1].
FA5/FA6 shown: [2] [3]
Except '14 –'19 FA
models and after '19 Disconnect the gear position switch 8P (Gray)
R.
RS IÓ

TM/FM models: connector [2].

'14 –'19 FA models: Disconnect the shift drum position switch 10P (Gray)
TO UC

connector [2].
After '19 TE/FE/FA Disconnect the sensor harness 8P (Black) connector [2]
models: and neutral switch 1P connector [3].
MO RIB
AL ST

[1]
Remove the rubber cap [1], nut [2] and starter motor
BR DI

[2]/[3] [4]/[5] [6]/[7]

cable [3] from the starter motor terminal.
Remove the bolt [4] and battery ground cable [5].
CA SU

Remove the bolt [6] and engine-to-frame ground cable

[7].
Remove the wire band [8].
24 O
-20 BID
-07 HI

[1] [8]
28 O
PR

16-5
 dummyhead

ENGINE REMOVAL/INSTALLATION
Remove the crankcase breather hose [1].
[1]
Disconnect the rear VS sensor 3P (Black) connector
[2].

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]
Except TM/FM Disconnect the shift spindle angle sensor 3P (Gray)
[1] [3] [2]

LM U
models: connector [1].

RA O A
'14 – '19 FA models Disconnect the reverse switch connector [2].
only:

Except after '19 TE/ Remove the bolt [3] and reverse selector arm [4].

AB N
FE/FA models: Disconnect the selector cable [5] from the arm and
remove it from the holder [6].

-C O
L. US [4] [6] [5]
S. N O
Except TM/FM Disconnect the shift control motor 2P (Black) connector
[1]
models: [1].
FA models only: Disconnect the EOT sensor 2P (Black) connector [2].
R.
RS IÓ
TO UC
MO RIB
AL ST

[2]
FA models only: Remove the wire clip [1] from the stay.
BR DI

[2]
Disconnect the shift solenoid valve 2P (Brown)
connector [2] and dual clutch PC solenoid valve 2P
CA SU

(Black) connector [3].

24 O
-20 BID
-07 HI

[3] [1]
28 O
PR

16-6
dummyhead

ENGINE REMOVAL/INSTALLATION
Loosen the band screws [1] and disconnect the water
[1]
hoses [2] from the engine.

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]
Except TM/TE Remove the bolts [1] and 2WD/4WD selector lever
[2]

LM U
models: assembly [2] from the frame.

RA O A
AB N
-C O
L. US [1]
S. N O
Except TM/TE Remove the following:
[4] [1]
models:
– front final gear case mounting nuts [1] and bolts [2]
– two bolts [3] and mounting bracket [4]
R.
RS IÓ

Move the front final gear case assembly forward for

maximum clearance between the propeller shaft joint
TO UC

and engine.
Turn the handlebar to the right side fully to get the
clearance between the gear case and tie-rod.
MO RIB
AL ST

[3] [2]
BR DI

[1]
CA SU
24 O
-20 BID
-07 HI

[2]
28 O
PR

16-7
 dummyhead

ENGINE REMOVAL/INSTALLATION
Except TM/TE Pull the shaft joint [1] out of the output shaft [2] of the
[1] [3]
models: engine.
Remove the O-ring [3] from the output shaft.

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]
Except TM/TE Remove the boot band [1] and release the propeller
[1] [2] [5]

LM U
models: shaft boot [2] off the pinion joint [3] of the gear case
assembly.

RA O A
Pull the propeller shaft [4] to force the stopper ring past
the groove in the pinion joint to remove the propeller
shaft.

AB N
Remove the stopper ring [5] from the propeller shaft.

-C O
L. US [3] [4]
S. N O
Place a jack or other adjustable support under the
[5] [4]
engine.
R.
RS IÓ

• The jack height must be continually adjusted to

relieve stress for ease of bolt removal.
TO UC

Remove the following from the engine upper mount:

– two 8 mm engine hanger bolts [1]
– 10 mm engine hanger nut [2] and bolt [3]
MO RIB

– hanger bracket [4]

– mounting rubbers [5]
AL ST

[2]/[3] [1]
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

16-8
dummyhead

ENGINE REMOVAL/INSTALLATION
Remove the following from each engine lower mount:
Right side: [4] [3]
– engine hanger nut [1] and bolt [2]
– spacer [3]
– mounting rubbers [4]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2] [1]

LM U
Left side: [3] [4]

RA O A
AB N
-C O
L. US [1] [2]
S. N O
Move the engine forward and disconnect the output
[3]
shaft [1] from the universal joint [2].
Hold the engine Remove the engine out of the frame to the left side.
R.
RS IÓ

securely and take

Remove the O-ring [3] from the output shaft.
care not to damage
TO UC

the frame and

engine.
MO RIB
AL ST

[1] [2]

Remove the dust seals [1] and engine mounting

BR DI

[1]
bushings [2].
Check the mounting rubber, bushings and dust seals
CA SU

for deterioration, wear or damage.

24 O
-20 BID
-07 HI

[2]
28 O
PR

16-9
 dummyhead

ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
• Route the wires, cables and hoses properly

S. O
(page 1-30).

L.
S AD
Install the lower engine mounting bushings [1] into the
[2]
engine.

R.
Install the dust seals with the lip side [2] facing out.

OR RIZ
OT TO
LM U
RA O A
[1]
During engine Using a jack or other adjustable support, carefully place

AB N
[1]
installation, hold the the engine in the frame from the left side and maneuver
engine securely it into place.

-C O
and be careful not
Coat a new O-ring [1] with molybdenum disulfide
to damage the
grease and install it into the groove in the output shaft

L. US
frame and engine.
[2].
Apply molybdenum disulfide grease to the splines in the
universal joint [3].
S. N O
Carefully move the engine and engage the output shaft
with the universal joint.
R.
RS IÓ

[2] [3]
TO UC

Be sure the Install the mounting rubbers [1] onto the lower mounting
Right side: [1] [2]
universal joint is not bushing with the large I.D. side facing in.
disengaged. Install the spacer [2] and the hanger bolt [3] (from the
front side) while aligning the bolt holes carefully.
MO RIB

Loosely install the hanger nut [4].

Install the other side mounting fasteners in the same
manner as above.
AL ST
BR DI
CA SU

[3] [4]

Left side: [2] [1]

24 O
-20 BID
-07 HI
28 O
PR

[4] [3]

16-10
dummyhead

ENGINE REMOVAL/INSTALLATION
Install the mounting rubbers [1] onto the upper
[1] [2]
mounting bushing in the hanger bracket [2] with the
large I.D. side facing in.
Install the hanger bracket with the 10 mm hanger bolt

S. O
[3] (from the front side) and nut [4].
Install the two 8 mm hanger bolts [5].

L.
S AD
After installing all the mounting fasteners and seat
them, tighten the fasteners in order as follows:

R.
– left and right lower engine hanger nut

OR RIZ
TORQUE: 63 N·m (6.4 kgf·m, 46 lbf·ft)
– engine side upper engine hanger bolts

OT TO
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft) [3]/[4] [5]

– frame side upper engine hanger nut

LM U
TORQUE: 63 N·m (6.4 kgf·m, 46 lbf·ft)

RA O A
Except TM/TE Install a new stopper ring [1] into the groove in the
[3] [1]
models: propeller shaft [2] end.
Apply 5 – 8 g of molybdenum disulfide grease to the

AB N
propeller shaft splines.
Apply molybdenum disulfide grease to the front end of

-C O
the propeller shaft.
Place the boot band [3] over the pinion joint [4]

L. US
temporarily.
Install the propeller shaft into the pinion joint, aligning
the splines until the stopper ring seats in the groove.
Make sure the stopper ring is seated properly by pulling
S. N O
the propeller shaft lightly. 5–8g
Install the boot [5] over the pinion joint groove securely [5] [4] [2]
and the boot band into the boot groove.
R.
RS IÓ

Except TM/TE Move the gear case assembly forward for maximum
[1]
models: clearance between the shaft joint and output shaft.
Turn the handlebar to the right side fully to get the
TO UC

clearance between the gear case and tie-rod.

Coat a new O-ring [1] with molybdenum disulfide
MO RIB

grease and install it into the output shaft [2] groove.

Apply molybdenum disulfide grease to the propeller
shaft joint [3] splines.
Engage the shaft joint over the output shaft and move
AL ST

the gear case assembly rearward.

BR DI

[3] [2]
CA SU

Except TM/TE Install the 2WD/4WD selector lever assembly [1] onto
[1]
models: the frame and tighten the two bolt [2].
24 O
-20 BID
-07 HI
28 O
PR

[2]

16-11
 dummyhead

ENGINE REMOVAL/INSTALLATION
Except TM/TE Align the lower mounting bolt holes in the gear case
models: and frame, insert the mounting bolt [1] from the right [2]
side and install a new mounting nut [2].
Install the mounting bracket [3] and tighten the two bolts

S. O
[4].
Install the upper mounting bolt [5] from the right side

L.
S AD
and a new mounting nut [6].

R.
Tighten the gear case mounting nuts.

OR RIZ
TORQUE: 10 mm: 44 N·m (4.5 kgf·m, 32 lbf·ft)
Install the removed parts in the reverse order of
removal.

OT TO
TORQUE: [1]
Gearshift pedal pinch bolt (TM1/FM1/FM2 only):
20 N·m (2.0 kgf·m, 15 lbf·ft) [3] [6]

LM U
Install the following:

RA O A
– fuel tank (page 7-16)
– throttle body (page 7-20)
– battery (–) cable (page 22-5)

AB N
– exhaust system (page 2-14)
– engine guard (page 2-8)
– center mudguards (page 2-5)

-C O
Except TM/TE Check the 2WD/4WD selector cable (page 3-28).

L. US
models:

Check the reverse selector cable.

[4] [5]
S. N O
– ’14 model: page 3-33
– Except ’14 model and after '19 TE/FE/FA models:
page 3-34
Fill the engine with recommended oil.
R.
RS IÓ

– Except FA models: page 3-18

– FA models: page 3-20
TO UC

Fill and bleed the cooling system (page 8-5).

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

16-12
dummytext

17. FRONT WHEEL/SUSPENSION/STEERING

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 17-2 WHEEL HUB AND KNUCKLE··············· 17-13

RA O A
TROUBLESHOOTING ·························· 17-3 SUSPENSION ARM ···························· 17-20

AB N
SYSTEM COMPONENTS ······················ 17-4 FRONT SHOCK ABSORBER················ 17-23

-C O
HANDLEBAR ······································ 17-6 STEERING SHAFT

L. US
(Except FM2/FA2/FA6 models)············· 17-24
THROTTLE HOUSING ·························· 17-9
STEERING SHAFT/EPS UNIT
S. N O
FRONT WHEEL ··································17-10 (FM2/FA2/FA6 models) ······················· 17-27

TIRES ···············································17-10 TIE-ROD ··········································· 17-32

R.
RS IÓ
TO UC

17
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

17-1
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION
FRONT WHEEL/SUSPENSION/STEERING

GENERAL
• This section covers service of the front wheel, suspension and steering (including EPS unit; FM2/FA2/FA6 models). For

S. O
electrical system service of the EPS, see Electric Power Steering (EPS) section (page 25-2).
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a

L.
S AD
high quality brake degreasing agent.

R.
• A jack or other support is required to support the vehicle.
• Adjust toe whenever the tie-rod, knuckle or steering shaft are replaced or removed (page 3-37).

OR RIZ
• Do not twist or bend the brake hose when servicing.
• Use Honda genuine replacement bolts and nuts for all suspension pivots and mounting points.
• For brake system service, see Brake System section (page 19-4).
• For each switch inspection, see Lights/Meters/Switches section.

OT TO
– handlebar switch (page 23-11)
– front brake switch (page 23-12)
– rear brake switch (page 23-13)

LM U
• FM2/FA2/FA6 model only: Perform the torque sensor initialization when you service the following components (page 25-9).

RA O A
Service Location Replacement Removal/Installation
Cables and harness around handlebar INITIALIZE INITIALIZE
Handlebar INITIALIZE INITIALIZE
Steering shaft and steering shaft bushing INITIALIZE INITIALIZE

AB N
Steering arm and nut INITIALIZE INITIALIZE
EPS unit INITIALIZE INITIALIZE

-C O
EPS ECU INITIALIZE NO NEED

L. US
TOOLS
S. N O
Attachment, 42 x 47 mm Attachment, 52 x 55 mm Attachment, 40 x 42 mm
07746-0010300 07746-0010400 07746-0010900
R.
RS IÓ
TO UC
MO RIB

Attachment, 20 mm I.D. Pilot, 20 mm Driver

AL ST

07746-0020400 07746-0040500 07749-0010000

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

17-2
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Attachment, 28 x 30 mm Ball joint remover, 28 mm Remover/installer, 42.5 x 43 mm
07946-1870100 07MAC-SL00201 07WMF-HN00100

S. O
L.
S AD
R.
OR RIZ
OT TO
07MAC-SL00202 (U.S.A. only)

LM U
TROUBLESHOOTING

RA O A
Hard steering
• Steering shaft holder too tight
• Damaged steering shaft bearing/bushing

AB N
• Insufficient tire pressure
• Faulty EPS (FM2/FA2/FA6 models) (page 25-5)

-C O
Steers one side or does not track straight
• Incorrect wheel alignment

L. US
• Unequal tire pressure
• Bent tie-rod, suspension arm or frame
• Worn or damaged knuckle bearing
• Weak shock absorber
S. N O
Front wheel wobbling
• Bent rim
• Worn or damaged knuckle bearing
• Faulty tire
R.
RS IÓ

• Loose wheel hub nut

Soft suspension
TO UC

• Weak shock absorber spring

• Oil leakage from damper unit
Stiff suspension
MO RIB

• Damaged shock absorber damper

• Faulty shock absorber pivot bushings
• Improperly installed suspension arms
AL ST

• Faulty suspension arm bushings

Front suspension noise
• Faulty front shock absorber
BR DI

• Loose front suspension fasteners

• Worn front suspension pivot bushings
• Damaged suspension components
CA SU
24 O
-20 BID
-07 HI
28 O
PR

17-3
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
SYSTEM COMPONENTS
Except FM2/FA2/FA6 models
’14 – ’16 FA1 model shown:

S. O
L.
S AD
32 N·m (3.3 kgf·m, 24 lbf·ft)

R.
OR RIZ
OT TO
LM U
RA O A
33.5 N·m (3.4 kgf·m,
25 lbf·ft)

AB N
-C O
L. US
S. N O
33.5 N·m (3.4 kgf·m,
25 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
R.
RS IÓ

54 N·m (5.5 kgf·m, 40 lbf·ft)

TO UC

29 N·m (3.0 kgf·m, 21 lbf·ft)

108 N·m (11.0

MO RIB

kgf·m, 80 lbf·ft)

11 N·m (1.1 kgf·m,

AL ST

8 lbf·ft)
BR DI

30 N·m (3.1 kgf·m,

22 lbf·ft)
54 N·m (5.5 kgf·m,
CA SU

40 lbf·ft)
24 O
-20 BID

11 N·m (1.1 kgf·m, 8 lbf·ft)

29 N·m (3.0 kgf·m, 21 lbf·ft)
-07 HI
28 O

137 N·m (14.0 kgf·m, 101

lbf·ft)
PR

64 N·m (6.5 kgf·m, 47 lbf·ft)

17-4
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
FM2/FA2/FA6 models (equipped with electric power steering)
’14 – ’19 FA2 model shown:

S. O
32 N·m (3.3 kgf·m, 24 lbf·ft)

L.
S AD
R.
OR RIZ
OT TO
60 N·m (6.1 kgf·m, 44 lbf·ft) 33.5 N·m (3.4 kgf·m,

LM U
25 lbf·ft)

RA O A
AB N
-C O
L. US
33.5 N·m (3.4 kgf·m, 25 lbf·ft)
S. N O
54 N·m (5.5 kgf·m, 40 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
R.
RS IÓ

29 N·m (3.0 kgf·m, 21 lbf·ft)

TO UC
MO RIB

11 N·m (1.1 kgf·m, 8 lbf·ft)

AL ST

30 N·m (3.1 kgf·m, 22 lbf·ft)

BR DI

54 N·m (5.5 kgf·m,

CA SU

40 lbf·ft)
24 O
-20 BID

11 N·m (1.1 kgf·m, 8 lbf·ft) 29 N·m (3.0 kgf·m, 21 lbf·ft)

-07 HI

137 N·m (14.0 kgf·m, 101

28 O

lbf·ft)
PR

64 N·m (6.5 kgf·m, 47 lbf·ft)

17-5
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR
REMOVAL
Remove the handlebar cover/stay assembly from the

S. O
FA models shown:
handlebar (page 23-6).

L.
S AD
Remove the following:

R.
– two wire bands [1]

OR RIZ
OT TO
LM U
[1]

RA O A
Keep the master – two screws [1] FA models shown: [5] [3]
cylinder upright to – throttle housing holder [2]
prevent air from – throttle housing [3] [7]

AB N
entering the – connectors [4]
hydraulic system. – two bolts [5]
– master cylinder holder [6]

-C O
– brake master cylinder [7]

L. US
S. N O
[2]

[4] [6] [1]

R.
RS IÓ

– two screws [1]

FA models shown: [3]
– bracket holder [2]
TO UC

– rear brake lever bracket [3]

– two screws (TM1/FM1/FM2) [1]
three screws (TE1/FE1/FA1/FA2/FA5/FA6)
– handlebar switch [4]
MO RIB
AL ST
BR DI

[4] [2]
CA SU

– grip ends [1] (turn the grip end to release the setting
[3]
tabs [2] and pry it using a screwdriver)
– handlebar grips [3]
[2]
24 O

[1]
-20 BID
-07 HI
28 O
PR

17-6
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
– four bolts [1]
[1] [4] [1]
– upper holders [2]
– handlebar [3]

S. O
INSTALLATION

L.
S AD
[2]

R.
• Route the wires and cables properly (page 1-30).

OR RIZ
Align the punch Install the handlebar and upper holders with the punch
mark on the mark [4] facing forward. Tighten the front bolts first, then
handlebar with the tighten the rear bolts.
top edge of the

OT TO
lower holder. Align [3]

Apply Honda Bond A or Pro Honda Handgrip Cement

LM U
[1]
(U.S.A. only) to the inside surface of each handlebar
grip [1] and to the clean surfaces of the handlebar.

RA O A
[3]
Allow the adhesive Wait 3 – 5 minutes and install the grips. Rotate the grip
to dry for an hour for even application of the adhesive.
before using. [2]
Install new grip ends [2] by aligning the tabs [3] with the

AB N
holes in the handlebar.

-C O
L. US
S. N O
TM1/FM1/FM2 Install the handlebar switch [1]. Tighten the upper screw
TM1/FM1/FM2 models: [2] Align
models: first, then tighten the lower screw.
Align the locating
R.
pin on the switch
RS IÓ

housing with the

hole in the
TO UC

handlebar.
Align the edge of Install the brake lever bracket [2] and holder [3] with the Align
the bracket with the punch mark [4] facing up. Tighten the upper screw first,
MO RIB

punch mark on the then tighten the lower screw.

handlebar.
AL ST

[1] [4] [3]

TE1/FE1/FA1/FA2/ Install the handlebar switch [1]. Tighten the inside
BR DI

TE1/FE1/FA1/FA2/FA5/FA6: [1]
FA5/FA6: screw [2] first, then tighten the outside screws [3].
Align the seam of
the switch with the
CA SU

Align
punch mark on the
handlebar.
24 O
-20 BID
-07 HI

[2] [3]
28 O
PR

17-7
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
TE1/FE1/FA1/FA2/ Install the brake lever bracket [1] and holder [2] with the
TE1/FE1/FA1/FA2/FA5/FA6: [2] [4]
FA5/FA6: punch mark [3] facing up. Tighten the upper screw [4]
Align the locating first, then tighten the lower screw [5].
pin on the bracket [1]
with the hole in the

S. O
switch housing.

L.
S AD
R.
OR RIZ
Align

OT TO
[3] [5]
Align the edge of Install the brake master cylinder [2] and holder [3] with
[4] [5] [2] [1]

LM U
the master cylinder the "UP" mark [4] facing up. Tighten the upper bolt [5]
with the punch first, then tighten the lower bolt [6] to the specified

RA O A
mark [1] on the torque.
handlebar.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Connect the connectors [7].

AB N
-C O
L. US [7] [6] [3]
S. N O
Align the lug [1] on Install the throttle housing [2] and holder [3] against the
[4] [2]
the throttle housing master cylinder [4]. Tighten the front screw first [5], then
with the mating line tighten the rear screw [6].
of the master
R.
RS IÓ

cylinder and holder.

TO UC
MO RIB

Align
AL ST

[1] [5] [6] [3]

Secure the wires with the wire bands [1].

BR DI

FA models shown:
Install the handlebar cover/stay assembly (page 23-6).
FM2/FA2/FA6 only: Perform the torque sensor
CA SU

initialization (page 25-9).

24 O
-20 BID
-07 HI

[1]
28 O
PR

17-8
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
THROTTLE HOUSING
DISASSEMBLY
Remove the following:

S. O
[1] [2]
– three screws [1]

L.
S AD
– throttle housing cover [2]
– gasket [3]

R.
Slide the boot [4] off the throttle cable adjuster.

OR RIZ
[4]

OT TO
LM U
[3]

RA O A
Loosen the lock nut [1] and cable adjuster [2].
[2] [1] [4] [3] [6]
Bend down the lock washer tab and remove the
following:

AB N
– pivot nut [3]
– lock washer [4]

-C O
– throttle lever and plastic washer [5]
– return spring [6]

L. US
– throttle arm [7] (by disconnecting the cable [8])
– dust seal (from the housing)
S. N O
[8] [7] [5]
R.
RS IÓ

ASSEMBLY
Coat a new dust seal [1] lip with grease and install it into
TO UC

the housing until it is fully seated.

Apply grease to the throttle cable end [2] and connect it
to the throttle arm.
MO RIB

[1]
Insert the throttle lever [3] with the plastic washer [4]
into the housing. [4]
Install the throttle arm [5] with the spring [6] over the
AL ST

throttle lever pivot by aligning the flat surfaces.

Install a new lock washer [7] and the nut [8], and tighten
the it.
BR DI

Bend up the lock washer tab against the nut.

CA SU

[3]

[7] [8] [6]

24 O
-20 BID
-07 HI
28 O
PR

[2]
[5]

17-9
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the housing cover [1] with a new gasket [2] and
[3] [1]
tighten the three screws [3].

TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

S. O
Adjust the throttle lever freeplay (page 3-8).

L.
S AD
R.
OR RIZ
OT TO
[2]

FRONT WHEEL

LM U
REMOVAL

RA O A
Loosen the wheel nuts [1].
[2]
Support the vehicle using a hoist or equivalent and
raise the front wheels off the ground.

AB N
Remove the wheel nuts and wheel.

-C O
[3]

L. US
INSTALLATION
Do not interchange Install the front wheel with the tire valve facing out and
the left and right the arrow mark [2] facing in the normal rotating
S. N O
wheels direction.
Install the wheel nuts with the tapered side [3] facing
inward and tighten them.
[1]
R.
RS IÓ

TORQUE: 64 N·m (6.5 kgf·m, 47 lbf·ft)

TIRES
TO UC

REMOVAL
MO RIB

• This service requires the ATV Bead Buster

(KLS379024).
• Remove and install the tire from the rim side
opposite the valve stem.
AL ST

Remove the core from the valve stem.

Use a pneumatic tire changer or equivalent to remove
BR DI

the tire from the rim. If a tire changer is not available,

rim protectors and tire irons may be used.
CA SU

Adjust the bottom rim supports [1] to the proper rim

[1]
size. Align the flat side of the support with the
corresponding rim size indicator.
24 O

Use only water as a Lube the bead area of the tire with water, pressing
lubricant when down on the tire sidewall/bead area in several places to
-20 BID

removing or allow the water to run into and around the bead.
mounting tires.
Soap or some
mounting lubricants
-07 HI

may leave a
slippery
28 O

residue which can

cause the tire to
PR

shift on the rim and

lose tire pressure
during riding.

17-10
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Place the wheel assembly over the center shaft [1] and
[1]
use the correct size cone [2] to keep the wheel centered
during operation.
Install the bottom hold down nut [3], bearing side down, [3]
[2]

S. O
and finger tighten it so the wheel can rotate freely
during operation.

L.
S AD
R.
OR RIZ
OT TO
Install the breaker arm assembly [1] over the center

LM U
[1] [3]
shaft and adjust the upper rim supports [2] to fit the
outside rim diameter.

RA O A
Install the top hold down nut [3] and tighten it finger
tight.

AB N
-C O
L. US [2]
S. N O
Failure to back out Pull the leverage bar [1] down so the breaker shoe is
[1]
the breaker shoe just below the rim lip. Turn the crank [2] to fully push the
two turns will cause breaker shoe [3] between the tire bead and rim. Once
the shoe contacts the rim, back the crank out two turns
R.
the shoe to scratch
RS IÓ

the bead lock, to allow the shoe to clear the rim’s bead lock.
which may cause
TO UC

the tire to leak.

MO RIB

[2]

[3]
AL ST

Push down on the leverage bar [1] to push the tire bead
BR DI

[1]
over the bead lock. Use only short strokes on the
handle. While the shoe [2] is still engaged, turn the
wheel as far as it will go between strokes as you break
CA SU

the bead around the rim.

Remove the breaker arm assembly and flip the wheel
over. Install the breaker arm assembly, adjust the shoe
24 O

properly and break the other bead by following the

above procedures.
-20 BID

Remove the tire from the rim using a tire changing

machine or tire irons and rim protectors. [2]
-07 HI
28 O
PR

17-11
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
TIRE REPAIR

• Use the manufacturer’s instructions for the tire repair

kit you are using. If your kit does not have

S. O
instructions, use the procedures provided here.

L.
S AD
Check the tire for puncturing objects.
Chalk mark the punctured area and remove the

R.
puncturing object.

OR RIZ
Inspect and measure the injury.
Tire repairs for injuries larger than 15 mm (5/8 in)
should be a section repair.
Section repairs should be done by a professional tire

OT TO
repair shop.
If the injury is smaller than 15 mm (5/8 in), proceed with
the repair as described here.

LM U
RA O A
AB N
Install a rubber plug into the injury as follows:
Apply a cement to a plug inserting needle and work the
needle into the injury to clean and lubricate it.

-C O
Do this three times.
Do not let the cement dry.

L. US
Be careful not to Insert and center a rubber plug through the eye of the
push the plug all the inserting needle.
way into the tire to
S. N O
Apply cement to the rubber plug.
prevent it from
Push the inserting needle with plug into the injury until
falling inside.
the plug is slightly above the tire.
Twist the needle and remove it from the tire; the plug
will stay in the tire.
R.
RS IÓ
TO UC

Trim the plug 6 mm (1/4 in) above the tire surface.

Repeat the above procedure if the puncture is large.
Do not use more than two plugs per injury.
MO RIB

Allow the repair to dry. Drying time will vary with air
temperature. Refer to the tire repair kit manufacturer’s
recommendations.
AL ST

Inflate the tire and test the seal by dabbing a small

amount of cement around the plug. Escaping air will
cause a bubble in the cement. If there is leakage,
BR DI

remove the tire (page 17-10)and apply a cold patch to

the inside of the tire as described below.
CA SU

If a plug has been inserted, trim it even with the inner

24 O

tire surface.
Temporarily place a rubber patch that is at least twice
-20 BID

the size of the puncture over the injury. Make a mark

around the patch, slightly larger than the patch itself.
Rough the area marked inside the tire with a tire buffer
or a wire brush. Clean the rubber dust from the buffed
-07 HI

area.
28 O

Apply cement over the area marked and allow it to dry

until tacky.
PR

Do not touch the cement with dirty or greasy hands.

Remove the lining from the patch and center it over the
injury.

17-12
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Press the patch against the injury using a special roller.

S. O
L.
S AD
R.
OR RIZ
OT TO
ASSEMBLY

LM U
Install the tire onto the rim, where the rim shoulder

RA O A
width is the narrowest, to simplify installation.
Clean the rim bead seat and flanges.
Use only water as a Apply clean water to the rim flanges, bead seat and

AB N
lubricant when base.
removing or
Install the valve core in the valve stem.

-C O
mounting tires.
Install the tire with the arrow mark facing in the normal
Soap or some
rotating direction.

L. US
mounting lubricants
Inflate the tire to seat the tire bead.
may leave a
slippery residue Deflate the tire. Wait 1 hour and inflate the tire to the
which can cause the specified pressure.
S. N O
tire to shift on the
rim and lose air
RECOMMENDED TIRE PRESSURE
pressure during Front: Standard: 30 kPa (0.30 kgf/cm2, 4.4 psi)
riding. With cargo: 30 kPa (0.30 kgf/cm2, 4.4 psi)
Rear: Standard: 30 kPa (0.30 kgf/cm2, 4.4 psi)
R.
RS IÓ

With cargo: 30 kPa (0.30 kgf/cm2, 4.4 psi)

TO UC

Check for air leaks and install the valve cap.

WHEEL HUB AND KNUCKLE

MO RIB

REMOVAL
Remove the wheel center cap [1] and cotter pin [2].
AL ST

[1] [2]
Apply front brake and loosen the hub nut [3].
BR DI
CA SU
24 O
-20 BID

[3]
-07 HI
28 O
PR

17-13
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the front wheel (page 17-10).
Remove the two hose clamp bolts [1] from the upper
arm.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

Except TM1/TE1: Remove the two setting bolts [1] and

LM U
[3] [4]
outboard guard [2].

RA O A
Support the caliper Remove the following:
so that it does not
– two mounting bolts [3]
hang from the brake
– brake caliper [4]
hose. Do not twist or

AB N
bend the brake
hose.

-C O
L. US [1] [2]
S. N O
– hub nut [1]
’14 model shown: [1]
– wheel hub [2]
– TM1/TE1 only: front axle shaft
R.
RS IÓ
TO UC
MO RIB
AL ST

[2]

– three socket bolts [1]

BR DI

– splash guard [2]

CA SU
24 O
-20 BID
-07 HI

[1] [2]
28 O
PR

17-14
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
– cotter pin [1] (from the tie-rod ball joint stud)
[3] [4]
– ball joint nut [2] (by holding the joint stud flat
surfaces [3])
– tie-rod [4]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2] [1]

– cotter pins [1]

LM U
Loosen the ball joint nuts [2], but do not remove them

RA O A
yet.

AB N
-C O
L. US [1]/[2]
S. N O
Release the ball joints, using the special tool according
to the following instructions.

TOOL:
R.
RS IÓ

Ball joint remover, 28 mm [1] 07MAC-SL00201 or

07MAC-SL00202
TO UC

(U.S.A. only)
MO RIB
AL ST

[1]

Apply grease to the ball joint remover at the point

BR DI

[1]
shown.
This will ease installation of the tool and prevent
damage to the pressure bolt [1] threads.
CA SU

Insert the jaws carefully, making sure that you do not

damage the ball joint boot.
Adjust the jaw spacing by turning the pressure bolt.
24 O

If necessary, apply
penetrating type
-20 BID

lubricant to loosen
the ball joint.
-07 HI
28 O
PR

17-15
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
To prevent the tool from dropping, tie the strap [1] on a
[1]
neighboring solid part such as the lower arm, tie-rod,
etc. before operation.

S. O
• Do not tie the strap on the brake hose, brake pipe,
rubber boot, and other parts that can be damaged

L.
S AD
easily.

R.
OR RIZ
OT TO
Once the tool is in place, turn the adjusting bolt [1] as

LM U
[2]
necessary to make the jaws parallel.
Then hand-tighten the pressure bolt [2] and recheck the

RA O A
jaws to make sure they are still parallel.
Tighten the pressure bolt with a wrench until the ball
joint stud pops loose.

AB N
Remove the ball joint nuts and the knuckle from the
upper and lower arms.

-C O
L. US [1]
S. N O
INSPECTION
Turn the inner race of each bearing in the knuckle with
your finger. The bearing should turn smoothly and
R.
RS IÓ

quietly. Also check that the bearing outer race fits tightly
in the knuckle.
TO UC

Inspect the knuckle for damage or cracks.

Inspect the ball joint boot for tears or other damage by
moving the ball joint stud.
MO RIB

It should move freely and smoothly.

BRAKE DISC REPLACEMENT

AL ST

Remove the four disc bolts [1] and brake disc [2] from
’14 model shown: [3]
the wheel hub [3].
BR DI

[1]
Do not get grease Install a new brake disc with the stepped surface facing
on the brake disc or up (knuckle side).
stopping power will Install new disc bolts and tighten them.
CA SU

be reduced.
TORQUE: 42 N·m (4.3 kgf·m, 31 lbf·ft)
24 O
-20 BID

[2]
-07 HI
28 O
PR

17-16
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
BEARING REPLACEMENT
Remove the snap ring [1] and drive the bearing [2] out
[1] [2]
of the knuckle.

S. O
TOOLS:
Driver 07749-0010000

L.
S AD
Attachment, 40 x 42 mm 07746-0010900

R.
OR RIZ
OT TO
LM U
Drive in a new bearing squarely with the marked side
[1]

RA O A
facing up until they are fully seated.

TOOLS:
Driver [1] 07749-0010000

AB N
Attachment, 52 x 55 mm [2] 07746-0010400
Install the snap ring into the knuckle groove with the

-C O
chamfered side facing in.

L. US
S. N O
[2]

BALL JOINT REPLACEMENT

R.
RS IÓ

Remove the snap ring [1] from the ball joint [2].
[2] [1]
TO UC
MO RIB
AL ST
BR DI

Set the knuckle [1] and special tools with "A" mark [2]
CA SU

[2] [1]
side of the remover/installer [3] facing to the ball joint in
the vise as shown.
Press the ball joint [4] out of the knuckle.
24 O

TOOLS:
Remover/Installer 42.5 x 43 mm 07WMF-HN00100
-20 BID

Attachment, 28 x 30 mm [5] 07946-1870100

-07 HI
28 O

[3] [4] [5]

PR

17-17
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Set the knuckle [1] and special tools with "B" mark [2]
[2]
side of the remover/installer [3] facing to the ball joint in
the vise as shown.
Press the ball joint [4] into the knuckle until it is fully

S. O
seated.
TOOLS:

L.
S AD
Remover/Installer 42.5 x 43 mm 07WMF-HN00100

R.
Attachment, 20 mm I.D. [5] 07746-0020400

OR RIZ
If you feel strong resistance when compressing the
vise, stop. Reset the attachment of the tool so that the

OT TO
ball joint head can go into the hollow of the attachment [3] [4] [5] [1]
and try again.
Install the snap ring [1] with the chamfered edge facing

LM U
[1]
in.

RA O A
AB N
-C O
L. US
S. N O
INSTALLATION
Install the knuckle onto the drive shaft (Except TM1/
R.
TE1 models), and lower and upper arms with the ball
RS IÓ

joint nuts [1].

Tighten each joint nut to the specified torque and further
TO UC

tighten until its grooves align with the cotter pin hole.
TORQUE: 29 N·m (3.0 kgf·m, 21 lbf·ft)
MO RIB

Install new cotter pins [2].

AL ST
BR DI

[1]/[2]

Install the tie-rod [1] into the knuckle with a new joint nut
[3] [1]
[2].
CA SU

Tighten the nut by holding the joint stud flat surfaces [3].
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)
24 O

Install a new cotter pin [4].

-20 BID
-07 HI
28 O

[2] [4]
PR

17-18
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the splash guard [1] with new bolts [2] and
[3]
tighten them.
TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft)

S. O
Except TM1/TE1: Apply molybdenum disulfide grease
to the drive shaft splines [3].

L.
S AD
TM1/TE1 only: Install the front axle shaft into the

R.
knuckle.

OR RIZ
OT TO
[2] [1]

Apply sealant to the hub nut [1] threads.

LM U
’14 model shown: [1]
Install the wheel hub [2] and hub nut, and temporarily

RA O A
tighten the nut.

AB N
-C O
L. US [2]
S. N O
Install the brake caliper [1] with new mounting bolts [2]
[2] [1]
and tighten them.

TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)

R.
RS IÓ

Except TM1/TE1: Install the drive shaft guard [3] and

tighten the bolts [4].
TO UC

TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft)

MO RIB
AL ST

[4] [3]

Install the hose clamps with new clamp bolts [1] and
BR DI

tighten them.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

CA SU

Install the front wheel (page 17-10).

24 O
-20 BID
-07 HI

[1]
28 O
PR

17-19
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Apply front brake, tighten the hub nut [1] to the specified
[3] [2]
torque and further tighten until its grooves align with the
cotter pin hole.

TORQUE: 137 N·m (14.0 kgf·m, 101 lbf·ft)

S. O
Install a new cotter pin [2].

L.
S AD
Install the wheel center cap [3].

R.
OR RIZ
OT TO
[1]

SUSPENSION ARM

LM U
REMOVAL

RA O A
Remove the wheel hub and knuckle (page 17-13).
[2]
Remove the following:

AB N
– pivot nuts [1] and bolts [2]
– lower arm [3]

-C O
L. US
S. N O
[1] [3]
R.
RS IÓ

– shock absorber lower mounting nut [1] and bolt [2]

– pivot nuts [3], and bolts [4] and plate [5] [4]
TO UC

– upper arm [6]

MO RIB
AL ST
BR DI

[6] [3] [1] [2]

[2]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

[5]

17-20
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Check the pivot bushings [1] for wear or damage.
[1] [2]
Inspect the ball joint boot [2] on the upper arm for tears

S. O
or other damage by moving the ball joint stud.
It should move freely and smoothly.

L.
S AD
Replace the bolt Except TM1/TE1: Remove the bolt [3] and inboard

R.
with a new one guard [4] from the lower arm if necessary.
when installing.

OR RIZ
OT TO
LM U
[4] [3]

RA O A
AB N
-C O
L. US
S. N O [1]

BALL JOINT REPLACEMENT

R.
Remove the snap ring [1] from the ball joint [2].
RS IÓ

[1]
TO UC
MO RIB
AL ST
BR DI

[2]

Set the upper arm [1] and special tools with "A" mark [2]
CA SU

[4]
side of the remover/installer [3] facing to the ball joint in
the hydraulic press as shown.
Press the ball joint out of the upper arm.
24 O

TOOLS:
Remover/Installer 42.5 x 43 mm 07WMF-HN00100
-20 BID

Attachment, 28 x 30 mm [4] 07946-1870100

-07 HI
28 O

[1] [2] [3]

PR

17-21
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Set the upper arm [1] and special tools with "B" mark [2]
side of the remover/installer [3] facing to the ball joint as
shown.
Press the ball joint into the upper arm until it is fully [4]

S. O
seated.
TOOLS:

L.
S AD
Remover/Installer 42.5 x 43 mm 07WMF-HN00100

R.
Attachment, 20 mm I.D. [4] 07746-0020400

OR RIZ
If you feel strong resistance when lowering the press,
stop. Reset the attachment of the tool so that the ball

OT TO
joint head can go into the hollow of the attachment and [1] [2] [3]
try again.
Install the snap ring [1] with the chamfered edge facing

LM U
[1]
in.

RA O A
AB N
-C O
L. US
S. N O
INSTALLATION
Insert the bolts from Install the upper arm [1] into the frame with the plate [2],
bolts [3] (10 x 65 mm) and new nuts [4]. [3]
R.
the outside of the
RS IÓ

upper arm.
TO UC

Insert the bolt from Connect the shock absorber to the upper arm with the
the rear side. bolt [5] (10 x 45 mm) and a new nut [6].
Loosely tighten the nuts.
MO RIB
AL ST

[1]
[1] [4] [5]
[4]
BR DI

[6]
CA SU
24 O
-20 BID
-07 HI
28 O

[2]
PR

17-22
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Insert the bolts from Install the lower arm [1] with the pivot bolts [2] and new
the front side. nuts [3], and loosely tighten nuts. [2]

Install the knuckle and wheel hub (page 17-18).

Install the front wheel (page 17-10).

S. O
Place the vehicle on level ground, and tighten the

L.
S AD
suspension arm and shock absorber mounting nuts.

R.
OR RIZ
OT TO
[3] [1]

FRONT SHOCK ABSORBER

LM U
REMOVAL/INSTALLATION

RA O A
Support the vehicle using a hoist or equivalent and
[1]/[2] [4]
raise the front wheels off the ground.
Support the lower arm. Remove the mounting nuts [1],

AB N
bolts (upper: 10 x 40 mm [2], lower: 10 x 45 mm [3]) and
front shock absorber [4].

-C O
Insert the bolts from Installation is in the reverse order of removal.

L. US
the rear side.
S. N O
[1]/[3]
R.
RS IÓ

INSPECTION
Check the pivot bushings [1] for wear or damage.
TO UC

Check the damper unit for leakage or other damage.

Replace the shock absorber assembly if necessary.
MO RIB
AL ST
BR DI
CA SU

[1]
24 O
-20 BID
-07 HI
28 O
PR

17-23
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
STEERING SHAFT (Except FM2/FA2/
FA6 models)
REMOVAL

S. O
Remove the following:

L.
S AD
[2] [1]
– front fender/carrier (page 2-8) [2]

R.
– handlebar cover/stay assembly (page 23-6)
– cotter pins [1] (from the tie-rods)

OR RIZ
– joint nuts [2] (by holding the joint stud flat surfaces)
– tie-rods [3] (from the steering arm)
– cotter pin [4] (from the steering shaft)
– shaft end nut and washer [5]

OT TO
– steering arm [6] [6]
[5]

LM U
RA O A
[4] [3]

Support the – hose clamp bolt [1]

[3] [6]

AB N
handlebar securely – hose clamp [2]
while keeping the – handlebar holder bolts [3]
master cylinder – stay [4]

-C O
[2]
reservoir upright. – handlebar holders [5]
– handlebar assembly [6] (from the steering shaft)

L. US
S. N O
[1]
R.
RS IÓ

[5] [4]

Release the brake hose [1] from the clamp [2].

TO UC

[1]
Remove the following:
– bolts [3] [6]
MO RIB

– steering shaft holder [4]

– shaft bushing [5]
– steering shaft [6]
[5]
AL ST
BR DI
CA SU

[2] [3] [4]

– three trim clips [1]

[3] [1] [1]
– radiator mounting bolts [2]
24 O

Release the fan motor breather hose [3] and front final
gear case breather hose [4] from the radiator grille
-20 BID

covers.
Remove the radiator mounting bosses from the
grommets and move the radiator assembly forward.
-07 HI
28 O
PR

[2] [4] [2]

17-24
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the nuts [1], bolt [2] and bearing holder [3].
[1] [1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[3] [2]

BEARING REPLACEMENT

LM U
Turn the inner race of the steering shaft bearing with
[3] [2]

RA O A
your finger.
The bearing should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
bearing holder.

AB N
Remove the following from the bearing holder [1]:
– dust seals [2]

-C O
– snap ring [3]
– bearing [4]

L. US
S. N O
[4] [2] [1]

Pack the cavities of a new bearing [1] with 2 – 3 g (0.07

– 0.11 oz) of molybdenum disulfide grease.
R.
RS IÓ

Drive the bearing into the bearing holder [2] with the
marked side facing up. [3]
TO UC

TOOLS:
Driver [3] 07749-0010000
Attachment, 42 x 47 mm [4] 07746-0010300
MO RIB

[4]
Pilot 20 mm [5] 07746-0040500
AL ST

[2]
[1] [5]
BR DI

Make sure the snap Install the snap ring [1] into the groove properly with the
[1] [2]
ring is firmly seated chamfered edge facing down.
CA SU

in the groove.
Coat the lips of new dust seals [2] with molybdenum
disulfide grease.
Install each dust seal with the flat side facing out so that
24 O

it is flush with the bearing holder edge.

-20 BID
-07 HI

[2]
28 O
PR

17-25
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Temporarily install the following:
[3] [3]
– lower steering bearing holder [1]

S. O
– bolt [2]
– new nuts [3]

L.
S AD
R.
OR RIZ
OT TO
[1] [2]

LM U
Apply 2 – 3 g (0.07 – 0.11 oz) of grease to the shaft
[6] [2] [4]

RA O A
bushing [1] sliding surface.
Install the shaft bushing onto the steering shaft [2] with
the arrow mark [3] facing up.
Install the steering shaft into the bearing in the bearing

AB N
holder.
Install the steering shaft holder [4] and tighten the bolts

-C O
[5] alternately in several steps to the specified torque.

L. US
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)
Install the brake hose [6] into the clamp [7].
S. N O
[3] [1] [7] [5]

Tighten the bearing holder nut to the specified torque in

[1] [2] [3]
the following sequence:
R.
RS IÓ

1. front left nut [1]

2. front right nut [2]
TO UC

3. rear nut [3]

TORQUE: 33.5 N·m (3.4 kgf·m, 25 lbf·ft)
MO RIB
AL ST
BR DI

Install the radiator assembly in place by inserting the

[3] [2] [2]
bosses into the grommets.
CA SU

Install the following:

– radiator mounting bolts [1]
– three trim clips [2]
24 O

– fan motor breather hose [3]

– front final gear case breather hose [4]
-20 BID
-07 HI
28 O

[1] [4] [1]

PR

17-26
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the handlebar [1] and upper holders [2] with the
[3] [5] [1]
punch mark [3] facing forward.
Install the stay [4] and bolts [5].
Align the punch mark [6] on the handlebar with the top [7]

S. O
edge of the lower holder and tighten the front bolts first,
then tighten the rear bolts.

L.
S AD
Install the hose clamp [7] with a new clamp bolt [8] and
tighten it to the specified torque.

R.
OR RIZ
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[8]

OT TO
[2] [6] [4]

Apply molybdenum disulfide grease to the steering

LM U
[1]
shaft spline [1].

RA O A
Install the steering arm [2] over the steering shaft with
the marked side facing down by aligning the wide
groove with the wide tooth.
Install the washer and a new end nut [3], and tighten the

AB N
nut to the specified torque.
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)

-C O
Install a new cotter pin [4].

L. US
Install the tie-rods [5] into the steering arm.
Install new joint nuts [6] and tighten them to the
specified torque by holding the joint stud flat surfaces. Align [2]
S. N O
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)
[6] [7]
Install new cotter pins [7] into the ball joint studs. [6]
R.
RS IÓ

Install the following:

– front fender/carrier (page 2-8)
TO UC

– handlebar cover/stay assembly (page 23-6)

[2]
MO RIB

[3]
AL ST

[4] [5]

STEERING SHAFT/EPS UNIT (FM2/FA2/

BR DI

FA6 models)
CA SU

REMOVAL
Remove the following:
[7] [6] [2] [1] [2]
– front fender/carrier (page 2-8)
24 O

– handlebar cover/stay assembly (page 23-6)

– cotter pins [1] (from the tie-rods)
-20 BID

– joint nuts [2] (by holding the joint stud flat surfaces)
– tie-rods [3] (from the steering arm)
– cotter pin [4] (from the steering shaft)
– shaft end nut [5] and washer [6]
-07 HI

– steering arm [7]

28 O
PR

[4] [5] [3] Hold

17-27
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Support the – hose clamp bolt [1]
[2] [3] [6]
handlebar securely – hose clamp [2]
while keeping the – handlebar holder bolts [3]
master cylinder – stay [4]
– handlebar holders [5]

S. O
reservoir upright.
– handlebar assembly [6] (from the steering shaft)

L.
S AD
R.
OR RIZ
OT TO
[1] [5] [4]

Release the brake hose [1] from the clamp [2].

[1]

LM U
Remove the following:

RA O A
– bolts [3]
– steering shaft holder [4]
– shaft bushing [5]

AB N
[5]

-C O
L. US [2] [3] [4]
S. N O
Remove the bolt [1] and steering shaft [2].
R.
RS IÓ
TO UC
MO RIB
AL ST

[1] [2]

Disconnect the following:

BR DI

[1]
– EPS motor 2P (Gray) connector [1]
– torque sensor 3P (Gray) connector [2]
CA SU
24 O
-20 BID
-07 HI

[2]
28 O
PR

17-28
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
– three trim clips [1]
[1] [1]
– radiator mounting bolts [2]
Remove the radiator mounting bosses from the
grommets and move the radiator assembly forward.

S. O
L.
S AD
R.
OR RIZ
OT TO
[2] [2]

Hold the EPS unit Remove the nuts [1], bolt [2] and EPS unit [3].
[3]

LM U
securely and
maneuver it out of

RA O A
the frame to the left
side, being careful
not to damage the
shaft splines.

AB N
-C O
L. US [1] [2]
S. N O
INSPECTION
Inspect the following parts for damage, abnormal wear,
bend, distortion.
R.
RS IÓ

– steering shaft
– shaft bushing
TO UC

– EPS unit

INSTALLATION
MO RIB

Hold the EPS unit Install the EPS unit [1] into the frame.
[1]
securely and
Install the mounting bolt [2] from the left side and new
carefully maneuver
nuts [3], but do not tighten them yet.
AL ST

it into place, being

careful not to
damage the shaft
BR DI

splines.
CA SU
24 O

[3] [2]
-20 BID
-07 HI
28 O
PR

17-29
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Connect the following:
[1]
– EPS motor 2P (Gray) connector [1]
– torque sensor 3P (Gray) connector [2]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

Install the steering shaft [1] over the EPS unit input

LM U
[1] [3]
shaft [2] by aligning the wide groove with the wide tooth.

RA O A
Install a new steering shaft pinch bolt [3] by aligning the
bolt holes and groove, and tighten it to the specified
torque.
TORQUE: 60 N·m (6.1 kgf·m, 44 lbf·ft)

AB N
-C O
L. US [2] Align
S. N O
Apply 2 – 3 g (0.07 – 0.11 oz) of grease to the shaft
[6] [2] [4]
bushing [1] sliding surface.
Install the shaft bushing onto the steering shaft [2] with
R.
RS IÓ

the arrow mark [3] facing up.

Install the steering shaft holder [4] and loosely install
TO UC

the bolts [5].

Tighten the steering shaft holder bolts alternately in
several steps to the specified torque.
MO RIB

TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)

Install the brake hose [6] into the clamp [7].
AL ST

[3] [1] [7] [5]

Tighten the bearing holder nut to the specified torque in

BR DI

[3]
the following sequence:
1. front left nut [1]
CA SU

2. front right nut [2]

3. rear nut [3]
TORQUE: 33.5 N·m (3.4 kgf·m, 25 lbf·ft)
24 O
-20 BID
-07 HI

[2] [1]
28 O
PR

17-30
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the radiator assembly in place by inserting the
[2] [2]
bosses into the grommets.
Install the following:

S. O
– radiator mounting bolts [1]
– three trim clips [2]

L.
S AD
R.
OR RIZ
OT TO
[1] [1]

Install the handlebar [1] and upper holders [2] with the

LM U
[7] [3] [5] [1]
punch mark [3] facing forward.
Install the stay [4] and bolts [5].

RA O A
Align the punch mark [6] on the handlebar with the top
edge of the lower holder and tighten the front bolts first,
then tighten the rear bolts.

AB N
Install the hose clamp [7] with a new clamp bolt [8] and
tighten it to the specified torque.

-C O
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

L. US [8] [2] [6] [4]

S. N O
Apply molybdenum disulfide grease to the splines of the
[1] [3]
EPS unit output shaft [1].
Install the steering Install the steering arm [2] onto the output shaft by
R.
RS IÓ

arm with the "HR3" aligning the wide groove with the wide tooth.
mark facing the
Install the washer [3] and a new nut [4], and tighten the
TO UC

EPS unit.
nut to the specified torque.
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)
MO RIB

Install a new cotter pin [5].

AL ST

[2] Align [5] [4]

Install the tie-rods [1] into the steering arm [2].

BR DI

[4]
Install new joint nuts [3] and tighten them to the
specified torque by holding the joint stud flat surfaces.
CA SU

TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)

Install new cotter pins [4] into the ball joint studs.
Install the following:
24 O

– front fender/carrier (page 2-8) [3]

-20 BID

– handlebar cover/stay assembly (page 23-6)

Perform the torque sensor initialization (page 25-9).
-07 HI

[1] [2]
28 O
PR

17-31
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
TIE-ROD
REMOVAL
Remove the following:

S. O
– center mudguard (page 2-5)

L.
S AD
– front wheel (page 17-10)

R.
Remove the cotter pins [1].

OR RIZ
Remove the joint nuts [2] by holding the joint stud flat
surfaces with an open end wrench.
Remove the tie-rod [3] from the steering arm and [3]
knuckle.

OT TO
LM U
[2] [1]

RA O A
[1]

AB N
-C O
[3]

L. US
[2]
S. N O
R.
RS IÓ

INSPECTION
Inspect the tie-rod [1] for distortion or damage.
TO UC

[1]
Inspect the ball joint boots [2] for tears or other damage
and the ball joints for looseness by moving the ball joint
studs [3].
MO RIB

They should move freely and smoothly without binding.

AL ST
BR DI
CA SU

[3] [2]

DISASSEMBLY/ASSEMBLY
Loosen the lock nuts [1], and remove the ball joints and
24 O

[1]
lock nuts from the tie-rod.
-20 BID

Install the right-hand threads nut and unmarked ball

joint on the flat [2] (wrench holding area for toe
adjustment) side of the tie-rod, and the left-hand
threads nut and "L" marked [3] ball joint on the opposite
-07 HI

side.
28 O
PR

[2] [3]

17-32
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Note the reference distances (between the lock nut and
thread end).

REFERENCE DISTANCES:
Except FA5/FA6: A: 6.8 mm (0.27 in)

S. O
B: 6.8 mm (0.27 in)

L.
S AD
FA5/FA6: A: 7.3 mm (0.29 in)
B: 7.3 mm (0.29 in)

R.
A difference between distances A and B should be 3

OR RIZ
mm (0.12 in) max. B A
Tighten these nuts Temporarily tighten the lock nuts while the ball joint
after installing the positions are approximately 180° from each other.

OT TO
tie-rod and
adjusting the toe.

LM U
INSTALLATION

RA O A
Install the tie-rod with the flats [1] of the rod toward the
Hold
knuckle.
Install new joint nuts [2] and tighten them by holding the

AB N
joint stud flat surfaces.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)

-C O
Install new cotter pins [3].
[1]

L. US
Install the front wheel (page 17-10).
Adjust the toe (page 3-37).
Install the center mudguard (page 2-5)
S. N O
[2] [3]
R.
RS IÓ

[3]
TO UC
MO RIB

[2]
AL ST
BR DI

Hold
CA SU
24 O
-20 BID
-07 HI
28 O
PR

17-33
 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

18. REAR WHEEL/SUSPENSION

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 18-2 REAR SHOCK ABSORBER··················· 18-6

RA O A
TROUBLESHOOTING ·························· 18-3 SWINGARM (Except FA5/FA6) ·············· 18-9

AB N
SYSTEM COMPONENTS ······················ 18-4 REAR WHEEL HUB/KNUCKLE
(FA5/FA6)·········································· 18-10

-C O
REAR WHEEL····································· 18-6

L. US
REAR SUSPENSION ARM (FA5/FA6) ···· 18-13
S. N O
R.
RS IÓ
TO UC
MO RIB

18
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

18-1
 dummyhead

REAR WHEEL/SUSPENSION
SERVICE INFORMATION
REAR WHEEL/SUSPENSION

GENERAL
• This section covers service of the rear wheel, rear shock absorber, swingarm (except FA5/FA6) and rear suspension arm (FA5/

S. O
FA6).
• A jack or other support is required to support the vehicle.

L.
S AD
• Use Honda genuine replacement bolts and nuts for all suspension pivots and mounting points.

R.
• For tire information, see Front Wheel/Suspension/Steering section (page 17-10).
• For brake system service, see Brake System section (page 19-2).

OR RIZ
• For driving mechanism service, see Rear Driving Mechanism section (page 20-2).

TOOLS

OT TO
Driver Attachment, 62 x 68 mm
07749-0010000 07746-0010500

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

18-2
dummyhead

REAR WHEEL/SUSPENSION
TROUBLESHOOTING
Except FA5/FA6:
Rear wheel wobbling

S. O
• Bent rim
• Worn or damaged rear axle bearings

L.
S AD
• Faulty tire

R.
• Axle fastener not tightened properly
• Loose wheel hub nut

OR RIZ
• Faulty swingarm pivot bushings
Rear wheel hard to turn
• Faulty rear axle bearings

OT TO
• Bent rear axle
• Rear brake drag
Soft suspension

LM U
• Weak shock absorber spring
• Oil leakage from damper unit

RA O A
Stiff suspension
• Damaged shock absorber damper
• Faulty shock absorber pivot bushings

AB N
• Damaged swingarm pivot bushings
Rear suspension noise

-C O
• Faulty rear shock absorber
• Loose rear suspension fasteners

L. US
• Worn rear suspension pivot bushings
FA5/FA6:
Rear wheel wobbling
S. N O
• Bent rim
• Worn or damaged knuckle bearings
• Faulty tire
• Loose wheel hub nut
R.
RS IÓ

• Loose rear suspension fasteners

Soft suspension
TO UC

• Weak shock absorber spring

• Oil leakage from damper unit
Stiff suspension
MO RIB

• Damaged shock absorber damper

• Faulty shock absorber pivot bushings
• Improperly installed suspension arms
• Faulty suspension arm bushings
AL ST

Rear suspension noise

• Faulty rear shock absorber
BR DI

• Loose rear suspension fasteners

• Worn suspension pivot bushings
• Damaged suspension components
CA SU

Steers to one side or does not track straight

• Unequal tire pressure
• Bent suspension arm or frame
• Worn or damaged knuckle bearing
24 O

• Weak shock absorber

-20 BID
-07 HI
28 O
PR

18-3
 dummyhead

REAR WHEEL/SUSPENSION
SYSTEM COMPONENTS
Except FA5/FA6:

S. O
L.
S AD
R.
OR RIZ
OT TO
64 N·m (6.5 kgf·m, 47 lbf·ft)

LM U
RA O A
AB N
-C O
L. US
S. N O

113 N·m (11.5 kgf·m, 83 lbf·ft)

R.
RS IÓ

’14 – ’19: 130 N·m (13.3 kgf·m, 96 lbf·ft)

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

After ’19: 120 N·m (12.2 kgf·m, 89 lbf·ft)

28 O
PR

34 N·m (3.5 kgf·m, 25 lbf·ft)

18-4
dummyhead

REAR WHEEL/SUSPENSION
FA5/FA6:

44 N·m (4.5 kgf·m, 32 lbf·ft)

44 N·m (4.5 kgf·m, 32 lbf·ft)

S. O
L.
S AD
R.
OR RIZ
44 N·m (4.5 kgf·m, 32 lbf·ft)

OT TO
LM U
RA O A
AB N
88 N·m (9.0 kgf·m,

-C O
65 lbf·ft)

L. US
S. N O
34 N·m (3.5 kgf·m,
25 lbf·ft)
R.
RS IÓ
TO UC

26.5 N·m (2.7 kgf·m, 20 lbf·ft)

MO RIB

44 N·m (4.5 kgf·m,

32 lbf·ft)
AL ST
BR DI

39 N·m (4.0 kgf·m, 29 lbf·ft)

CA SU
24 O
-20 BID

137 N·m (14.0 kgf·m, 101 lbf·ft)

-07 HI
28 O
PR

64 N·m (6.5 kgf·m, 47 lbf·ft)

18-5
 dummyhead

REAR WHEEL/SUSPENSION
REAR WHEEL
REMOVAL
Loosen the wheel nuts.

S. O
[2]
Support the vehicle using a hoist or equivalent and

L.
S AD
raise the rear wheels off the ground.

R.
Remove the wheel nuts [1] and rear wheel.

OR RIZ
For tire removal/installation and repair, see Front [3]
Wheel/Suspension/Steering section (page 17-10).

OT TO
INSTALLATION
Do not interchange Install the rear wheel with the tire valve facing out and
the left and right the arrow mark [2] facing in the normal rotating

LM U
wheels direction.
[1]

RA O A
Install the wheel nuts with the tapered side [3] facing
inward and tighten them.
TORQUE: 64 N·m (6.5 kgf·m, 47 lbf·ft)

AB N
REAR SHOCK ABSORBER

-C O
L. US
REMOVAL/INSTALLATION
Except FA5/FA6:
Remove the seat (page 2-3).
S. N O
[2] [1]
Support the vehicle using a hoist or equivalent and
raise the rear wheels off the ground.
Loosen the shock absorber mounting nuts [1] and
R.
RS IÓ

remove them.
Support the swingarm, and remove the mounting bolts
TO UC

[2] and shock absorber [3].

Insert the bolts from Install the shock absorber [1] with the mounting bolts [2]
the right side. and new nuts [3].
MO RIB

Tighten the upper mounting nut.

Tighten the lower mounting bolt to the specified torque.
TORQUE: 113 N·m (11.5 kgf·m, 83 lbf·ft)
AL ST

Install the seat (page 2-3). [3]

BR DI
CA SU
24 O
-20 BID

[1] [2]
-07 HI
28 O
PR

18-6
dummyhead

REAR WHEEL/SUSPENSION
FA5/FA6:
Raise the rear wheel off the ground.
[2]
Remove the following:

S. O
– lower mounting nut [1]
– mounting bolt [2] and two washers [3]

L.
S AD
R.
OR RIZ
OT TO
[1] [3]

LM U
– upper mounting nut [1] and bolt [2]

RA O A
– rear shock absorber [3] [1] [2]

AB N
-C O
L. US
S. N O
[3]

Remove the pivot collar [1] and dust seals [2].

[1]
Install new dust seals into the lower pivot with the flat
R.
RS IÓ

side facing the bushing until they are fully seated.

Apply molybdenum disulfide grease to the lower pivot
TO UC

bushing and dust seal lips.

Install the pivot collar.
MO RIB
AL ST

[2]
BR DI

Insert the bolt from Install the shock absorber [1] with the mounting bolt [2]
the front side. and a new nut [3]. [3] [2]
CA SU
24 O
-20 BID
-07 HI

[1]
28 O
PR

18-7
 dummyhead

REAR WHEEL/SUSPENSION
Insert the bolt from Connect the shock absorber [1] to the lower arm with
[1]
the rear side. the mounting bolt [2], washers [3] (on both sides of the
pivot) and a new nut [4].
Tighten the mounting nuts to the specified torque.

S. O
[2]
TORQUE:

L.
S AD
Upper: 44 N·m (4.5 kgf·m, 32 lbf·ft)
Lower: 88 N·m (9.0 kgf·m, 65 lbf·ft)

R.
OR RIZ
OT TO
[4] [3]

INSPECTION

LM U
Except FA5/FA6:

RA O A
Check the pivot bushing [1] for wear or damage.
[2]
Check the damper unit [2] for leakage or other damage.
Replace the shock absorber assembly if necessary.

AB N
-C O
L. US
S. N O
[1]

FA5/FA6:
R.
RS IÓ

Check the pivot bushings [1] for wear or damage.

Check the damper unit [2] for leaks or other damage. [2]
TO UC

Check the lower pivot collar [3] for wear or damage.

Replace the shock absorber assembly if necessary.
MO RIB
AL ST
BR DI

[1]
[3]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

18-8
dummyhead

REAR WHEEL/SUSPENSION
SWINGARM (Except FA5/FA6)
REMOVAL
Remove the following:

S. O
[1]
– final gear assembly (page 21-13)

L.
S AD
– final gear case breather hose [1] (from the clamps)
– shock absorber lower mounting nut [2] and bolt [3]

R.
OR RIZ
OT TO
LM U
[2]/[3]

RA O A
– two nuts [1], bolts [2] and trailer hitch [3]
[1]/[2] [6]
– two pivot nuts [4], bolts [5] and swingarm [6]

AB N
-C O
L. US
S. N O
[4]/[5] [3]
R.
RS IÓ

Check the pivot bushings [1] for wear or damage.

[3] [1]
If the universal joint guard [2] is removed, install it with
TO UC

new bolts [3] and tighten the bolts to the specified

torque.
MO RIB
AL ST
BR DI

[1] [2]
CA SU

INSTALLATION
Insert the bolts from Install the swingarm [1] with the pivot bolts [2] and new
[1] [5]/[6]
the outside. nuts [3].
24 O

’14 – ’19: Tighten the nuts to the specified torque.

-20 BID

TORQUE: 130 N·m (13.3 kgf·m, 96 lbf·ft)

After ’19: Tighten the bolts to the specified torque.

TORQUE: 120 N·m (12.2 kgf·m, 89 lbf·ft)
-07 HI

Install the trailer hitch [4] with the bolts [5] and new nuts
28 O

[6], and tighten the nuts to the specified torque.

TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
PR

[2]/[3] [4]

18-9
 dummyhead

REAR WHEEL/SUSPENSION
Install the shock absorber [1], lower mounting bolt [2]
[4]
and new nut [3], and tighten the nut to the specified
torque.
TORQUE: 113 N·m (11.5 kgf·m, 83 lbf·ft)

S. O
Install the final gear case breather hose [4] into the

L.
S AD
clamps.

R.
Install the final gear assembly (page 21-26).

OR RIZ
OT TO
[2]/[3] [1]

REAR WHEEL HUB/KNUCKLE (FA5/

LM U
FA6)

RA O A
REMOVAL
Remove the following:

AB N
[2] [1]
– rear wheel (page 18-6)
– cotter pin [1]

-C O
– hub nut [2]
– wheel hub [3]

L. US
S. N O
R.
RS IÓ

[3]
– pivot nuts [1] and bolts [2]
TO UC

– knuckle [3] [2]

MO RIB
AL ST
BR DI
CA SU

[1] [3]

– seal caps [1]

[3]
– pivot collars [2] [1]
24 O

– dust seals [3]

-20 BID

[2]
-07 HI
28 O
PR

[3]

18-10
dummyhead

REAR WHEEL/SUSPENSION
INSPECTION
Check the knuckle [1] for damage or cracks.
[1] [4]
Check the pivot collars [2] and bushings [3] for wear or

S. O
damage.
Turn the inner race of the bearing [4] in the knuckle with

L.
S AD
your finger. The bearing should turn smoothly and
quietly. Also check that the bearing outer race fits tightly

R.
in the knuckle.

OR RIZ
[3]

OT TO
[2]

LM U
BEARING REPLACEMENT

RA O A
Remove the snap ring [1].
[2]
Press the bearing [2] out of the knuckle using a suitable
collar.

AB N
-C O
L. US
S. N O
[1]
R.
Carefully press a new bearing [1] in the knuckle [2] with
RS IÓ

[3]
the marking side facing up until it is fully seated.
TO UC

TOOLS: [4]
[3] Driver 07749-0010000
[4] Attachment, 62 x 68 mm 07746-0010500
MO RIB

[2]
AL ST
BR DI

[1]

Install the snap ring [1] into the knuckle with the
CA SU

[1]
chamfered edge facing in while aligning its open end
with the knuckle groove.
24 O
-20 BID
-07 HI
28 O

Align
PR

18-11
 dummyhead

REAR WHEEL/SUSPENSION
INSTALLATION
Install new dust seals [1] onto the knuckle pivot as
specified and apply molybdenum disulfide grease to the [3]
0.2 – 0.8 mm
seal lips. (0.01 – 0.03 in)

S. O
Apply molybdenum disulfide grease to the bushing-to-

L.
S AD
pivot collar contacting surfaces.
Install the pivot collars [2] into the knuckle.

R.
Install the dust seal caps [3] onto the knuckle.

OR RIZ
[1]

OT TO
[2]

LM U
Install the knuckle [1] with its "UP" mark [2] facing up. [2] [3]

RA O A
Insert the bolt from Install the pivot bolts [3] and new nuts [4] and tighten
the front side. them.
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

AB N
-C O
L. US
S. N O
[4] [1]

Apply molybdenum disulfide grease to the drive shaft

splines. [1]
R.
RS IÓ

Install the wheel hub [1].

TO UC
MO RIB
AL ST
BR DI

Apply sealant to the wheel hub nut [1] threads

(page 1-23). [1] [2]
CA SU

Install the wheel hub nut.

Apply rear brake and tighten the hub nut to the
specified torque and further tighten until its grooves
align with the cotter pin hole.
24 O

TORQUE: 137 N·m (14.0 kgf·m, 101 lbf·ft)

-20 BID

Install a new cotter pin [2].

Install the rear wheel (page 18-6).
-07 HI
28 O
PR

18-12
dummyhead

REAR WHEEL/SUSPENSION
REAR SUSPENSION ARM (FA5/FA6)
REMOVAL
UPPER AND LOWER ARMS

S. O
Remove the following:
[1]

L.
S AD
[2]
– wheel hub and knuckle (page 18-10)

R.
– pivot nut [1] and bolt [2]
– upper arm [3]

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

– stabilizer link nut [1] (to disconnect the link) [5]/[6]

– shock absorber lower mounting nut [2] and bolt [3]

AB N
– washers [4]
– lower arm pivot nuts [5] and bolts [6]

-C O
– lower arm [7]

L. US
[1]
S. N O
[2]
R.
[3]
RS IÓ

[4] [7]

STABILIZER ARM AND LINK

TO UC

Remove the following:

[1]
– skid plate (page 2-11)
MO RIB

– link nuts [1]

– stabilizer links [2]
AL ST
BR DI
CA SU

[2]

– four bolts [1] and arm holders [2] [2]

24 O

– stabilizer arm [3] [1]

– stabilizer bushings [4]
-20 BID
-07 HI
28 O

[4]
PR

[3]

18-13
 dummyhead

REAR WHEEL/SUSPENSION
INSPECTION
SUSPENSION ARMS
Remove the bolt [1] and lower arm guard [2].

S. O
[1]

L.
S AD
R.
OR RIZ
OT TO
LM U
[2]

RA O A
Check the pivot bushings [1] for wear or damage.
[2]
Check the suspension arms [2] for distortion or
damage.

AB N
-C O
L. US
S. N O
[1]

STABILIZER ARM AND LINK

R.
RS IÓ

Check the stabilizer bushings [1] for wear or damage.

[2]
TO UC

Check the stabilizer arm [2] for distortion or damage.

MO RIB
AL ST
BR DI

[1]
CA SU

Inspect the ball joint boot [1] of the link for tears or other
damage. [1]
24 O
-20 BID
-07 HI
28 O
PR

18-14
dummyhead

REAR WHEEL/SUSPENSION
INSTALLATION
STABILIZER ARM AND LINK
Apply grease to the arm contacting surfaces of the
bushings [1]. [2]

S. O
[3]
Install the bushings and arm holders [2] onto the

L.
S AD
stabilizer arm [3] with the weld nut on the holder facing
the inside as shown.

R.
OR RIZ
OT TO
LM U
[1]

RA O A
Install the stabilizer arm assembly [1] onto the frame
[2]
with the four bolts [2].

AB N
-C O
L. US
S. N O
[1]

Install each stabilizer link [1] into the stabilizer arm and
R.
RS IÓ

[1]
lower arm with its identification mark [2] facing down.
• "R" mark: right link
TO UC

• "L" mark: left link

Install new nuts [3] and tighten the following fastener to
the specified torque.
MO RIB

TORQUE:
Stabilizer arm holder bolt: [2]
26.5 N·m (2.7 kgf·m, 20 lbf·ft)
AL ST

Stabilizer link nut:

39 N·m (4.0 kgf·m, 29 lbf·ft)
BR DI

Install the skid plate (page 2-11).

CA SU

[3] [2]
24 O
-20 BID
-07 HI
28 O

[1]
PR

18-15
 dummyhead

REAR WHEEL/SUSPENSION
LOWER AND UPPER ARMS
Insert the pivot Install the lower arm [1] into the frame with the pivot [2]/[3]
bolts from the front bolts [2] and new nuts [3], and loosely tighten them.
side.

S. O
Insert the mounting Connect the shock absorber with the lower mounting

L.
S AD
bolt from the rear bolt [4], washers [5] (on both sides of the pivot) and a
side. new nut [6] and tighten it to the specified torque.

R.
[7]
TORQUE: 88 N·m (9.0 kgf·m, 65 lbf·ft)

OR RIZ
Connect the stabilizer link with a new nut [7] and tighten
it to the specified torque. [6]

OT TO
TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft)
[4] [1]
[5]

LM U
Insert the pivot bolt Install the upper arm [1] into the frame with the pivot
[3]

RA O A
from the rear side. bolt [2] and a new nut [3], and loosely tighten them. [2]
Install the knuckle and wheel hub (page 18-12).
Place the vehicle on a level ground and tighten the

AB N
following fasteners to the specified torque.
TORQUE:

-C O
Upper arm pivot nut (frame side):
44 N·m (4.5 kgf·m, 32 lbf·ft)

L. US
Lower arm pivot nut (frame side):
34 N·m (3.5 kgf·m, 25 lbf·ft)
Upper and lower arm pivot nut (knuckle side):
S. N O
44 N·m (4.5 kgf·m, 32 lbf·ft)
[1]
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

18-16
dummytext

19. BRAKE SYSTEM

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 19-2 FRONT BRAKE CALIPER ···················· 19-14

RA O A
TROUBLESHOOTING ·························· 19-3 REAR BRAKE DRUM/SHOES
(Except FA5/FA6) ······························· 19-16

AB N
SYSTEM COMPONENTS ······················ 19-4
REAR BRAKE PEDAL

-C O
BRAKE FLUID REPLACEMENT/AIR (Except FA5/FA6) ······························· 19-20

L. US
BLEEDING ········································· 19-7
REAR BRAKE MASTER CYLINDER/BRAKE
BRAKE PAD/DISC ······························19-10 PEDAL (FA5/FA6)······························· 19-21
S. N O
FRONT MASTER CYLINDER················19-12 REAR BRAKE CALIPER (FA5/FA6)······· 19-24
R.
REAR BRAKE LEVER (FA5/FA6) ·········· 19-30
RS IÓ
TO UC
MO RIB

19
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

19-1
 dummyhead

BRAKE SYSTEM
SERVICE INFORMATION
BRAKE SYSTEM

GENERAL

S. O
L.
S AD
Frequent inhalation of brake pad or lining dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.

R.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

OR RIZ
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful

OT TO
whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
• A contaminated brake disc, pad, drum or shoe reduces stopping power. Discard contaminated pads or shoes, and clean a
contaminated disc or drum with a high quality brake degreasing agent.

LM U
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.

RA O A
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as
they may not be compatible.
• Always check brake operation before riding the vehicle.

AB N
TOOLS

-C O
Base assembly, 56 x 66 mm Attachment, 62 x 68 mm Attachment, 72 x 75 mm

L. US
070MF-MEC0300 07746-0010500 07746-0010600
S. N O
R.
RS IÓ
TO UC

or Support base
07965-SD90100 (U.S.A. only)
MO RIB

Lock nut wrench, 20 x 24 mm Snap ring pliers Driver

07716-0020100 07914-SA50001 07749-0010000
AL ST
BR DI
CA SU
24 O

or 07914-3230001
-20 BID
-07 HI
28 O
PR

19-2
dummyhead

BRAKE SYSTEM
TROUBLESHOOTING
FRONT DISC BRAKE (All models)/REAR DISC BRAKE (FA5/FA6)
Brake lever/pedal soft or spongy

S. O
• Air in hydraulic system
• Leaking hydraulic system

L.
S AD
• Contaminated brake pad/disc

R.
• Worn caliper piston seal
• Worn master cylinder piston cups

OR RIZ
• Worn brake pad/disc
• Contaminated caliper
• Contaminated master cylinder
• Caliper not sliding properly

OT TO
• Low brake fluid level
• Clogged fluid passage
• Warped/deformed brake disc

LM U
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston

RA O A
• Bent brake lever/pedal
Brake lever/pedal hard
• Clogged/restricted brake system

AB N
• Sticking/worn caliper piston
• Sticking/worn master cylinder piston
• Caliper not sliding properly

-C O
• Bent brake lever/pedal

L. US
Brake drags
• Contaminated brake pad/disc
• Badly worn brake pad/disc
• Warped/deformed brake disc
S. N O
• Caliper not sliding properly
• Clogged/restricted fluid passage
• Sticking caliper piston
R.
RS IÓ

REAR DRUM BRAKE (Except FA5/FA6)

TO UC

Poor brake performance

• Brake not adjusted properly
• Worn or contaminated brake shoes
MO RIB

• Worn or contaminated brake drum

• Water in brake drum
• Incorrectly installed rear brake arm
• Worn rear brake cam
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

19-3
 dummyhead

BRAKE SYSTEM
SYSTEM COMPONENTS
FRONT:

S. O
L.
S AD
12 N·m (1.2 kgf·m, 9 lbf·ft) 2 N·m (0.2 kgf·m, 1.5 lbf·ft)

R.
OR RIZ
OT TO
LM U
RA O A
AB N
-C O
34 N·m (3.5 kgf·m, 25 lbf·ft)

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

30 N·m (3.1 kgf·m, 22 lbf·ft)

17.2 N·m (1.8 kgf·m, 13 lbf·ft)
28 O

34 N·m (3.5 kgf·m, 25 lbf·ft)

PR

2.4 N·m (0.2 kgf·m, 1.8 lbf·ft)

11 N·m (1.1 kgf·m, 8 lbf·ft)

19-4
dummyhead

BRAKE SYSTEM
REAR (Except FA5/FA6):

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

20 N·m (2.0 kgf·m, 15 lbf·ft)

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

137 N·m (14.0 kgf·m, 101 lbf·ft)

-07 HI
28 O
PR

19-5
 dummyhead

BRAKE SYSTEM
REAR (FA5/FA6):

S. O
34 N·m (3.5 kgf·m, 25 lbf·ft)

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

34 N·m (3.5 kgf·m, 25 lbf·ft)

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

30 N·m (3.1 kgf·m, 22 lbf·ft)

19-6
dummyhead

BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING

S. O
FRONT BRAKE:

L.
S AD
Turn the handlebar to the left until the reservoir is level
[2] [1]

R.
before removing the reservoir cap [1].

OR RIZ
Remove the screws [2], reservoir cap, set plate and
diaphragm.

OT TO
LM U
RA O A
AB N
Connect a bleed hose [1] to the front brake caliper
[1]
bleed valve [2].

-C O
Loosen the bleed valve and pump the front brake lever
until no more fluid flows out of the bleed valve.

L. US
Perform above procedure for the other side bleed valve.
S. N O
R.
RS IÓ

[2]
TO UC

REAR BRAKE (FA5/FA6)

Remove the rear brake reservoir cap [1], set plate [2]
MO RIB

and diaphragm [3]. [1]/[2]/[3]

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

19-7
 dummyhead

BRAKE SYSTEM
Connect a bleed hose [1] to the rear brake caliper bleed
valve [2]. [2]
Loosen the bleed valve and pump the brake pedal until
no more fluid flows out of the bleed valve.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

BRAKE FLUID FILLING/BLEEDING

LM U
FRONT BRAKE:

RA O A
Close each brake caliper bleed valve.
[1]
Fill the master cylinder reservoir to the casting ledge [1]
with DOT 4 brake fluid from a sealed container.

AB N
Follow the Connect a commercially available brake bleeder to the
manufacturer’s bleed valve.

-C O
operating
Operate the brake bleeder and loosen the bleed valve.
instructions.

L. US
Check the fluid level If an automatic refill system is not used, add fluid when
often while bleeding the fluid level in the reservoir is low.
the brake to prevent
air from being
S. N O
pumped into the
system.
If air enters the Perform the bleeding procedure until the system is
bleeder from completely flushed/bled.
R.
RS IÓ

around the bleed

Perform air bleeding for the other side bleed valve.
valve threads, seal
TO UC

the threads with After bleeding air, operate the front brake lever. If it still
teflon tape. feels spongy, bleed the system again.
If the brake bleeder is not available, perform the
[1]
MO RIB

following procedure:
Pump up the system pressure with the front brake lever
until the lever resistance is felt.
AL ST

Connect a bleed hose [1] to the front brake caliper

bleed valve [2] and bleed the system as follows:
Do not release the 1. Squeeze the brake lever all the way and loosen the
BR DI

brake lever until the bleed valve 1/4 of a turn. Wait several seconds and
bleed valve has then close the bleed valve.
been closed.
CA SU

2. Release the brake lever slowly and wait several

seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air [2]
bubbles in the bleed hose.
24 O

Tighten the bleed valve.

-20 BID

TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)

Perform air bleeding for the other side bleed valve.
-07 HI

After bleeding air, operate the front brake lever. If it still

feels spongy, bleed the system again.
28 O

Fill the master cylinder reservoir to the casting ledge

with DOT 4 brake fluid from a sealed container.
PR

Install the diaphragm, set plate and reservoir cap, and

tighten the screws.
TORQUE: 2 N·m (0.2 kgf·m, 1.5 lbf·ft)

19-8
dummyhead

BRAKE SYSTEM
REAR BRAKE (FA5/FA6):
Close the rear brake caliper bleed valve.
[1]
Fill the rear brake reservoir to the "UPPER" level line [1]
with DOT 4 brake fluid from a sealed container.

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
Follow the Connect a commercially available brake bleeder [1] to

RA O A
manufacturer’s the bleed valve [2]. [2]
operating
Operate the brake bleeder and loosen the bleed valve.
instructions.

AB N
Check the fluid level If an automatic refill system is not used, add fluid when
often while bleeding the fluid level in the reservoir is low.

-C O
the brake to prevent
air from being

L. US
pumped into the
system.

If air enters the Perform the bleeding procedure until the system is
S. N O
bleeder from completely flushed/bled. [1]
around the bleed
Tighten the bleed valve.
valve threads, seal
the threads with TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
R.
RS IÓ

teflon tape.
After bleeding air, operate the brake pedal. If it still feels
spongy, bleed the system again.
TO UC

If a brake bleeder is not available, perform the following

procedure:
MO RIB

Pump up the system pressure with the brake pedal until

pedal resistance is felt.
Connect a bleed hose to the rear brake caliper bleed
valve and bleed the system as follows:
AL ST

Do not release the 1. Depress the brake pedal all the way and loosen the
brake pedal until the bleed valve 1/4 of a turn. Wait several seconds and
BR DI

bleed valve has then close the bleed valve.

been closed.
2. Release the brake pedal slowly and wait several
seconds after it reaches the end of its travel.
CA SU

3. Repeat steps 1 and 2 until there are no air bubbles

in the bleed hose.
Tighten the bleed valve to the specified torque.
24 O

TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)

-20 BID

After bleeding air, operate the brake pedal. If it still feels

spongy, bleed the system again.
Fill the reservoir to the "UPPER" level with DOT 4 brake
-07 HI

fluid from a sealed container.

28 O

Install the diaphragm, set plate and reservoir cap.

PR

19-9
 dummyhead

BRAKE SYSTEM
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT
FRONT BRAKE PAD:

S. O
Remove the front wheel (page 17-10).
[4]

L.
S AD
Remove the pad pin plugs [1]. [1] [2]

R.
Loosen the pad pins [2].

OR RIZ
Remove the two mounting bolts [3] and brake caliper
[4].
Check the fluid level Push the caliper piston all the way in by prying the

OT TO
in the master brake pads to allow installation of new pads.
cylinder reservoir as
this operation

LM U
causes the fluid
level to rise.

RA O A
[3]

Pull the pad pins [1] out of the caliper while pushing the
[1]
brake pads [2] in against the pad spring [3], and remove

AB N
the pads.

-C O
Make sure the pad Install new brake pads into the caliper body.
spring is installed Align the pad pin holes in the caliper body and pads by

L. US
correctly. pushing the pads in against the pad spring, and install
Always replace the the pad pins.
brake pads in pairs
to ensure even disc
S. N O
pressure.
R.
RS IÓ

[2] [3]

Install the brake caliper [1] so the disc is positioned

TO UC

[1]
between the pads, being careful not to damage the
pads. [3] [4]
Install new mounting bolts [2] and tighten them to the
MO RIB

specified torque.
TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)
Tighten the pad pins [3] to the specified torque.
AL ST

TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbf·ft)

Install the pad pin plugs [4] and tighten them to the
BR DI

specified torque.
TORQUE: 2.4 N·m (0.2 kgf·m, 1.8 lbf·ft)
CA SU

[2]
Squeeze the front brake lever to seat the caliper piston
against the pad.
Install the front wheel (page 17-10).
24 O
-20 BID
-07 HI
28 O
PR

19-10
dummyhead

BRAKE SYSTEM
REAR BRAKE PAD (FA5/FA6)
Remove the bracket pin retaining bolt [1] and bracket
pin bolt [2]. [2]
Remove the caliper body [3] from the caliper bracket.

S. O
Remove the brake pads [4] from the caliper bracket.

L.
S AD
R.
OR RIZ
OT TO
[3]
[4] [1]

LM U
Rotate the caliper piston clockwise using the special
[2]

RA O A
tool or equivalent to retract it and align the piston
groove [1] with the index mark [2] on the caliper body.

TOOL:
Lock nut wrench, 20 x 24 mm 07716-0020100

AB N
Make sure the pad spring is installed correctly.

-C O
L. US [1]
S. N O
Always replace the Install new pads [1] onto the caliper bracket properly so
brake pads in pairs the wear indicator [2] on the front pad is facing the lower [1]
R.
RS IÓ

to ensure even disc side.

pressure.
TO UC
MO RIB
AL ST

[2]
BR DI

Install the caliper body [1] over the pads and caliper
bracket, aligning the groove in the piston with the pin on [2]
CA SU

the pad.
Install the bracket pin bolt [2] and bracket pin retaining
bolt [3], and tighten them.
24 O

TORQUE:
Bracket pin bolt: 32 N·m (3.3 kgf·m, 24 lbf·ft)
-20 BID

Retaining bolt: 22 N·m (2.2 kgf·m, 16 lbf·ft)

Operate the brake pedal to seat the caliper piston
against the pad. [1]
-07 HI

[3]
28 O

BRAKE DISC INSPECTION

PR

Visually inspect the brake disc for damage or cracks.

Measure the brake disc according to BRAKE SYSTEM
SPECIFICATIONS (page 1-15)and replace if
necessary.

19-11
 dummyhead

BRAKE SYSTEM
FRONT MASTER CYLINDER
DISASSEMBLY/ASSEMBLY
Drain the brake fluid (page 19-7).

S. O
[3]
When removing the Remove the following:

L.
S AD
oil bolt, cover the
– brake switch connectors [1]
end of the hose to

R.
– oil bolt [2]
prevent [4]
– sealing washers [3]

OR RIZ
contamination.
– brake hose [4]

OT TO
LM U
[2] [1]

RA O A
Loosen the screw [1] and rotate the throttle housing [2]
FA models shown: [2]
forward.

AB N
-C O
L. US
S. N O
[1]
R.
RS IÓ

Remove the bolts [1], holder [2] and master cylinder [3].
[3]
TO UC
MO RIB
AL ST
BR DI

[2] [1]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

19-12
dummyhead

BRAKE SYSTEM
Disassemble and assemble the remaining parts as
shown in the illustration.
• Replace the master piston, spring, piston cups and
snap ring as a set.

S. O
• Do not allow the piston cup lips to turn inside out.
• Be certain the snap ring is firmly seated in the groove.

L.
S AD
R.
1.0 N·m (0.1 kgf·m, 0.7
SEPARATOR

OR RIZ
OT TO
PISTON
MASTER SPRING
CUP

LM U
PISTON

RA O A
5.9 N·m (0.6 kgf·m,
4.4 lbf·ft)
(Lever contacting
area)

AB N
SNAP RING

-C O
L. US
PISTON BOOT
S. N O
(Lever pivot)

BRAKE LEVER 1.2 N·m (0.1 kgf·m, 0.9

R.
RS IÓ

Install the master cylinder [1], holder [2] with the "UP"
[1] Align
TO UC

mark [3] facing up, and bolts [4].

Align the edge of the master cylinder with the punch
mark on the handlebar and tighten the upper bolt first,
MO RIB

then tighten the lower bolt to the specified torque.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
AL ST
BR DI

[2] [3] [4]

CA SU

Align the lug on the throttle housing [1] with the mating [1]
FA models shown:
line of the master cylinder and holder, and tighten the
screw [2].
24 O

Align
-20 BID
-07 HI
28 O
PR

[2]

19-13
 dummyhead

BRAKE SYSTEM
Install the brake hose [1] with the new sealing washers
[2]
[2] and oil bolt [3] by setting the brake hose joint
between the stopper groove in the master cylinder.
Tighten the oil bolt to the specified torque.

S. O
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) [1]

L.
S AD
Connect the brake switch connectors [4]

R.
Fill and bleed the hydraulic system (page 19-8).

OR RIZ
OT TO
[3] [4]

INSPECTION

LM U
Check the following parts for scoring, scratches,

RA O A
deterioration or damage.
– Master cylinder
– Master piston
– Piston cups

AB N
– Spring
– Boot

-C O
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-15)and replace if

L. US
necessary.

FRONT BRAKE CALIPER

S. N O
DISASSEMBLY/ASSEMBLY
Remove the front wheel (page 17-10).
R.
RS IÓ

Drain the brake fluid (page 19-7).

TO UC

Except TM1/TE1: Remove the two bolts [1] and

outboard guard [2].
MO RIB

[1]
AL ST
BR DI

[2]
When removing the Remove the following:
[3]
CA SU

oil bolt, cover the

– oil bolt [1]
end of the hose to
– sealing washers [2]
prevent
– brake hose [3]
contamination.
– slide pin plug [4]
24 O

Loosen the slide pin [5].

-20 BID

Remove the brake pads (page 19-10).

[2]
-07 HI

[1]
28 O

[4] [5]
PR

19-14
dummyhead

BRAKE SYSTEM
Disassemble and assemble the remaining parts as
shown in the illustration.

S. O
CALIPER BODY
0.4 g (0.014 oz)

L.
S AD
minimum
SLIDE PIN PISTON SEAL

R.
22 N·m (2.2 kgf·m, 16 lbf·ft)

OR RIZ
0.2 g (0.007 oz)
minimum
SLIDE PIN PLUG
PISTON BOOT

OT TO
LM U
CALIPER PISTON
PAD SPRING

RA O A
AB N
SLIDE PIN BOOT

-C O
BRACKET PIN BOOT

L. US
0.4 g (0.014 oz)
minimum
S. N O
BRACK

CALIPER BRACKET
R.
RS IÓ

SPRING WASHER
TO UC

Tighten the slide pin [1] to the specified torque.

[4] [3]
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)
MO RIB

Install the slide pin plug [2].

Rest the brake hose joint [3] onto the stopper on the
caliper body.
AL ST

Connect the brake hose [4] with the oil bolt [5] and new
sealing washers [6], and tighten the oil bolt] to the
specified torque.
[6]
BR DI

TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft) [5]

CA SU

[1] [2]

Except TM1/TE1: Install the outboard guard [1] and

tighten the bolts [2] to the specified torque.
24 O

TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft)

-20 BID

Fill and bleed the hydraulic system (page 19-8).

Install the front wheel (page 17-10).
-07 HI
28 O

[2]
PR

[1]

19-15
 dummyhead

BRAKE SYSTEM
INSPECTION
Check the caliper cylinder and piston for scoring,
scratches or damage.

S. O
– Caliper cylinder
– Caliper piston

L.
S AD
Measure the brake disc according to BRAKE SYSTEM
SPECIFICATIONS (page 1-15)and replace if

R.
necessary.

OR RIZ
REAR BRAKE DRUM/SHOES (Except

OT TO
FA5/FA6)
BRAKE DRUM REMOVAL

LM U
Remove the right rear wheel (page 18-6).
[3]

RA O A
Remove the following:
– cotter pin [1]
– hub nut [2]
– wheel hub [3]

AB N
[2]

-C O
L. US
S. N O
[1]

– six bolts [1]

[1]
– drum cover [2]
R.
RS IÓ

– dust seal [3]

TO UC
MO RIB
AL ST

[2] [3]
BR DI

– O-ring [1]
[1]
– brake drum [2]
CA SU
24 O
-20 BID
-07 HI

[2]
28 O
PR

19-16
dummyhead

BRAKE SYSTEM
INSPECTION
Check the dust seal in the brake panel for wear or
damage.

S. O
Measure the brake drum according to BRAKE SYSTEM
SPECIFICATIONS (page 1-15)and replace if

L.
S AD
necessary.

R.
For dust seal replacement, see Rear Driving
Mechanism section (page 21-9).

OR RIZ
DISASSEMBLY

OT TO
Always replace the Remove the following:
[4]
brake shoes in
– cotter pins [1]
pairs.
– setting plate [2] [1]

LM U
– brake shoes [3]
– springs [4]

RA O A
AB N
-C O
[3]

L. US
[2]

– adjusting nuts [1]

[4]
– brake cables [2]
S. N O
– joint pins [3]
– springs [4]
– Brake panel drain bolt [5] and washer [6]
R.
RS IÓ

[2]
TO UC

[1]
MO RIB

[5] [6] [3]

AL ST

– nut [1] and bolt [2]

[3]
– brake arm [3]
– wear indicator [4]
BR DI

– return spring [5]

– brake cam [6]
[5]
– felt seal
CA SU

– dust seal

[2]
24 O
-20 BID

[1] [4] [6]

-07 HI
28 O
PR

19-17
 dummyhead

BRAKE SYSTEM
ASSEMBLY
Apply grease to the lips of a new dust seal [1] and
install it with the flat side facing toward the brake arm
until it is fully seated.

S. O
Apply 0.2 – 0.3 g (0.007 – 0.011 oz) of grease to the

L.
S AD
brake cam [2] spindle and install it.

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

LM U
Apply engine oil to a new felt seal [1] and install it over
[1] [2]

RA O A
the brake cam.
Install the return spring [2] by aligning its end with the
hole [3].

AB N
Install the wear indicator [4] by aligning the wide teeth
with the wide groove.

-C O
L. US
[3]
S. N O
Align [4]

Install the brake arm [1] by aligning the punch marks.

[1]
R.
Install the pinch bolt [2] from the punch mark side and
RS IÓ

the nut [3], and tighten it.

TO UC

TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

MO RIB
AL ST

Align

[3] [2]
BR DI

Install the brake cables [1] into the cable holders on the
[2]
brake panel (upper holder for lever brake cable and
CA SU

lower holder for pedal brake cable).

Install the cable springs [2] onto the cables and the joint
pins [3] into the brake arm. Connect the brake cables to
the brake arm with the adjusting nuts [4].
24 O

[1]
Install the brake panel drain bolt with a new sealing
-20 BID

washer [5] and tighten the bolt [6].

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[4]
-07 HI
28 O

[6] [5] [3]

PR

19-18
dummyhead

BRAKE SYSTEM
Apply 0.20 – 0.30 g (0.007 – 0.011 oz) of grease to
[2]
each anchor pin groove and brake cam sliding
surfaces.
Do not get grease Assemble the brake shoes [1] and springs [2] so that

S. O
onto the shoe the spring ends are facing outside as shown and install
linings. the assembly onto the brake panel.

L.
S AD
The cotter pins are Install the setting plate [3] with the chamfered side

R.
installed from the (rolled edge side) facing in and secure it with new cotter

OR RIZ
front side. pins [4].

[1]

OT TO
[4] [3]

BRAKE DRUM INSTALLATION

LM U
Do not get grease Install the brake drum [1] onto the axle until it is fully
[2]

RA O A
to the brake drum seated.
and shoes.
Coat a new O-ring [2] with grease and install it into the
groove in the brake panel [3].

AB N
-C O
L. US
S. N O
[1] [3]

Pack the seal lips of a new dust seal [1] with 3 – 4 g of

[2] [3]
grease.
R.
RS IÓ

Install the dust seal into the drum cover so that it is flush
with the cover surface.
TO UC

TOOLS:
Driver [2] 07749-0010000
Attachment, 62 x 68 mm [3] 07746-0010500
MO RIB

Base Assembly 56 x 66 mm [4] 070MF-MEC0300

U.S.A. TOOLS:
Driver 07749-0010000
AL ST

Attachment, 72 x 75 mm 07746-0010600
Support base 07965-SD90100
[4] [1] (3 – 4 g)
BR DI

Install the drum cover [1], aligning the bolt holes.

[2]
Install the six bolts [2] and tighten them.
CA SU
24 O
-20 BID
-07 HI
28 O

[1]
PR

19-19
 dummyhead

BRAKE SYSTEM
Do not get grease Apply molybdenum disulfide grease to the axle spline
[2] [1]
on the axle threads. [1] and install the wheel hub [2] onto the axle.

S. O
L.
S AD
R.
OR RIZ
OT TO
Apply sealant to the hub nut threads.

LM U
Install the hub nut [1] and tighten it to the specified
torque and further tighten until its grooves align with the

RA O A
cotter pin hole.
TORQUE: 137 N·m (14.0 kgf·m, 101 lbf·ft)
Install a new cotter pin [2].

AB N
Install the right rear wheel (page 18-6).

-C O
Adjust the rear brake (page 3-31).

L. US [2] [1]
S. N O
REAR BRAKE PEDAL (Except FA5/FA6)
REMOVAL/INSTALLATION
R.
RS IÓ

Remove the right center mudguard (page 2-5).

[1] [2]
Disconnect the pedal brake cable from the brake arm
TO UC

(page 19-17).
Remove the following:
MO RIB

– switch spring [1]

– return spring [2]
– brake cable [3] (from the cable holder [4] and pedal)
AL ST
BR DI

[3] [4]
CA SU

– cotter pin [1]

[1]
– washer [2]
24 O
-20 BID
-07 HI
28 O
PR

[2]

19-20
dummyhead

BRAKE SYSTEM
– brake pedal [1]
[1]
– dust seals [2]
Installation is in the reverse order of removal.

S. O
• Replace the dust seals and cotter pin with new ones.
• Apply grease to the brake pedal pivot sliding surface

L.
S AD
and dust seal lips.
• Install the dust seals with the flat side facing out so

R.
that they are flush with the pedal.
• Install the return spring [3] and switch spring [4] in

OR RIZ
the direction as shown.
Adjust the brake pedal freeplay (page 3-31).

OT TO
[2]

[4] [3]

LM U
RA O A
AB N
-C O
L. US
S. N O
REAR BRAKE MASTER CYLINDER/
BRAKE PEDAL (FA5/FA6)
R.
RS IÓ

REMOVAL
Drain the brake fluid from the rear brake hydraulic
TO UC

[1] [2]
system (page 19-7).
Remove the right center mudguard (page 2-5).
MO RIB

Remove the bolt [1] and rear brake reservoir [2]. [4]
Disconnect the brake hose [3] from the master cylinder
by removing the oil bolt [4] and sealing washers [5].
AL ST

[3]
BR DI

[5]
CA SU

Remove the switch spring [1] and return spring [2]. [1]
[5]
Remove the cotter pin [3] and washer [4] from the pedal
24 O

[2]
pivot.
-20 BID

Remove the mounting bolts [5] and the master cylinder/

pedal assembly [6].
-07 HI

[4]
28 O
PR

[6] [3]

19-21
 dummyhead

BRAKE SYSTEM
Remove the following from the master cylinder: [3]
– cotter pin [1] and joint pin [2] (to separate the master
cylinder from the rear brake pedal [3])
– dust seals [4]

S. O
L.
S AD
R.
OR RIZ
[1]

OT TO
[4] [2]

DISASSEMBLY/ASSEMBLY

LM U
• Replace the master piston, spring, piston cups and

RA O A
snap ring as a set.
• Do not allow the piston cup lips to turn inside out.
• Be certain the snap ring is firmly seated in the groove.

AB N
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

-C O
RESERVOIR CAP

L. US
SET PLATE O-RING
79 – 81 mm (3.1 – 3.2 in)
S. N O
R.
RS IÓ

MASTER
TO UC

CYLINDER
MO RIB

DIAPHRAGM (0.1 g)
SPRING
SNAP
RING
AL ST

CUP
BR DI

BOOT
CA SU

MASTER
PISTON
24 O
-20 BID

INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
-07 HI

– Master cylinder/piston
– Piston cups
28 O

– Spring
– Boot
PR

Measure the parts according to BRAKE SYSTEM

SPECIFICATIONS (page 1-15)and replace if
necessary.

19-22
dummyhead

BRAKE SYSTEM
INSTALLATION
Apply grease to the lips of new dust seals [1].
[2]
Install the dust seals with the flat surface facing out until
they are fully seated.

S. O
Assemble the master cylinder and brake pedal [2] with

L.
S AD
the joint pin [3] (outside) and a new cotter pin [4]
(inside).

R.
OR RIZ
[4]

OT TO
[1] [3]

LM U
Apply grease to the groove in the pivot shaft [1].

RA O A
Install the master cylinder/pedal assembly [2] onto the
pivot shaft.

AB N
-C O
L. US
[2]
S. N O
[1]

Install the washer [1] and a new cotter pin [2]. [5]
[3]
R.
Install and tighten the two mounting bolts [3].
RS IÓ

[4]
Install the return spring [4] and switch spring [5] in the
direction as shown.
TO UC
MO RIB

[1]
AL ST

[2]
BR DI

Connect the brake hose [1] to the master cylinder with

[5] [4]
the oil bolt [2] and new sealing washers [3].
CA SU

Rest the hose joint against the stopper and tighten the
oil bolt.
[2]
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
24 O

Install the rear brake reservoir [4] and tighten the bolt
-20 BID

[5]. [1]
Fill and bleed the rear brake hydraulic system
(page 19-9).
-07 HI

Install the right center mudguard (page 2-5). [3]

28 O
PR

19-23
 dummyhead

BRAKE SYSTEM
REAR BRAKE CALIPER (FA5/FA6)
REMOVAL
Drain the brake fluid from the rear brake hydraulic

S. O
[2]
system (page 19-7).

L.
S AD
Remove the brake adjusting nut [1]. Disconnect the
brake cable [2] from the brake arm [3] and remove the

R.
joint pin [4].

OR RIZ
Remove the brake cable from the caliper body.
[4]

OT TO
LM U
[1] [3]

RA O A
Disconnect the brake hose [1] from the caliper body by
[2]
removing the oil bolt [2] and sealing washers [3].

AB N
-C O
L. US
S. N O
[3] [1]
R.
RS IÓ

Loosen the bracket pin bolt [1].

[2] [1]
Remove the two mounting bolts [2] and the brake
TO UC

caliper [3] out of the frame.

MO RIB
AL ST
BR DI

[3]
CA SU

DISASSEMBLY
Remove the slide pin bolt [1] and pivot the caliper body
[2]
[2].
24 O
-20 BID
-07 HI
28 O
PR

[1]

19-24
dummyhead

BRAKE SYSTEM
Remove the brake pads [1] and pad spring [2]. [1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]
Separate the caliper body [1] from the caliper bracket

LM U
[2]. [1] [2]

RA O A
Remove the boots [3] and collar [4] from the caliper
bracket.
[4]

AB N
-C O
L. US [3] [3]
S. N O
Remove the caliper piston [1] by turning it
[2]
counterclockwise.
Remove the piston boot [2].
R.
RS IÓ
TO UC
MO RIB
AL ST

[1]
Be careful not to Push the piston seal [1] in and lift it out.
BR DI

damage the piston [1]

sliding surface.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

19-25
 dummyhead

BRAKE SYSTEM
Remove the snap ring [1] using the special tool.
[1]
TOOL:
[2] Snap ring pliers 07914-SA50001 or
07914-3230001

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

Remove the following:

LM U
[8]
– spring guide [1] [6]

RA O A
– adjusting spring B [2]
– spacer [3] [4]
– bearing A [4]
– adjusting bolt [5]

AB N
– cup [6]
[2]
– sleeve piston [7] [9]
– O-ring [8]

-C O
– rod [9]

L. US
[7]
[5]
[3] [1]
S. N O
– return spring [1]
[4] [2]/[3]
– parking brake arm nut [2] [5]
– spring washer [3]
R.
RS IÓ

– brake arm [4]

– brake cam [5]
– dust cover [6]
TO UC

Clean the disassembled parts.

MO RIB
AL ST

[1] [6]

INSPECTION
BR DI

Check the caliper cylinder and piston for scoring or

other damage.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

19-26
dummyhead

BRAKE SYSTEM
ASSEMBLY

ROD CALIPER BRACKET

PAD SPRING BOOTS

S. O
(0.35 g
(0.4 g
minimum)
minimum)

L.
S AD
COLLAR
CALIPER BODY

R.
O-RING
BRACKET PIN BOLT

OR RIZ
32 N·m (3.3 kgf·m,
RETAINING BOLT 24 lbf·ft)
22 N·m (2.2 kgf·m, 16 lbf·ft)

OT TO
SLEEVE
PISTON
RETAINER
DUST COVER

LM U
(0.35 g minimum) (0.8 g
minimum)

RA O A
BRAKE CAM BEARING A
PISTON SEAL
(0.35 g SPRING
BRAKE
GUIDE

AB N
minimum) ARM CUP
CALIPER PISTON
RETURN

-C O
SPRING (0.1 g minimum)

L. US
SLIDE PIN
WASHER ADJUSTING
BOLT
(0.4 g
S. N O
minimum) SPACER
SNAP RING
ARM NUT
27 N·m (2.8 kgf·m, 20 lbf·ft) ADJUSTING
SPRING B
R.
PISTON BOOT (Seal area: 0.2 g,
RS IÓ

inside: 0.5 – 0.7 g)

TO UC

Apply 0.35 g minimum of silicone grease to the dust

[2] [3] [4]/[5]
cover [1] lips and install it into the caliper body.
Apply 0.35 g minimum of silicone grease to the brake
MO RIB

cam [2] groove and install it into the caliper body with
the groove facing the caliper cylinder.
Install the brake arm [3] and spring washer [4].
AL ST

Apply locking agent to the parking brake arm nut [5]

threads, then install and tighten it to the specified
torque.
BR DI

TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)

Install the return spring [6] as shown.
CA SU

[1] [6]

Coat a new O-ring [1] with silicone grease and install it

into the sleeve piston [2] groove. [1]
24 O

Coat a new cup [3] with 0.1 g minimum of silicone

-20 BID

grease and install it onto the adjusting bolt [4].

[3]
Install the adjusting bolt into the sleeve piston.
Coat the rod [5] ends with 0.35 g minimum of silicone
grease and install it into the sleeve piston. [6]
-07 HI

Apply 0.8 g minimum of silicone grease to the sleeve [8]

piston assembly and install it in the caliper cylinder by [5]
28 O

aligning the pins of the piston with the holes in the

caliper. [2]
PR

[4]
Install bearing A [6], spacer [7], adjusting spring B [8]
and spring guide [9] onto the adjusting bolt. [7]
[9]

19-27
 dummyhead

BRAKE SYSTEM
Install the snap ring [1] using the special tool
[1]
TOOL:
[2] Snap ring pliers 07914-SA50001 or
07914-3230001

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

Coat a new piston seal [1] with clean brake fluid and

LM U
install it into the seal groove in the caliper.

RA O A
Coat the caliper piston [2] with clean brake fluid.
Apply 0.2 g of silicone grease to the seal area, and 0.5 [3]
– 0.7 g to the inside of a new piston boot [3].
Install the piston boot onto the caliper piston.

AB N
Install the piston boot into the groove in the caliper.
Install the caliper piston into the caliper cylinder and
onto the adjusting bolt by turning it clockwise.

-C O
Install the piston boot into the groove in the caliper

L. US
piston.

[1]
[2]
S. N O
Apply 0.4 g minimum of silicone grease to the sliding
[3] [1]
area of new boots [1] and install them into the caliper
bracket.
R.
RS IÓ

Apply 0.4 g minimum of silicone grease to the inner

surface of the bracket pin collar [2] and install it into the
TO UC

caliper bracket.
Coat the slide pin [3] of the caliper body with 0.4 g
minimum of silicone grease and install it into the caliper
MO RIB

bracket.
AL ST

[2]

Install the pad spring [1] in the caliper body as shown.

BR DI

[2]
Install the brake pads [2] onto the caliper bracket.
• Align the piston groove with the index mark
CA SU

(page 19-11).
24 O
-20 BID
-07 HI

[1]
28 O
PR

19-28
dummyhead

BRAKE SYSTEM
Pivot the caliper body [1] over the pads and bracket.
[1]
Temporarily install the bracket pin bolt [2].

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

LM U
INSTALLATION

RA O A
Install the brake caliper [1] with new mounting bolts [2] [3]
and tighten them. [2]

TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)

AB N
Tighten the bracket pin bolt [3].

-C O
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)

L. US
S. N O
[1]
R.
RS IÓ

Connect the brake hose [1] to the brake caliper with the
[2]
oil bolt [2] and new sealing washers [3].
TO UC

Rest the hose joint pin against the stopper and tighten
the oil bolt.
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)
MO RIB
AL ST
BR DI

[3] [1]

Install the rear brake cable [1] into the cable holder of
CA SU

[1]
the caliper body and connect it to the brake arm [2] with
the joint pin [3].
Install the adjusting nut [4].
24 O

Fill and bleed the rear brake hydraulic system

(page 19-9).
-20 BID

[3]
Adjust the brake lever freeplay (page 3-32).
-07 HI
28 O

[2]
PR

[4]

19-29
 dummyhead

BRAKE SYSTEM
REAR BRAKE LEVER (FA5/FA6)
REMOVAL/INSTALLATION
Remove the rear brake lever switch (page 23-13).

S. O
[2]
Loosen the rear brake cable adjuster (page 3-32).

L.
S AD
Loosen the reverse selector cable adjuster (page 3-34).
[3]

R.
Remove the following:

OR RIZ
– pivot nut [1]
– wire holder plate [2] (by releasing the brake lever
switch wire [3])

OT TO
LM U
Align [1]

RA O A
– pivot bolt [1]
– spring [2] [1]
– reverse arm [3] and rear brake lever [4] (from the

AB N
lever bracket)
Disconnect the rear brake cable [5].

-C O
Except after '19 Disconnect the reverse selector cable [6] from the lever.

L. US
Installation is in the reverse order of removal.
• Apply grease to the rear brake cable end.
• Hook the spring ends as shown.
S. N O
• Install the wire holder plate by aligning its hole with
the lever holder boss.
• Tighten the pivot nut while holding the pivot bolt. [2]

TORQUE:
R.
RS IÓ

Rear brake lever pivot bolt: [5] [4]

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
TO UC

Rear brake lever pivot nut:

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
MO RIB

Adjust the rear brake cable (page 3-32).

Except after '19 Adjust the reverse selector cable (page 3-34).
AL ST
BR DI

[6] [3]
CA SU
24 O
-20 BID
-07 HI
28 O
PR

19-30
dummytext

20. FRONT DRIVING MECHANISM (Except TM1/TE1 models)

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 20-2 FRONT FINAL CLUTCH······················· 20-17

RA O A
TROUBLESHOOTING ·························· 20-4 FRONT FINAL GEAR DISASSEMBLY/
INSPECTION ····································· 20-23

AB N
SYSTEM COMPONENTS ······················ 20-5
GEAR CASE AND COVER BEARING

-C O
FRONT DRIVE SHAFT·························· 20-6 REPLACEMENT ································· 20-30

L. US
FRONT FINAL DRIVE REMOVAL ··········20-13
S. N O FRONT FINAL GEAR ASSEMBLY········· 20-33

FRONT PROPELLER SHAFT ···············20-16 FRONT FINAL DRIVE INSTALLATION ··· 20-37
R.
RS IÓ
TO UC
MO RIB
AL ST

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

20-1
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

SERVICE INFORMATION
FRONT DRIVING MECHANISM (Except TM1/TE1 models)

GENERAL
• Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The

S. O
extension lines from the gear engagement surfaces should intersect at one point.
• Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage the gear

L.
S AD
case.

R.
• When using the lock nut wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the
torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The

OR RIZ
specification given is the actual torque applied to the lock nut, not the reading on the torque wrench. Do not overtighten the lock
nut. The specification later in the text gives both actual and indicated.
• Replace the ring and pinion gears as a set.
• Replace the cam followers (12 pieces) as a set, and the cam followers, face cams and differential housing as an assembly if the

OT TO
face cam or differential housing is faulty.

LM U
TOOLS

RA O A
Bearing clip compressor, 26 mm Threaded adaptor Remover weight
070ME-HP50100 070MF-HP50100 07741-0010201

AB N
-C O
L. US
S. N O
or 070ME-HP5A100 (U.S.A. only) or 070MF-HP5A100 (U.S.A. only) 07936-371020A (U.S.A. only)
Attachment, 52 x 55 mm Attachment, 24 x 26 mm Attachment, 22 x 24 mm
R.
RS IÓ

07746-0010400 07746-0010700 07746-0010800

TO UC
MO RIB
AL ST

Attachment, 20 mm I.D. Attachment, 35 mm I.D. Pilot, 12 mm

BR DI

07746-0020400 07746-0030400 07746-0040200

CA SU
24 O
-20 BID
-07 HI
28 O
PR

20-2
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Pilot, 15 mm Pilot, 30 mm Fork Seal Driver Weight
07746-0040300 07746-0040700 07747-0010100

S. O
L.
S AD
R.
OR RIZ
OT TO
Fork Seal Driver Attachment, Driver Locknut Wrench, 34 x 44 mm
33 mm I.D. 07749-0010000 07916-ME50001
07747-0010501 (not available in

LM U
U.S.A.)

RA O A
AB N
-C O
Remover head, 12 mm
L. US Remover shaft, 12 mm Remover shaft, 15 mm
S. N O
07936-1660110 07936-1660120 07936-KC10100 (not available in
U.S.A.)
R.
RS IÓ
TO UC
MO RIB

or 07936-166010A (U.S.A. only)

Remover head, 15 mm
AL ST

Bearing remover, 15 mm Driver

07936-KC10200 (not available in 07936-KC10500 (U.S.A. only) 07949-3710001
U.S.A.)
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

20-3
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Puller shaft and nut Attachment, 40 mm I.D. Pinion Puller Base
07965-VM00200 07GAF-SE00200 07HMC-MM80110

S. O
L.
S AD
R.
OR RIZ
OT TO
or 07931-ME4010B and or 07HMC-MM8011A (U.S.A. only)
07931-HB3020A (U.S.A. only)
Differential inspection tool Pilot 32 mm Half shaft disassembly mould

LM U
07KMK-HC50101 07MAD-PR90200 070MF-HR3A100 (U.S.A. only)

RA O A
AB N
-C O
L. US
or 07KMK-HC5010A (U.S.A. only)
S. N O
TROUBLESHOOTING
R.
RS IÓ

Consistent noise during cruising

• Oil level too low
TO UC

• Foreign matter contaminating gear oil

• Worn or damaged bearing
• Worn or damaged ring gear and pinion gear
• Deformed ring gear or gear case
MO RIB

• Improper tooth contact between ring gear and pinion gear

Gear noises while running
• Oil level too low
AL ST

• Foreign matter contaminating gear oil

• Chipped or damaged gears
• Improper tooth contact between ring gear and pinion gear
BR DI

Gear noises while coasting

• Chipped or damaged gears
CA SU

Abnormal noises when turning

• Worn or damaged ring gear bearing
• Worn or damaged face cams and cam followers
• Worn or damaged differential housing grooves
24 O

• Worn cone spring or shim

Abnormal noises at start or during acceleration
-20 BID

• Excessive backlash between ring gear and pinion gear

• Worn differential splines
• Loose fasteners
• Worn cone spring or shim
-07 HI

Oil leak
28 O

• Oil level too high

• Clogged breather
PR

• Damaged seals
• Loose case cover bolt
Overheating
• Oil level too low
• Insufficient backlash between ring gear and pinion gear

20-4
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 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
44 N·m (4.5 kgf·m, 32 lbf·ft)
R.
RS IÓ
TO UC

10 N·m (1.0 kgf·m, 7 lbf·ft)

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

10 N·m (1.0 kgf·m, 7 lbf·ft)

-07 HI
28 O
PR

44 N·m (4.5 kgf·m, 32 lbf·ft)

20-5
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

FRONT DRIVE SHAFT
REMOVAL
Remove the knuckle (page 17-13).

S. O
[1]
To prevent damage Hold the inboard joint [1] of the drive shaft and tug firmly

L.
S AD
to the differential oil to force the stopper ring on the inboard joint end past
seal, hold the the groove while prying with a screwdriver.

R.
inboard joint

OR RIZ
horizontal until the
drive shaft is clear
of the differential.

OT TO
LM U
RA O A
Remove the stopper ring [1] from the inboard joint.
[1]

AB N
-C O
L. US
S. N O
R.
RS IÓ

DISASSEMBLY/INSPECTION
Check the boots [1] for cuts or other damage.
TO UC

’14 – ’19 shown: [1]

Check the drive shaft joints [2] for excessive play or
noise by moving the joints in a circular direction.
Outboard
If the outboard joint seems to be worn or damaged, the
MO RIB

drive shaft must be replaced.

• To replace the outboard boot, first remove the

AL ST

inboard boot as described in following steps.

Then remove bands and the outboard boot off the
inboard end of the shaft.
BR DI

• The outboard joint can not be disassembled.

Inboard
CA SU

[2]

Cut off and remove the boot bands [1] from inboard
[1]
boot [2].
24 O

Remove the boot from the inboard joint.

-20 BID

Slide the inboard boot away from the inboard joint.

-07 HI
28 O
PR

[2]

20-6
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Remove the following:
– stopper ring [1]
– inboard joint [2]

S. O
[1]

L.
S AD
R.
OR RIZ
OT TO
[2]
Except After ’16 Remove the following:
[3]

LM U
FM1/FE1/FA2:
– snap ring [1]

RA O A
– bearing [2]
– inboard boots [3]
[1]

AB N
-C O
L. US [2]
S. N O
After ’16 FM1/FE1/ Remove the balls [1] from the bearing cage [2] and
[2] [1]
FA2: inner race [3] by tilting the cage as shown.
Slide the bearing cage down into the inboard boot.
R.
RS IÓ
TO UC
MO RIB
AL ST

[3]
After ’16 FM1/FE1/ While holding the drive shaft [1], press it out of the inner
BR DI

[1]
FA2 (Except A, AC race [2] using a suitable tool as shown.
types):
CA SU
24 O
-20 BID
-07 HI

[2]
28 O
PR

20-7
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

After ’16 FM1/FE1/ Place the drive shaft [1] in a vise using a special tool.
[3]
FA2 (A, AC types Do not tighten the vise onto the shaft.
only):
TOOL:
Half shaft disassembly mould [2] 070MF-HR3A100

S. O
While holding the drive shaft, drive it out of the inner

L.
S AD
race [3] using a suitable rod.

R.
OR RIZ
OT TO
[2] [1]
After ’16 FM1/FE1/ Remove the stopper ring [1], inner race [2] and inboard
[2]

LM U
FA2: boot [3] from the drive shaft.

RA O A
AB N
-C O
L. US [3] [1]
S. N O
Replace these Check the following for wear or damage.
[4]
components as an
– bearing cage [1]
assembly.
– race [2]
R.
RS IÓ

– steel balls [3]

– inboard joint [4] [3]
TO UC
MO RIB
AL ST

[1] [2]

Cut off and remove the boot bands [1] from outboard
BR DI

’14 – ’19 shown: [1]

boot [2].
Remove the outboard boot.
CA SU
24 O
-20 BID
-07 HI

[2]
28 O
PR

20-8
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

ASSEMBLY
’14 – ’19 shown: DRIVE SHAFT
SHAFT BOOT BAND

S. O
INBOARD JOINT

L.
S AD
OUTBOARD BOOT

R.
OR RIZ
OUTBOARD JOINT

OT TO
OUTBOARD BOOT BAND

LM U
RA O A
SNAP RING (’14 –’16)

AB N
-C O
BEARING
STOPPER RING

L. US
(After ’16)
S. N O STOPPER RING

INBOARD BOOT BAND

INBOARD BOOT
SHAFT BOOT BAND
R.
RS IÓ

Pack the inboard and outboard joint insides with specified grease.
TO UC

The outboard boot [1] is large and the inboard boot [2]
is small. Do not interchange them.
MO RIB

[2] [1]
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

20-9
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Each boot band has following identification number [1].
’14 – ’19 outboard boot band shown: [1]
’14 – ’16:
INBOARD BOOT BAND: 77
SHAFT BOOT BAND: 78

S. O
OUTBOARD BOOT BAND: 79

L.
S AD
’17 – ’19:

R.
INBOARD BOOT BAND: 68
SHAFT BOOT BAND: 75

OR RIZ
OUTBOARD BOOT BAND: 70
After ’19:

OT TO
INBOARD SHAFT BOOT BAND: 23.75
INBOARD BOOT BAND: 64
OUTBOARD SHAFT BOOT BAND: 0255

LM U
OUTBOARD BOOT BAND: 0710

RA O A
Pack the outboard joint with specified grease.
[1]
’14 – ’16:

AB N
Specified grease: NKG814 (Kyodo Yushi)
Volume: 35 – 55 g (1.2 – 1.9 oz)

-C O
After ’16:

L. US
Specified grease: G.A. Besmoly CE (Brugarolas)
Volume: 50 – 70 g (1.8 – 2.5 oz)
Install the following:
S. N O
– outboard boot [1]
– inboard boot [2]

Specified grease [2]

R.
RS IÓ

Except After ’16 Install the bearing [1] with the small O.D. facing the
FM1/FE1/FA2: drive shaft.
TO UC

Install the snap ring [2] with the chamfered side facing
the bearing.
MO RIB
AL ST
BR DI

[2] [1]
CA SU

After ’16 FM1/FE1/ Install the bearing cage [1] with the small O.D. facing
[1]
FA2: the drive shaft.
Install a new stopper ring [2] into the drive shaft groove.
24 O
-20 BID
-07 HI
28 O
PR

[2]

20-10
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

After ’16 FM1/FE1/ Install the inner race [1] with the chamfered I.D. [2]
[3]
FA2: facing the drive shaft (ring groove [3] side facing
opposite side).
Drive the shaft with a copper hammer until the stopper
ring seats in the ring groove.

S. O
L.
S AD
R.
OR RIZ
OT TO
[2] [1]
After ’16 FM1/FE1/ Assemble the bearing cage [1] and six balls [2] onto the
[2]

LM U
FA2: inner race [3].

RA O A
AB N
-C O
L. US [1] [3]
S. N O
Pack the inboard joint with specified grease.
Specified [2]
’14 – ’16: grease
Specified grease: NKG814 (Kyodo Yushi)
R.
RS IÓ

Volume: 50 – 70 g (1.8 – 2.5 oz)

After ’16:
TO UC

Specified grease: G.A. Besmoly CE (Brugarolas)

Volume: 65 – 85 g (2.3 – 3.0 oz)
MO RIB

Install the inboard joint [1] over the bearing.

Install the stopper ring [2] into the groove in the inboard
joint properly.
Install the boot over the inboard joint.
AL ST

[1]

Adjust the length of the drive shaft to the figure given

BR DI

below.
’14 – ’19
CA SU

DRIVE SHAFT LENGTH:

Except FA5/FA6: Left: 335.9 mm (13.22 in)
Right: 357.5 mm (14.07 in)
FA5/FA6: Left: 361.9 mm (14.25 in)
24 O

Right: 381.1 mm (15.00 in)

-20 BID

After ’19
DRIVE SHAFT LENGTH:
Except FA5/FA6: Left: 336.1 mm (13.23 in)
-07 HI

Right: 357.1 mm (14.06 in)

FA5/FA6: Left: 361.6 mm (14.24 in)
28 O

Right: 381.1 mm (15.00 in)

PR

20-11
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Install new shaft boot band [1] and inboard boot band
[4]
[2] onto the inboard boot [3].

• Note the installation direction of the band.

S. O
Lock
Lock the boot bands using the following tool.

L.
S AD
TOOL:

R.
CV boot band pliers [4] OET14100134
(U.S.A. only) [1]

OR RIZ
[3]

OT TO
[2]

’14 – ’19: Install new shaft boot band [1] and outboard boot band

LM U
[4]
[2] onto the outboard boot [3].

RA O A
• Note the installation direction of the band.
Lock
Lock the boot bands using the following tool.
[3]

AB N
TOOL:
CV boot band pliers [4] OET14100134

-C O
(U.S.A. only) [1]

L. US [2]
S. N O
After ’19: Install new shaft boot band [1] and outboard boot band
[2] onto the outboard boot [3].
R.
RS IÓ

• Note the installation direction of the band. [3]

Lock the boot bands.
TO UC

Lock
MO RIB
AL ST

[1]
[2]
BR DI

INSTALLATION
CA SU

Install a new stopper ring [1] into the groove in the

[1]
inboard joint.
24 O
-20 BID
-07 HI
28 O
PR

20-12
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Be careful not to Install the drive shaft by holding the inboard joint [1]
[1]
damage the oil seal until the stopper ring seats in the groove of the
in the gear case. differential.
Make sure that the stopper ring is seated properly by

S. O
pulling on the inboard joint lightly.

L.
S AD
Install the knuckle (page 17-18).

R.
OR RIZ
OT TO
FRONT FINAL DRIVE REMOVAL

LM U
Drain the front final gear oil (page 3-27).

RA O A
[2] [1]
Remove the following:
– tank cover assembly (page 2-4)
– FA models only: front VS sensor (page 13-77)

AB N
– left drive shaft (page 20-6)
Disconnect the breather hose [1] and select switch

-C O
connector [2] from the final gear case.

L. US
S. N O
Remove the following:
[3]
R.
RS IÓ

– cover bolt [1]

– clutch arm cover [2] (by releasing the two tabs [3])
TO UC
MO RIB
AL ST
BR DI

[2] [1]

– adjusting nut [1]

[4] [3]
– cable retaining plate [2]
CA SU

– selector cable [3] (remove from the cable holder [4]

and joint pin [5])
– cable spring [6]
– joint pin [1]
24 O
-20 BID
-07 HI
28 O

[5] [6] [2]

PR

20-13
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

– base bolts [1]
[2]
– arm cover base [2]
– holder bracket [3]

S. O
L.
S AD
R.
OR RIZ
OT TO
[1] [3]

– final gear case mounting nuts [1] and bolts [2]

LM U
[4] [1]/[2]
– two bolts [3] and mounting bracket [4]

RA O A
AB N
-C O
L. US [3]
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST

[1]/[2]
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

20-14
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Move the gear case assembly forward for maximum
[1] [8]
clearance between the propeller shaft joint [1] and
engine.
Pull the shaft joint out of the output shaft [2] of the

S. O
engine.

L.
S AD
Remove the boot band [3] and release the propeller
shaft boot [4] off the pinion joint [5] of the gear case

R.
assembly.
Pull the propeller shaft [6] to force the stopper ring [7]

OR RIZ
past the groove in the pinion joint to remove the
propeller shaft.
Remove the stopper ring from the propeller shaft.

OT TO
Remove the O-ring [8] from the output shaft. [2]

LM U
[3] [4] [7]

RA O A
AB N
-C O
L. US [5] [6]
S. N O
Separate the right drive shaft [1] from the final gear
[2]
case assembly [2] by tapping the right drive shaft end
lightly through the gear case, using a screwdriver or
R.
equivalent.
RS IÓ

Remove the gear case assembly from the frame.

TO UC
MO RIB
AL ST

[1]

OPERATION CHECK
BR DI

Turn the pinion joint [1] while the clutch arm [2] is set to
[1]
the rear (4WD position), and check that the gear turns
CA SU

smoothly and quietly without binding.

If the gear does not turn smoothly or quietly, the pinion
gear, ring gear, bearing and/or clutch components may
be damaged or faulty. They must be checked after
24 O

disassembly; replace them if necessary.

-20 BID

Operate the change-over mechanism while turning the

pinion joint, check for smooth engagement/
disengagement.
-07 HI
28 O

[2]
PR

20-15
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

FRONT PROPELLER SHAFT
DISASSEMBLY/INSPECTION
Remove the outer boot band [1] and the shaft boot [2]

S. O
[4] [1]
from the propeller shaft joint [3], and remove the joint
from the shaft [4].

L.
S AD
R.
OR RIZ
OT TO
[2]

LM U
[3]

RA O A
Remove the following:
[5] [3] [2]
– joint spring [1]
– shaft seal [2]

AB N
– inner boot bands [3] [5]
– shaft boots [4]

-C O
Check the splines [5] of the propeller shaft and joint for

L. US
wear or damage.
If they are damaged, check the splines of the output
shaft and pinion joint.
Check the boots for cuts, deterioration or damage.
S. N O
Check the seal lips of the pinion joint side boot and
shaft seal for damage.
[4] [1]
R.
RS IÓ

ASSEMBLY
TO UC

Seal lip area on shaft SEAL LIP

MO RIB
AL ST
BR DI

SPLINES
CA SU

PROPELLER
PROPELLER SHAFT JOINT
SHAFT
24 O

Place the inner boot bands [1] on the propeller shaft.

[1] [3]
-20 BID

Do not allow the Apply molybdenum disulfide grease to the seal lips of
seal lip to turn pinion joint side boot and shaft seal.
outside in Install the boots [2] onto the shaft grooves, being
careful not to damage the seal lip.
-07 HI

Install the boot bands into the each boot groove.

Install the shaft seal [3] into the shaft groove.
28 O

Install the joint spring [4] into the propeller shaft

securely.
PR

[2] [4]

20-16
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Apply 5.0 – 8.0 g (0.18 – 0.28 oz) of molybdenum
[2] [4]
disulfide grease to the propeller shaft joint [1] splines.
Set the shaft joint onto the propeller shaft [2] while
compressing the spring, then install the boot [3] over

S. O
the shaft joint groove and the outer boot band [4] into
the boot groove to secure it.

L.
S AD
R.
OR RIZ
[3]

OT TO
[1]

FRONT FINAL CLUTCH

LM U
DISASSEMBLY/INSPECTION

RA O A
The housing is Remove the following:
[3] [8]
under spring
– select switch and sealing washer [1]
pressure; hold the
– three bolts [2]

AB N
housing when
– final clutch housing [3] (by releasing the shift fork [4]
loosening the bolt.
from the clutch sleeve [5])

-C O
– clutch sleeve
– O-ring [6]

L. US
– dowel pins [7]
Check the splines of the pinion joint [8], clutch sleeve [1]
and pinion gear shaft [9] for wear or damage.
S. N O
Check the needle bearing [10] in the pinion gear shaft
for wear or damage.

[2]
R.
RS IÓ

[10]
TO UC

[9]
[4]
MO RIB

[7]
AL ST
BR DI

[5] [6]
CA SU

Release the clutch spring end [1] from the stopper plate
[1] [2]
[2] by pulling the arm shaft [3].
24 O
-20 BID
-07 HI
28 O
PR

[3]

20-17
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Remove the fork bolt [1].
[1]
Pry the clutch arm tab [2] to release it from the collar [3]
and slide the shaft [4] outward.

[3]

S. O
L.
S AD
R.
OR RIZ
OT TO
[4] [2]

Remove the following:

LM U
[1] [5]
– clutch spring [1] [3] [6]

RA O A
– stopper plate [2]
– shift fork [3] [7]
– clutch arm shaft [4]
– lock spring [5]

AB N
– collar [6]
– O-ring [7]
– oil seal [8]

-C O
L. US [2] [8] [4]
S. N O
Check the shift fork craws [1] for wear or damage.
[4] [2]
Check the arm shaft [2] and stopper plate [3] for
deformation or damage.
R.
Check the springs [4] for fatigue or damage.
RS IÓ
TO UC
MO RIB
AL ST

[3] [1]

PINION JOINT BALL BEARING

BR DI

REPLACEMENT
Remove the snap ring [1] and drive the pinion joint [2]
CA SU

[2]
out of the bearing.
24 O
-20 BID
-07 HI
28 O

[1]
PR

20-18
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Remove the oil seal [1] and the snap ring [2].
[1] [2]
Drive the bearing [3] out of the housing.

S. O
L.
S AD
R.
OR RIZ
OT TO
[3]

Drive a new bearing into the housing.

LM U
TOOLS:

RA O A
Driver [1] 07749-0010000 [1]
Attachment, 52 x 55 mm [2] 07746-0010400
Pilot, 32 mm [3] 07MAD-PR90200

AB N
-C O
L. US [3] [2]
S. N O
Install the snap ring [1] into the housing groove securely
[1]
with the chamfered edge facing the bearing.
Pack the seal lips of a new oil seal [2] with grease.
R.
RS IÓ

Install the oil seal so that it is flush with the housing end.
TO UC
MO RIB
AL ST

[2]
Be careful not to Hold the bearing inner race and press the pinion joint
BR DI

damage the oil seal [1] into the bearing until it is fully seated.
lips.
TOOLS: [1]
CA SU

Fork seal driver weight [2] 07747-0010100

Fork seal driver attachment, [3]
33 mm I.D. [3] 07747-0010501
24 O
-20 BID
-07 HI

[2]
28 O
PR

20-19
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Install the snap ring [1] into the pinion joint groove
securely with the chamfered edge facing the bearing.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

ASSEMBLY

LM U
SNAP RING

RA O A
BEARING (32 x 58 x 13)

AB N
PINION JOINT
SNAP RING
CLUTCH SPRING

-C O
OIL SEAL

L. US
STOPPER PLATE OIL SEAL
S. N O
CLUTCH ARM
SHIFT FORK
LOCK SHAFT
R.
RS IÓ

SPRING COLLAR
TO UC

O-RING

Coat a new O-ring [1] with grease and install it into the
arm shaft groove.
MO RIB

Apply grease to the arm shaft outer surface. [2]

Install the collar [2] and the lock spring [3] with the short
[3]
end toward the collar, and set the spring end into the
AL ST

hole [4] in the collar.

BR DI
CA SU

[4] [1]
24 O

[3]
-20 BID

Collar side
-07 HI
28 O

Collar
PR

side
Fork side

20-20
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Apply grease to the lips of a new oil seal [1] and install it
[3] Align [1]
into the clutch housing until it is fully seated.
Take care not to let Install the arm shaft assembly [2], being careful not to
the lock spring damage the oil seal.

S. O
come off the collar
Install the shift fork [3] and align the groove with the lock
during assembly.

L.
S AD
spring end.

R.
OR RIZ
OT TO
[2]

Install the stopper plate [1] onto the arm shaft by

LM U
[1] [2] [4]
aligning the flat surfaces, so that the plate rests on the
fork lug [2].

RA O A
Install the clutch spring [3] with the bended end [4]
toward the shift fork.
While holding the shift fork, push the arm shaft inward

AB N
and insert its end into the pivot hole in the housing.

-C O
L. US Align [3]
S. N O
Align the bolt hole in the fork with the groove in the shaft
and install a new fork bolt [1].
Tighten the fork bolt.
R.
RS IÓ

[3]
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
TO UC

Turn the arm shaft [2] clockwise by holding the collar [3]
with a open end wrench and align the arm tab with the
collar groove, then tap the shaft to fit them securely.
MO RIB

[1]
AL ST

[2]
BR DI

Align
CA SU
24 O
-20 BID
-07 HI
28 O
PR

20-21
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Turn the arm shaft [1] and set the clutch spring [2] ends
[2] [4]
onto the housing ledge [3] and the reverse side of the
stopper plate [4] as shown.
Check the arm shaft for smooth operation.

S. O
L.
S AD
R.
OR RIZ
OT TO
[3] [1]

Install the clutch sleeve [1] with the large O.D. side

LM U
[2] [3]
facing down.

RA O A
Coat a new O-ring [2] with grease and install it into the
case groove.
Install the two dowel pins [3].

AB N
-C O
L. US [1]
S. N O
Aligning the fork claws [1] with the sleeve groove [2],
[4] [3]
install the final clutch housing [3] while turning the
clutch arm [4], then secure it with the bolts [5].
R.
Tighten the three bolts.
RS IÓ

TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft)

TO UC

Install the select switch [6] with a new sealing washer

[7] and tighten it.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
MO RIB
AL ST

[2] [1]
BR DI

[7]
CA SU
24 O
-20 BID

[6]
-07 HI

[5]
28 O
PR

20-22
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

FRONT FINAL GEAR DISASSEMBLY/
INSPECTION
BACKLASH INSPECTION

S. O
Remove the final clutch housing (page 20-17).

L.
S AD
[1]
Set the final gear case into a jig or vise with soft jaws.

R.
Remove the oil filler cap.
[5]

OR RIZ
Cover the clutch Hold the pinion gear [1] with the special tools. [4]
housing mating
surface with
TOOLS:
protective tape or Pinion puller base [1] 07HMC-MM80110
[3]

OT TO
an equivalent to Puller shaft and nut [2] 07965-VM00200
prevent damaging Threaded adaptor [3] 070MF-HP50100
it. U.S.A. TOOLS:

LM U
Pinion puller base 07HMC-MM8011A
Puller shaft 07931-ME4010B

RA O A
Special nut 07931-HB3020A
[2]
Threaded adaptor 070MF-HP5A100
Install the differential inspection tool into the left side of

AB N
the gear case.
TOOL:

-C O
Differential inspection tool [5] 07KMK-HC50101 or

L. US
07KMK-HC5010A
(U.S.A. only)
Set a horizontal type dial indicator on the ring gear
through the filler hole.
S. N O
Turn the ring gear back and forth to read backlash.
STANDARD: 0.05 – 0.25 mm (0.002 – 0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in)
R.
RS IÓ

Remove the dial indicator. Turn the ring gear 120° and
measure backlash. Repeat this procedure once more.
TO UC

Compare the difference of the three measurements.

SERVICE LIMIT: 0.2 mm (0.01 in)
MO RIB

If the difference in measurements exceeds the service

limit, it indicates that the bearing is not installed
squarely, or the case is deformed.
Inspect the bearings and case.
AL ST

If the backlash is excessive, replace the ring gear left

side shim [1] with a thinner one.
BR DI

If the backlash is too small, replace the ring gear left

side shim with a thicker one.
The backlash is changed by about 0.06 mm (0.002 in) [2]
when the thickness of the shim is changed by 0.10 mm
CA SU

(0.004 in).
[1]
• Twenty-three different thickness shims are available
24 O

from the thinnest (0.50 mm thickness: A) shim to the

thickest (1.60 mm thickness: W) in intervals of 0.05
-20 BID

mm.

Ring gear shims:

A: (thinnest): 0.50 mm (0.020 in)
-07 HI

K: (standard): 1.00 mm (0.039 in)

W: (thickest): 1.60 mm (0.063 in)
28 O

Change the right side shim [2] as follows: If the left shim
PR

was replaced with a 0.10 mm (0.004 in) thicker shim,

replace the right shim with one that is 0.10 mm (0.004
in) thinner.

20-23
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

DIFFERENTIAL REMOVAL
Loosen the six cover bolts [1] in a crisscross pattern in
[2] [3]
several steps and remove them.

S. O
Pry the final gear case cover [2] at the points [3] as
shown by using a screwdriver and remove it.

L.
S AD
R.
OR RIZ
OT TO
[3] [1]

LM U
Remove the O-ring [1].

RA O A
[2] [1]
Remove the differential assembly [2] and shims [3].
Turn the inner race of each bearing in the gear case
and case cover with your finger. The bearings should

AB N
turn smoothly and quietly. Also check that the bearing
outer race fits tightly in the case or cover.

-C O
L. US
S. N O
[3]

GEAR TOOTH CONTACT PATTERN

CHECK
R.
RS IÓ

Keep dust and dirt Apply thin coat of Prussian Blue to the pinion gear teeth
[1] (Left Shim)
out of the case and for a tooth contact pattern check.
TO UC

cover.
Install the ring gear shims [1] onto the differential
assembly [2].
MO RIB

Install the differential assembly into the gear case.

AL ST
BR DI

Apply Prussian Blue

CA SU

[2]
24 O
-20 BID
-07 HI
28 O
PR

[1] (Right Shim)

20-24
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

It is important to Install the case cover and tighten the bolts [1] in several
[2]
turn the pinion gear steps until the cover [2] evenly touches the gear case.
while tightening the Then, while rotating the pinion gear, tighten the bolts to
bolts. If the ring the specified torque in a crisscross pattern in several
steps.

S. O
gear shim is too
thick, the gears will
TORQUE: 10 mm bolt: 46.5 N·m (4.7 kgf·m, 34 lbf·ft)

L.
S AD
lock after only light
tightening. 8 mm bolt: 25 N·m (2.5 kgf·m, 18 lbf·ft)

R.
OR RIZ
[1]
(10 mm)

OT TO
[1] (8 mm)

Rotate the ring gear several times in both directions of

LM U
rotation. NORMAL:
HEEL

RA O A
Check the gear tooth contact pattern through the oil
filler hole.
TOE
The pattern is indicated by the Prussian Blue applied to
the pinion.
FACE

AB N
Contact is normal if the Prussian Blue is transferred to FACE
the approximate center of each tooth, but slightly to the
heel side and to the flank side.

-C O
If the patterns are not correct, remove and change the FLANK FLANK

L. US
pinion shim with one of an alternate thickness. Drive side Coast side
S. N O
Replace the pinion shim [1] with a thicker one if the
contact pattern is too high, toward the face. TOO HIGH:

[1]
R.
RS IÓ
TO UC
MO RIB

FACE FACE
AL ST

Drive side Coast side

Replace the pinion shim [1] with a thinner one if the

BR DI

contact pattern is too low, toward the flank. TOO LOW:

[1]
The pattern will shift about 0.5 – 1.0 mm (0.02 – 0.04 in)
CA SU

when the thickness of the shim is changed by 0.12 mm

(0.005 in).
24 O

• Fifteen different thickness shims are available from

the thinnest (1.64 mm thickness: A) shim to the
-20 BID

thickest (2.48 mm thickness: O) in intervals of 0.06

mm.

Pinion shims: A (thinnest): 1.64 mm (0.065 in) Drive side Coast side
-07 HI

G (standard): 2.00 mm (0.079 in)

O (thickest): 2.48 mm (0.098 in) FLANK FLANK
28 O

Pinion shim replacement (page 20-29).

PR

20-25
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

DIFFERENTIAL INSPECTION
Install the inspection tools into both sides of the
differential.

S. O
TOOL:
Differential inspection tool [1] 07KMK-HC50101 or

L.
S AD
(2 required) 07KMK-HC5010A
(U.S.A. only)

R.
[1]

OR RIZ
Hold the flat surface of the tool with a bench vise [2].
Attach a torque wrench to the other tool and measure
the limited slip torque.
STANDARD:

OT TO
14 – 17 N·m (1.45 – 1.75 kgf·m, 10 – 13 lbf·ft)
SERVICE LIMIT: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[2]

LM U
If the slip torque is out of specification, disassemble the
differential and perform the components inspection

RA O A
(page 20-27)since the differential may be faulty.

DIFFERENTIAL DISASSEMBLY

AB N
Remove the ten bolts [1], then place the differential
[1]
assembly with the ring gear [2] side up.

-C O
L. US
S. N O
R.
RS IÓ
TO UC

[2]

Remove the following:

[2]
MO RIB

– ring gear [1]

– side cone spring [2]
– shim [3]
AL ST
BR DI
CA SU

[3] [1]
24 O

– face cam [1]

[1]
-20 BID
-07 HI
28 O
PR

20-26
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

– six cam followers A and six cam followers B [1]
[1] [2]
– face cam [2]

S. O
L.
S AD
R.
OR RIZ
OT TO
DIFFERENTIAL COMPONENTS

LM U
INSPECTION

RA O A
RING GEAR
Check the sliding surface of the ring gear for damage or
discoloration.
Measure the depth of the ring gear from the mating

AB N
surface as shown.

-C O
SERVICE LIMIT: 6.55 mm (0.258 in)

L. US
S. N O
R.
RS IÓ

DIFFERENTIAL HOUSING/FACE CAM/CAM

FOLLOWER
TO UC

If the differential Check the sliding surface and grooves of the housing
[1]
housing and/or cam [1] for damage or discoloration.
face are faulty,
MO RIB

replace the
differential as an
assembly.
AL ST
BR DI
CA SU

Check the shim, face cams [1] and followers [2] for
[1]
24 O

damage.
-20 BID
-07 HI
28 O
PR

[2]

20-27
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Temporarily assemble the differential housing, face
cams and cam followers (page 20-34). 1.47 kN (150 kgf)
Measure the height of face cam from the housing
mating surface as shown while applying a load of

S. O
1.47 kN (150 kgf) to the face cam boss using a
hydraulic press.

L.
S AD
SERVICE LIMIT: 3.3 mm (0.13 in)

R.
If the height is less than the limit, replace the differential

OR RIZ
as an assembly.

OT TO
SIDE CONE SPRING

LM U
Check the cone spring for damage.

RA O A
Measure the height of the spring.
SERVICE LIMIT: 2.6 mm (0.10 in)

AB N
-C O
L. US
S. N O
PINION GEAR REMOVAL
Unstake the bearing lock nut [1] with a drill or grinder.
R.
Be careful that
RS IÓ

[1] Unstake
metal particles do
not enter the
TO UC

bearing and the

threads of the case
are not damaged.
MO RIB
AL ST
BR DI

Remove the lock nut and discard it.

CA SU

[1]
TOOL:
Lock nut wrench, 34 x 44 mm [1] 07916-ME50001
24 O
-20 BID
-07 HI
28 O
PR

20-28
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Cover the clutch Install the special tools with a washer onto the pinion
[2]
housing mating gear shaft and gear case.
surface with
aluminum shims or TOOLS:
Pinion puller base [1] 07HMC-MM80110

S. O
an equivalent to
prevent damaging Puller shaft and nut [2] 07965-VM00200 [1]

L.
S AD
it. Threaded adaptor [3] 070MF-HP50100
U.S.A. TOOLS:

R.
Pinion puller base 07HMC-MM8011A

OR RIZ
Puller shaft 07931-ME4010B
Special nut 07931-HB3020A [3]
Threaded adaptor 070MF-HP5A100

OT TO
Pull the pinion assembly [4] out from the gear case.
[4]

PINION BALL BEARING AND SHIM

LM U
REPLACEMENT

RA O A
Take care not to Press the pinion gear out of the bearing.
contact the support
Remove the bearing and shim.
blocks against the
gear teeth. Replace the pinion joint needle bearing in the shaft end

AB N
if necessary (page 20-30).

-C O
L. US
S. N O

Install a new shim [1] and a new bearing [2] onto the
R.
RS IÓ

[3]
pinion gear [3].
TO UC

• When the gear set, differential bearing, differential [1]

housing and/or gear case has been replaced, use a
2.00 mm (0.079 in) thick shim for initial reference.
[2]
MO RIB
AL ST
BR DI

Press the pinion gear into the bearing until it is fully

CA SU

seated by supporting the bearing inner race.

TOOL:
Attachment, 35 mm I.D. [1] 07746-0030400
24 O
-20 BID
-07 HI
28 O

[1]
PR

20-29
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

PINION JOINT NEEDLE BEARING
REPLACEMENT
Remove the pinion ball bearing (page 20-29).
[2]

S. O
Be sure to wear Heat the pinion gear [1] to about 80°C (176°F) and
heavy gloves to remove the needle bearing [2], using the special tools.

L.
S AD
avoid burns when
handling the heated
TOOLS:

R.
gear. Remover head, 12 mm 07936-1660110

OR RIZ
Using a torch to Remover shaft, 12 mm 07936-1660120 or
heat the gear may 07936-166010A
cause warpage. (U.S.A. only)
Remover weight 07741-0010201 or

OT TO
07936-371020A
(U.S.A. only)

LM U
[1]

RA O A
Press a new bearing into the pinion gear with the
marking facing up so that it is flush with the shaft end.
[1]
TOOLS:

AB N
Driver [1] 07749-0010000
Attachment, 22 x 24 mm [2] 07746-0010800

-C O
Pilot, 12 mm [3] 07746-0040200 [2]
Install the pinion ball bearing (page 20-29).

L. US
[3]
S. N O

GEAR CASE AND COVER BEARING

R.
RS IÓ

REPLACEMENT
TO UC

DIFFERENTIAL BEARING
Remove the oil seals [1] from the gear case and cover.
[2] [1]
MO RIB

Drive the bearings [2] out of the case and cover.

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

20-30
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Drive the bearings into the gear case and cover.
TOOLS:
[1]
Driver [1] 07749-0010000

S. O
Attachment, 52 x 55 mm [2] 07746-0010400
Pilot 30 mm [3] 07746-0040700

L.
S AD
[2]

R.
OR RIZ
OT TO
[3]

Apply grease to the seal lips of new dust seals [1].

LM U
[2]
Install each dust seal into the case and cover with the

RA O A
metal side facing out.
TOOL:
Attachment, 20 mm I.D. [2] 07746-0020400

AB N
-C O
L. US [1]
S. N O
PINION NEEDLE BEARING
Rotate the stopper ring [1] until its end appears in the
[3]
access hole [2].
R.
RS IÓ

Strike gently near the end of the ring with a punch to

bend the end upward.
TO UC

Grasp the end of the ring with needle-nose pliers and

pull the stopper ring out through the access hole.
Remove the oil filler cap.
MO RIB

Be sure to wear Heat the gear case to about 80°C (176°F) and remove
heavy gloves to the needle bearing [3], using the special tools.
[1]
avoid burns when
TOOLS:
AL ST

handling the heated

gear case. Remover head, 15 mm 07936-KC10200
Using a torch to Remover shaft, 15 mm 07936-KC10100
Remover weight 07741-0010201 [2]
BR DI

heat the gear case

may cause U.S.A. TOOLS:
warpage. Bearing remover, 15 mm 07936-KC10500
CA SU

Remover weight 07936-371020A

Install a new stopper ring [1] into the groove in a new
[1]
bearing.
24 O

Make sure the Install the bearing into the compressor until the stopper
stopper ring stays in ring is flush with the end of the tool.
-20 BID

the groove.
TOOL:
Bearing clip compressor, 070ME-HP50100 or
26 mm [2] 070ME-HP5A100
-07 HI

(U.S.A. only)
28 O
PR

[2]

20-31
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Place the driver, attachment and pilot on the top of the
[2]
bearing and tape the driver to the compressor [1].
TOOLS:
[3]
Driver [2] 07949-3710001

S. O
Attachment, 24 x 26 mm [3] 07746-0010700

L.
S AD
Pilot, 15 mm [4] 07746-0040300

R.
Place the bearing and tool assembly into a freezer for at
least 30 minutes.

OR RIZ
[1]
Heat the gear case to 80°C (176°F).
Remove the bearing and tool assembly from the freezer
and drive the bearing into the gear case using the

OT TO
special tools. [4] [5]
Only strike the driver once. If you strike it more than

LM U
once, the ring may slip out of the groove. If this
happens, remove the ring and bearing, and install a

RA O A
new ring.
Make sure the stopper ring [5] is securely set in the
groove of the gear case.

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

20-32
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

FRONT FINAL GEAR ASSEMBLY

S. O
L.
S AD
PINION BALL

R.
PINION JOINT BEARING (6206)

OR RIZ
NEEDLE BEARING
(12 x 18 x 12)
SIDE CONE SPRING 98 N·m
PINION

OT TO
(10.0 kgf·m,
PINION GEAR
SHIM 72 lbf·ft)

RING GEAR

LM U
DIFFERENTIAL SHIM

RA O A
PINION NEEDLE
BEARING (16 x 26 x 23)

AB N
-C O
L. US
10 mm BOLTS FINAL CLUTCH
46.5 N·m (4.7 kgf·m, 34 lbf·ft) STOPPER HOUSING
RING
S. N O
RING GEAR SHIM

DIFFERENTIAL BEARING
R.
RS IÓ

(32 x 58 x 13)
OIL SEAL
TO UC

12 N·m (1.2 kgf·m, 4WD SELECT SWITCH

9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
25 N·m
MO RIB

RING GEAR SHIM (2.5 kgf·m,

18 lbf·ft)
SEALING WASHER DOWEL PINS
AL ST

CLUTCH SLEEVE
OIL SEAL
BR DI

LEFT FACE CAM

CA SU

8 mm BOLTS
25 N·m (2.5 kgf·m,
18 lbf·ft)
24 O

GEAR CASE COVER

-20 BID

CAM FOLLOWERS
DIFFERENTIAL BEARING
(29 x 52 x 12)
-07 HI

49 N·m (5.0 kgf·m, RIGHT FACE CAM

36 lbf·ft)
28 O

DIFFERENTIAL HOUSING
PR

: O-RINGS

20-33
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

PINION GEAR INSTALLATION
Drive the pinion gear assembly into the gear case.
[1]
TOOLS:

S. O
Driver [1] 07749-0010000
Attachment, 40 mm I.D. [2] 07GAF-SE00200

L.
S AD
[2]

R.
OR RIZ
OT TO
LM U
Install a new lock nut [1] and tighten it.

RA O A
[1] [2]
TOOL:
Locknut Wrench, 34 x 44 mm [2] 07916-ME50001

AB N
Refer to "Service TORQUE: Actual: 98 N·m (10.0 kgf·m, 72 lbf·ft)
Information" for Indicated: 89 N·m (9.1 kgf·m, 66 lbf·ft)
torque wrench

-C O
reading information

L. US
(page 20-2).
S. N O
Be careful not to Stake the lock nut [1] into the case groove.
[1]
damage the threads
R.
RS IÓ

of the case. Stake

TO UC
MO RIB
AL ST
BR DI

DIFFERENTIAL ASSEMBLY
Install the face cam into the differential housing.
CA SU

Keep dust and dirt

[2] [1]
out of the
Install six cam followers A (rib) [1] and six followers B
differential housing.
(flat) [2] into the specified grooves in the housing [3] by
two and two as shown.
24 O
-20 BID

• The housing grooves are sized differently to

accommodate the differently sized cam followers A
and B. Make sure to install the followers correctly.
-07 HI
28 O
PR

[3]

20-34
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Install the face cam [1] onto the cam followers.
[1]
Measure the depth of the ring gear (page 20-27)and the
height of the housing-to-cam (page 20-28), and record
them.

S. O
Calculate the shim thickness using the equation below.

L.
S AD
The correct shim is nearly this dimension.
A = B – C – 1.6 mm

R.
A: New shim thickness

OR RIZ
B: Recorded ring gear depth
C: Recorded cam height

OT TO
Select the shim [1] and install it onto the face cam.

LM U
[2]
Differential shims:

RA O A
A: 1.3 mm (0.051 in) E: 1.7 mm (0.067 in)
B: 1.4 mm (0.055 in) F: 1.8 mm (0.071 in)
C: 1.5 mm (0.059 in) G: 1.9 mm (0.075 in)
D: 1.6 mm (0.063 in)

AB N
Install the cone spring [2] with the concave side facing

-C O
up (ring gear side).
Install the ring gear [3].

L. US [1] [3]
S. N O
Install new ring gear bolts [1] and screw them until the
[1]
seating surfaces of all the bolts touches the housing,
but do not tighten them yet.
R.
RS IÓ
TO UC
MO RIB
AL ST

Temporarily install the drive shafts [1] into the

BR DI

[1] [2] [3] [1]

differential assembly without the stopper rings until they
are fully seated to align the face cams [2] with the
differential housing [3].
CA SU

Tighten the ring gear bolts [4] to the specified torque in

a crisscross pattern in several steps.
TORQUE: 49 N·m (5.0 kgf·m, 36 lbf·ft)
24 O

Remove the drive shafts.

-20 BID

Inspect the slip torque (page 20-26).

If the slip torque is out of specification, perform the shim
adjustment. Replace the differential assembly when the
-07 HI

replacement shim is changed by 0.3 mm or more from [4]

the selected shim.
28 O
PR

20-35
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

FINAL GEAR CASE ASSEMBLY

• When the gear set, bearing, differential housing and/

or gear case has been replaced, check the tooth

S. O
contact pattern (page 20-24)and gear backlash

L.
S AD
(page 20-23).
Keep dust and dirt Blow compressed air through the breather hole in the

R.
out of the case and case cover.

OR RIZ
cover.

OT TO
LM U
RA O A
AB N
Install the proper ring gear shims [1] onto the differential
[1]
assembly.

-C O
L. US
S. N O
R.
RS IÓ
TO UC

Install the differential assembly [1] into the gear case

[1] [3]
[2].
MO RIB

Coat a new O-ring [3] with grease and install it into the
case cover groove.
Install the cover over the gear case.
AL ST
BR DI
CA SU

[2]
24 O

It is important to Apply locking agent to the threads of the two 10 mm

turn the pinion gear bolts.
-20 BID

while tightening the Install the six bolts [1] and tighten them several steps
bolts. If the ring until the cover evenly touches the case. Then, while
gear shim is too rotating the pinion gear, tighten the bolts to the
thick, the gears will specified torque in a crisscross pattern in several steps.
-07 HI

lock after only light

tightening.
TORQUE: 10 mm bolt: 46.5 N·m (4.7 kgf·m, 34 lbf·ft)
8 mm bolt: 25 N·m (2.5 kgf·m, 18 lbf·ft)
28 O

Make sure that the gear assembly rotates smoothly

PR

without binding.
[1]
Install the final clutch housing (page 20-22). (10 mm)

[1] (8 mm)

20-36
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

FRONT FINAL DRIVE INSTALLATION
Place the final gear case assembly [1] into the frame.
[1]
If both drive shafts Install the right drive shaft [2] into the gear case (page

S. O
are removed, install 20-12).

L.
S AD
them after mounting
the gear case

R.
assembly
completely.

OR RIZ
OT TO
[2]

LM U
Install a new stopper ring [1] into the groove in the

RA O A
[1] [3]
propeller shaft [2].
Apply 5.0 – 8.0 g (0.18 – 0.28 oz) of molybdenum
disulfide grease to the propeller shaft splines.

AB N
Apply molybdenum disulfide grease to the seal lip [3] of
the front side boot [4].

-C O
Make sure the seal lip is not turned outside in.

L. US
Apply molybdenum disulfide grease to the front end of
the propeller shaft
S. N O
[4] [2]

Place the boot band [1] over the pinion joint temporarily.
[1] [4] [3]
R.
RS IÓ

Install the propeller shaft [2] into the pinion joint,

aligning the splines until the stopper ring seats in the
TO UC

groove.
Make sure the stopper ring is seated properly by pulling
the propeller shaft lightly.
MO RIB

Install the boot [3] over the pinion joint groove securely
and the boot band [4] into the boot groove.
AL ST
BR DI

[2]

Coat a new O-ring [1] with molybdenum disulfide

[1]
grease and install it into the output shaft groove.
CA SU

Apply molybdenum disulfide grease to the propeller

shaft joint [2] splines.
Move the gear case assembly forward for maximum
24 O

clearance between the shaft joint and output shaft [3].

-20 BID

Engage the shaft joint over the output shaft and move
the gear case assembly rearward.
-07 HI
28 O

[2] [3]
PR

20-37
 dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Align the lower mounting bolt holes in the gear case
and frame, then install the mounting bolt [1] and a new
nut [2].
Install the mounting bracket [3] with the two bolts [4].

S. O
Install the front mounting bolt [5] and a new mounting

L.
S AD
nut [6].
Tighten the lower mounting nut.

R.
OR RIZ
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)
Tighten the mounting bracket bolts.
Tighten the front mounting nut.

OT TO
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft) [1]/[2]

LM U
[3] [5]/[6]

RA O A
AB N
-C O
L. US [4]
S. N O
Connect the switch connector [1] and breather hose [2].
[1] [2]
R.
RS IÓ
TO UC
MO RIB
AL ST

Install the holder bracket [1] and cover base [2] with the
BR DI

[2]
two bolts [3], and tighten bolts.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
CA SU
24 O
-20 BID
-07 HI

[3] [1]
28 O
PR

20-38
dummyhead

FRONT DRIVING MECHANISM (Except TM1/TE1 models)

Insert the selector cable [1] into the cable holder [2] and
[2] [1]
spring [3], and connect it to the clutch arm with the joint
pin [4] and adjusting nut [5].
Set the groove in the cable grommet [6] onto the cover

S. O
base end properly.
[5]

L.
S AD
Install the retaining plate [7] between the cable and
holder to secure the cable.

R.
Adjust the selector cable (page 3-28).

OR RIZ
Install the following: [6]
– left drive shaft (page 20-12)
– FA models only: front VS sensor (page 13-77)

OT TO
– tank cover assembly (page 2-4) [4] [3] [7]
Fill the front final gear case with the recommended oil
(page 3-27).

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

20-39
 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

21. REAR DRIVING MECHANISM

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 21-2 REAR DRIVE SHAFT (FA5/FA6) ··········· 21-12

RA O A
TROUBLESHOOTING ·························· 21-4 REAR FINAL DRIVE (Except FA5/FA6) ··· 21-13

AB N
SYSTEM COMPONENTS ······················ 21-5 REAR FINAL DRIVE (FA5/FA6)············· 21-27

-C O
REAR AXLE (Except FA5/FA6)·············· 21-7

L. US
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI

21
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-1
 dummyhead

REAR DRIVING MECHANISM

SERVICE INFORMATION
REAR DRIVING MECHANISM

GENERAL
• Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. The

S. O
extension lines from the gear engagement surfaces should intersect at one point.
• Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage the gear

L.
S AD
case.

R.
• When using the lock nut wrench and torque wrench adaptor, use a deflecting beam type torque wrench 20 inches long. The tool
increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the nut.

OR RIZ
The specification given is the actual torque applied to the nut, not the reading on the torque wrench. Do not overtighten the nut.
The specification later in the text gives both actual and indicated.
• Replace the ring and pinion gears as a set.

OT TO
TOOLS

LM U
Bearing clip compressor, 26 mm Remover weight Attachment, 42 x 47 mm
070ME-HP50100 07741-0010201 07746-0010300

RA O A
AB N
-C O
or 070ME-HP5A100 (U.S.A. only)
L. US
or 07936-371020A (U.S.A. only)
S. N O
Attachment, 52 x 55 mm Attachment, 62 x 68 mm Attachment, 24 x 26 mm
07746-0010400 07746-0010500 07746-0010700
R.
RS IÓ
TO UC
MO RIB
AL ST

Attachment, 35 mm I.D. Pilot, 15 mm Pilot, 35 mm

07746-0030400 07746-0040300 07746-0040800
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-2
dummyhead

REAR DRIVING MECHANISM

Pilot, 28 mm Fork seal driver weight Driver
07746-0041100 07747-0010100 07749-0010000

S. O
L.
S AD
R.
OR RIZ
OT TO
07AAF-S3VA101 (U.S.A. only)
Lock nut wrench, 30 x 64 mm Special nut Puller shaft and nut
07916-MB00002 07931-HB3020A (U.S.A. only) 07931-ME40000

LM U
RA O A
AB N
-C O
L. US
Puller shaft Remover shaft, 15 mm Remover head, 15 mm
07931-ME4010B (U.S.A. only) 07936-KC10100 (not available in 07936-KC10200 (not available in
S. N O
U.S.A.) U.S.A.)
R.
RS IÓ
TO UC
MO RIB

Bearing remover, 15 mm Driver Oil seal driver attachment

07936-KC10500 (U.S.A. only)
AL ST

07949-3710001 07GAD-PG40100
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-3
 dummyhead

REAR DRIVING MECHANISM

Pinion puller base Pilot, 32 mm Fork Seal Driver, 39.2 mm
07HMC-MM80110 07MAD-PR90200 07947-4630100

S. O
L.
S AD
R.
OR RIZ
OT TO
or 07HMC-MM8011A (U.S.A. only)
Pinion holder Driver attachment Oil seal driver
07SMB-HM70200 07LAD-PW50500 07965-KE80200

LM U
RA O A
AB N
-C O
L. US
07746-0010400 (U.S.A. only)
Attachment Holding tool
S. N O
07746-0030300 Snap-on YA6010A or equivalent
R.
RS IÓ
TO UC
MO RIB
AL ST

TROUBLESHOOTING
BR DI

Excessive noise
• Worn or scored ring gear and axle splines
• Worn or scored pinion gear and propeller shaft splines
CA SU

• Worn or damaged bearing

• Worn pinion and ring gears
• Excessive backlash between pinion and ring gears
• Oil level too low
24 O

Wobble or vibration in vehicle

• Axle not tightened properly
-20 BID

• Bent axle
Oil leak
• Oil level too high
-07 HI

• Clogged breather
• Damaged seals
28 O

• Loose case cover bolt

PR

21-4
dummyhead

REAR DRIVING MECHANISM

SYSTEM COMPONENTS
Except FA5/FA6:

S. O
L.
S AD
74 N·m (7.5 kgf·m, 55 lbf·ft)

R.
OR RIZ
OT TO
LM U
RA O A
137 N·m (14.0 kgf·m, 101 lbf·ft)

AB N
-C O
L. US
S. N O
46.5 N·m (4.7 kgf·m, 34 lbf·ft)
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-5
21-6
FA5/FA6:
PR
dummyhead

28 O

44 N·m (4.5 kgf·m, 32 lbf·ft)

-07 HI
-20 BID
24 O
REAR DRIVING MECHANISM

CA SU
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
OR RIZ
S AD
S. O
R.
L.
dummyhead

REAR DRIVING MECHANISM

REAR AXLE (Except FA5/FA6)
REMOVAL
Remove the left rear wheel (page 18-6).

S. O
[3]
Remove the cotter pin [1] and loosen the hub nut [2]

L.
S AD
while applying the rear brake.

R.
Remove the hub nut and rear wheel hub [3].

OR RIZ
Remove the brake drum (page 19-16).

OT TO
LM U
[1] [2]

RA O A
Do not get grease Remove the following:
[1] [5] [4] [7]
onto the brake shoe
– breather hose [1]
linings.
– adjusting nuts [2]

AB N
– joint pins [3]
– springs [4]

-C O
– brake cables [5]
– four panel nuts [6]

L. US
– brake panel assembly [7]
– O-ring [8] (from the brake panel)
S. N O
[8] [6] [3] [2]
R.
RS IÓ

Remove the four bolts [1], turn the left axle housing [2]
[2]
90 degrees and remove it.
TO UC
MO RIB
AL ST
BR DI

[1]
CA SU

Remove the side collar [1].

[1] [2]
Remove the O-ring [2] from the left axle housing.
24 O
-20 BID
-07 HI
28 O
PR

21-7
 dummyhead

REAR DRIVING MECHANISM

Remove the rear axle [1] by driving it from the left side
using a rubber mallet.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

INSPECTION

LM U
AXLE

RA O A
Set the axle in V-blocks and measure the axle runout
with a dial indicator.
Axle runout is 1/2 the total indicator reading. Indicator

AB N
SERVICE LIMIT: 3.0 mm (0.12 in)
20 mm
(0.8 in)

-C O
AXLE BEARING

L. US
Turn the inner race of the bearing with your finger.
The bearing should turn smoothly and quietly. 20 mm
Hold (0.8 in) Hold
Also check that the bearing outer race fits tightly in the
axle housing or brake panel.
S. N O
Indicator

AXLE BEARING REPLACEMENT

R.
RS IÓ

AXLE HOUSING
TO UC

Remove the oil seal [1] and drive the axle bearing [2]
[2] [1]
out of the axle housing.
MO RIB
AL ST
BR DI
CA SU

Drive a new bearing [1] into the axle housing until the
[2]
depth from the axle housing end is 11.0 – 11.5 mm
24 O

(0.43 – 0.45 in). 11.0 – 11.5 mm

-20 BID

TOOLS: (0.43 – 0.45 in)

Driver [2] 07749-0010000
Attachment, 52 x 55 mm [3] 07746-0010400
Pilot, 32 mm [4] 07MAD-PR90200
-07 HI
28 O
PR

[3] [4] [1]

21-8
dummyhead

REAR DRIVING MECHANISM

Apply grease to the lip of a new oil seal [1].
[2]
Install the oil seal with the metal plate side facing up so
that it is flush with the axle housing end.

S. O
TOOLS:
Driver [2] 07749-0010000

L.
S AD
Attachment, 62 x 68 mm [3] 07746-0010500

R.
OR RIZ
OT TO
[3] [1]

BRAKE PANEL

LM U
Remove the dust seal [1] and snap ring [2].
[1] [2] [3]

RA O A
Drive the axle bearing [3] out of the brake panel.

AB N
-C O
L. US
S. N O
Pack the cavities of a new bearing [1] with 4 – 5 g (0.14
[2]
– 0.18 oz) of grease.
R.
RS IÓ

Support the bearing Drive the bearing squarely with the sealed side facing
housing section of up until it is fully seated.
TO UC

the brake panel

when installing.
TOOLS:
Driver [2] 07749-0010000
Attachment, 62 x 68 mm [3] 07746-0010500
MO RIB

Pilot, 28 mm [4] 07746-0041100

AL ST

[3] [1] [4]

BR DI

Install the snap ring [1] with the chamfered edge facing
[2] [1]
the bearing securely.
CA SU

Apply grease to the lip of a new dust seal [2].

Install the dust seal with the flat side facing up so that it
is flush with the panel.
24 O
-20 BID
-07 HI
28 O
PR

21-9
 dummyhead

REAR DRIVING MECHANISM

REAR BRAKE PANEL STUD BOLT
REPLACEMENT
Thread two nuts onto the stud bolt and tighten them
together, and use a wrench on them to turn the stud bolt

S. O
out.

L.
S AD
Install new stud bolts

R.
After installation, check that the length from the bolt
head to the steering bearing holder surface is within

OR RIZ
specification.
16 – 18 mm
(0.6 – 0.7 in)

OT TO
LM U
RA O A
INSTALLATION
Apply molybdenum disulfide grease to the center spline
(ring gear contacting area) of the axle [1].

AB N
Install the axle into the final gear case from the right
side until it is fully seated.

-C O
L. US
S. N O Gear case side

[1]
R.
RS IÓ

Coat a new O-ring [1] with grease and install it into the
[2] [1]
groove in the left axle housing.
TO UC

Install the side collar [2] onto the rear axle with the
tapered side facing inward.
MO RIB
AL ST
BR DI
CA SU

Install the left axle housing [1] and turn it 90 degrees.

[1]
Install the four mounting bolts [2] and tighten them to
the specified torque.
24 O

TORQUE: 74 N·m (7.5 kgf·m, 55 lbf·ft)

-20 BID
-07 HI
28 O
PR

[2]

21-10
dummyhead

REAR DRIVING MECHANISM

Do not get grease Coat a new O-ring [1] with grease and install it into the
[1]
onto the brake shoe panel groove.
linings.

S. O
L.
S AD
R.
OR RIZ
OT TO
Install the brake panel assembly [1] onto the axle.
[7] [3] [4] [1]

LM U
Install new brake panel nuts [2] and tighten them to the
specified torque.

RA O A
TORQUE: 46.5 N·m (4.7 kgf·m, 34 lbf·ft)
Install the brake cables [3] into the cable holders of the
brake panel (upper holder for lever brake cable and

AB N
lower holder for pedal brake cable).
Install the cable springs [4] onto the cables.

-C O
Connect the brake cables to the brake arm with the joint
pins [5] and adjusting nuts [6].

L. US
Connect the breather hose [7] to the hose joint on the
brake panel.
[2] [5] [6]
Whenever both hub Install the brake drum, drum cover and right wheel hub,
S. N O
nuts are removed, and tighten the right wheel hub nut (page 19-19).
tighten the right side
first, then tighten the
left side.
R.
RS IÓ

Do not get grease Apply molybdenum disulfide grease to the axle spline
[2]
on the axle threads. [1] and install the wheel hub [2] onto the axle.
TO UC
MO RIB
AL ST
BR DI

[1]
CA SU

Apply sealant to the hub nut threads and install it.

Apply rear brake and tighten hub nut [1] to the specified
torque and further tighten it until its grooves align with
24 O

the cotter pin hole.

-20 BID

TORQUE: 137 N·m (14.0 kgf·m, 101 lbf·ft)

Install a new cotter pin [2].
Install the left rear wheel (page 18-6).
-07 HI

Fill the gear case with the recommended oil if the gear
case was disassembled (page 3-25).
28 O
PR

[2] [1]

21-11
 dummyhead

REAR DRIVING MECHANISM

REAR DRIVE SHAFT (FA5/FA6)
REMOVAL/INSTALLATION
Remove the rear wheel hub/knuckle (page 18-10).

S. O
[1]
To prevent damage Hold the inboard joint [1] of the drive shaft and tug firmly

L.
S AD
to the oil seal, hold to force the stopper ring on the inboard joint end past
the inboard joint the groove while prying with a screwdriver.

R.
horizontal until the

OR RIZ
drive shaft is clear
of the gear case.

OT TO
LM U
RA O A
Remove the stopper ring [1] from the inboard joint.
[1]
Install a new stopper ring into the groove in the inboard
joint spline.

AB N
Apply molybdenum disulfide grease to the inboard joint

-C O
spline.

L. US
S. N O
R.
RS IÓ

Be careful not to Install the drive shaft by holding the inboard joint [1]
damage the oil seal until the stopper ring seats in the groove of the ring [1]
TO UC

in the gear case. gear.

Make sure that the stopper ring is seated properly by
pulling on the inboard joint lightly.
MO RIB

Install the rear wheel hub/knuckle (page 18-12).

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

21-12
dummyhead

REAR DRIVING MECHANISM

DISASSEMBLY/INSPECTION/
ASSEMBLY
The rear drive shaft service can be performed in a same
manner as that of front drive shaft (page 20-6).

S. O
REAR DRIVE SHAFT LENGTH:

L.
S AD
Left/Right: 428.7 mm (16.88 in)

R.
OR RIZ
OUTBOARD SHAFT
INBOARD JOINT BOOT BAND (24)

OT TO
OUTBOARD BOOT

DRIVE SHAFT

LM U
RA O A
OUTBOARD JOINT

AB N
SNAP RING

-C O
L. US
BEARING S. N O
STOPPER RING
OUTBOARD BOOT
BAND (69)
INBOARD BOOT
R.
BAND (72.5)
RS IÓ

INBOARD BOOT INBOARD SHAFT

TO UC

BOOT BAND (25)

'14 – '19 models:
Pack the following with specified grease NKG509 (Kyodo Yushi):
MO RIB

Inboard joint and boot insides: 60 – 80 g (2.1 – 2.8 oz)

Outboard joint and boot insides: 40 – 60 g (1.4 – 2.1 oz)
After '19 model:
AL ST

Pack the following with specified grease OLISTAMOLY 2LN584LO (Castrol):

Inboard joint and boot insides 70 – 90 g (2.5 – 3.2 oz)
Outboard joint and boot insides 70 – 90 g (2.5 – 3.2 oz)
BR DI

REAR FINAL DRIVE (Except FA5/FA6)

CA SU

REMOVAL
Drain the gear case oil (page 3-25).
[1]
Remove the following:
24 O

– skid plate (page 2-11)

-20 BID

– rear axle (page 21-7)

Disconnect the breather hose [1] from the final gear
case.
-07 HI
28 O
PR

21-13
 dummyhead

REAR DRIVING MECHANISM

Remove the following:
[2] [3]
– four bolts [1] (while supporting the gear case
securely)
– gear case assembly [2]

S. O
– O-ring [3]

L.
S AD
R.
OR RIZ
OT TO
[1]

– joint spring [1]

LM U
[4] [2]
– propeller shaft [2]
– universal joint [3]

RA O A
– O-rings [4] (from the propeller shaft and output shaft)

AB N
-C O
L. US [3] [1]
S. N O
INSPECTION
PROPELLER SHAFT
Check the splines [1] of the drive shaft [2] for wear or
R.
RS IÓ

[2] [3]
damage.
If the they are damaged, check the pinion and universal
TO UC

joint splines also.

Check the joint spring [3] for fatigue or damage.
MO RIB
AL ST
BR DI

[1]

UNIVERSAL JOINT
CA SU

Check the boot [1] for cuts or other damage.

[1]
Check that the joint moves smoothly without binding or
noise.
24 O
-20 BID
-07 HI
28 O
PR

21-14
dummyhead

REAR DRIVING MECHANISM

OPERATION CHECK
Temporarily install the propeller shaft [1].
Turn the propeller shaft and check that the gears turn
smoothly and quietly without binding.

S. O
If the gears do not turn smoothly or quietly, the gears

L.
S AD
and/or bearing may be damaged or faulty.
They must be checked after disassembly; replace them

R.
if necessary.

OR RIZ
OT TO
[1]

LM U
JOINT BOOT REPLACEMENT

RA O A
Bend up the lock tabs [1] and raise each band end [2] to
[2] [1]
loosen the boot bands.
Remove the boot bands and joint boot [3].

AB N
Install a new boot and set it onto the universal joint
properly.

-C O
L. US
S. N O
[3] [2]

Install new boot bands [1] so the band ends [2] are
R.
RS IÓ

facing opposite the forward direction.

Viewed from the rear side:
Bend down each band end and secure it with the lock
TO UC

tabs [3]. Tap the lock tabs with a plastic hammer.

Forward direction
MO RIB

[3]
AL ST
BR DI

[1] [2]

BACKLASH INSPECTION
CA SU

Remove the oil filler cap.

[3] [2]
Set the gear case assembly in a vise.
Hold the pinion gear with the special tools.
24 O

TOOLS:
-20 BID

Puller shaft and nut [1] 07931-ME40000

Pinion puller base [2] 07HMC-MM80110
U.S.A. TOOLS:
Puller shaft 07931-ME4010B
-07 HI

Special nut 07931-HB3020A

Pinion puller base 07HMC-MM8011A
28 O

Install the rear axle [3] into the gear case assembly.
PR

[1]

21-15
 dummyhead

REAR DRIVING MECHANISM

Set a horizontal type dial indicator [1] on the ring gear
[2]
[2] through the oil filler hole.
Turn the ring gear back and forth with the axle to read
backlash.

S. O
STANDARD: 0.05 – 0.25 mm (0.002 – 0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in)

L.
S AD
Remove the dial indicator. Turn the ring gear 120° and

R.
measure backlash. Repeat this procedure once more.

OR RIZ
Compare the difference of the three measurements.
SERVICE LIMIT: 0.2 mm (0.01 in)
If the difference in measurements exceeds the service

OT TO
limit, it indicates that the bearing is not installed [1]
squarely, or the case is deformed.
Inspect the bearings and case.

LM U
If the backlash is excessive, replace the ring gear right
[2]

RA O A
side shim [1] with a thinner one.
If the backlash is too small, replace the ring gear right
side shim with a thicker one.
Backlash changed by about 0.06 mm (0.002 in) when

AB N
thickness of the shim is changed by 0.12 mm (0.005 in).
Ring gear shims:

-C O
A: 1.26 mm (0.050 in) G: 1.62 mm (0.064 in))
B: 1.32 mm (0.052 in) H: 1.68 mm (0.066 in)

L. US
C: 1.38 mm (0.054 in)) I: 1.74 mm (0.069 in)
D: 1.44 mm (0.057 in) J: 1.80 mm (0.071 in)
E: 1.50 mm (0.059 in) K: 1.86 mm (0.073 in)
S. N O
F: 1.56 mm (0.061 in)
[1]
Change the left side shim [2] as follows: If the right shim
was replaced with a 0.12 mm (0.005 in) thicker shim,
replace the left shim with one that is 0.12 mm (0.005 in)
R.
RS IÓ

thinner.
REAR FINAL GEAR CASE
TO UC

DISASSEMBLY
Loosen the eight cover bolts [1] in a crisscross pattern
[1]
MO RIB

in several steps and remove them.

Be careful not to Remove the case cover [2] by lightly tapping it.
damage the mating
surfaces.
AL ST
BR DI
CA SU

[2]
24 O
-20 BID
-07 HI
28 O
PR

21-16
dummyhead

REAR DRIVING MECHANISM

Remove the ring gear [1] and shims [2].
[1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

BEARING INSPECTION

LM U
Turn the inner race of the bearing [1] with your finger.
[1]

RA O A
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
gear case or cover.
Ring gear bearing replacement (page 21-20).

AB N
-C O
L. US
S. N O
GEAR TOOTH CONTACT PATTERN
CHECK
R.
RS IÓ

Keep dust and dirt Clean sealing material off the mating surfaces of the
Apply Prussian Blue [2]
out of the case and gear case and cover, being careful not to damage them.
TO UC

cover.
Apply thin coat of Prussian Blue to the pinion gear teeth
for a tooth contact pattern check.
MO RIB

Install the right shim [1] onto the ring gear [2].
AL ST
BR DI

[1]
CA SU

Install the ring gear [1] with the shim into the gear case.
[1]
Install the left shim [2] onto the ring gear.
24 O
-20 BID
-07 HI
28 O
PR

[2]

21-17
 dummyhead

REAR DRIVING MECHANISM

It is important to Install the case cover [1], 10 mm bolts [2] and 8 mm
[2] [3]
turn the pinion gear bolts [3], and tighten the bolts in several steps until the
while tightening the cover evenly touches the gear case.
bolts. If the ring Then, while rotating the pinion gear, tighten the bolts to
the specified torque in a crisscross pattern in several

S. O
gear shim is too
thick, the gears will steps.

L.
S AD
lock after only light
tightening. TORQUE: 10 mm bolt: 46.5 N·m (4.7 kgf·m, 34 lbf·ft)

R.
8 mm bolt: 25 N·m (2.5 kgf·m, 18 lbf·ft)

OR RIZ
OT TO
[1]

Remove the oil filler cap.

LM U
Normal:
Rotate the ring gear several times in both directions of

RA O A
rotation.
Check the gear tooth contact pattern through the oil Heel
filler hole.
The pattern is indicated by the Prussian Blue applied to

AB N
Toe
the pinion gear.
Contact is normal if the Prussian Blue is transferred to Face Face

-C O
the approximate center of each tooth, but slightly to the
heel side and to the flank side.

L. US
Flank Flank
If the patterns are not correct, remove and change the
pinion shim with one of an alternate thickness. Drive side Coast side
S. N O
Replace the pinion shim [1] with a thicker one if the
Too High: [1]
contact pattern is too high, toward the face.
R.
RS IÓ
TO UC
MO RIB

Face Face
AL ST

Drive side Coast side

Replace the pinion shim [1] with a thinner one if the

BR DI

Too Low: [1]

contact pattern is too low, toward the flank.
The pattern will shift about 0.5 – 1.0 mm (0.02 – 0.04 in)
CA SU

when the thickness of the shim is changed by 0.12 mm

(0.005 in).
Pinion shims:
24 O

A: 1.82 mm (0.072 in) F: 2.12 mm (0.083 in)

B: 1.88 mm (0.074 in) G: 2.18 mm (0.086 in)
-20 BID

C: 1.94 mm (0.076 in) H: 2.24 mm (0.088 in)

D: 2.00 mm (0.079 in) I: 2.30 mm (0.091 in)
E: 2.06 mm (0.081 in) Drive side Coast side
-07 HI

Pinion shim replacement (page 21-20).

Flank Flank
28 O
PR

21-18
dummyhead

REAR DRIVING MECHANISM

PINION GEAR REMOVAL
Remove the oil seal [1] from the gear case.
[1]

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
Be careful that Unstake the bearing lock nut [1] with a drill or grinder.
[1] Unstake

RA O A
metal particles do
not enter the
bearing and the
threads of the case

AB N
are not damaged.

-C O
L. US
S. N O
Remove the lock nut and discard it.
[1]
R.
RS IÓ

TOOL:
Lock nut wrench, 30 x 64 mm [1] 07916-MB00002
TO UC
MO RIB
AL ST
BR DI

Install the special tools onto the pinion gear and gear
[1]
case.
CA SU

TOOLS:
Puller shaft and nut [1] 07931-ME40000
Pinion puller base [2] 07HMC-MM80110
24 O

U.S.A. TOOLS:
Puller shaft 07931-ME4010B
-20 BID

Special nut 07931-HB3020A

Pinion puller base 07HMC-MM8011A
Pull the pinion gear assembly [3] out from the gear
-07 HI

case.
28 O

[2] [3]
PR

21-19
 dummyhead

REAR DRIVING MECHANISM

PINION BEARING AND SHIM
REPLACEMENT
Pull the bearing [1] from the pinion gear [2] with a
[1] [2]
commercially available bearing puller.

S. O
Remove the bearing and shim.

L.
S AD
R.
OR RIZ
OT TO
LM U
RA O A
Install the shim [1] and a new bearing [2] onto the pinion
[3] [2]
gear [3].

AB N
• When the gear set, ring gear bearing, and/or gear
case has been replaced, use a 2.00 mm (0.079 in)
thick shim for initial reference.

-C O
L. US
S. N O
[1]

Press the pinion gear [1] into the bearing [2] until it is
R.
RS IÓ

[1]
fully seated by supporting the bearing inner race.

TOOL:
TO UC

Attachment, 35 mm I.D. [3] 07746-0030400

MO RIB
AL ST
BR DI

[2] [3]

RING GEAR BEARING REPLACEMENT

CA SU

Remove the oil seals [1] from the gear case and cover.
[1]
Drive the bearings [2] out of the gear case and cover.
24 O
-20 BID
-07 HI
28 O
PR

[2]

21-20
dummyhead

REAR DRIVING MECHANISM

Drive new bearings into the gear case and cover.
Cover side: [1]
TOOLS:
Cover side:

S. O
Driver [1] 07749-0010000
Attachment, 62 x 68 mm [2] 07746-0010500

L.
S AD
Pilot, 35 mm [3] 07746-0040800
Case side:

R.
Driver [1] 07749-0010000

OR RIZ
Oil seal driver attachment [4] 07GAD-PG40100
Pilot, 35 mm [3] 07746-0040800

OT TO
[3] [2]

LM U
Case side: [1]

RA O A
AB N
-C O
L. US [3] [4]
S. N O
Apply grease to the seal lips of new oil seals.
[2]
Install each oil seal [1] with the flat side facing out so
that it is flush with the case or cover.
R.
RS IÓ

TOOLS:
Driver [2] 07749-0010000
TO UC

Attachment, 52 x 55 mm [3] 07746-0010400

MO RIB
AL ST

[3] [1]

PINION NEEDLE BEARING

BR DI

REPLACEMENT
Rotate the stopper ring [1] until its end appears in the
CA SU

[3]
access hole [2].
Strike gently near the end of the ring with a punch to
bend the end upward.
Grasp the end of the ring with needle-nose pliers and
24 O

pull the stopper ring out through the access hole.

-20 BID

Remove the oil filler cap.

Be sure to wear Heat the gear case to about 80°C (176°F) and remove
heavy gloves to the needle bearing [3], using the special tools.
-07 HI

avoid burns when

handling the heated
TOOLS:
gear case. Remover head, 15 mm 07936-KC10200
28 O

Using a torch to Remover shaft, 15 mm 07936-KC10100

heat the gear case Remover weight 07741-0010201 [1]
PR

may cause U.S.A. TOOLS:

warpage. Bearing remover, 15 mm 07936-KC10500
Remover weight 07936-371020A

21-21
 dummyhead

REAR DRIVING MECHANISM

Install a new stopper ring [1] into the groove in a new
[1]
bearing.
Make sure the Install the bearing into the compressor until the stopper
stopper ring stays in ring is flush with the end of the tool.

S. O
the groove.
TOOL:

L.
S AD
Bearing clip compressor, 070ME-HP50100 or
26 mm [2] 070ME-HP5A100

R.
(U.S.A. only)

OR RIZ
OT TO
[2]

Place the driver, attachment and pilot on the top of the

LM U
[2] [3]
bearing and tape the driver to the compressor [1].

RA O A
TOOLS:
Driver [2] 07949-3710001
Attachment, 24 x 26 mm [3] 07746-0010700
Pilot, 15 mm [4] 07746-0040300

AB N
Place the bearing and tool assembly into a freezer for at

-C O
least 30 minutes.
Heat the gear case to 80°C (176°F).

L. US
Remove the bearing and tool assembly from the freezer
and drive the bearing into the gear case using the
special tools. [4] [5] [1]
S. N O
Only strike the driver once. If you strike it more than
once, the stopper ring [5] may slip out of the groove. If
this happens, remove the ring and bearing, and install a
new ring.
R.
RS IÓ

Make sure the stopper ring is securely set in the groove

of the gear case.
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-22
dummyhead

REAR DRIVING MECHANISM

REAR FINAL GEAR CASE ASSEMBLY

GEAR CASE 12 N·m (1.2 kgf·m, 9 lbf·ft)

S. O
L.
S AD
O-RING

R.
OIL SEAL
BALL BEARING

OR RIZ
(35 x 60 x 14)
RING GEAR
STOPPER RING

OT TO
SHIM
BALL BEARING
NEEDLE
(6007)
BEARING

LM U
(15 x 26 x 17) 8 mm BOLT

RA O A
SHIM 25 N·m (2.5 kgf·m,
18 lbf·ft)

AB N
12 N·m (1.2 kgf·m,
9 lbf·ft)

-C O
L. US
STOP PIN
OIL SEAL S. N O
PINION GEAR
SHIM
SHIM
R.
RS IÓ

GEAR CASE COVER

BALL BEARING
TO UC

(6007)

OIL SEAL
MO RIB

98 N·m (10.0 10 mm BOLT

12 N·m (1.2 kgf·m,
kgf·m, 72 lbf·ft) 46.5 N·m (4.7 kgf·m,
9 lbf·ft)
34 lbf·ft)
AL ST

PINION GEAR INSTALLATION

Blow compressed air through the breather hole [1] in
BR DI

[1]
the gear case.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-23
 dummyhead

REAR DRIVING MECHANISM

Drive the pinion gear assembly into the gear case.
[1]
TOOLS:
Driver [1] 07749-0010000

S. O
Attachment, 42 x 47 mm [2] 07746-0010300
Fork seal driver weight [3] 07747-0010100

L.
S AD
07AAF-S3VA101
(U.S.A. only)

R.
OR RIZ
OT TO
[3] [2]

Install a new lock nut [1] and tighten it.

LM U
[1]
TOOL:

RA O A
Lock nut wrench, 30 x 64 mm [2] 07916-MB00002

Refer to "Service TORQUE: Actual: 98 N·m (10.0 kgf·m, 72 lbf·ft)

Information" for Indicated: 89 N·m (9.1 kgf·m, 66 lbf·ft)

AB N
torque wrench
reading information

-C O
(page 21-2).

L. US [2]
S. N O
Be careful not to Stake the lock nut into the case groove.
Stake
damage the threads
of the case.
R.
RS IÓ
TO UC
MO RIB
AL ST

Apply grease to the lips of a new oil seal [1] and install it
BR DI

[1]
so that it is flush with the gear case.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-24
dummyhead

REAR DRIVING MECHANISM

RING GEAR CLEARANCE
INSPECTION
Install the ring gear [1] with the left shim into the case
[3]
cover [2].

S. O
Measure the clearance between the ring gear and stop
pin [3] with a feeler gauge.

L.
S AD
CLEARANCE: 0.3 – 0.6 mm (0.01 – 0.02 in)

R.
Remove the ring gear.

OR RIZ
Be sure to wear If the clearance exceeds the standard value, heat the
heavy gloves to case cover to approximately 80°C (176°F) and remove
avoid burns when the stop pin by tapping the cover.

OT TO
handling the heated
Install a stop pin shim [4] to obtain the correct
case cover.
clearance.
Using a torch to

LM U
heat the cover may Stop pin shims: [1] [2] [4]
cause warpage. A: 0.10 mm (0.004 in)

RA O A
B: 0.15 mm (0.006 in)
Install the shim and drive the stop pin into the case
cover.

AB N
FINAL GEAR CASE ASSEMBLY

-C O
• When the gear set, bearing, and/or gear case has

L. US
been replaced, check the tooth contact pattern
(page 21-17)and gear backlash (page 21-15).
Keep dust and dirt Clean the mating surface of the gear case and cover,
S. N O
[2]
out of the case and being careful not to damage them.
cover.
Install the proper ring gear shims [1] onto the ring gear
[2] and install them into the gear case.
R.
RS IÓ
TO UC
MO RIB

[1]
AL ST

Apply liquid sealant (TB1215 or equivalent) to the

[1]
mating surface of the case cover [1].
Install the cover onto the gear case [2].
BR DI
CA SU
24 O
-20 BID

[2]
-07 HI
28 O
PR

21-25
 dummyhead

REAR DRIVING MECHANISM

It is important to Apply locking agent to the threads of the two 10 mm
[1] [2]
turn the pinion while bolts [1].
tightening the bolts. Install the two 10 mm bolts and six 8 mm bolts [2], and
If the ring gear shim tighten them several steps until the cover [3] evenly
touches the case. Then, while rotating the pinion gear,

S. O
is too thick, the
gears will lock after tighten the bolts to the specified torque in a crisscross

L.
S AD
only light tightening. pattern in several steps.
TORQUE: 10 mm bolt: 46.5 N·m (4.7 kgf·m, 34 lbf·ft)

R.
8 mm bolt: 25 N·m (2.5 kgf·m, 18 lbf·ft)

OR RIZ
Make sure that the gear assembly rotates smoothly
without binding.

OT TO
[3]

INSTALLATION

LM U
Coat a new O-ring [1] with molybdenum disulfide
[1] [2]

RA O A
grease and install it into the groove in the output shaft.
Apply molybdenum disulfide grease to the splines of
both sides in the universal joint [2].

AB N
Install with the small Install the universal joint onto the output shaft until it is
O.D. side facing the fully seated.
engine.

-C O
L. US
S. N O
Coat a new O-ring [1] with molybdenum disulfide
[1]
grease and install it into the groove in the propeller
R.
RS IÓ

shaft [2].
Install the propeller shaft into the universal joint until it is
fully seated.
TO UC
MO RIB
AL ST

[2]
BR DI

Coat a new O-ring [1] with grease and install it into the
[1]
gear case groove.
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-26
dummyhead

REAR DRIVING MECHANISM

Apply molybdenum disulfide grease to the splines of the
[1] [2] [3]
propeller shaft [1].
Install the joint spring [2] into the propeller shaft firmly.

S. O
Install the gear case assembly [3] onto the propeller
shaft by aligning the splines, and onto the swingarm.

L.
S AD
R.
OR RIZ
OT TO
Install the four mounting bolts [1] and tighten them to

LM U
the specified torque.

RA O A
TORQUE: 74 N·m (7.5 kgf·m, 55 lbf·ft)

AB N
-C O
L. US [1]
S. N O
Connect the breather hose [1] to the final gear case.
[1]
Install the following:
R.
RS IÓ

– rear axle (page 21-10)

– skid plate (page 2-11)
TO UC
MO RIB
AL ST

REAR FINAL DRIVE (FA5/FA6)

BR DI

REMOVAL
CA SU

Drain the rear final drive oil (page 3-26).

[4] [3] [3] [4]
Remove the following:
– rear wheels (page 18-6)
24 O

– right rear drive shaft (page 21-12)

– right rear lower arm (page 18-13)
-20 BID

– breather hose [1]

– rear brake caliper mounting bolts [2]
– bolts [3] and brake hose clamps [4]
-07 HI
28 O
PR

[1] [2]

21-27
 dummyhead

REAR DRIVING MECHANISM

– left rear shock absorber lower mounting nut [1], bolt
[4]
[2] and washers [3]
– left stabilizer link nut [4]

S. O
L.
S AD
[2]

R.
OR RIZ
OT TO
[1] [3]
– left lower arm pivot nuts [1] and bolts [2]

LM U
[1]/[2]
Release the lower arm [3] from the frame.

RA O A
AB N
-C O
L. US [3]
S. N O
Support the gear case with wooden blocks to relieve
[1]/[2] [3] [1]/[2]
stress for ease of bolt removal, and remove the gear
case mounting nuts [1], bolts [2] and collar [3].
R.
RS IÓ
TO UC
MO RIB
AL ST

Release the gear case assembly from the mounting

BR DI

[2]
points by pulling it rearward and disconnect the
propeller shaft [1] from the universal joint.
CA SU

Remove the O-ring [2] from the propeller shaft.

24 O
-20 BID
-07 HI

[1]
28 O
PR

21-28
dummyhead

REAR DRIVING MECHANISM

Hold the inboard joint [1] of the left rear drive shaft and
[2]
tug firmly to force the stopper ring [2] on the inboard
joint end past the groove while prying with a
screwdriver.

S. O
Remove the gear case assembly from the right side.

L.
S AD
R.
OR RIZ
OT TO
[1]

Remove the stopper ring [1] from the inboard joint.

[1]

LM U
RA O A
AB N
-C O
L. US
S. N O
Disconnect the universal joint [1] from the engine output
[1] [2]
shaft [2] and remove the O-ring [3].
R.
RS IÓ
TO UC
MO RIB
AL ST

[3]

Remove the boot bands [1] and release the propeller

BR DI

[1] [3]
shaft boot [2] off the pinion joint [3] of the gear case.
CA SU
24 O
-20 BID
-07 HI

[2]
28 O
PR

21-29
 dummyhead

REAR DRIVING MECHANISM

Remove the spring [1] and boot [2] from the propeller
shaft [3]. [1]

S. O
L.
S AD
R.
[3]

OR RIZ
OT TO
[2]

INSPECTION

LM U
UNIVERSAL JOINT

RA O A
For universal joint inspection and service (page 21-15).
PROPELLER SHAFT
Check the splines [1] of the propeller shaft for wear or

AB N
damage. [1]
If they are damaged, check the pinion and universal

-C O
joint splines also.

L. US
S. N O
R.
RS IÓ
TO UC

OPERATION CHECK
Turn the pinion joint [1] and check that the gear turns
smoothly and quietly without binding.
MO RIB

If the gears do not turn smoothly or quietly, the gears [1]

and/or bearing may be damaged or faulty.
They must be checked after disassembly; replace them
if necessary.
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

21-30
dummyhead

REAR DRIVING MECHANISM

BACKLASH INSPECTION
Remove the rear brake disc (page 21-32).
[1]
Remove the oil filler cap.

S. O
Install the special tool into the pinion joint, and set the
final drive assembly and tool in a vise.

L.
S AD
TOOL:

R.
[1] Pinion holder 07SMB-HM70200

OR RIZ
Install the drive shaft [2] into the final drive assembly
and hold it.

OT TO
[2]

LM U
Set a horizontal type dial indicator on the ring gear [1]
[1]

RA O A
through the filler hole.
Turn the ring gear back and forth with the drive shaft to
read backlash.
STANDARD: 0.05 – 0.25 mm (0.002 – 0.010 in)

AB N
SERVICE LIMIT: 0.4 mm (0.02 in)

-C O
Remove the dial indicator. Turn the ring gear 120° and
measure backlash.

L. US
Repeat this procedure once more.
Compare the difference of the three measurements.
SERVICE LIMIT: 0.2 mm (0.01 in)
S. N O
If the difference in measurements exceeds the service
limit, it indicates that the bearing is not installed [2]
R.
RS IÓ

squarely, or the case is deformed.

Inspect the bearings and case.
TO UC

If the backlash is excessive, replace the ring gear right

shim [1] with a thinner one.
If the backlash is too small, replace the ring gear right
MO RIB

shim with a thicker one.

Backlash is changed by about 0.05 mm (0.002 in) when
thickness of the shim is changed by 0.10 mm (0.004 in).
AL ST

• Twenty-three different shims (from A to W) are [1]

available in thickness increments of 0.05 mm (0.002
in).
BR DI

Right ring gear shims:

A: 0.50 mm (0.020 in) M: 1.10 mm (0.043 in)
CA SU

B: 0.55 mm (0.022 in) N: 1.15 mm (0.045 in)

C: 0.60 mm (0.024 in) O: 1.20 mm (0.047 in)
D: 0.65 mm (0.026 in) P: 1.25 mm (0.049 in)
24 O

E: 0.70 mm (0.028 in) Q: 1.30 mm (0.051 in)

F: 0.75 mm (0.030 in) R: 1.35 mm (0.053 in)
-20 BID

G: 0.80 mm (0.031 in) S: 1.40 mm (0.055 in)

H: 0.85 mm (0.033 in) T: 1.45 mm (0.057 in)
I: 0.90 mm (0.035 in) U: 1.50 mm (0.059 in)
-07 HI

J: 0.95 mm (0.037 in) V: 1.55 mm (0.061 in)

K: 1.00 mm (0.039 in) W: 1.60 mm (0.063 in)
L: 1.05 mm (0.041 in)
28 O

Change the left shim [2] thickness in an opposite

PR

amount of what the right shim was changed; If the right

shim was replaced with a 0.10 mm (0.004 in) thicker
one, replace the left shim with a 0.10 mm (0.004 in)
thinner one.

21-31
 dummyhead

REAR DRIVING MECHANISM

FINAL GEAR CASE DISASSEMBLY
Remove the bolts [1] and rear brake disc [2].
[1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

LM U
Loosen the cover bolts [1] in a crisscross pattern in

RA O A
several steps and remove them. [1]

AB N
-C O
L. US
S. N O
Pry the case cover [1] at the prying points [2] using a [1]
screwdriver and remove the case cover.
R.
RS IÓ
TO UC
MO RIB
AL ST

[2]
BR DI

Remove the ring gear [1] and shims [2].

[1]
CA SU
24 O

[2]
-20 BID
-07 HI
28 O
PR

21-32
dummyhead

REAR DRIVING MECHANISM

BEARING INSPECTION
Turn the inner race of each bearing [1] in the gear case
and case cover with your finger. The bearings should [1]
turn smoothly and quietly. Also check that the bearing

S. O
outer race fits tightly in the case and cover.

L.
S AD
For ring gear bearing replacement (page 21-36).

R.
OR RIZ
OT TO
LM U
GEAR TOOTH CONTACT PATTERN

RA O A
CHECK
Keep dust and dirt Clean the mating surfaces of the gear case and cover. [2]
out of the case and
Apply a thin coat of Prussian Blue to the pinion gear
cover.

AB N
teeth for a tooth contact pattern check. Apply Prussian Blue
Install the ring gear shims [1] onto the ring gear [2].

-C O
Install the ring gear with the shims into the gear case.

L. US
S. N O
[1] (Right Shim)
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI

[1] (Left Shim)

CA SU

Align the bolt holes and install the case cover [1].
[1]
It is important to turn Install the cover bolts and tighten them in several steps
the pinion while until the cover evenly touches the gear case.
24 O

Then, while rotating the pinion gear, tighten the bolts to [2]
tightening the bolts.
If the ring gear shim the specified torque in a crisscross pattern in several
-20 BID

is too thick, the steps.

gears will lock after
only light tightening.
TORQUE:
10 mm bolt [2]: 46.5 N·m (4.7 kgf·m, 34 lbf·ft)
-07 HI

8 mm bolt [3]: 25 N·m (2.5 kgf·m, 18 lbf·ft)

28 O
PR

[3]

21-33
 dummyhead

REAR DRIVING MECHANISM

Remove the oil filler cap.
NORMAL:
Rotate the ring gear several times in both directions of
rotation.

S. O
Check the gear tooth contact pattern through the oil HEEL
filler hole.

L.
S AD
The pattern is indicated by the Prussian Blue applied to TOE
the pinion.

R.
Contact is normal if the Prussian Blue is transferred to FACE
FACE
the approximate center of each tooth, but slightly to the

OR RIZ
heel side and to the flank side. FLANK FLANK
If the pattern are not correct, remove and change the
Drive Coast
pinion shim with one of an alternate thickness.

OT TO
side side

Replace the pinion shim [1] with a thicker one if the

LM U
TOO HIGH:
contact pattern is too high, toward the face.

RA O A
AB N
-C O
[1]
FACE FACE

L. US Drive side Coast side

S. N O
Replace the pinion shim [1] with a thinner one if the
TOO LOW:
contact pattern is too low, toward the flank.
The pattern will shift about 0.5 – 1.0 mm (0.02 – 0.04 in)
R.
RS IÓ

when the thickness of the shim is changed by 0.12 mm

(0.005 in).
TO UC

Pinion gear shims:

A: 1.32 mm (0.052 in) F: 1.62 mm (0.064 in)
B: 1.38 mm (0.054 in) G: 1.68 mm (0.066 in)
MO RIB

C: 1.44 mm (0.057 in) [1]

D: 1.50 mm (0.059 in)
E: 1.56 mm (0.061 in)
FLANK FLANK
AL ST

For pinion shim replacement (page 21-36). Drive side Coast side

PINION GEAR REMOVAL

BR DI

Install the special tool into the pinion joint [1], and set
the final drive assembly and tool in a vise. [1]
CA SU

[2]
TOOL:
[2] Pinion holder 07SMB-HM70200
Loosen the pinion joint nut [3], and remove the joint nut
24 O

Take care not to

drop the final drive and pinion joint.
-20 BID

assembly from the

vise.
-07 HI

[3]
28 O
PR

21-34
dummyhead

REAR DRIVING MECHANISM

Remove the oil seals [1] and O-ring [2].
[1]

S. O
L.
S AD
R.
OR RIZ
OT TO
[2]

Be careful that Unstake the pinion bearing lock nut [1] with a drill or

LM U
metal particles do grinder. Unstake
not enter the [1]

RA O A
bearing and the
threads of the case
are not damaged.

AB N
-C O
L. US
S. N O
Remove the lock nut using the special tool.
[1]
TOOL:
[1] Holding tool Snap-on YA6010A or equivalent
R.
RS IÓ
TO UC
MO RIB
AL ST

Install the special tools onto the pinion gear shaft and
BR DI

gear case. [2]

TOOLS:
CA SU

[1] Pinion puller base 07HMC-MM80110 or

07HMC-MM8011A
(U.S.A. only)
24 O

[2] Puller shaft and nut 07931-ME40000 or

07931-ME4010B and
-20 BID

07931-HB3020A
(U.S.A. only) [1]
Pull the pinion gear assembly out from the gear case.
-07 HI
28 O
PR

21-35
 dummyhead

REAR DRIVING MECHANISM

PINION GEAR BEARING/SHIM
REPLACEMENT
Press the pinion gear [1] out of the pinion bearing [2]
using a hydraulic press.

S. O
Remove the pinion shim [3].
[1]

L.
S AD
R.
OR RIZ
OT TO
LM U
[3] [2]

RA O A
Install the shim [1] and a new bearing [2] onto the pinion
[1]
gear [3].

[2]

AB N
• When the gear set, ring gear bearing, and/or gear
case has been replaced, use a 1.50 mm (0.059 in)
thick shim for initial reference.

-C O
L. US
S. N O
[3]

Press the pinion gear [1] until it is seated by supporting

R.
RS IÓ

the inner race of the bearing [2] with the special tool.

TOOL:
TO UC

[1]
[3] Attachment 07746-0030300
MO RIB
AL ST
BR DI

[3] [2]

RING GEAR BEARING REPLACEMENT

CA SU

Remove the oil seals [1] from the case and cover.
[1] [2]
Drive the bearings [2] out of the case and cover.
24 O
-20 BID
-07 HI
28 O
PR

21-36
dummyhead

REAR DRIVING MECHANISM

Drive each new bearing [1] using the special tools.
TOOLS: [2]
Case cover:

S. O
[2] Driver 07749-0010000
[3] Attachment, 62 x 68 mm 07746-0010500

L.
S AD
[4] Pilot, 35 mm 07746-0040800
Gear case: [3]/[4]

R.
Driver 07749-0010000

OR RIZ
Attachment, 62 x 68 mm 07746-0010500
Pilot, 35 mm 07746-0040800
[1]

OT TO
Apply grease to new oil seal [1] lips.

LM U
Install each oil seal with the metal side facing out until it [3]
is fully seated.

RA O A
TOOLS:
[2] Fork seal driver, 39.2 mm 07947-4630100 [4]
[3] Driver 07749-0010000

AB N
[4] Attachment, 62 x 68 mm 07746-0010500

-C O
L. US
[2]

[1]
S. N O
PINION NEEDLE BEARING
REPLACEMENT
Remove the stopper ring [1] by rotating it until the end
R.
RS IÓ

of the stopper ring appears in the access hole [2]. [3]

Strike gently near the end of the ring with a punch to
TO UC

bend the end upward.

Grasp the end of the ring with needle-nosed pliers and
pull the stopper ring out through the access hole.
MO RIB

Be sure to wear Heat the gear case to 80°C (176°F) and remove the
heavy gloves to needle bearing [3] by using the special tool.
avoid burns when
handling the heated
TOOLS:
AL ST

gear case. Using a Remover head, 15 mm 07936-KC10200

torch to heat the Remover shaft, 15 mm 07936-KC10100 or
gear case may Bearing remover, 15 mm 07936-KC10500
BR DI

cause warpage. (U.S.A. only) [1] [2]

Remover weight 07741-0010201 or
07936-371020A
CA SU

(U.S.A. only)
Remove the bearing cage and bearings from the inside
of the pinion bearing to allow the special tool to grip the
24 O

bearing.
-20 BID
-07 HI
28 O
PR

21-37
 dummyhead

REAR DRIVING MECHANISM

Install a new stopper ring [1] into the groove in a new
bearing [2].
[1]
Install the bearing into the special tool until the stopper
ring is flush with the end of the tool.

S. O
TOOL:
Bearing clip compressor, 070ME-HP50100 or

L.
S AD
26 mm [3] 070ME-HP5A100

R.
(U.S.A. only)

OR RIZ
Freeze the pinion bearing in a freezer.
Heat the gear case to 80°C (176°F).
[2]

OT TO
[3]

Tape the clip Drive the pinion bearing [2] into the gear case using the

LM U
compressor [1] to special tools as follows. [4]/[5] [3]
the driver for

RA O A
bearing installation. TOOLS:
[3] Driver 07949-3710001
[4] Attachment, 24 x 26 mm 07746-0010700
[5] Pilot, 15 mm 07746-0040300

AB N
[1]
Only strike the driver once. If you strike it more than

-C O
once, the stopper ring [6] may slip out of the groove.
If this happens, remove the ring and bearing, and install

L. US
a new one again.
Make sure that the stopper ring is securely set in the
groove of the gear case.
[2] [6]
S. N O
REAR FINAL DRIVE ASSEMBLY
12 N·m (1.2 kgf·m, 9 lbf·ft) RIGHT RING :O-RINGS
R.
RS IÓ

GEAR BEARING
OIL SEAL
GEAR CASE
RING GEAR
TO UC

SHIM
SHIM
STOPPER RING
MO RIB

LEFT RING GEAR BEARING

PINION NEEDLE
BEARING 25 N·m (2.5 kgf·m, 18 lbf·ft)
AL ST

PINION GEAR
BR DI

SHIM
CA SU

STOP
PINION BEARING
PIN
24 O

SHIM OIL SEAL

-20 BID

LOCK NUT*
PINION JOINT GEAR CASE COVER
-07 HI

INNER OIL SEAL

28 O

46.5 N·m (4.7 kgf·m, 34 lbf·ft)

OUTER OIL SEAL
PR

20 N·m (2.0 kgf·m,

15 lbf·ft)
*Actual: 98 N·m (10.0 kgf·m, 72 lbf·ft)
PINION JOINT LOCK NUT
BRAKE DISC Indicated: 89 N·m (9.1 kgf·m, 66 lbf·ft)
108 N·m (11.0 kgf·m, 80 lbf·ft)

21-38
dummyhead

REAR DRIVING MECHANISM

PINION GEAR INSTALLATION
Keep the driver Drive the pinion gear assembly [1] into the gear case.
centered with the
[2]
bearing outer race TOOL:

S. O
during installation. [2] Oil seal driver 07965-KE80200 or
07746-0010400

L.
S AD
(U.S.A. only)

R.
OR RIZ
OT TO
[1]

LM U
RA O A
Be sure to wear Freeze the pinion gear and bearing.
heavy gloves to Heat the gear case to 80°C (176°F).
avoid burns when Drop the cold pinion assembly into the warm gear case.

AB N
handling the heated
gear case. Using a
torch to heat the

-C O
gear case may
cause warpage.

L. US
Install a new lock nut [1] and tighten it using the special
[2]
tool.
S. N O
TOOL:
[2] Holding tool Snap-on YA6010A or equivalent

Refer to torque TORQUE:

wrench reading
R.
Actual: 98 N·m (10.0 kgf·m, 72 lbf·ft)
RS IÓ

information on Indicated: 89 N·m (9.1 kgf·m, 66 lbf·ft)

"Service
TO UC

Information"
(page 21-2).
MO RIB

[1]

Be careful not to Stake the lock nut [1] into the case groove.
Stake
damage the threads
AL ST

of the case. [1]

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

21-39
 dummyhead

REAR DRIVING MECHANISM

Coat a new O-ring [1] with grease and install it onto the
pinion gear shaft.
Apply grease to the lips of new oil seals. [2]
[3]
Install the inner oil seal [2] into the gear case until it is 10.0 – 10.5 mm

S. O
10.0 – 10.5 mm (0.39 – 0.41 in) from the top surface of (0.39 – 0.41 in)
gear case.

L.
S AD
TOOLS: [4]

R.
[3] Driver 07749-0010000

OR RIZ
[4] Driver attachment 07LAD-PW50500

OT TO
[1]

Install the outer oil seal [1] into the gear case until it is

LM U
flush with the gear case outer surface, using the same
tool.

RA O A
[2]
TOOLS:
[3]
[2] Driver 07749-0010000
[3] Driver attachment 07LAD-PW50500

AB N
-C O
L. US [1]
S. N O
Clean the threads of the pinion gear shaft thoroughly.
Install the pinion joint [1] onto the pinion gear shaft, [1]
being careful not to damage the oil seal lips. [3]
R.
RS IÓ

Apply locking agent to the threads of the pinion joint nut

[2] and screw it in by hand as far as it goes.
TO UC

Hold the pinion joint with the special tool and tighten the
joint nut.
TOOL:
MO RIB

[3] Pinion holder 07SMB-HM70200

TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)

AL ST

[2]

RING GEAR CLEARANCE

BR DI

INSPECTION
Install the ring gear [1] with the shim [2] into the case
CA SU

cover [3]. [2] [1]

Measure the clearance between the ring gear and stop

pin [4] with a feeler gauge.
24 O

CLEARANCE: 0.3 – 0.6 mm (0.01 – 0.02 in)

-20 BID
-07 HI
28 O

[3] [4]
PR

21-40
dummyhead

REAR DRIVING MECHANISM

Remove the ring gear.
[1]
Be sure to wear If the clearance is not within specification, heat the case
heavy gloves to cover to approximately 80°C (176°F) and remove the
avoid burns when stop pin [1] by tapping the cover.

S. O
handling the heated
Install a stop pin shim [2] to obtain the correct
case cover. Using a

L.
S AD
clearance.
torch to heat the

R.
case cover may STOP PIN SHIMS:
cause warpage. A: 0.10 mm (0.004 in)

OR RIZ
B: 0.15 mm (0.006 in)
Drive the stop pin into the case cover.

OT TO
[2]

FINAL GEAR CASE ASSEMBLY

LM U
RA O A
• When the gear set, bearing, and/or gear case has
been replaced, check the tooth contact pattern
(page 21-33).
Check the gear backlash (page 21-31).

AB N
Keep dust and dirt Clean the mating surface of the gear case and cover,
out of the case and being careful not to damage them.

-C O
cover.
Blow compressed air through the breather holes in the

L. US
gear case and cover.
S. N O
R.
RS IÓ
TO UC

Install the proper ring gear shims [1] onto the ring gear
[2] and install them into the gear case. [2]
MO RIB
AL ST
BR DI
CA SU

[1]
24 O
-20 BID
-07 HI
28 O
PR

21-41
 dummyhead

REAR DRIVING MECHANISM

Apply sealant to the case cover [1] mating surface.
[1]
Install the case cover onto the gear case.
Apply locking agent to the threads of the two 10 mm [2]
bolts [2].

S. O
It is important to turn Install the cover bolts [3] and tighten them in several

L.
S AD
the pinion while steps until the cover evenly touches the case. Then,
while rotating the pinion gear, tighten the bolts to the

R.
tightening the bolts.
If the ring gear shim specified torque in a crisscross pattern in several steps.

OR RIZ
is too thick, the
gears will lock after
TORQUE:
only light tightening. 10 mm bolt [2]: 46.5 N·m (4.7 kgf·m, 34 lbf·ft)
8 mm bolt [3]: 25 N·m (2.5 kgf·m, 18 lbf·ft)

OT TO
[3]
Check that the gear assembly turns smoothly without
binding.

LM U
Install the rear brake disc [1].

RA O A
Install and tighten new brake disc bolts [2] [2]
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

AB N
-C O
L. US
S. N O
[1]

INSTALLATION
Install the boot [1] and joint spring [2] to the propeller
R.
RS IÓ

shaft [3]. [2]

Apply 5 – 8 g of molybdenum disulfide grease to the
TO UC

pinion joint splines.

Connect the propeller shaft while aligning the splines
properly while compressing the joint spring.
MO RIB

[3]
AL ST
BR DI

[1]

Apply molybdenum disulfide grease to the boot [2]

CA SU

contacting area of propeller shaft and pinion joint. [3]

Install the propeller shaft boot [1] onto the pinion joint
[2] of the gear case.
24 O

Install the boot bands [3] into the grooves of the boot.
-20 BID
-07 HI
28 O

[1]
PR

21-42
dummyhead

REAR DRIVING MECHANISM

Coat a new O-ring [1] with molybdenum disulfide
[3] [2]
grease and install it into the groove in the engine output
shaft [2].
Apply molybdenum disulfide grease to the splines of the

S. O
both sides in the universal joint [3].

L.
S AD
Install the universal joint to the engine output shaft until
it is fully seated.

R.
OR RIZ
OT TO
[1]

Install a new stopper ring [1] into the groove in the

[1]

LM U
inboard joint splines of the left rear drive shaft.

RA O A
Apply molybdenum disulfide grease to the inboard joint
spline.

AB N
-C O
L. US
S. N O
Place the gear case assembly [1] into the frame.
[1]
Be careful not to Install the left rear drive shaft by holding the inboard
damage the oil seal joint [2] until the stopper ring seats in the groove of the
R.
RS IÓ

in the gear case. ring gear.

Make sure that the stopper ring is seated properly by
TO UC

pulling on the inboard joint lightly.

MO RIB
AL ST

[2]

Coat a new O-ring [1] with molybdenum disulfide

BR DI

[1]
grease and install it into the groove in the propeller
shaft [2].
CA SU

Connect the propeller shaft into the universal joint [3]

until it is fully seated.
24 O
-20 BID
-07 HI

[2] [3]
28 O
PR

21-43
 dummyhead

REAR DRIVING MECHANISM

Align the bolt holes and install the mounting bolts [1]
from the right side. [1]/[3] [2] [1]/[3]
Set the rear collar [2] between the left side of gear case
and frame.

S. O
Install new mounting nuts [3] and tighten them.

L.
S AD
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

R.
OR RIZ
OT TO
Position the left lower arm [1] into the frame pivot point.

LM U
[2]/[3]
Install the pivot bolts Install the lower arm pivot bolts [2] and new nuts [3],

RA O A
from the front side. then loosely tighten them.
• Tighten the pivot nuts to the specified torque
(page 18-16)after placing the vehicle on level
ground.

AB N
-C O
L. US [1]
S. N O
Connect the stabilizer link [1] with a new nut [2] and
[1] [2]
tighten it to the specified torque while holding the stud
bolt end.
R.
RS IÓ

TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft)

TO UC

Install the bolt from Install the washers [3], bolt [4] and a new shock
the rear side. absorber lower mounting nut [5] and tighten it to the [4]
specified torque.
MO RIB

TORQUE: 88 N·m (9.0 kgf·m, 65 lbf·ft)

AL ST

[5] [3]

Set the rear brake caliper in position, then install new

BR DI

[2] [3] [3] [2]

mounting bolts [1] and tighten them to the specified
torque.
CA SU

TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)

Set the rear brake hose clamps [2] to the frame, then
install and tighten new bolts [3].
24 O

Connect the rear final gear case breather hose [4].

-20 BID

Install the following:

– right rear lower arm (page 18-16)
– right rear drive shaft (page 21-12)
-07 HI

– rear wheels (page 18-6)

[4] [1]
Fill the gear case with the recommended oil
28 O

(page 3-26).
PR

21-44
dummytext

22. BATTERY/CHARGING SYSTEM

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 22-2 CHARGING SYSTEM INSPECTION ········ 22-6

RA O A
TROUBLESHOOTING ·························· 22-3 ALTERNATOR CHARGING COIL ··········· 22-7

AB N
COMPONENT LOCATION ····················· 22-3 REGULATOR/RECTIFIER ····················· 22-7

-C O
SYSTEM DIAGRAM ····························· 22-4 MAIN POWER RELAY ·························· 22-8

L. US
BATTERY··········································· 22-5
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU

22
24 O
-20 BID
-07 HI
28 O
PR

22-1
 dummyhead

BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
BATTERY/CHARGING SYSTEM

GENERAL

S. O
L.
S AD
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.

R.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing

OR RIZ
and a face shield.
– If electrolyte gets on your skin, flush with water.
– If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.

OT TO
– If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately.

LM U
• Always turn OFF the ignition switch before disconnecting any electrical component.

RA O A
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space.

AB N
• For a battery remaining in a stored vehicle, disconnect the negative battery cable from the battery.
• The maintenance free battery must be replaced when it reaches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions

-C O
contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after
2 – 3 years.

L. US
• Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop quickly and eventually die
out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in
the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage
does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level
S. N O
goes down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight on for long periods of time without riding the vehicle.
• The battery will self-discharge when the vehicle is not in use. For this reason, charge the battery every two weeks to prevent
R.
RS IÓ

sulfation from occurring.

• When checking the charging system, always follow the steps in the troubleshooting (page 22-3).
TO UC

• For alternator removal/installation, refer to Alternator/Starter Clutch section (page 14-7).

• The following color codes are used throughout this section.
MO RIB

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
BATTERY CHARGING
AL ST

• Turn power ON/OFF at the charger, not at the battery terminal.

• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending
the charging time may damage the battery.
BR DI

• Quick charging should only be done in an emergency; slow charging is preferred.

BATTERY TESTING
CA SU

Refer to the instructions in the Operation Manual for the recommended battery tester for details about battery testing. The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.

Recommended battery tester: MDX604P (U.S.A. only)

24 O
-20 BID
-07 HI
28 O
PR

22-2
dummyhead

BATTERY/CHARGING SYSTEM
TOOLS
Motorcycle battery analyzer Christie battery charger
MDX604P (U.S.A. only) MC1012/2T (U.S.A. only)

S. O
or OptiMate Pro-4 battery charger
Model: TMNTS53 (U.S.A. only)

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

AB N
Unusual condition Probable cause (Check in numerical order)
Battery Battery is damaged or weak 1. Faulty battery

-C O
2. Current leakage higher than specified value
– Faulty ignition switch

L. US
– Shorted wire harness
3. Faulty alternator charging coil
4. Faulty regulator/rectifier
5. Faulty main power relay or its circuit
S. N O
6. Open circuit or loose connection in the wire harness

COMPONENT LOCATION
R.
RS IÓ

FA2 model shown:

TO UC

PCM/ECM IGNITION SWITCH

MO RIB

FUSE BOX: RELAY BOX

– MAIN FUSE 1 (30 A) – MAIN POWER RELAY
– MAIN FUSE 2 (10 A)
AL ST

– IGN FUSE (20 A)

– DIODE
BR DI
CA SU
24 O
-20 BID

CKP SENSOR
BATTERY
-07 HI
28 O

REGULATOR/
ALTERNATOR
RECTIFIER
PR

22-3
 dummyhead

BATTERY/CHARGING SYSTEM
SYSTEM DIAGRAM
DIODE MAIN FUSE 2
(10 A)

S. O
R/Y
MAIN FUSE 1

L.
S AD
(30 A)

R.
R/Bl
IGNITION SWITCH

OR RIZ
Bl
IGN FUSE MAIN

OT TO
(20 A) POWER
RELAY CKP
Y Y Y R G R
Bl/R V/W SENSOR

LM U
RA O A
REGULATOR/
PCM/ECM
RECTIFIER Bu/Y
ALTERNATOR G BATTERY

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

22-4
dummyhead

BATTERY/CHARGING SYSTEM
BATTERY
REMOVAL/INSTALLATION
Remove the rear fender cover (page 2-12).

S. O
’14 model shown: [2]
Turn the ignition switch OFF and disconnect the

L.
S AD
negative (–) cable [1] first, then disconnect the positive [1]
(+) cable [2] by removing the terminal bolts.

R.
Remove the battery holder band [3].

OR RIZ
Remove the battery [4].
Installation is in the reverse order of removal.

OT TO
• Connect the positive (+) cable first and then the
negative (–) cable.

LM U
• If the battery is being replaced, the battery boot
(50334-HR0-F001) should be taken off the battery [4] [3]

RA O A
that is being removed and applied to the new
battery.

AB N
VOLTAGE INSPECTION
Remove the rear fender cover (page 2-12).

-C O
Measure the battery voltage using a commercially

L. US
available digital multimeter.
VOLTAGE (20°C/68°F):
Fully charged: 13.0 – 13.2 V
S. N O
Under charged: Below 12.3 V
R.
RS IÓ
TO UC

BATTERY TESTING
MO RIB

Remove the battery (page 22-5).

Refer to the instructions that are appropriate to the
battery testing equipment available to you.
AL ST

TOOL:
Motorcycle battery MDX604P (U.S.A. only)
BR DI

analyzer
CA SU

BATTERY CHARGING (U.S.A. only)

Remove the battery (page 22-5).
Refer to the instructions that are appropriate to the
24 O

battery charging equipment available to you.

-20 BID

TOOL:
Christie battery charger MC1012/2T (U.S.A. only) or
OptiMate Pro-4 battery Model: TMNTS53 (U.S.A.
charger only)
-07 HI
28 O
PR

22-5
 dummyhead

BATTERY/CHARGING SYSTEM
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Remove the rear fender cover (page 2-12).

S. O
[3] [2]
Turn the ignition switch OFF and disconnect the

L.
S AD
negative (–) cable [1] from the battery.

R.
Connect the amp meter (+) probe [2] to the negative (–)
cable and the amp meter (–) probe [3] to the battery (–)

OR RIZ
terminal [4].
With the ignition switch turned OFF, check for current
leakage.

OT TO
• When measuring current using a tester, set it to a
high range, and then bring the range down to an

LM U
appropriate level. Current flow higher than the range
[4] [1]

RA O A
selected may blow out the fuse in the tester.
• While measuring current, do not turn the ignition
switch ON. A sudden surge of current may blow out
the fuse in the tester.

AB N
SPECIFIED CURRENT LEAKAGE:
TM1: 0.012 mA maximum

-C O
FM1/FM2/FE1: 0.27 mA maximum

L. US
TE1: 0.31 mA maximum
FA1/FA2/FA5/FA6: 0.3 mA maximum
If current leakage exceeds the specified value, a
shorted circuit is likely.
S. N O
Locate the short by disconnecting connections one by
one and measuring the current.
R.
RS IÓ

CHARGING VOLTAGE INSPECTION

TO UC

• Be sure the battery is in good condition before

performing this test.
MO RIB

Remove the rear fender cover (page 2-12).

Warm up the engine to normal operating temperature.
Connect the multimeter between the battery positive (+)
AL ST

and negative (–) terminals.

BR DI

• To prevent a short, make absolutely certain which

are the positive (+) and negative (–) terminals or
cables.
CA SU

• Do not disconnect the battery or any cable in the

charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tester or electrical components.
24 O

Restart the engine and turn the headlight on.

-20 BID

Measure the voltage on the multimeter when the engine

runs at 5,000 rpm.
Standard:
-07 HI

Measured BV < Measured CV < 15.5 V

• BV = Battery voltage (page 22-5)
28 O

• CV = Charging voltage
PR

22-6
dummyhead

BATTERY/CHARGING SYSTEM
ALTERNATOR CHARGING COIL
INSPECTION
Remove the rear fender cover (page 2-12).

S. O
[1]
Disconnect the alternator 3P (Gray) connector [1].

L.
S AD
Check the connector for loose contacts or corroded

R.
terminals.

OR RIZ
Measure the resistance between the Yellow wire
terminals of the alternator side connector.
Standard: 0.1 – 1.0 Ω (20°C/68°F)

OT TO
Check for continuity between each Yellow wire terminal
of the alternator side connector and ground.
There should be no continuity.

LM U
Replace the alternator stator if resistance is out of

RA O A
specification, or if any wire has continuity to ground.
For alternator stator replacement (page 14-7).

AB N
REGULATOR/RECTIFIER

-C O
REMOVAL/INSTALLATION

L. US
Remove the two mounting bolts [1] and regulator/
CM type shown:
rectifier [2].
Disconnect the stator 3P (Gray) connector [3] and
S. N O
regulator/rectifier 3P (Black) connector [4].
Installation is in the reverse order of removal.
[4] [3]
R.
RS IÓ
TO UC
MO RIB

[1] [2]

WIRE HARNESS INSPECTION

Remove the rear fender cover (page 2-12).
AL ST

[1]
Disconnect the regulator/rectifier 3P (Black) [1]
connector.
BR DI

Check the connectors for loose contacts or corroded

terminals.
CA SU

Check the following at the wire harness side

connectors.
Battery Line (Black connector):
Measure the voltage between the Red wire terminal
24 O

and ground.
-20 BID

There should be battery voltage at all times.

Ground Line (Black connector):
Check for continuity between the Green wire terminal
and ground.
-07 HI

There should be continuity at all times.

28 O
PR

G R

22-7
 dummyhead

BATTERY/CHARGING SYSTEM
MAIN POWER RELAY
RELAY INSPECTION
Remove the relay box lid (page 6-11).

S. O
’14 model shown:
Turn the ignition switch OFF.

L.
S AD
Remove the main power relay [1].

R.
OR RIZ
OT TO
LM U
[1]

RA O A
Connect an ohmmeter to the main power relay [1]
[1]
terminals.
Connect a 12 V battery to the relay terminals as shown.

AB N
There should be continuity when the 12 V battery is

-C O
connected and no continuity when the battery is
disconnected.

L. US
S. N O
R.
RS IÓ

DIODE INSPECTION
Remove the rear fender cover (page 2-12).
TO UC

’14 model shown:

Remove the fuse box cover and diode [1].
[1]
MO RIB
AL ST
BR DI
CA SU

Check for continuity between the diode [1] terminals.

[1]
When there is continuity, a small resistance value will
24 O

register.
-20 BID

If there is continuity in one direction, the diode is

normal.

C A
-07 HI
28 O

B
A
PR

C B

22-8
dummytext

23. LIGHTS/METERS/SWITCHES

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 23-2 GEAR POSITION SWITCH (Except '14 -'19 FA
and after '19 TM/FM models)················ 23-11

RA O A
COMPONENT LOCATION ····················· 23-3
FRONT BRAKE SWITCH ····················· 23-12

AB N
HEADLIGHT ······································· 23-4
REAR BRAKE SWITCH ······················· 23-13

-C O
BRAKE/TAILLIGHT······························ 23-5

L. US
COOLING FAN··································· 23-14
COMBINATION METER/INDICATOR ······ 23-6
FUEL GAUGE/FUEL INDICATOR/FUEL
S. N O
IGNITION SWITCH ······························23-10 LEVEL SENSOR································· 23-15

HANDLEBAR SWITCH ························23-11 4WD SELECT SWITCH/4WD INDICATOR

R.
(Except TM1/TE1 models) ··················· 23-18
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU

23
24 O
-20 BID
-07 HI
28 O
PR

23-1
 dummyhead

LIGHTS/METERS/SWITCHES
SERVICE INFORMATION
LIGHTS/METERS/SWITCHES

GENERAL

S. O
L.
S AD
• Note the following when replacing the halogen headlight bulb.
– Wear clean gloves while replacing the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the

R.
bulb and cause it to fail.
– If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.

OR RIZ
• All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
• To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be
made without removing the part from the vehicle. Simply disconnect the connectors and connect a continuity tester to the

OT TO
terminals or connections.
• The following color codes are used throughout this section.

LM U
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

RA O A
TOOL

AB N
Pin Probe Male (2 pack)
07ZAJ-RDJA110

-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

23-2
dummyhead

LIGHTS/METERS/SWITCHES
COMPONENT LOCATION
'14 – '19 models

S. O
FA2 model shown: REAR BRAKE SWITCH COMBINATION METER
(LEVER SIDE)

L.
S AD
FRONT BRAKE SWITCH

R.
HANDLEBAR SWITCH

OR RIZ
IGNITION SWITCH

OT TO
LM U
RA O A
AB N
-C O
L. US
COOLING FAN MOTOR
S. N O
4WD SELECT SWITCH (Except TM1/TE1)
REAR BRAKE SWITCH
(PEDAL SIDE)
GEAR POSITION SWITCH
R.
RS IÓ

After '19 model

TO UC

FA6 model shown: HANDLEBAR SWITCH REAR BRAKE SWITCH

(LEVER SIDE)
COMBINATION METER
MO RIB

IGNITION SWITCH FRONT BRAKE SWITCH

AL ST
BR DI

COOLING FAN MOTOR

CA SU
24 O
-20 BID
-07 HI
28 O

REAR BRAKE SWITCH 4WD SELECT SWITCH (Except TM1/TE1)

PR

(PEDAL SIDE)
GEAR POSITION SWITCH
(TM/FM models only)

23-3
 dummyhead

LIGHTS/METERS/SWITCHES
HEADLIGHT
BULB REPLACEMENT
Remove the headlight cover cap [1].

S. O
[3]
Disconnect the headlight 3P connector [2].
Remove the headlight bulb [3] by turning it

L.
S AD
counterclockwise.

R.
[2]

OR RIZ
Avoid touching halogen headlight bulb. Finger prints
can create hot spots that cause a bulb to break.

OT TO
Align the bulb tabs Install a new bulb in the reverse order of removal.
with the headlight
grooves properly.

LM U
[1]

RA O A
REMOVAL/INSTALLATION
Remove the headlight cover cap [1].
Disconnect the headlight 3P connector [2].

AB N
Remove the following:

-C O
– screws [3] [3]
– mounting bolt [4]

L. US
– headlight assembly [5] [1]

[2]
S. N O
R.
RS IÓ

[5] [4]

Release the screw [1] from the headlight cover [2].

TO UC

[3]
Remove the headlight [3] by unhooking its bosses [4]
from the headlight cover holes [5]. [1]
MO RIB

Route the headlight Install the headlight unit in the reverse order of removal.
wire into the groove
• After installing the headlight to the cover, align the
in the headlight
headlight lens snap fit with the headlight cover lug
cover properly.
by turning the adjusting screw as shown.
AL ST

[4]
BR DI
CA SU

[5]
24 O

Align [2]
-20 BID
-07 HI
28 O
PR

23-4
dummyhead

LIGHTS/METERS/SWITCHES
After installing the headlight assembly, adjust the
headlight aim by turning the adjusting screw [1] if
necessary.

S. O
L.
S AD
R.
OR RIZ
OT TO
[1]

BRAKE/TAILLIGHT

LM U
REPLACEMENT

RA O A
Except FA5/FA6:
Open the tool box lid.
[5] [1]

AB N
Remove the clip [1].
Remove the brake/taillight [2] from the tool box lid by

-C O
releasing the bosses [3] from the grommets [4].
Disconnect the brake/taillight 3P connector [5].

L. US
Route the wire Install a new brake/taillight in the reverse order of
properly (page 1- removal.
30).
S. N O

[4]
R.
RS IÓ
TO UC
MO RIB

[2] [3]

FA5/FA6:
Open the tool box lid.
AL ST

[1]
Remove the clips [1].
[5]
Remove the brake/taillight [2] from the tool box lid by
BR DI

releasing the bosses [3] from the grommets [4].

Disconnect the brake/taillight 3P connector [5].
CA SU

Route the wire Install a new brake/taillight in the reverse order of

properly (page 1- removal.
30).
24 O
-20 BID
-07 HI

[4]
28 O

[3]
PR

[2]

23-5
 dummyhead

LIGHTS/METERS/SWITCHES
COMBINATION METER/INDICATOR
INITIAL OPERATION CHECK (Except
TM1 model)

S. O
When the ignition switch is turned ON, the combination

L.
S AD
meter turns all the indicators on and shows all the LCD
digital segments for a few seconds.

R.
If the combination meter does not shows the initial

OR RIZ
operation, check its power/ground lines (page 23-7).
If the power/ground lines are OK, replace the
combination meter assembly (page 23-6).

OT TO
LM U
RA O A
REMOVAL/INSTALLATION

AB N
Remove the three bolts [1] and handlebar cover/stay
[2]
assembly [2].

-C O
L. US
S. N O
R.
RS IÓ

[1]
TO UC

Except TM1 model: Slide the boot [1] and disconnect

[3] [5]
the 16P connector [2] from the combination meter.
MO RIB

TM1 model: Raise the rear of the front fender/carrier

(page 23-10), remove the indicator socket 10P (Gray)
connector from the clip and disconnect it.
Remove the three cover screws [3] and handlebar
AL ST

cover [4] from the meter cover stay [5].

BR DI
CA SU

[4] [2] [1]

Except TM1 model: Remove the three combination

[2]
24 O

meter mounting screws [1] and meter [2] from the meter
cover stay.
-20 BID

TM1 model: Remove the three screws [1] and indicator

stay from the meter cover stay.
Installation is in the reverse order of removal.
-07 HI

TORQUE:
Combination meter mounting screw:
28 O

0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)

PR

[1]

23-6
dummyhead

LIGHTS/METERS/SWITCHES
CLOCK ADJUSTMENT
Turn the ignition switch ON and select the digital clock
mode with the mode select button [1].

S. O
To enter the adjustment mode, press and hold mode
select button until the clock display start blinking.

L.
S AD
To advance the clock display, press and hold the mode
select button.

R.
• First 5.5 seconds, the clock display will advance one

OR RIZ
unit at a time.
• After 5.5 seconds, the clock display will advance five
unit at a time.

OT TO
• After 10.5 seconds, the clock display will advance
ten unit at a time.
After completing the adjustment, press the mode select [1]

LM U
button or turn the ignition switch OFF.
POWER/GROUND LINE INSPECTION

RA O A
(Except TM1 model)
Remove the handlebar cover/stay assembly
(page 23-6).

AB N
Slide the boot [1] and disconnect the 16P connector [2]
from the combination meter.

-C O
Check the power and ground lines at the wire harness

L. US
side 16P connector.
S. N O
R.
RS IÓ

[2] [1]

POWER INPUT LINE

TO UC

Measure the voltage between the 16P connector [1]

[1] Bl/R
terminal and ground.
MO RIB

Connection: Black/red (+) – Ground (–)

There should be battery voltage with the ignition switch
turned ON.
AL ST

If there is no voltage, check the following:

– faulty circuit between the battery and IGN fuse
BR DI

(20 A) (page 4-43)

– Black/red wire between the combination meter and
fuse box for an open circuit
CA SU

BACK-UP VOLTAGE LINE

24 O

Measure the voltage between the 16P connector [1]

[1]
terminal and ground.
-20 BID

R/Y
Connection: Red/yellow (+) – Ground (–)
There should be battery voltage with the ignition switch
-07 HI

turned ON.
If there is no voltage, check the following:
28 O

– MAIN fuse 2 (10 A)

PR

– Red/yellow wire between the combination meter and

fuse box for an open circuit

23-7
 dummyhead

LIGHTS/METERS/SWITCHES
GROUND LINE
Check for continuity between the combination meter
[1]
16P connector [1] terminal and ground.
There should be continuity all times.

S. O
Connection: Green – Ground

L.
S AD
If there is no continuity, check for an open circuit in the

R.
Green wire.

OR RIZ
G

OT TO
LM U
SERIAL COMMUNICATION LINE

RA O A
(Except TM1 model)
Gear position indicator continuously blinks "–",
MIL, engine coolant temperature, neutral and
reverse indicators stay on

AB N
1. PCM/ECM Power Input Inspection

-C O
Check that the engine can be started normally.
Can the engine start?

L. US
YES – GO TO STEP 2.
NO – Check the PCM/ECM power/ground line
(page 4-42).
S. N O
2. Connector Inspection
Check the combination meter 16P connector and
PCM/ECM 33P (Black) connector for loose contacts
R.
RS IÓ

or corroded terminals.
Are the connectors in good condition?
TO UC

YES – GO TO STEP 3.
NO – Loose or poor contacts at the combination
MO RIB

meter 16P connector or PCM/ECM 33P

(Black) connector
3. Serial Communication Line Short Circuit
Inspection
AL ST

Turn the ignition switch OFF. [1]

Disconnect the PCM/ECM 33P (Black) connector [1]
BR DI

(page 4-42)and combination meter 16P connector

(page 23-6).
Check for continuity between the wire harness side
CA SU

PCM/ECM 33P (Black) connector terminal and

ground.
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
24 O

Connection: Pink (A21) – ground

-20 BID

Is there continuity?
P (A21)
YES – Short circuit in the Pink wire
-07 HI

NO – GO TO STEP 4.
28 O
PR

23-8
dummyhead

LIGHTS/METERS/SWITCHES
4. Serial Communication Line Open Circuit
Inspection
Check for continuity between the 33P (Black)
connector [1] and 16P connector [2] terminals. V or P

S. O
TOOL:

L.
S AD
Pin Probe Male (2 pack) 07ZAJ-RDJA110

R.
Connection:
’14 model: Pink (A21) – Violet

OR RIZ
After ’14: Pink (A21) – Pink
Is there continuity?

OT TO
YES – GO TO STEP 5. P (A21)

NO – Open circuit in the Pink or Violet wire

LM U
[2] [1]

RA O A
5. PCM/ECM Circuit Inspection
Connect the PCM/ECM 33P (Black) connector.
[1]
Turn the ignition switch ON and wait 5 seconds or
more. Measure resistance at the 16P connector [1]

AB N
terminals. V or P

Connection:

-C O
’14 model: Violet – Green
After ’14: Pink – Green

L. US
Is the resistance 0.1 kΩ – 100 kΩ?
YES – Replace the combination meter with a
G
S. N O
known good one, and recheck.
NO – Replace the PCM/ECM with a known good
one, and recheck.
R.
RS IÓ

SPEEDOMETER (Except TM1 model)

Speedometer does not operate
TO UC

1. Combination Meter Inspection

Check the combination meter initial operation (page
MO RIB

23-6).
Does the combination meter operate properly?
YES – • Except FA models: GO TO STEP 2.
AL ST

• FA models: GO TO STEP 3.
NO – Check the combination meter power/
BR DI

ground lines (page 23-7).

2. ESP System DTC Inspection
Check the ESP system DTC (page 24-8).
CA SU

Is DTC 11-1 indicated?

YES – Perform the DTC 11-1 troubleshooting
24 O

(page 24-12).
NO – GO TO STEP 4.
-20 BID

3. DCT System DTC Inspection

Check the DCT system DTC (page 13-27).
-07 HI

Is DTC 66-1 indicated?

YES – Perform the DTC 66-1 troubleshooting
28 O

(page 13-51).
PR

NO – GO TO STEP 4.

23-9
 dummyhead

LIGHTS/METERS/SWITCHES
4. Speedometer Line Open Circuit Inspection
Disconnect the VS sensor 3P (Black) connector
[2] [1]
(page 24-27)and combination meter 16P connector
(page 23-6).

S. O
Check for continuity between the 16P connector [1]
and 3P (Black) connector [2] terminals.

L.
S AD
Connection: Pink/green – Pink

R.
Is there continuity?

OR RIZ
YES – Replace the combination meter
(page 23-6).
P P/G
NO – • Open circuit in the Pink/green or Pink

OT TO
wire
• Loose or poorly connected related
connectors

LM U
IGNITION SWITCH

RA O A
INSPECTION
Remove the tank cover assembly (page 2-4).
[3]

AB N
Loosen the lower bolts [1] on both sides of the front
fender/carrier.

-C O
Remove the trim clips [2] and bolts [3] from both sides
of the front fender/carrie.

L. US
[2]
S. N O
R.
RS IÓ

[1]

Remove the eight trim clips [1] from both right and left
TO UC

[1] [2]
center mudguards.
Remove the fuel tank cap [2] and raise the rear of the
front fender/carrier slightly.
MO RIB

Install the fuel tank cap.

AL ST
BR DI
CA SU

[1]

Remove the ignition switch 4P connector [1] from the

clip and disconnect it.
24 O

Check for continuity between the switch side connector

terminals in each switch position according to the wiring
-20 BID

diagrams.
-07 HI
28 O
PR

[1]

23-10
dummyhead

LIGHTS/METERS/SWITCHES
REPLACEMENT
Disconnect the ignition switch 4P connector
[2]
(page 23-10).

S. O
Remove the handlebar cover/stay assembly
(page 23-6).

L.
S AD
Release the ignition switch wire from the wire band and
wire guides.

R.
Remove the ignition switch [1] from the handlebar cover

OR RIZ
by pushing in the two stoppers [2].
Install a new ignition switch by aligning the locating tab
[3] with the cover groove.

OT TO
Install the removed parts in the reverse order of
removal. [3] [1]

LM U
HANDLEBAR SWITCH

RA O A
INSPECTION
Raise the rear of the front fender/carrier (page 23-10).
[1]

AB N
Remove the 14P (TM1 model: 8P) (Green) connector
[1] and disconnect it.

-C O
Check for continuity between the switch side connector
terminals in each switch position according to the wiring

L. US
diagrams.
S. N O
R.
RS IÓ

GEAR POSITION SWITCH (Except '14 -

TO UC

'19 FA and after '19 TM/FM models)

MO RIB

• Shift drum position switch service for FA models

(page 13-72).
INSPECTION
AL ST

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

’14 - ’21 models shown:
BR DI

’14 - ’21 models Remove the gear position switch 8P (Gray) connector [1]
[1] from the frame and disconnect it.
CA SU

After ’21 model Remove the gear position switch 8P (Black) connector
[1] from the frame and disconnect it.
If the transmission Check for continuity at the switch side connector
24 O

will not shift with the terminals.

-20 BID

gearshift switches, There should be continuity in each gear position as

use the gear follows:
change tool
included with the Gear position Connection
Reverse Gray – ground
-07 HI

tool kit (TE1/FE1

models). Neutral Light green/red – ground
1st White/green – ground
28 O

2nd White/red – ground

PR

3rd Blue – ground

4th Yellow – ground
5th Light blue/white – ground

23-11
 dummyhead

LIGHTS/METERS/SWITCHES
REPLACEMENT
Remove the rear crankcase cover (page 14-7).
[4] [1]
Remove the two wire clamp bolts [1].

S. O
Remove the wire grommet [2] from the rear crankcase
cover.

L.
S AD
Remove the retaining bolt [3] and gear position switch
[4] from the rear crankcase cover.

R.
Apply locking agent to all the bolt threads.

OR RIZ
Install a new gear position switch onto the rear
crankcase cover and tighten the retaining bolt.
Apply liquid sealant to the grommet seating surface.
Route the wire as shown and install the grommet into

OT TO
the crankcase cover groove properly.
Install the two clamp bolts and tighten them to the
specified torque. [3] [2]

LM U
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

RA O A
Install the rear crankcase cover (page 14-11).

FRONT BRAKE SWITCH

AB N
INSPECTION

-C O
Disconnect the front brake switch connectors [1].

L. US
[1]
Check for continuity between the switch terminals.
There should be continuity with the front brake lever
squeezed and no continuity with the lever released.
S. N O
R.
RS IÓ
TO UC
MO RIB

REPLACEMENT
Slide the dust cover [1] and disconnect the front brake
[4] [1] Align
switch connectors [2].
AL ST

Squeeze the front brake lever and secure it.

Remove the screw [3] and front brake switch [4].
BR DI

Install the front brake switch onto the master cylinder by

aligning the boss with the hole.
Install the screw and tighten it to the specified torque.
CA SU

TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)

Connect the switch connectors and install the dust
cover properly.
24 O
-20 BID

[2] [3]
-07 HI
28 O
PR

23-12
dummyhead

LIGHTS/METERS/SWITCHES
REAR BRAKE SWITCH
LEVER SIDE INSPECTION
Remove the dust cover [1] from the rear brake switch.

S. O
’14 model shown:
Disconnect the rear brake switch connectors [2] and

L.
S AD
check for continuity between the switch terminals. [1]

R.
There should be continuity with the rear brake lever
squeezed and no continuity with the lever released.

OR RIZ
OT TO
LM U
[2]

RA O A
LEVER SIDE REPLACEMENT
Apply parking brake.
’14 model shown: [4]

AB N
Remove the dust cover [1] from the rear brake switch
[1] [2]
[2].

-C O
Disconnect the rear brake switch connectors [3].

L. US
Remove the screw [4] and switch from the brake lever
bracket. S. N O
R.
RS IÓ

[3]

Install the screw [1] and spacer [2] onto the rear brake
TO UC

’14 model shown: [2]

switch [3]
[3]
Install the switch onto the brake lever bracket by
aligning the boss with the hole.
MO RIB

Tighten the screw to the specified torque.

TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
AL ST

Connect the connectors to the switch.

Install the dust cover onto the switch properly.
BR DI
CA SU

Align [1]

PEDAL SIDE INSPECTION

Remove the air cleaner housing (page 7-17).
24 O

Disconnect the rear brake switch 2P (Black) connector

-20 BID

[1] and check for continuity between the switch side

connector terminals.
There should be continuity with the rear brake pedal
depressed and no continuity with the pedal released.
-07 HI
28 O
PR

[1]

23-13
 dummyhead

LIGHTS/METERS/SWITCHES
COOLING FAN
Cooling fan does not start
1. Fuse Inspection

S. O
Check the following:

L.
S AD
– TM1/FM1/FM2: FAN fuse (20 A)
– TE1/FE1/FA1/FA2/FA5/FA6: ES fuse (30 A)

R.
Is the fuse blown?

OR RIZ
YES – Replace the fuse.
NO – GO TO STEP 2.

OT TO
2. PGM-FI System DTC Inspection
Check the PGM-FI system DTC (page 4-10).

LM U
Is DTC 7-1 and/or 7-2 indicated?

RA O A
YES – • Perform the DTC 7-1 troubleshooting
(page 4-19).
• Perform the DTC 7-2 troubleshooting
(page 4-20).

AB N
NO – GO TO STEP 3.
3. Ground Line Inspection

-C O
Disconnect the PCM/ECM 5P (Black) connector [1]
[1]

L. US
(page 4-43).
Check for continuity between the PCM/ECM 5P
(Black) connector [1] terminal and ground.
Connection: Green – ground
S. N O
Is there continuity?
YES – GO TO STEP 4.
R.
RS IÓ

NO – Open circuit in the Green wire

G
TO UC
MO RIB

4. Cooling Fan Operation Inspection

Connect the PCM/ECM 5P (Black) connector [1]
[1]
terminals with jumper wire [2].
AL ST

Connection: Green/black – green G/Bl

Check the cooling fan when connecting the jumper
BR DI

wire. [2]
Does the cooling fan start?
CA SU

YES – Replace the PCM/ECM with a known good

one, and recheck.
NO – GO TO STEP 5.
24 O

G
-20 BID
-07 HI
28 O
PR

23-14
dummyhead

LIGHTS/METERS/SWITCHES
5. Cooling Fan Ground Line Inspection
Remove the cooling fan 2P connector [1] from the
frame and disconnect it (page 8-7).
With the jumper wire connected to the PCM/ECM

S. O
5P connector, check for continuity between the fan
motor 2P connector [2] terminal and ground.

L.
S AD
Connection: Green/black – ground G/Bl

R.
Is there continuity?

OR RIZ
YES – GO TO STEP 6.
NO – Open circuit in the Green/black wire

OT TO
[1]

LM U
6. Cooling Fan Power Input Line Inspection

RA O A
Measure the voltage between the fan motor 2P [1]
terminal (+) and ground (–).
Connection: Red/white (+) – ground (–)

AB N
Is there battery voltage?
YES – Replace the cooling fan with a new one

-C O
(page 8-8). R/W

L. US
NO – Open circuit in the Red/white wire between
the cooling fan and fuse box
S. N O
[1]

FUEL GAUGE/FUEL INDICATOR/FUEL

R.
RS IÓ

LEVEL SENSOR
TO UC

SYSTEM INSPECTION (Except TM1

model)
MO RIB

Check that the combination meter shows the initial

operation (page 23-6).
If the fuel mark and fuel gauge are blinking with the
AL ST

ignition switch ON, check for open or short circuit in the

Green/yellow and/or Yellow/white wire between the fuel
pump unit and combination meter.
BR DI

If the wires are normal, replace the combination meter

(page 23-6).
CA SU
24 O
-20 BID
-07 HI
28 O
PR

23-15
 dummyhead

LIGHTS/METERS/SWITCHES
Remove the fuel pump unit (page 7-12).
Connect the fuel pump unit 4P (Gray) connector.
With the fuel level sensor float [1] at the top (FULL)

S. O
position [2], turn the ignition switch ON and check the [2]
fuel gauge.

L.
S AD
All segments up to segment "F" should come on.

R.
Turn the ignition switch OFF.

OR RIZ
OT TO
[1]

LM U
RA O A
Move the float to the bottom (EMPTY) position, turn the
ignition switch ON and check the fuel gauge.

AB N
The fuel mark and fuel gauge should blink three times,
then the fuel mark and "LOW FUEL" message should

-C O
blink three times. This indication is repeated.

L. US
If the fuel gauge does not function properly, check the
fuel level sensor (page 23-17).
If the fuel level sensor is OK, replace the combination
meter.
S. N O
If all segments blink during inspection, replace the
combination meter.
Turn the ignition switch OFF.
R.
RS IÓ

Install the fuel pump unit (page 7-13).

TO UC

SYSTEM INSPECTION (TM1 model)

Turn the ignition switch ON and check that the fuel
MO RIB

[1]
indicator [1] comes on for about 2 seconds and goes
off.
If the fuel indicator does not operate properly and the
AL ST

other indicator operate properly, check as follows:

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

23-16
dummyhead

LIGHTS/METERS/SWITCHES
Turn the ignition switch OFF.
[1]
Disconnect the ECM 33P (Black) connector
(page 4-42).

S. O
Ground the wire harness side 33P (Black) connector [1]
terminal with a jumper wire.

L.
S AD
TOOL:

R.
Pin Probe Male (2 pack) 07ZAJ-RDJA110

OR RIZ
Connection: A33 – ground
Turn the ignition switch ON and check the fuel indicator.
A33
If the fuel indicator comes on, replace the ECM with a

OT TO
known good one (page 4-43).
If the fuel indicator does not come on, check the

LM U
following:

RA O A
– Open circuit in the Green/yellow wire between the
ECM and
– Faulty fuel indicator bulb
– Open circuit in the Black/red wire between the fuel
indicator and joint connector

AB N
Remove the fuel pump unit (page 7-12).

-C O
Connect the fuel pump unit 4P (Gray) connector.

L. US
Turn the ignition switch ON.
[3]
The fuel indicator should come on with the fuel level
sensor float [1] at the bottom (EMPTY) position [2], and
should go off when the float is moved to the top (FULL)
S. N O
position [3].
If the fuel indicator does not operate properly, check the
fuel level sensor (page 23-17). [2]
R.
RS IÓ
TO UC

[1]

FUEL LEVEL SENSOR INSPECTION

MO RIB

Remove the fuel pump unit (page 7-12).

Measure the fuel level sensor resistance with the float
[1] at the top (FULL) [2] and bottom (EMPTY) [3]
positions.
AL ST

[2]
Connection:
TM model: Green – Yellow/white
BR DI

Except TM: Green/yellow – Yellow/white

FLOAT POSITION RESISTANCE (20°C/68°F)

CA SU

TOP (FULL) 19.0 – 21.0 Ω

BOTTOM (EMPTY) 772.0 – 788.0 Ω [3]
24 O

[1]
-20 BID

Y/W
-07 HI
28 O
PR

G or G/Y

23-17
 dummyhead

LIGHTS/METERS/SWITCHES
4WD SELECT SWITCH/4WD
INDICATOR (Except TM1/TE1 models)
SYSTEM INSPECTION

S. O
If the gear position indicator continuously blinks "–",

L.
S AD
[1]
MIL, engine coolant temperature, neutral and reverse
indicators stay on, check the serial communication line

R.
(page 23-8).

OR RIZ
Disconnect the 4WD select switch connector [1].
Ground the switch connector terminal with a jumper
wire.

OT TO
Turn the ignition switch to ON and check the 4WD
indicator [2].

LM U
The indicator should light when the connector terminal
is grounded.

RA O A
The indicator should not light when the jumper wire is
removed.
FM2/FA2/FA6 If the 4WD indicator operation is abnormal, check the

AB N
models: Brown/white wire between the 4WD select switch and
EPS ECU, and the Blue wire between the EPS ECU

-C O
and PCM/ECM.
If the 4WD indicator operation is abnormal, check the

L. US
Except FM2/FA2/
FA6 models: Brown/white wire between the 4WD select switch and
PCM/ECM.
S. N O
R.
[2]
RS IÓ

SWITCH INSPECTION
TO UC

Disconnect the 4WD select switch connector [1].

[1]
Check for continuity between the switch terminal and
ground.
MO RIB

There should be continuity when the 2WD/4WD select

lever is 4WD position, and no continuity when the lever
is 2WD position.
AL ST
BR DI
CA SU

REPLACEMENT
24 O

Disconnect the 4WD select switch connector [1].

[1]/[2]/[3]
-20 BID

Remove the 4WD select switch [2] and sealing washer

[3].
Install the 4WD select switch with a new sealing washer
and tighten it.
-07 HI

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

28 O

Connect the 4WD select switch connector.

PR

23-18
dummytext

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

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 24-2 DTC INDEX········································ 24-10

RA O A
COMPONENT LOCATION ····················· 24-3 DTC TROUBLESHOOTING ·················· 24-12

AB N
SYSTEM DIAGRAM ····························· 24-4 VS SENSOR ······································ 24-27

-C O
BEFORE TROUBLESHOOTING ············· 24-6 SHIFT SPINDLE ANGLE SENSOR ········ 24-28

L. US
SYMPTOM TROUBLESHOOTING ·········· 24-6
S. N O TR SENSOR (After '19 model) ·············· 24-30

ELECTRIC SHIFT DOES NOT OPERATE ··· 24-7 NEUTRAL SWITCH (After '19 model) ···· 24-31

TROUBLESHOOTING INFORMATION ···· 24-8 SHIFT CONTROL MOTOR/REDUCTION

R.
RS IÓ

GEARS ············································· 24-31

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

24
-20 BID
-07 HI
28 O
PR

24-1
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

SERVICE INFORMATION
ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

GENERAL
• Refer to "Before Troubleshooting" first and begin the troubleshooting (page 24-6).

S. O
• When performing the DTC troubleshooting, read "Troubleshooting Information" carefully, and inspect and troubleshoot
according to the DTC. Observe each step of the procedures one by one. Note the DTC and probable faulty part before starting

L.
S AD
diagnosis and troubleshooting.

R.
• A faulty ESP system is often related to poorly connected or corroded connectors. Check those connections before proceeding.
• The PCM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may

OR RIZ
damage the PCM. Always turn off the ignition switch before disconnecting or connecting the connectors.
• Use a digital tester for ESP system inspection.
• 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
For ESP Troubleshooting

RA O A
The PCM controls the PGM-FI and ESP systems. Therefore some detection items are shared by the PGM-FI and ESP and they
may affect the operation of both systems.
Before starting any troubleshooting, check the items as follows and refer to the appropriate troubleshooting.

AB N
1. MIL blinks or DTC for the PGM-FI system (page 4-10).
2. Gear position indicator blinks or DTC for the ESP (page 24-8).
3. Symptom of the ESP operation (page 24-6).

-C O
Refer to PGM-FI System section for "General Troubleshooting" information (page 4-9).

L. US
TOOLS
S. N O
SCS Short Connector Pin Probe Male (2 pack)
070PZ-ZY30100 07ZAJ-RDJA110
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

24-2
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

COMPONENT LOCATION
'14 – '19 FE1 model shown:

S. O
L.
S AD
R.
UPSHIFT SWITCH

OR RIZ
COMBINATION METER
DOWNSHIFT SWITCH – GEAR POSITION INDICATOR

OT TO
IGNITION SWITCH

LM U
PCM
DLC

RA O A
FUSE BOX:
– MAIN FUSE 1 (30 A) RELAY BOX
– ES FUSE (30 A) – MAIN POWER RELAY

AB N
– MAIN FUSE 2 (10 A)
– IGN FUSE (10 A)

-C O
– ACC FUSE (20 A)
– DIODE

L. US
S. N O
R.
RS IÓ
TO UC
MO RIB

BATTERY
AL ST

SHIFT CONTROL MOTOR

BR DI

SENSOR UNIT
(TP SENSOR)
CA SU

VS SENSOR After '19 model:

24 O

NEUTRAL SWITCH
-20 BID

SHIFT SPINDLE ANGLE SENSOR '14 – '19 models: GEAR POSITION SWITCH
After '19 model: TR SENSOR
-07 HI
28 O
PR

24-3
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

SYSTEM DIAGRAM
'14 – '19 models

S. O
ES FUSE (30 A)

L.
S AD
R R/W

R.
MAIN POWER REGULATOR/
RELAY RECTIFIER

OR RIZ
R/Bl R R
IGNITION SWITCH IGN FUSE (20A)
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

LM U
MAIN FUSE 2 (10A) DIODE

RA O A
PRC B31 V/W
GEAR Up
SHIFT SWITCH

AB N
W/Bu A6 SFT UP PVB C4 R/W
(42)
W/Y A16 SFT DWN
Dwon MAIN B1 Bl/R

-C O
L. US
MOM C2 Bl SHIFT CONTROL
MOP C1 R MOTOR
(22)

Br/W Br/W B3 VCC

TP
S. N O
Bu/Bl B14 TH
SENSOR
G/W G/W B2 SG
(8)

PCM
R.
RS IÓ

W/Bl
TO UC

Br/W K - LINE B17 O/W

SHIFT SPINDLE G/Y A23 ANGLE
G/Bu SCS B29 Br/R
ANGLE SENSOR
G/W G
(21)(22)
DLC SCS SERVICE CONNECTOR
MO RIB

Lb/W A13 GP 5
GEAR
POSITION Y A2 GP 4
SWITCH Bu A26 GP 3 MIL
4 3
(41) 5
2 W/R A27 GP 2
AL ST

R
N 1 W/G A24 GP 1 LCD
Lg/R A17 GP N
M-TXDRXD A21 P SERIAL IGN Bl/R

Gr A25 GP R SP GND
BR DI

COMBINATON G
P/G
G B13 LG METER
RR VSP B16 P/G
G B21 PG1 P
SEN VB1 A5 Bl/R Bl/W
CA SU

G B10 PG2

G C5 PG3
G
VS SENSOR
(11)
24 O
-20 BID
-07 HI

PCM C-1 C-3

A-1 A-11 B-1 B-11
A-12 A-22 B-12 B-22
28 O

( ): Gear position indicator Bl: Black Lb: Light blue

brink Br: Brown O: Orange
Bu: Blue P: Pink
: Short terminals for
PR

G: Green R: Red
reading DTC Gr: Gray W: White
Lg: Light green Y: Yellow

C-4 C-5 A-23 A-33 B-23 B-33

5P (Black) CONNECTOR 33P (Black) CONNECTOR 33P (Gray) CONNECTOR

24-4
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

After '19 model

ES FUSE (30 A)

S. O
R R/W

L.
S AD
MAIN POWER REGULATOR/
RELAY RECTIFIER

R.
R/Bl R R
IGNITION SWITCH IGN FUSE (20A)

OR RIZ
R Bl Bl/R Bl/R V/W
MAIN FUSE 1 (30 A)
R R/Bl R/Bl P W/Bl

ACC FUSE (20A)

OT TO
BATTERY R/Bl R/Y R

MAIN FUSE 2 (10A) DIODE

LM U
RA O A
PRC B31 V/W
GEARSHIFT Up
SWITCH W/Bu A6 SFT UP PVB C4 R/W
W/Y A16 SFT DOWN
Down MAIN B1 Bl/R

AB N
Br/W

-C O
MOM C2 Bl SHIFT CONTROL
MOP C1 R MOTOR

L. US
Br/W Br/W B3 VCC
TP SENSOR Bu/Bl B14 TH
G/W G/W B2 SG
S. N O
PCM
R.
RS IÓ

W/Bl
SHIFT Br/W
SPINDLE K - LINE B17 O/W
G/Y G/Bu A23 ANGLE SCS B29 Br/R
ANGLE DLC
G/R G/W G
TO UC

SENSOR

Br Br/W
TR Bu A26 DP
SENSOR G/W COMBINATON METER
MO RIB

GEAR
MIL POSITION
NEUTRAL INDICATOR
Lg Lg A17 DP N
SWITCH

M-TXD A21 P UART IGN Bl/R

AL ST

SP GND

P/G
G B13 LG RR VSP B16 P/G
BR DI

G B21 PG1 P G
SEN VB A5 Bl/R Bl/W
G B10 PG2
G C5 PG3 G
CA SU

VS SENSOR
24 O
-20 BID

1 2 3
-07 HI

4 5
28 O

PCM 5P (Black) PCM 33P (Black) CONNECTOR A PCM 33P (Gray) CONNECTOR B
CONNECTOR C (PCM SIDE) (PCM SIDE)
PR

(PCM side)
Bl .... Black O .... Orange
Br .... Brown P .... Pink
Bu .... Blue R .... Red
G .... Green V .... Violet
Gr .... Gray W .... White
Lg .... Light green Y .... Yellow

24-5
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

BEFORE TROUBLESHOOTING
• If the ATV has any ESP trouble, the gear position indicator blinks to indicate the DTC (Diagnostic Trouble Code) (page 24-8).

S. O
Check the DTC and refer to the DTC index and begin the appropriate troubleshooting procedure (page 24-10).
• If there are no DTC stored in the PCM memory, do the troubleshooting as "Symptom Troubleshooting" (page 24-6).

L.
S AD
R.
VERIFY THE COMPLAINT

OR RIZ
• Check the accuracy of the customer complaint by test riding the ATV.
• Note the symptoms.
• Do not begin disassembly or testing until you have determined if the problem is electrical or mechanical by shifting the gear
manually (page 24-7).

OT TO
• Temporarily failures can occur. Under certain conditions, the ESP system can "miss a shift." When this happens, the PCM may
record a DTC. Be sure to note and erase any stored DTC(s) when verifying the customer’s complaint. If the customer’s
complaint is duplicated during the test-ride, and the blinking gear position indicator displays a DTC, proceed with

LM U
troubleshooting.

RA O A
PRELIMINARY ESP SYSTEM INSPECTION
Inspect the following before diagnosing the system:

AB N
– Make sure the battery is fully charged and in good condition (page 22-5).
– Make sure the clutch is adjusted properly (page 3-35).

-C O
– Check the main fuse 1 (30 A), ES fuse 2 (30 A) and IGN fuse (20 A) for blown.

L. US
SYMPTOM TROUBLESHOOTING S. N O
Symptom Diagnosis Also check for
Shift control failure, but no DTC set Troubleshoot the "Electric Shift Does Clutch adjustment (page 3-35)
Not Operate" (page 24-7)
Gear position indicator blinks "–" Inspect the serial communication line
–
R.
RS IÓ

constantly (No DTC set) (page 23-8)

Gear position indicator is no indication Check for short circuit in the Brown/ Short circuit in the DLC related wire
and MIL stays on, but no DTC is set red wire of the DLC.
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

24-6
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

ELECTRIC SHIFT DOES NOT OPERATE
1. Shifting Operation Check
DTC 23-1 will Remove the left center mudguard (page 2-5).

S. O
[2]
be indicated Turn the ignition switch OFF.
with the ignition Manually shift the transmission by rotating the

L.
S AD
switch turned gearshift spindle [1] with the emergency gear
ON. change tool [2].

R.
Can the gears be changed manually?

OR RIZ
YES – GO TO STEP 2.
NO – Check the gearshift linkage (page 12- Down

OT TO
17)and the transmission (page 15-7).

LM U
Up
[1]

RA O A
2. Gearshift Switch Inspection at PCM Connector
Disconnect the PCM 33P connectors [1]
(page 4-42). [1] A6

AB N
Check for continuity between the wire harness side B3
PCM 33P (Black) connector [1] and 33P (Gray)

-C O
connector [2] terminals while pushing the gearshift
switch.

L. US
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

Connection:
S. N O
With the upshift switch pushed:
B3 – A6
With the downshift switch pushed:
A16
R.
[2]
RS IÓ

B3 – A16
Is there continuity?
TO UC

YES – Loose or poor contact of the PCM 33P

connectors
NO – GO TO STEP 3.
MO RIB

3. Gearshift Switch Inspection

Check the gearshift switch (page 24-22).
AL ST

Is the gearshift switch normal?

YES – • Open circuit in the following wire
between the handlebar switch 14P
BR DI

(Green) connector and PCM 33P

connectors
– Brown/white or White/blue
CA SU

– Brown/white or White/yellow
NO – Faulty gearshift switch
24 O
-20 BID
-07 HI
28 O
PR

24-7
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Refer to the "GENERAL TROUBLESHOOTING" in "PGM-FI system" (page

S. O
4-9)

L.
S AD
SYSTEM DESCRIPTION

R.
SELF-DIAGNOSIS SYSTEM

OR RIZ
The PCM controls the PGM-FI and ESP systems. Therefore some detection
items are shared by the PGM-FI and ESP and they may affect the operation
of both systems.
The ESP system is equipped with the self-diagnostic system. When any

OT TO
abnormality occurs in the ESP system, the PCM stops system function,
have the gear position indicator [1] blinking and stores a DTC in its erasable
memory for the relevant system failure.

LM U
INDICATOR BLINKING PATTERN

RA O A
• The number of indicator blinks is the equivalent of the main code of the
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 0.4 seconds.

AB N
One long blink is the equivalent of ten short blinks. For example, when
[1]
two long blinks are followed by three short blinks, the DTC is 23 (two

-C O
long blink = 20 blinks, plus three short blinks).
• When the PCM stores more than one DTC, the indicator displays in the

L. US
order from the lowest number to highest number.
CURRENT DTC/STORED DTC
The DTC is indicated in two ways according to the failure status.
S. N O
• If the PCM detects the problem at present, the gear position indicator will
blink at all times. It is possible to readout the indicator blink pattern as
the current DTC.
• If the PCM does not detect any problem at present but has a problem
R.
RS IÓ

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
TO UC

readout procedure.

MCS INFORMATION
MO RIB

Refer to the "MCS INFORMATION" in "PGM-FI system" (page 4-10).

AL ST

DTC READOUT
BR DI

• If the MIL blinks, readout the DTC (page 4-10)and troubleshoot the
PGM-FI system first. Then recheck the ESP system after erasing the
PGM-FI DTC.
CA SU

• After performing diagnostic troubleshooting, erase the problem DTC(s)

(page 24-9)and test-ride 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 (page
24 O

4-10).
-20 BID

Read the DTC and stored data, and follow the troubleshooting index (page
24-10).
To read the DTC with the gear position indicator, use the following
-07 HI

procedure.
[1]
28 O
PR

24-8
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

Reading DTC with the gear position indicator
Turn the ignition switch ON and read the gear position indicator blinking.
[1]
The number of blinks indicates the current DTC.
Refer to the troubleshooting index (page 24-10).

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 the gear position indicator blinking.
The number of blinks indicates the stored DTC. [2]

LM U
Refer to the troubleshooting index (page 24-10).

RA O A
ERASING DTC

AB N
• When erasing the ESP DTC, 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 ESP DTC.

-C O
Connect the MCS to the DLC (page 4-10).

L. US
Erase the DTC with the MCS while the engine is stopped.
To erase the DTC without MCS, refer to the following procedure.
S. N O
How to erase the DTC without MCS
1. Remove the dummy connector (page 4-10).
2. Turn the ignition switch OFF.
R.
RS IÓ

3. Short the DLC [1] terminals using the special tool.

[1]
TOOL:
TO UC

SCS Short Connector [2] 070PZ-ZY30100

Connection: Brown/red – Green

MO RIB

4. Turn the ignition switch ON.

5. Remove the special tool from the DLC.
AL ST
BR DI

[2]
CA SU

6. The gear position indicator [1] will display for approximately 5 seconds.
While the indicator displays, short the DLC terminals again with the
special tool. The self-diagnostic memory is erased if the indicator starts
blinking.
24 O
-20 BID

• The DLC must be jumped while the indicator displays. If not, the
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
PR

[1]

CIRCUIT INSPECTION
Refer to the "INSPECTION AT PCM/ECM CONNECTOR" information in
"PGM-FI system" (page 4-11).

24-9
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

DTC INDEX
• When the gear position indicator "–" is blinking constantly (and the MIL and coolant temperature, neutral and reverse indicators

S. O
stay on), but no DTC is indicated or retrievable, check the serial communication line (page 23-8).
'14 – '19 models

L.
S AD
R.
DTC Refer
Function Failure Symptom/Fail-safe function
("–" blinks) to

OR RIZ
TP sensor circuit Low voltage • Poor engine acceleration
8-1 (8) • TP sensor or its circuit malfunction • Fail-safe value: 0° 4-21
• ESP does not work

OT TO
TP sensor circuit High voltage • Poor engine acceleration
8-2 (8) • Loose or poor contact of the TP sensor connector • Fail-safe value: 0° 4-23
• TP sensor or its circuit malfunction • ESP does not work

LM U
VS sensor no signal • Engine operates normally
• Loose or poor contact of the Rear VS sensor • ESP does not work
11-1 (11) 24-12

RA O A
connector
• Rear VS sensor or its circuit malfunction
Shift spindle angle sensor circuit Low voltage • ESP does not work
• Loose or poor contact of the shift spindle angle
21-1 (21) 24-14

AB N
sensor connector
• Shift spindle angle sensor or its circuit malfunction

-C O
Shift spindle angle sensor circuit High voltage (more • ESP does not work
21-2 (21) than 4.62 V) 24-15

L. US
• Shift spindle angle sensor or its circuit malfunction
Shift spindle operation malfunction (while operating • ESP does not work
gearshift mechanism)
22-1 (22) 24-16
• Control motor or its circuit malfunction
S. N O
• Shift spindle angle sensor or its circuit malfunction
Shift spindle operation malfunction (after operating • ESP does not work
gearshift mechanism)
23-1 (23) 24-17
• Shift spindle angle sensor installation problem
R.
RS IÓ

• Shift spindle angle sensor or its circuit malfunction

Shift control motor drive circuit • ESP does not work
24-1 (24) • Control motor or its circuit malfunction 24-18
TO UC

• Control motor drive circuit malfunction

Fail-safe relay circuit • ESP does not work
32-1 (32) 24-21
• Fail-safe relay circuit malfunction
MO RIB

Gear position switch circuit • Engine does not start

41-1 (41) • Gear position switch circuit malfunction (Short) • ESP does not work 24-21
• Gear position indicator blinks "–"
Gear position switch circuit • ESP does not work
AL ST

41-2 (41) 24-21

• Gear position switch circuit malfunction (Open) • Gear position indicator blinks "–"
Gearshift (UP/DOWN) switch circuit • ESP does not work
42-1 (42) • Gearshift (UP/DOWN) switch circuit malfunction 24-22
BR DI

(Short)
CA SU
24 O
-20 BID
-07 HI
28 O
PR

24-10
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

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
TP sensor circuit Low voltage (less than 0.225 V) • Poor engine acceleration

L.
S AD
8-1 • Loose or poor contact of the TP sensor connector • ESP does not work 4-21
• TP sensor or its circuit malfunction

R.
TP sensor circuit High voltage (more than 4.922 V) • Poor engine acceleration
8-2 4-23

OR RIZ
• TP sensor or its circuit malfunction • ESP does not work
VS sensor no signal • Engine operates normally
• Loose or poor contact of the Rear VS sensor • ESP does not work
11-1 24-12
connector

OT TO
• Rear VS sensor or its circuit malfunction
Shift spindle angle sensor circuit Low voltage (less than • ESP does not work
0.215 V)

LM U
21-1 • Loose or poor contact of the shift spindle angle 24-14
sensor connector

RA O A
• Shift spindle angle sensor or its circuit malfunction
Shift spindle angle sensor circuit High voltage (more • ESP does not work
21-2 than 4.619 V) 24-15
• Shift spindle angle sensor or its circuit malfunction

AB N
Shift spindle operation malfunction (while operating • ESP does not work
gearshift mechanism)

-C O
22-1 24-16
• Control motor or its circuit malfunction
• Shift spindle angle sensor or its circuit malfunction

L. US
Shift spindle operation malfunction (after operating • ESP does not work
gearshift mechanism)
23-1 24-17
• Shift spindle angle sensor installation problem
• Shift spindle angle sensor or its circuit malfunction
S. N O
Shift control motor drive circuit • ESP does not work
24-1 • Control motor or its circuit malfunction 24-18
• Control motor drive circuit malfunction
R.
Shift drum position malfunction • ESP does not work
RS IÓ

27-1 • TR sensor or its circuit malfunction 24-19

• Faulty gearshift mechanism
TO UC

Fail-safe relay circuit • ESP does not work

32-1 24-21
• Fail-safe relay circuit malfunction
PCM EEPROM malfunction • Does not hold the self-diagnosis
33-2* 24-21
MO RIB

data
Gearshift (UP/DOWN) switch circuit • ESP does not work
42-1 • Gearshift (UP/DOWN) switch circuit malfunction 24-22
(Short)
AL ST

TR sensor Low voltage (less than 0.410 V) • ESP does not work
51-1 • Loose or poor contact of the TR sensor connector 24-24
• TR sensor or its circuit malfunction
BR DI

TR sensor High voltage (more than 4.702 V) • ESP does not work
51-2 24-25
• TR sensor or its circuit malfunction
Neutral switch stuck OFF • ESP does not work
CA SU

52-1 • Loose or poor contact of the neutral switch connector 24-26

• Neutral switch or its circuit malfunction
Neutral switch stuck ON • ESP does not work
52-2 24-26
• Neutral switch or its circuit malfunction
24 O

Gearshift mechanism malfunction • ESP does not work

-20 BID

57-1 • TR sensor malfunction 24-27

• Faulty shifter mechanism
Gear position malfunction (jumps out of gear) • ESP does not work
57-2 • TR sensor malfunction 24-27
-07 HI

• Faulty shifter mechanism

* DTC can be readout/erased only by MCS.

28 O
PR

24-11
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

DTC TROUBLESHOOTING
• After troubleshooting, erase the DTC (page 24-9)

S. O
and test-ride the vehicle to be sure that the system is
normal.

L.
S AD
R.
DTC 11-1 (VS SENSOR NO SIGNAL)

OR RIZ
• Before starting the troubleshooting, check the VS
sensor 3P (Black), engine sub-wire harness 6P

OT TO
(Black), and PCM 33P connectors for loose or poor
contact, and recheck the DTC.
• Make sure the battery is fully charged.

LM U
1. VS Sensor System Inspection

RA O A
Erase the DTC (page 24-9).
Test-ride the vehicle and check the VS sensor
signal with the MCS.
Is the VS sensor signal indicated normally?

AB N
YES – Intermittent failure

-C O
NO – GO TO STEP 2.
2. VS Sensor Input Voltage Inspection

L. US
Turn the ignition switch OFF.
[1]
Disconnect the VS sensor 3P (Black) connector
(page 24-27).
S. N O
Turn the ignition switch ON.
Measure the voltage between the wire harness side
VS sensor 3P (Black) connector [1] terminal and
ground
R.
RS IÓ

Connection: Black/white (+) – Ground (–)

Is the voltage more than 10 V?
TO UC

Bl/W
YES – GO TO STEP 4.
NO – GO TO STEP 3.
MO RIB

3. VS Sensor Input Line Open Circuit Inspection

AL ST

Turn the ignition switch OFF.

[1] A5 [2]
Disconnect the PCM 33P (Black) connector
(page 4-42).
BR DI

Check for continuity between the wire harness side

PCM 33P (Black) connector [1] and VS sensor 3P
(Black) connector [2] terminals.
CA SU

TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
24 O

Connection: A5 – Black/white
Is there continuity?
-20 BID

Bl/W
YES – Replace the PCM with a known good one
(page 4-43), and recheck.
NO – Open circuit in the Black/white wire
-07 HI
28 O
PR

24-12
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

4. VS Sensor Ground Line Open Circuit Inspection
Measure the voltage between the wire harness side
[1]
VS sensor 3P (Black) connector [1] terminals.
Connection: Black/white (+) – Green (–)

S. O
Is the voltage more than 10 V?

L.
S AD
YES – GO TO STEP 5.

R.
NO – Open circuit in the Green wire

OR RIZ
Bl/W G

OT TO
LM U
5. VS Sensor Signal Line Open Circuit Inspection

RA O A
Turn the ignition switch OFF.
[2] [1]
Disconnect the PCM 33P (Gray) connector
(page 4-42).
Check for continuity between the wire harness side

AB N
PCM 33P (Gray) connector [1] and VS sensor 3P
(Black) connector [2] terminals.

-C O
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

L. US
Connection: B16 – Pink
Is there continuity?
S. N O
P B16
YES – GO TO STEP 6.
NO – Open circuit in the Pink or Pink/green wire
R.
6. VS Sensor Signal Line Short Circuit Inspection
RS IÓ

Check for continuity between the wire harness side

[1]
VS sensor 3P (Black) connector [1] and ground.
TO UC

Connection: Pink – Ground

Is there continuity?
MO RIB

YES – Short circuit in the Pink or Pink/green wire

NO – GO TO STEP 7.
AL ST

P
BR DI
CA SU

7. VS Sensor Inspection
Turn the ignition switch OFF.
Replace the VS sensor with a new one
24 O

(page 24-27).
Erase the DTC (page 24-9).
-20 BID

Test-ride the vehicle and recheck the DTC.

Is the DTC 11-1 indicated?
-07 HI

YES – Replace the PCM with a known good one

(page 4-43), and recheck.
28 O

NO – Faulty original VS sensor

PR

24-13
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

DTC 21-1 (SHIFT SPINDLE ANGLE
SENSOR LOW VOLTAGE)
• Before starting the troubleshooting, check the shift
spindle angle sensor 3P (Gray), engine sub-wire

S. O
harness 6P (Black), and PCM 33P connectors for

L.
S AD
loose contacts or corroded terminals, and recheck
the DTC.

R.
1. Shift Spindle Angle Sensor System Inspection

OR RIZ
Check the shift spindle angle sensor with the MCS.
Is about 0 V indicated?
YES – GO TO STEP 2.

OT TO
NO – Intermittent failure
2. Shift Spindle Angle Sensor Input Voltage

LM U
Inspection

RA O A
Turn the ignition switch OFF.
[1]
Disconnect the shift spindle angle sensor 3P (Gray)
connector (page 24-28).
Turn the ignition switch ON.

AB N
Measure the voltage between the wire harness side
3P (Gray) connector [1] terminals.

-C O
Connection: Brown/white (+) – Green/red (–)

L. US
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 3.
NO – Replace the PCM with a known good one
S. N O
(page 4-43), and recheck.
Br/W (+) G/R (–)

3. Shift Spindle Angle Sensor Output Line Short

R.
RS IÓ

Circuit Inspection
Check for continuity between the wire harness side
TO UC

[1]
3P (Gray) connector [1] terminal and ground.
Connection: Green/yellow – ground
MO RIB

Is there continuity?
YES – Short circuit in the Green/yellow or Green/
blue wire
AL ST

NO – GO TO STEP 4.
BR DI

G/Y
CA SU

4. Shift Spindle Angle Sensor Inspection

Replace the shift spindle angle sensor with a known
24 O

good one (page 24-28).

Connect the shift spindle angle sensor 3P (Gray)
-20 BID

connector and PCM 33P (Black) connector.

Turn the ignition switch ON.
Check the shift spindle angle sensor with the MCS.
-07 HI

Is about 0 V indicated?
YES – Replace the PCM with a known good one
28 O

(page 4-43), and recheck.

PR

NO – Faulty original shift spindle angle sensor

24-14
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

DTC 21-2 (SHIFT SPINDLE ANGLE
SENSOR HIGH VOLTAGE)
1. Shift Spindle Angle Sensor System Inspection

S. O
Check the shift spindle angle sensor with the MCS.

L.
S AD
Is about 5 V indicated?
YES – GO TO STEP 2.

R.
NO – Intermittent failure

OR RIZ
2. Shift Spindle Angle Sensor Input Voltage
Inspection
Turn the ignition switch OFF.

OT TO
[1]
Disconnect the shift spindle angle sensor 3P (Gray)
connector (page 24-28).
Turn the ignition switch ON.

LM U
Measure the voltage between the wire harness side
3P (Gray) connector [1] terminals.

RA O A
Connection: Brown/white (+) – Green/red (–)
Is the voltage within 4.75 – 5.25 V?

AB N
YES – GO TO STEP 4.
NO – GO TO STEP 3.

-C O
Br/W (+) G/R (–)

L. US
3. Shift Spindle Angle Sensor Input Line Open
Circuit Inspection
S. N O
Turn the ignition switch OFF.
[1] B3 [2]
Disconnect the PCM 33P (Gray) connector
(page 4-42).
Check for continuity between the wire harness side
R.
RS IÓ

PCM 33P (Gray) connector [1] and shift spindle

angle sensor 3P (Gray) connector [2] terminals.
TO UC

TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
MO RIB

Connection: B3 – Brown/white
Is there continuity?
Br/W
YES – Open circuit in the Green/red or Green/
AL ST

white wire
NO – Open circuit in the Brown/white wire
BR DI

4. Shift Spindle Angle Sensor Output Line Open

Circuit Inspection
Turn the ignition switch OFF.
CA SU

[1] [2]
Disconnect the PCM 33P (Black) connector
(page 4-42).
Check for continuity between the wire harness side
33P (Black) connector [1] and 3P (Gray) connector
24 O

[2] terminals.
-20 BID

TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110

Connection: A23 – Green/blue

-07 HI

Is there continuity?
28 O

YES – GO TO STEP 5. A23 G/Bu

PR

NO – Open circuit in the Green/yellow or Green/

blue wire

24-15
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

5. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a known
good one (page 24-28).
Connect the shift spindle angle sensor 3P (Gray)

S. O
connector and PCM 33P (Black) connector.
Turn the ignition switch ON.

L.
S AD
Check the shift spindle angle sensor with the MCS.

R.
Is about 5 V indicated?

OR RIZ
YES – Replace the PCM with a known good one
(page 4-43), and recheck.
NO – Faulty original shift spindle angle sensor

OT TO
DTC 22-1 (SHIFT SPINDLE ANGLE
SENSOR MALFUNCTION: While

LM U
operating gearshift mechanism)

RA O A
1. Shift Spindle Angle Sensor System Inspection
Check the shift spindle angle sensor with the MCS.
Is Low voltage (about 0 V) or High voltage (about

AB N
5 V) indicated?

-C O
YES – • About 0 V: See DTC 21-1 (page 24-14)
• About 5 V: See DTC 21-2 (page 24-15)

L. US
NO – GO TO STEP 2.
2. Shift Control Motor/Reduction Gear Condition
Inspection
S. N O
Turn the ignition switch OFF.
Check that the shift control motor and reduction
gears are installed properly and are not damaged
(page 24-31).
R.
RS IÓ

Are the shift control motor and reduction gears

in normal condition?
TO UC

YES – GO TO STEP 3.
NO – Install the shift control motor and reduction
MO RIB

gears properly or replace faulty parts.

3. Shift Control Motor Inspection
Remove the shift control motor (page 24-31).
AL ST

Connect a fully charged 12 V battery [1] to the

control motor 2P connector [2] terminals to check
the motor operation.
BR DI

Change the battery connection to check the reverse

operation.
Does the shift control motor turn in both
CA SU

direction?
YES – GO TO STEP 4.
NO – Faulty shift control motor
24 O
-20 BID

[2] [1]
-07 HI
28 O
PR

24-16
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

4. Shift Spindle Angle Sensor System Inspection
Remove the shift spindle angle sensor with the
connector connected.
Turn the ignition switch ON.

S. O
While turning the shift spindle angle sensor shaft,
check the shift spindle angle sensor voltage with the

L.
S AD
MCS.

R.
When turning the sensor shaft clockwise:
Voltage increase

OR RIZ
When turning the sensor shaft
counterclockwise:
Voltage decrease

OT TO
Does the voltage vary properly?
YES – GO TO STEP 5.

LM U
NO – Faulty shift spindle angle sensor

RA O A
5. Shift Spindle Angle Sensor Condition Inspection
Check that the shift spindle angle sensor is installed
properly.

AB N
Is the shift spindle angle sensor in normal
condition?

-C O
YES – GO TO STEP 6.

L. US
NO – Install the shift spindle angle sensor
properly.
6. DTC Recheck
S. N O
Recheck the DTC with the MCS.
Is DTC 22-1 indicated?
YES – Replace the PCM with a known good one
R.
RS IÓ

(page 4-43), and recheck.

NO – Intermittent failure
TO UC

DTC 23-1 (SHIFT SPINDLE ANGLE

SENSOR MALFUNCTION: After
MO RIB

operating gearshift mechanism)

Refer to DTC 22-1 (page 24-16).
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

24-17
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

DTC 24-1 (SHIFT CONTROL MOTOR
DRIVE CIRCUIT)

S. O
• Before starting the troubleshooting, check for loose
or poor contact of the control motor 2P (Black) and

L.
S AD
PCM 5P (Black) connectors, and recheck the DTC.

R.
1. PCM Motor Power Input Line Inspection

OR RIZ
Turn the ignition switch OFF.
[1]
Disconnect the PCM 5P (Black) connector
(page 4-42).
Measure the voltage between the wire harness side

OT TO
PCM 5P (Black) connector [1] terminal and ground.
Connection: C4 (+) – Ground (–)
Is there battery voltage?

LM U
YES – GO TO STEP 2.

RA O A
C4
NO – • Blown ES fuse (30 A)
• Open circuit in the Red/white or Red
wire

AB N
-C O
2. PCM Motor Power Ground Line Inspection

L. US
Check for continuity between the wire harness side
5P (Black) connector [1] terminal and ground. [1]
Connection: C5 – Ground
S. N O
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Green wire
R.
C5
RS IÓ
TO UC
MO RIB

3. Control Motor Line Open Circuit Inspection

Disconnect the control motor 2P (Black) connector
AL ST

(page 24-31).
[1]
Check for continuity between the wire harness side
5P (Black) connector [1] and 2P (Black) connector C2
BR DI

[2] terminals. R
Connection: C1 – Red
Bl
C2 – Black
CA SU

Is there continuity?
YES – GO TO STEP 4.
24 O

NO – • Open circuit in the Red wire C1

• Open circuit in the Black wire
-20 BID

[2]
-07 HI
28 O
PR

24-18
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

4. Control Motor Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
5P (Black) connector [1] terminals and ground. C2 C1
Connection: C1 – Ground

S. O
C2 – Ground

L.
S AD
Is there continuity?

R.
YES – • Short circuit in the Black wire

OR RIZ
• Short circuit in the Red wire
NO – GO TO STEP 5.

OT TO
LM U
5. Control Motor Inspection

RA O A
Remove the shift control motor (page 24-31).
Connect a fully charged 12 V battery [1] to the
control motor 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 control motor
S. N O
[2] [1]
R.
6. Electric Shift Failure Checking
RS IÓ

Connect the PCM 5P (Black) and control motor 2P

(Black) connectors.
TO UC

Erase the DTC (page 24-9).

Recheck the DTC with the MCS.
MO RIB

Is the DTC 24-1 indicated?

YES – Replace the PCM with a known good one
(page 4-43), and recheck. If the DTC
indicated again, replace the control motor.
AL ST

NO – Intermittent failure
BR DI

DTC 27-1
(SHIFT DRUM POSITION
CA SU

MALFUNCTION)
(After '19 model)
1. TR Sensor System Inspection
24 O

Check the TR sensor with the MCS.

-20 BID

Is Low voltage (about 0 V) or High voltage (about

5 V) indicated?
YES – • About 0 V: See DTC 51-1 (page 24-24).
• About 5 V: See DTC 51-2 (page 24-25).
-07 HI

NO – GO TO STEP 2.
28 O
PR

24-19
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 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 24-31).
[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 24-30).
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 24-30).
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

24-20
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

DTC 32-1 (FAIL-SAFE RELAY CIRCUIT)
1. Recheck DTC
Erase the DTC (page 24-9).

S. O
Turn the ignition switch OFF.
Recheck the current DTC with the MCS.

L.
S AD
Is the DTC 32-1 indicated?

R.
YES – Replace the PCM with a known good one

OR RIZ
(page 4-43), and recheck.
NO – Intermittent failure

OT TO
DTC 33-2 (EEPROM) (After ’19 model)
• Before starting the inspection, check for loose or
poor contact on the PCM 33P connectors, and

LM U
recheck the DTC.

RA O A
1. DTC Recheck
Erase the DTC (page 24-9).
Check the DTC with the MCS.

AB N
Is DTC 33-2 indicated?
YES – Replace the PCM with a known good one

-C O
(page 4-42), and recheck.

L. US
NO – Intermittent failure.

DTC 41-1, 41-2 (GEAR POSITION

S. N O
SWITCH CIRCUIT) ('14 – '19 models)

• Before starting the troubleshooting, check for loose

R.
RS IÓ

or poor contact of the gear position switch 8P (Gray)

and PCM 33P (Black) connectors, and recheck the
DTC.
TO UC

1. Gear Position Switch Inspection with MCS

Check the gear position switch status with the MCS
MO RIB

data list menu.

Is the gear position status normal?
YES – Intermittent failure
AL ST

NO – GO TO STEP 2.
2. Gear Position Switch Inspection
BR DI

Turn the ignition switch OFF.

Disconnect the gear position switch 8P (Gray)
connector (page 23-11).
CA SU

Lb/W Gr W/G Lg/R

Check for continuity between the switch side 8P
(Gray) connector [1] terminals and ground.
There should be continuity in each gear position,
[1]
24 O

and should be NO continuity in the other position.

Gear position Connection
-20 BID

Reverse Gray – Ground

Neutral Light green/red – Ground
1st White/green – Ground
2nd White/red – Ground
-07 HI

Y Bu W/R
3rd Blue – Ground
4th Yellow – Ground
28 O

5th Light blue/white – Ground

PR

Is the gear position switch normal?

YES – GO TO STEP 3.
NO – Faulty gear position switch

24-21
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

3. Gear Position Switch Inspection at PCM
Connector
Connect the gear position switch 8P (Gray)
[1]
connector and disconnect the PCM 33P (Black)

S. O
connector (page 4-42). A17 A2
Check for continuity between the wire harness side

L.
S AD
PCM 33P (Black) connector [1] terminals and
ground.

R.
There should be continuity in each gear position,

OR RIZ
and should be NO continuity in the other position.
TOOL: A13
Pin Probe Male (2 pack) 07ZAJ-RDJA110 A27

OT TO
Gear position Connection A26
Reverse A25 – Ground A25 A24
Neutral A17 – Ground

LM U
1st A24 – Ground

RA O A
2nd A27 – Ground
3rd A26 – Ground
4th A2 – Ground
5th A13 – Ground

AB N
Is the continuity normal condition?

-C O
YES – GO TO STEP 4.

L. US
NO – Open or short circuit in the wire harness
between the PCM and gear position switch
4. Recheck DTC
S. N O
Connect the PCM 33P (Black) connector.
Erase the DTC (page 24-9).
Shift the transmission into each gear and check the
DTC with the MCS.
R.
RS IÓ

Is the DTC 41-1 or 41-2 indicated?

YES – Replace the PCM with a known good one
TO UC

(page 4-43), and recheck.

NO – Intermittent failure
MO RIB

DTC 42-1 (GEARSHIFT SWITCH

CIRCUIT)
AL ST

• Before starting the troubleshooting, check for loose

or poor contact of the handlebar switch 14P (Green)
BR DI

and PCM 33P connectors, and recheck the DTC.

1. Gearshift Switch Inspection
CA SU

Check the gearshift switch status with the MCS data

list menu.
'14 – '19 models: UP DOWN
24 O

"Up" ON 3.64 – 4.08 V 1.76 – 2.09 V

"Down" ON 1.76 – 2.09 V 3.64 – 4.08 V
-20 BID

Both ON 4.0 – 4.99 V 4.0 – 4.99 V

Both OFF 0 – 0.99 V 0 – 0.99 V

After ’19 model: UP DOWN

-07 HI

"Up" ON 2.78 – 4.10 V 0.70 – 2.25 V

"Down" ON 0.70 – 2.25 V 2.78 – 4.10 V
28 O

Both ON 3.17 – 4.33 V 3.17 – 4.33 V

Both OFF 0 – 0.41 V 0 – 0.41 V
PR

Is the gearshift switch status normal?

YES – Intermittent failure
NO – GO TO STEP 2.

24-22
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

2. Gearshift Switch Inspection at Handlebar Switch
Connector
Turn the ignition switch OFF.
Disconnect the handlebar switch 14P (Green)

S. O
connector (page 23-11).
Check for continuity between the handlebar switch

L.
S AD
side 14P (Green) connector [1] terminals while W/Bu
pushing the gearshift switch.

R.
Connection: W/Y

OR RIZ
With the upshift switch pushed: Br/W
Brown/white – White/blue
With the downshift switch pushed:

OT TO
Brown/white – White/yellow
Br/W
Is there continuity?

LM U
YES – GO TO STEP 3. [1]

RA O A
NO – Faulty handlebar switch
3. Gearshift Switch Inspection at PCM Connector
Connect the handlebar switch 14P (Green)
connector and disconnect the PCM 33P (Black)

AB N
connectors (page 4-42).
Check for continuity between the wire harness side

-C O
33P (Black) connector [1] and (Gray) connector [2] A6 B3
terminals while pushing each switch.

L. US
TOOL:
Pin Probe Male (2 pack) 07ZAJ-RDJA110
S. N O
Connection:
A16 B3
With the upshift switch pushed:
A6 – B3
With the downshift switch pushed:
R.
RS IÓ

A16 – B3 [1] [2]

Is there continuity?
TO UC

YES – GO TO STEP 4.
NO – Open circuit in the White/blue, White/
MO RIB

yellow or Brown/white wire between the

switch and PCM.
4. Recheck DTC
AL ST

Connect the PCM 33P connectors.

Erase the DTC (page 24-9).
Check the DTC with the MCS.
BR DI

Is the DTC 42-1 indicated?

YES – Replace the PCM with a known good one
CA SU

(page 4-43), and recheck.

NO – Intermittent failure
24 O
-20 BID
-07 HI
28 O
PR

24-23
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

DTC 51-1 (TR SENSOR LOW
VOLTAGE) (After '19 model)

S. O
• Before starting the inspection, check for loose or
poor contact on the sensor harness 8P (Black), PCM

L.
S AD
33P (Black) and 33P (Gray) connectors, and
recheck the DTC.

R.
1. TR Sensor System Inspection

OR RIZ
Check the TR sensor with the MCS.
Is about 0 V indicated?

OT TO
YES – GO TO STEP 2.
NO – Intermittent failure
2. TR Sensor Input Voltage Inspection

LM U
Turn the ignition switch OFF.

RA O A
[1]
Disconnect the sensor harness 8P (Black)
connector (page 24-30).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 8P

AB N
(Black) connector [1] terminals.
Connection: Brown/white (+) – Green/white (–)

-C O
G/W Br/W
Is the voltage within 4.75 – 5.25 V?

L. US
YES – GO TO STEP 5.
NO – GO TO STEP 3.
S. N O
3. TR Sensor Input Line Open Circuit Inspection
R.
RS IÓ

Turn the ignition switch OFF.

[1] [2]
Disconnect the PCM 33P (Gray) connector (page 4-
42).
TO UC

Check for continuity between the wire harness side

8P (Black) connector [1] and 33P (Gray) connector Br/W B3
[2] terminals.
MO RIB

TOOL:
Test probe, 2 packs 07ZAJ-RDJA110
AL ST

Connection: Brown/white – B3
Is there continuity?
BR DI

YES – GO TO STEP 4.
NO – Open circuit in the Brown/white wire
CA SU

4. TR Sensor Ground Line Open Circuit Inspection

Check for continuity between the wire harness side
[1]
8P (Black) connector [1] and 33P (Gray) connector
[2] terminals.
24 O

TOOL:
-20 BID

Test probe, 2 packs 07ZAJ-RDJA110 G/W B2

Connection: Green/white – B2
-07 HI

Is there continuity?
YES – Replace the PCM with a known good one
28 O

(page 4-42)and recheck.

NO – Open circuit in the Green/white wire
PR

[2]

24-24
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

5. TR Sensor Signal Line Open Circuit Inspection
Turn the ignition switch OFF.
[1]
Disconnect the PCM 33P (Black) connector (page
4-42).

S. O
Check for continuity between the wire harness side
8P (Black) connector [1] and 33P (Black) connector Bu A26

L.
S AD
[2] terminals.

R.
TOOL:
Test probe, 2 packs 07ZAJ-RDJA110

OR RIZ
Connection: Blue – A26
Is there continuity?

OT TO
YES – GO TO STEP 6.
NO – Open circuit in the Blue wire [2]

LM U
6. TR Sensor Output Line Short Circuit Inspection

RA O A
Check for continuity between the wire harness side
[1]
8P (Black) connector [1] terminal and ground.
Connection: Blue – Ground

AB N
Is there continuity?
YES – Short circuit in the Blue wire

-C O
Bu
NO – GO TO STEP 7.

L. US
S. N O
R.
7. TR Sensor Inspection
RS IÓ

Replace the TR sensor with a known good one

(page 24-30).
TO UC

Connect the 8P (Black) connector, 33P (Black)

connector and 33P (Gray) connector.
Check the TR sensor with the MCS.
MO RIB

Is about 0 V indicated?
YES – Replace the PCM with a known good one
(page 4-42)and recheck.
AL ST

NO – Faulty original TR sensor

BR DI

DTC 51-2 (TR SENSOR HIGH

VOLTAGE) (After '19 model)
CA SU

1. TR Sensor System Inspection

Check the TR sensor with the MCS.
Is about 5 V indicated?
24 O

YES – GO TO STEP 2.
-20 BID

NO – Intermittent failure
2. TR Sensor Inspection
-07 HI

Replace the TR sensor with a known good one

(page 24-30).
Turn the ignition switch ON.
28 O

Check the TR sensor with the MCS.

PR

Is about 5 V indicated?
YES – Replace the PCM with a known good one
(page 4-42)and recheck.
NO – Faulty original TR sensor

24-25
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

DTC 52-1
(NEUTRAL SWITCH STUCK OFF)
(After '19 model)

S. O
• Before starting the inspection, check for loose or

L.
S AD
poor contact on the neutral switch 1P connectors
and PCM 33P (Black) connector, and recheck the

R.
DTC.

OR RIZ
1. DTC Recheck
Recheck the DTC with the MCS.
Is DTC 52-1 indicated?

OT TO
YES – GO TO STEP 2.
NO – Intermittent failure

LM U
2. Neutral Switch Line Open Circuit Inspection

RA O A
Turn the ignition switch OFF.
[1] [2]
Disconnect the PCM 33P (Black) connector (page
4-42).
Disconnect the neutral switch 1P connector (page

AB N
24-31).
Check for continuity between the wire harness side

-C O
33P (Black) connector [1] and neutral switch 1P
connector [2] terminals.

L. US
Connection: A17 – Light green A17 Lg

TOOL:
S. N O
Test probe, 2 packs 07ZAJ-RDJA110
Is there continuity?
YES – GO TO STEP 3.
R.
RS IÓ

NO – Open circuit in the Light green wire

3. Neutral Switch Inspection
TO UC

Replace the neutral switch with a known good one

(page 24-31).
Connect the PCM 33P (Black) connector.
MO RIB

Turn the ignition switch ON.

Recheck the DTC with the MCS.
Is DTC 52-1 indicated?
AL ST

YES – Replace the PCM with a known good one

(page 4-42)and recheck.
BR DI

NO – Faulty original neutral switch

CA SU

DTC 52-2
(NEUTRAL SWITCH STUCK ON)
(After '19 model)
24 O

1. Neutral Switch Line Short Circuit Inspection

Disconnect the neutral switch 1P connector (page
-20 BID

24-31).
Check for continuity between the neutral switch 1P
connector and ground.
-07 HI

Connection: Light green – Ground

Is there continuity?
28 O

YES – Short circuit in the Light green wire

PR

NO – GO TO STEP 2.

24-26
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

2. Neutral Switch Inspection
Replace the neutral switch with a known good one
(page 24-31).
Check the DTC with the MCS.

S. O
Is DTC 52-2 indicated?

L.
S AD
YES – Replace the PCM with a known good one
(page 4-42)and recheck.

R.
NO – Faulty original neutral switch

OR RIZ
DTC 57-1 (GEARSHIFT MECHANISM
MALFUNCTION)

OT TO
(After '19 model)
Refer to DTC 27-1 (page 24-19).

LM U
RA O A
DTC 57-2 (GEAR POSITION
MALFUNCTION) (JUMP OUT OF
GEAR)

AB N
(After '19 model)
Refer to DTC 27-1 (page 24-19).

-C O
L. US
VS SENSOR
REMOVAL/INSTALLATION
S. N O
Remove the tank cover assembly (page 2-4).
[1]
Disconnect the VS sensor 3P (Black) connector [1].
Remove the bolt [2] and VS sensor [3] from the rear
R.
RS IÓ

crankcase cover.
TO UC
MO RIB
AL ST

[2] [3]

Coat a new O-ring [1] with engine oil and install it onto
[1]
BR DI

the VS sensor [2].

Install the VS sensor to the rear crankcase cover and
tighten the bolt.
CA SU

Connect the VS sensor 3P (Black) connector.

Install tank cover assembly (page 2-4).
24 O
-20 BID
-07 HI

[2]
28 O
PR

24-27
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

SHIFT SPINDLE ANGLE SENSOR
REMOVAL
Remove the right center mudguard (page 2-5).

S. O
Remove the engine guard (page 2-8).

L.
S AD
After '19 model Remove the bolts [1], sensor cover [2], and collars [3].
[3]
only:

R.
[1]

OR RIZ
OT TO
LM U
RA O A
[2]

AB N
[3]

-C O
[2]

L. US
S. N O
R.
RS IÓ

[1]
TO UC

Disconnect the shift spindle angle sensor 3P (Gray)

'14 – '19 models shown: [1] [4]
connector [1].
Remove the two socket bolts [2] and shift spindle angle
MO RIB

sensor [3]. [3]

Remove the O-ring [4] from the shift spindle angle
sensor.
AL ST

Check the shift spindle angle sensor for wear or

damage.
BR DI
CA SU

[2]

INSTALLATION
24 O

Coat a new O-ring [1] with engine oil and install it into
'14 – '19 models shown: [1]
the shift spindle angle sensor [2] groove.
-20 BID

Carefully install the shift spindle angle sensor by

aligning the flat surfaces of the sensor shaft hole and
gearshift spindle end.
-07 HI
28 O
PR

Align [2]

24-28
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

Apply locking agent to the shift spindle angle sensor
'14 – '19 models shown: [2]
socket bolt [1] threads.
Install the two socket bolts and tighten them to the
specified torque.

S. O
TORQUE: 6 N·m (0.6 kgf·m, 4.4 lbf·ft)

L.
S AD
Connect the shift spindle angle sensor 3P (Gray)

R.
connector [2].

OR RIZ
OT TO
[1]
After '19 model Install the collars [1], sensor cover [2], and bolts [3].

LM U
only:

RA O A
[1]

[2]

AB N
-C O
L. US
S. N O
[3]
[1]
[3]
R.
RS IÓ
TO UC
MO RIB
AL ST

[2]

Install the right center mudguard (page 2-5).

BR DI

Install the engine guard (page 2-8).

CA SU
24 O
-20 BID
-07 HI
28 O
PR

24-29
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

TR SENSOR (After '19 model)
REMOVAL/INSTALLATION
Remove the center mudguards (page 2-5).

S. O
[1] [2]
Remove the engine guard (page 2-8).
Disconnect the shift spindle angle sensor connector

L.
S AD
(page 24-28).

R.
Disconnect the following connectors:

OR RIZ
– sensor harness 8P (Black) [1]
– neutral switch 1P [2]

OT TO
LM U
RA O A
Remove the following:
[1]
– wire band [1]
– wire clip [2]

AB N
– neutral switch 1P connector (switch side) [3]
– TR sensor bolt [4]

-C O
– sensor harness/TR sensor [5] and O-ring [6]

L. US
S. N O [3]

[2]
R.
RS IÓ

[5]/[6] [4]
TO UC

Installation is in the reverse order of removal.

[1]
TORQUE:
MO RIB

TR sensor bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
AL ST

• Replace the O-ring with a new one.

• Coat a new O-ring with engine oil. [2] [3]
BR DI

• Align the flat surfaces of the TR sensor [1] hole [2]

and gearshift spindle end [3].
CA SU
24 O
-20 BID
-07 HI
28 O
PR

24-30
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

NEUTRAL SWITCH (After '19 model)
REMOVAL/INSTALLATION
Remove the left center mudguard (page 2-5).

S. O
Disconnect the neutral switch 1P connector (switch

L.
S AD
side) [1].
[1]

R.
Remove the neutral switch [2] and sealing washer [3].

OR RIZ
Installation is in the reverse order of removal.
TORQUE:
Neutral switch:

OT TO
13 N·m (1.3 kgf·m, 10 lbf·ft)
[2]/[3]

• Replace the sealing washer with a new one.

LM U
RA O A
SHIFT CONTROL MOTOR/REDUCTION
GEARS

AB N
REMOVAL

-C O
CONTROL MOTOR

L. US
Remove the following:
[2] [3]
– right center mudguard (page 2-5)
– right front wheel (page 17-10)
S. N O
Disconnect the control motor 2P (Black) connector [1].
Remove the three bolts [2] and the control motor [3].
Remove the O-ring from the motor.
R.
RS IÓ
TO UC

[1]
MO RIB

REDUCTION GEARS
Remove the three bolts [1] and the gear cover [2].
[1]
AL ST
BR DI
CA SU
24 O
-20 BID

[2]
-07 HI
28 O
PR

24-31
 dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

Remove the following:
[1] [3]
– reduction gear [1]
– spindle gear [2]
– two dowel pins [3]

S. O
Check the gear teeth and splines for wear or damage.

L.
S AD
R.
OR RIZ
OT TO
[2]

INSTALLATION

LM U
RA O A
SPINDLE GEAR
UNIREX N3 GREASE

GEAR COVER

AB N
O-RING

-C O
L. US
S. N O UNIREX N3 GREASE

DOWEL PINS

REDUCTION GEAR
R.
RS IÓ
TO UC

CONTROL MOTOR DUST SEAL

Remove any grease from the gears, gear cover and

UNIREX N3 GREASE
MO RIB

crankcase cover. [2]

Clean the mating surfaces of the covers thoroughly,
being careful not to damage them.
AL ST

Install the spindle gear [1] by aligning with the reference

marks [2] on the crankcase cover.
Apply 2 – 4 g (0.07 – 0.14 oz) of specified grease to the
BR DI

reduction gear [3] journals (both sides) and teeth as

shown.
CA SU

SPECIFIED GREASE: UNIREX N3 grease (EXXON)

Install the reduction gear.
Install the dowel pins [4] into the crankcase cover.
24 O

[3] [4]
-20 BID
-07 HI
28 O
PR

[1]

24-32
dummyhead

ELECTRIC SHIFT PROGRAM (ESP: TE1/FE1 models)

Apply engine oil to the seal lips of a new dust seal [1].
[3]
Install the dust seal into the gear cover [2] with the flat
side facing out until it is fully seated.

S. O
Apply liquid sealant (ThreeBond 1215 or equivalent) to
the mating surface of the gear cover as shown.

L.
S AD
Tighten the bolts Install the gear cover with the three bolts [3].

R.
after installing the
control motor.

OR RIZ
OT TO
[2] [1]

LM U
RA O A
AB N
-C O
L. US
S. N O
Coat a new O-ring [1] with engine oil and install it into
[1] [2]
the control motor [2] groove.
R.
RS IÓ
TO UC
MO RIB
AL ST

Install the control motor [1] with the three bolts [2].
[2] [1]
BR DI

Tighten the six bolts in a crisscross pattern in several

steps.
CA SU

Connect the control motor 2P (Black) connector [3].

Install the following:
– right front wheel (page 17-10)
24 O

– right center mudguard (page 2-5)

-20 BID
-07 HI

[3]
28 O
PR

24-33
 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

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

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
SERVICE INFORMATION······················ 25-2 DTC INDEX········································ 25-11

RA O A
COMPONENT LOCATION ····················· 25-3 DTC TROUBLESHOOTING ·················· 25-13

AB N
SYSTEM DIAGRAM ····························· 25-4 EPS INDICATOR CIRCUIT INSPECTION ··· 25-26

-C O
SYMPTOM TROUBLESHOOTING ·········· 25-5 EPS ECU··········································· 25-29

L. US
TROUBLESHOOTING INFORMATION ···· 25-5
S. N O
R.
RS IÓ
TO UC
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID

25
-07 HI
28 O
PR

25-1
 dummyhead

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

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

GENERAL
• This section covers electrical system service of the EPS (FM2/FA2/FA6 models). For other service of the steering system, see

S. O
Front Wheel/Suspension/Steering section (page 17-27).
• When performing the DTC troubleshooting, read "Troubleshooting Information" carefully (page 25-5), and inspect and

L.
S AD
troubleshoot according to the DTC. Observe each step of the procedures one by one. Note the DTC and probable faulty part

R.
before starting diagnosis and troubleshooting.
• A faulty EPS system is often related to poorly connected or corroded connectors. Check those connections before proceeding.

OR RIZ
• The EPS ECU may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage
may damage the EPS ECU. Always turn off the ignition switch before disconnecting or connecting the connectors.
• 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
TOOLS
SCS Short Connector Test probe, 2 pack
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

25-2
dummyhead

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

COMPONENT LOCATION

S. O
L.
S AD
R.
OR RIZ
COMBINATION METER
– EPS INDICATOR
– 4WD INDICATOR

OT TO
IGNITION SWITCH

DLC

LM U
RA O A
EPS FUSE BOX
PCM/ECM EPS ECU
– EPS FUSE (40 A)

AB N
RELAY BOX
– MAIN POWER RELAY

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

EPS UNIT (Including EPS

Motor and Torque Sensor)
AL ST

BATTERY
BR DI

FUSE BOX: 4WD SELECT

– MAIN FUSE 1 (30 A) SWITCH
CA SU

– MAIN FUSE 2 (10 A)

– IGN FUSE (20 A)
– ACC FUSE (20 A)
VS SENSOR
CKP SENSOR
24 O
-20 BID
-07 HI
28 O
PR

25-3
 dummyhead

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

SYSTEM DIAGRAM

S. O
L.
S AD
MAIN POWER REGULATOR/

R.
RELAY RECTIFIER
IGNITION SWITCH IGN FUSE (20A)

OR RIZ
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 (20A)

OT TO
R/Bl R/Y R

MAIN FUSE 2 (10A) DIODE

LM U
RA O A
R
IG1 C7 Bl/R

AB N
EPS FUSE
(40A)
FM2: Bl
FA2: W/R A1 +B

-C O
L. US
PG A2 G

2WD/4WD
SELECT SWITCH
IGN
Br/W C12 4WD INDI
EPS IND C5 Y/G PS
S. N O
Y/R C1 VS1
G/O C2 T/S GND
PS (22) (23) TORQUE W/Bu C3 VS2 GND 4WD SERIAL P
SENSOR
COMBINATION METER
G

VS SENSOR P P/G C17 VSP

R.
RS IÓ

G
PS (11) (24) Bl/W
EPS ECU
CKP
SENSOR PS (13) (16)
TO UC

PS (11) (24) (17) (18)

Bu/Y G
(33) (35)

PCM/ECM
M (-) B1 R
MO RIB

PCP B23 Bu/Y

SEN VBI A5
TACHO A20
Bl/R
Bu/Bl Bu/Bl C20 NEP
M EPS
MOTOR
4WD SW B18 Bu Bu C11 4WD IND0 PS (13) (14)
M-TXDRXD A21 P M (+) B2 Bl (18) (21)
PRC B31 V/W
AL ST

W/Bl
K-LINE C14 O/W
SCS C9 Br/R
BR DI

G
DLC SCS SERVICE CONNECTOR
CA SU

C-7 C-1
EPS ECU
24 O

Bl: Black Lb: Light blue C-14 C-8

Br: Brown O: Orange
Bu: Blue P: Pink
-20 BID

G: Green R: Red
Gr: Gray W: White
Lg: Light green Y: Yellow

PS ( ): EPS indicator blink

-07 HI

: Short terminals for

reading DTC
28 O

A-2 A-1 B-2 B-1 C-21 C-15

PR

2P (Brown) CONNECTOR 2P (Gray) CONNECTOR 21P (Gray) CONNECTOR

25-4
dummyhead

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

SYMPTOM TROUBLESHOOTING
Symptom Diagnosis Also check for
EPS indicator does not come Inspect the EPS indicator circuit • Short circuit between the combination meter and

S. O
on (page 25-26) EPS ECU
• Faulty combination meter

L.
S AD
EPS indicator does not go Inspect the EPS indicator circuit • Open circuit between the combination meter and

R.
off, and no DTCs are stored (page 25-27) EPS ECU
• Short circuit in the DLC related wire

OR RIZ
• Open circuit in the EPS ECU line
• Open circuit in the motor power input line
• Open circuit in the power ground line

OT TO
TROUBLESHOOTING INFORMATION

LM U
GENERAL TROUBLESHOOTING

RA O A
Refer to the "GENERAL TROUBLESHOOTING" in "PGM-FI system" (page 4-9)

SYSTEM DESCRIPTION

AB N
SELF-DIAGNOSIS SYSTEM

-C O
The EPS system is equipped with the self-diagnostic system. If the EPS
ECU detects a system failure, it functions as follows:

L. US
1. Turns on the EPS indicator [1] to notify the rider of the problem.
2. Stores a DTC (Diagnostic Trouble Code) in its erasable memory.
3. Stops power assist (manual steering operation begins or reduces the
S. N O
assist power).
Self-diagnosis can be classified into three categories:
– Initial diagnosis: performed right after the engine starts and until the EPS
indicator goes off.
R.
RS IÓ

– Regular diagnosis: performed right after the initial diagnosis until the
ignition switch is turned OFF.
TO UC

– Revest: The EPS indicator turns on when the DTC is set. The EPS
indicator will turn off after the vehicle has recovered from the fail-safe [1]
condition, but the DTC will be stored in the EPS ECU. There was a
MO RIB

temporary problem, but the system is now fully operational.

DTC (Diagnostic Trouble Code)
The DTC(s) is memorized in the EEPROM (nonvolatile memory) therefore the memorized DTC(s) cannot be erased by
disconnecting the battery. Perform the specified procedures to erase the DTC(s) (page 25-7).
AL ST

EPS INDICATOR
Under normal conditions, the EPS indicator comes on when the ignition switch is turned ON, then goes off after starting the engine.
BR DI

This indicates that the LED and its circuit are operating correctly.
If there is any trouble in the system after the engine is started, the EPS indicator will stay on and the EPS ECU memorizes the DTC.
CA SU

(When the DTC 22 is stored; No initializing the torque sensor neutral position, the EPS indicator will blink.)
When a problem is detected and the EPS indicator comes on, there are cases that the indicator stays on until the ignition switch is
turned OFF, and the indicator goes off automatically when the system returns to normal.
24 O

If a problem is continuing after restarting the engine, the EPS indicator stays on and the EPS ECU stops the EPS function.
-20 BID

When the DTC 23 (torque sensor problem) is stored in the EPS ECU, the EPS indicator will stay on until the DTC is erased.

RESTRICTION ON POWER ASSIST OPERATION

-07 HI

Repeated extreme steering force, such as turning the handlebar continuously back-and-forth with the vehicle stopped, causes an
increase of power consumption in the EPS motor. The increase of electric current causes the motor to heat up. Because this heat
28 O

adversely affects the system, the EPS ECU monitors the electric current of the motor. When the EPS ECU detects heat build-up in
the motor, it reduces the electric current to the motor gradually to protect the system (motor and EPS ECU), this restricts the power
PR

assist operation. The EPS indicator does not come on during this function. When steering torque is not applied to the handlebar, or
when the ignition is turned off, and the system cools, the EPS ECU will gradually restore the power assist.

25-5
 dummyhead

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

TORQUE SENSOR NEUTRAL POSITION (Torque Sensor Initialization)
The EPS ECU stores the torque sensor neutral position in the EEPROM. The torque sensor must be initialized whenever the EPS
unit, the EPS ECU, etc is serviced (page 25-9).

S. O
Perform the Torque Sensor Initialization when you service the following components.

L.
S AD
REMOVAL/
MAINTENANCE LOCATION REPLACEMENT
INSTALLATION

R.
Cables and harness around handlebar INITIALIZE INITIALIZE
Handlebar INITIALIZE INITIALIZE

OR RIZ
Steering shaft and steering shaft bushing INITIALIZE INITIALIZE
Steering arm and end nut INITIALIZE INITIALIZE
EPS unit INITIALIZE INITIALIZE

OT TO
EPS ECU INITIALIZE NO NEED

LM U
• The torque sensor neutral position is not effected when erasing the DTC.

RA O A
HOW TO TROUBLESHOOT EPS DTC
1. Question the customer about the conditions when the problem occurred, and try to reproduce the same conditions for

AB N
troubleshooting. Find out when the EPS indicator came on, such as during EPS control, after EPS control, when the vehicle was
at a certain speed, etc.
2. When the EPS indicator does not come on during the test-ride, but troubleshooting is done based on the DTC, check for loose

-C O
connectors, poor terminal contact, etc., in the affected circuit before you start troubleshooting.
3. After troubleshooting, erase the DTC(s) (page 25-7)and test-ride the vehicle to be sure that the EPS indicator does not come on.

L. US
MCS INFORMATION
S. N O
Refer to the "MCS INFORMATION" in "PGM-FI system" (page 4-10).

DTC READOUT
R.
RS IÓ

• If the MCS is not available, DTC can be read from the EPS ECU memory by the EPS indicator blinking pattern (page 25-7).
TO UC

• After performing diagnostic troubleshooting, erase the DTC(s) (page 25-7)and test-ride the vehicle to be sure that the
problem(s) have been removed.
Start the engine and check the EPS indicator [1].
MO RIB

• Under normal conditions, the EPS indicator stays on with the ignition
switch is turned ON until the engine starts, and it goes off after starting
AL ST

the engine.
If the EPS indicator stays on or blinks with the engine running, connect the
MCS to the DLC (page 4-10).
BR DI

Read the DTC, stored data and follow the troubleshooting index
(page 25-11).
CA SU

To read the DTC without the MCS, refer to the following procedure.

[1]
24 O
-20 BID
-07 HI
28 O
PR

25-6
dummyhead

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

Reading DTC with the EPS indicator
Remove the dummy connector (page 4-10).
[1]
Short the DLC [1] terminals using the special tool.

S. O
TOOL:
SCS Short Connector [2] 070PZ-ZY30100

L.
S AD
CONNECTION: Brown/red – Green

R.
Turn the ignition switch ON, then read and not the EPS indicator blinks and

OR RIZ
refer to the troubleshooting index (page 25-11).

EPS Indicator Blinking Pattern

OT TO
• The number of EPS indicator blinks is the equivalent to the main code of
the DTC (the sub-code cannot be displayed by the indicator blinking). [2]
• The indicator has two types of blinks, a long blink and short blink. The

LM U
long blink lasts for 1.3 seconds, the short blink lasts for 0.3 seconds.
One long blink is the equivalent of ten short blinks. For example, when two long blinks are followed by one short blink, the DTC

RA O A
is 21 (two long blink = 20 blinks, plus one short blink).
• When the EPS ECU stores more than one DTC, the indicator blinks in the order from the lowest number to highest number.

AB N
ERASING DTC

-C O
• Perform this procedure using fully charged battery. The EPS indicator will stay lit and the EPS ECU will abort the process if you

L. US
use a low or dead battery.
Connect the MCS to the DLC (page 4-10).
Erase the DTC with the MCS while the engine is stopped.
S. N O
To erase the DTC without MCS, refer to the following procedure.
How to erase the DTC without MCS
1. Raise the front wheels off the ground and support the vehicle securely.
R.
RS IÓ

[1]
2. Remove the dummy connector (page 4-10).
TO UC

3. Short the DLC [1] terminals using the special tool.

TOOL:
SCS Short Connector [2] 070PZ-ZY30100
MO RIB

CONNECTION: Brown/red – Green

AL ST
BR DI

[2]

4. Place a 6 mm width screwdriver [1] between the right side of the steering
CA SU

[2]
stopper [2] and steering arm [3] as shown.
24 O
-20 BID
-07 HI
28 O

[3] [1]
PR

25-7
 dummyhead

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

5. Make sure the engine stop switch is turned " ".
[3]
Fully turn the handlebar [1] to the left to apply a load and hold it firmly. Left
6. Turn the ignition switch [2] ON.
The EPS indicator [3] comes on and it goes off after 4 seconds.

S. O
L.
S AD
R.
OR RIZ
4 seconds

OT TO
[1] [2]

7. Within 4 seconds after the EPS indicator [1] goes off, turn the handlebar
[1]

LM U
[2] in the straight ahead position and release it immediately. Straight
The EPS indicator comes on again 4 seconds.

RA O A
AB N
-C O
L. US
4 seconds
[2]
S. N O
8. Within 4 seconds after the EPS indicator [1] comes on, fully turn the
[1]
handlebar [2] to the left and hold it.
Left
The EPS indicator goes off after 4 seconds.
R.
RS IÓ
TO UC
MO RIB

4 seconds
AL ST

[2]

9. Within 4 seconds after the EPS indicator [1] goes off, turn the handlebar
BR DI

Straight [1]
[2] in the straight ahead position and release it immediately.
The EPS indicator blinks twice.
Turn the ignition switch [3] OFF within 5 seconds after the EPS indicator
CA SU

blinks twice (DTC erasure is completed at this time).

• The ignition switch must be turned OFF at this time. If it is not, the
24 O

system will be changed to the torque sensor initialization (page 25-9).

• If the EPS indicator does not blink twice, an error was made in the
-20 BID

procedure and the DTC was not erased. Turn the ignition switch OFF,
and repeat the operation from step 4.
10.Remove the special tool from the DLC and install the DLC to the dummy Blinks
-07 HI

connector.
[2] [3]
Remove the screwdriver inserted in Step 4.
28 O

11.Install the radiator cap lid.

PR

25-8
dummyhead

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

TORQUE SENSOR INITIALIZATION

• Perform this procedure using a fully charged battery. The EPS indicator will stay lit and the EPS ECU will abort the process if
you use a low or dead battery.

S. O
• The DTC will be erased when initializing the torque sensor.

L.
S AD
How to Initialize the Torque Sensor with MCS

R.
1. Raise the front wheels off the ground and support the vehicle securely.
Straight

OR RIZ
2. Connect the MCS to the DLC (page 4-10).
3. Turn the ignition switch ON and engine stop switch " ".
Turn the handlebar [1] straight ahead.
Initialize the torque sensor with the MCS while the engine is stopped.

OT TO
Follow the instructions of the MCS.

LM U
RA O A
[1]

AB N
How to Initialize the Torque Sensor without MCS

-C O
1. Raise the front wheels off the ground and support the vehicle securely.
[1]

L. US
2. Remove the DLC from the dummy connector (page 4-10).
3. Short the DLC [1] terminals using the special tool.
TOOL:
S. N O
SCS Short Connector [2] 070PZ-ZY30100

Connection: Brown/red – Green

R.
RS IÓ
TO UC

[2]
MO RIB

4. Place a 6 mm width screwdriver [1] between the right side of the steering
[2]
stopper [2] and steering arm [3] as shown.
AL ST
BR DI
CA SU
24 O

[3] [1]
-20 BID
-07 HI
28 O
PR

25-9
 dummyhead

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

5. Make sure the engine stop switch is turned " ".
[3]
Fully turn the handlebar [1] to the left to apply a load and hold it firmly. Left
6. Turn the ignition switch [2] ON.
The EPS indicator [3] comes on and it goes off after 4 seconds.

S. O
L.
S AD
R.
OR RIZ
4 seconds

OT TO
[1] [2]

7. Within 4 seconds after the EPS indicator [1] goes off, turn the handlebar
[1]

LM U
[2] in the straight ahead position and release it immediately. Straight
The EPS indicator comes on again for 4 seconds.

RA O A
AB N
-C O
L. US
4 seconds
[2]
S. N O
8. Within 4 seconds after the EPS indicator [1] comes on, fully turn the
[1]
handlebar [2] to the left and hold it immediately.
Left
The EPS indicator goes off for 4 seconds.
R.
RS IÓ
TO UC
MO RIB

4 seconds
AL ST

[2]

9. Turn the handlebar [1] in the straight ahead position (fully turn–to–
BR DI

Straight [1]
straight ahead time; within 1 second) and release it immediately after the
EPS indicator [2] goes off. Do not touch the handlebar after releasing the
handlebar.
CA SU

The EPS indicator blinks twice. Wait for 5 seconds and the EPS indicator
blinks 3 times.
Turn the ignition switch [3] OFF after the EPS indicator blinks 3 times
(torque sensor initialization is completed at this time).
24 O
-20 BID

• If the EPS indicator does not blink 3 times, an error was made in the
procedure and the torque sensor was not initialized. Turn the ignition
switch OFF, and repeat the operation from step 4. Blinks
-07 HI

10.Remove the special tool from the DLC, install the dummy connector to
[2] [3]
the DLC and the radiator cap lid (page 2-3).
Remove the screwdriver inserted in Step 4.
28 O
PR

CIRCUIT INSPECTION
Refer to the "INSPECTION AT PCM CONNECTOR" information in "PGM-FI system" (page 4-11).

25-10
dummyhead

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

DTC INDEX
DEFINITIONS
Latch: The EPS indicator turns on and stays on whenever the ignition switch is ON, or until the DTC is erased.

S. O
Reset:The EPS indicator turns on when the DTC is set. The EPS indicator will not turn on after the ignition switch is cycled from ON

L.
S AD
to OFF, but the DTC will be stored in the EPS ECU.

R.
Revest:The EPS indicator turns on when the DTC is set. The EPS indicator will turn off after vehicle has recovered from the fail-
safe condition, but the DTC will be stored in the EPS ECU. There was a temporary problem, but the system is now fully operational.

OR RIZ
Initial diagnosis: Performed right after the engine starts and until the EPS indicator goes off.
Regular diagnosis: Performed right after the initial diagnosis until the ignition switch is turned OFF.

OT TO
DTC
(EPS Symptom/Fail-safe Detection Refer
Function Failure Type
indicator function timing to

LM U
blinks)
Excessive change of vehicle speed Indicator ON/Substitution

RA O A
11-01 (11) Regular Revest 25-13
signal control of the engine rpm
Comparison between vehicle speed Indicator ON/Substitution
11-02 (11) Regular Revest 25-13
and engine speed signal control of the engine rpm
EPS ECU internal circuit Indicator ON/Disables

AB N
13-01 (13) Initial Reset 25-14
(Lower FET stuck ON) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables

-C O
13-02 (13) Initial Reset 25-15
(Upper FET stuck ON) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables

L. US
13-03 (13) Regular Reset 25-15
(FET stuck ON <over current>) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
13-04 (13) Regular Reset 25-15
(FET stuck ON (VM<Voltage Motor>)) steering assist immediately
S. N O
EPS ECU internal circuit Indicator ON/Disables
13-05 (13) (FET stuck ON (over steering assist immediately Regular Reset 25-15
current<accumulated>))
EPS ECU internal circuit Indicator ON/Disables
14-01 (14) Regular Reset 25-15
R.
RS IÓ

(Power relay stuck ON) steering assist immediately

EPS ECU internal circuit Indicator ON/Disables
14-02 (14) Initial Reset 25-16
(Fail-safe relay 1 stuck ON) steering assist immediately
TO UC

EPS ECU internal circuit Indicator ON/Disables

14-03 (14) Initial Reset 25-16
(Fail-safe relay 2 stuck ON) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
14-04 (14) Regular Reset 25-16
MO RIB

(Power relay stuck open) steering assist immediately

2WD/4WD select signal blinking 4WD indicator blink (EPS
15-01 (15) indicator will not come ON)/ Regular Revest 25-16
2WD assist power stabilized
AL ST

2WD/4WD select signal input line Indicator ON/2WD assist

15-02 (15) power stabilized or EPS Regular Revest 25-17
operation is normally
BR DI

EPS ECU internal circuit Indicator ON/Disables

16-01 (16) Regular Reset 25-17
(Direction determine logic circuit) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
CA SU

16-02 (16) Initial Reset 25-17

(INH output circuit) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
17-01 (17) Initial Reset 25-17
(Voltage raise transformation circuit) steering assist immediately
24 O

EPS ECU internal circuit Indicator ON/Disables

17-02 (17) (Voltage raise transformation circuit) steering assist under the Regular Reset 25-17
-20 BID

Specified condition
EPS ECU internal circuit Indicator ON/Disables
18-01 (18) Initial Reset 25-17
(Current sensor) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
-07 HI

18-02 (18) Regular Reset 25-17

(Current sensor off set) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
18-03 (18) Initial Reset 25-18
28 O

(Current sensor stuck low) steering assist immediately

EPS ECU internal circuit Indicator ON/Disables
PR

18-04 (18) Regular Reset 25-19

(Current sensor stuck low) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
18-05 (18) Regular Reset 25-17
(Motor current deflection) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
18-06 (18) Regular Reset 25-17
(IM2) steering assist immediately

25-11
 dummyhead

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

DTC
(EPS Symptom/Fail-safe Detection Refer
Function Failure Type
indicator function timing to
blinks)

S. O
Abnormal motor terminal voltage Indicator ON/Disables
21-01 (21) Initial Reset 25-19
steering assist immediately

L.
S AD
Abnormal motor terminal voltage Indicator ON/Disables
21-02 (21) Regular Reset 25-19
steering assist immediately

R.
Open in the motor harness Indicator ON/Disables
21-03 (21) Regular Reset 25-19

OR RIZ
steering assist immediately
Failure to initialize the torque sensor Indicator blink/Disables
22-01 (22) steering assist until the Regular Latch* 25-19
torque sensor is initialized

OT TO
Low/high voltage for the torque Indicator ON/Disables
23-01 (23) sensor steering assist until the DTC Regular Latch 25-20
(VT1 and VT2) is erased

LM U
Torque sensor Indicator ON/Disables
23-02 (23) (VT3 Differential-amplification steering assist until the DTC Regular Latch 25-22

RA O A
Function) is erased
Torque sensor Indicator ON/Disables
23-03 (23) (VT1, VT2 rapid change) steering assist until the DTC Regular Latch 25-23
is erased

AB N
Torque sensor Indicator ON/Disables
23-04 (23) Regular Reset 25-23
(Temperature sensor) steering assist immediately

-C O
Torque sensor Indicator ON/Disables
23-05 (23) (Sensor Coil) steering assist until the DTC Regular Latch 25-23

L. US
is erased
Engine speed signal Indicator ON/Disables
24-01 (24) steering assist under the Regular Revest 25-23
S. N O
Specified condition
Low/high IG1-terminal voltage Indicator ON/Disables
31-01 (31) steering assist under the Initial Revest 25-24
Specified condition
R.
RS IÓ

Low/high IG1-terminal voltage Indicator ON/Disables

31-02 (31) steering assist under the Regular Revest 25-24
Specified condition
TO UC

Low/high VBU voltage Indicator ON/Disables

32-01 (32) steering assist under the Regular Reset 25-25
Specified condition
MO RIB

EPS ECU internal circuit Indicator ON/Disables

33-02 (33) Initial Reset 25-17
(EEPROM) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables Initial and
35-01 (35) Reset 25-17
(CPU) steering assist immediately Regular
AL ST

EPS ECU internal circuit Indicator ON/Disables

35-03 (35) Initial Reset 25-17
(CPU communication) steering assist immediately
EPS ECU internal circuit Indicator ON/Disables
BR DI

35-04 (35) (CPU communication) steering assist under the Regular Reset 25-17
Specified condition
CA SU

*The stored DTC is erased by performing the torque sensor initialization.

24 O
-20 BID
-07 HI
28 O
PR

25-12
dummyhead

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

DTC TROUBLESHOOTING
• After troubleshooting, erase the DTC(s) (page 25-

S. O
7)and test-ride the vehicle to be sure that the EPS
indicator does not come on.

L.
S AD
R.
DTC 11-01: EXCESSIVE CHANGE OF

OR RIZ
VEHICLE SPEED SIGNAL (REGULAR
DIAGNOSIS)

OT TO
• Before starting the troubleshooting, check for loose
or poor contact of the following connectors, and
recheck the EPS indicator (page 25-6).

LM U
– FM2: engine sub-wire harness 3P (Black)
– FA2: engine sub-wire harness 6P (Black)

RA O A
– EPS ECU 21P (Gray)
– VS sensor 3P (Black)
• The system is reducing the assist power, the EPS
indicator will come on when the EPS ECU detects

AB N
conditions of DTC 11-01 and DTC 11-02.
1. VS Sensor Signal line Open Circuit Inspection

-C O
Turn the ignition switch OFF.
[2]

L. US
Disconnect the EPS ECU 21P (Gray) connector P
(page 25-29)and VS sensor 3P (Black) connector
(page 24-27).
Check for continuity between the wire harness side
S. N O
21P (Gray) connector [1] and 3P (Black) connector
[2] terminals.
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
R.
RS IÓ

Connection: C17 – Pink

TO UC

Is there continuity?
YES – GO TO STEP 2. [1] C17
MO RIB

NO – Open circuit in the Pink or Pink/green wire

2. VS Sensor Signal line Short Circuit Inspection
Check for continuity between the wire harness side
AL ST

[1]
21P (Gray) connector [1] terminal and ground.
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
BR DI

Connection: C17 – Ground

CA SU

Is there continuity?
YES – Short circuit in the Pink/green or Pink wire
NO – Replace the EPS ECU with a known good C17
24 O

one (page 25-29), and recheck.

-20 BID

DTC 11-02: COMPARISON BETWEEN

-07 HI

VEHICLE SPEED AND ENGINE SPEED

SIGNAL
28 O

(REGULAR DIAGNOSIS)
PR

Refer to DTC 11-01 (page 25-13).

25-13
 dummyhead

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

DTC 13-01: EPS ECU INTERNAL
CIRCUIT (LOWER FET STUCK ON)
(INITIAL DIAGNOSIS)

S. O
• Before starting the troubleshooting, check for loose

L.
S AD
or poor contact of the following connectors, and
recheck the EPS indicator (page 25-6).

R.
– EPS ECU 21P (Gray)

OR RIZ
– EPS motor 2P (Gray)
1. EPS ECU System Inspection
1. Erase the DTC (page 25-7).

OT TO
2. Start the engine.
3. Fully turn the handlebar to the left or right and
hold it 10 seconds.
4. Check the EPS indicator.

LM U
Does the EPS indicator come on?

RA O A
YES – GO TO STEP 2.
NO – Intermittent failure

AB N
2. Motor Line Ground Short Circuit Inspection
Turn the ignition switch OFF.

-C O
Disconnect the EPS ECU 2P (Gray) connector
Bl R
(page 25-29).

L. US
Check for continuity between the wire harness side
2P (Gray) connector [1] terminals and ground.
Connection: Black – Ground
Red – Ground
S. N O
Is there continuity?
YES – GO TO STEP 3. [1]
R.
RS IÓ

NO – GO TO STEP 4.
TO UC

3. Motor Short Circuit Inspection

MO RIB

Remove the right center mudguard (page 2-5)

[1]
Disconnect the EPS motor 2P (Gray) connector [1].
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

25-14
dummyhead

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

Check for continuity between the motor side 2P
[1] R
connector [1] terminals and ground. Bl
Connection: Red – Ground
Black – Ground

S. O
Is there continuity?

L.
S AD
YES – Replace the EPS unit with a new one

R.
(page 17-27), and recheck.

OR RIZ
NO – Short circuit in the Red or Black wire

OT TO
4. Motor Line Short Circuit Inspection

LM U
Disconnect the EPS motor 2P (Gray) connector

RA O A
(page 25-14).
Check for continuity between the wire harness side Bl R
EPS ECU 2P (Gray) connector [1] terminals.
Connection: Black – Red

AB N
Is there continuity?

-C O
YES – Short circuit in the Red and Black wires
NO – Recheck for loose or poor contact of the

L. US
EPS ECU 2P (Gray) connector and EPS
motor 2P (Gray) connector. If they are OK,
replace the EPS ECU with a new one
S. N O
(page 25-29).
[1]

DTC 13-02: EPS ECU INTERNAL

CIRCUIT (UPPER FET STUCK ON)
R.
RS IÓ

(INITIAL DIAGNOSIS)
Refer to DTC 13-01 (page 25-14).
TO UC

DTC 13-03: EPS ECU INTERNAL

MO RIB

CIRCUIT (FET STUCK ON <OVER

CURRENT>) (REGULAR DIAGNOSIS)
Refer to DTC 13-01 (page 25-14).
AL ST

DTC 13-04: EPS ECU INTERNAL

BR DI

CIRCUIT (FET STUCK ON

(VM<VOLTAGE MOTOR>)
(REGULAR DIAGNOSIS))
CA SU

Refer to DTC 13-01 (page 25-14).

24 O

DTC 13-05: EPS ECU INTERNAL

CIRCUIT (FET STUCK ON (OVER
-20 BID

CURRENT<ACCUMULATED>)
(REGULAR DIAGNOSIS))
Refer to DTC 13-01 (page 25-14).
-07 HI
28 O

DTC 14-01: EPS ECU INTERNAL

CIRCUIT (POWER RELAY STUCK ON)
PR

(REGULAR DIAGNOSIS)
Refer to DTC 13-01 (page 25-14).

25-15
 dummyhead

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

DTC 14-02: EPS ECU INTERNAL
CIRCUIT (FAIL-SAFE RELAY 1 STUCK
ON) (INITIAL DIAGNOSIS)
Refer to DTC 13-01 (page 25-14).

S. O
L.
S AD
DTC 14-03: EPS ECU INTERNAL

R.
CIRCUIT (FAIL-SAFE RELAY 2 STUCK
ON) (INITIAL DIAGNOSIS)

OR RIZ
Refer to DTC 13-01 (page 25-14).

OT TO
DTC 14-04: EPS ECU INTERNAL
CIRCUIT (POWER RELAY STUCK
OPEN) (REGULAR DIAGNOSIS)

LM U
Refer to DTC 13-01 (page 25-14).

RA O A
DTC 15-01: 2WD/4WD SELECT SIGNAL
BLINKING (REGULAR DIAGNOSIS)

AB N
-C O
• Before starting the troubleshooting, check for loose
or poor contact of the following connectors, and

L. US
recheck the 4WD indicator.
– 4WD select switch
– EPS ECU 21P (Gray)
– combination meter 21P (Black)
S. N O
• When this problem occurs, there are some of
problem of 2WD/4WD select system.
• Question the customer about the conditions when
the problem occurred, and try to reproduce the same
R.
RS IÓ

conditions for troubleshooting. Find out when the

4WD indicator blinked, such as during 4WD-to-2WD
selecting, 2WD-to-4WD, at what speed, etc.
TO UC

1. EPS ECU System Inspection

Erase the DTC (page 25-7).
MO RIB

Test-ride the vehicle and check the 4WD indicator

[1].
Does the 4WD indicator blinking?
AL ST

YES – Check the 4WD select switch

(page 23-18). If it is OK, inspect the 2WD/
4WD select system (page 20-17).
BR DI

NO – • Intermittent failure
• Loose or poor contact of the connector
CA SU

[1]
24 O
-20 BID
-07 HI
28 O
PR

25-16
dummyhead

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

DTC 15-02: 2WD/4WD SELECT SIGNAL
INPUT LINE (REGULAR DIAGNOSIS)

S. O
• Question the customer about the conditions when
the problem occurred, and try to reproduce the same

L.
S AD
conditions for troubleshooting. Find out when the
4WD indicator blinked, such as during 4WD-to-2WD

R.
selecting, 2WD-to-4WD selecting, at what speed,

OR RIZ
etc.
1. EPS ECU System Inspection
Erase the DTC (page 25-7).

OT TO
Start the engine and check the EPS indicator.
Does the indicator stay on?
YES – GO TO STEP 2.

LM U
NO – Intermittent failure

RA O A
2. 4WD Indicator Inspection
Stop the engine.
Turn the ignition switch ON.

AB N
Operate the 2WD/4WD select lever several times
and check the 4WD indicator [1].

-C O
Is the 4WD indicator operated normally?

L. US
YES – Replace the EPS ECU with a known good
one (page 25-29), and recheck.
NO – Check the 4WD select switch
S. N O
(page 23-18).
R.
RS IÓ

[1]

DTC 16-01, 16-02, 17-01, 17-02, 18-01,

TO UC

18-02, 18-05, 18-06, 33-02, 35-01, 35-03,

or 35-04: EPS ECU INTERNAL CIRCUIT
MO RIB

16-01 EPS ECU internal circuit (Direction determine logic circuit)

(Regular diagnosis)
16-02 EPS ECU internal circuit (INH output circuit)
(Initial diagnosis)
AL ST

17-01 EPS ECU internal circuit (Voltage raise transformation circuit)

(Initial diagnosis)
17-02 EPS ECU internal circuit (Voltage raise transformation circuit)
BR DI

(Regular diagnosis)
18-01 EPS ECU internal circuit (Current sensor)
(Initial diagnosis)
CA SU

18-02 EPS ECU internal circuit (Current sensor off set)

(Regular diagnosis)
18-05 EPS ECU internal circuit (Motor current deflection)
24 O

(Regular diagnosis)
18-06 EPS ECU internal circuit (IM2)
-20 BID

(Regular diagnosis)
33-02 EPS ECU internal circuit (EEPROM)
(Regular diagnosis)
35-01 EPS ECU internal circuit (CPU)
-07 HI

(Initial and regular diagnosis)

35-03 EPS ECU internal circuit (CPU communication)
28 O

(Initial diagnosis)
35-04 EPS ECU internal circuit (CPU communication)
PR

(Regular diagnosis)

25-17
 dummyhead

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

1. EPS ECU System Inspection
1. Erase the DTC (page 25-7).
2. Start the engine.
3. Fully turn the handlebar to the left or right and

S. O
hold it 10 seconds.
4. Check the EPS indicator.

L.
S AD
Does the EPS indicator come on?

R.
YES – GO TO STEP 2.

OR RIZ
NO – Intermittent failure
2. DTC Inspection

OT TO
1. Check the DTC (page 25-6).
Is DTC 16-01, 16-02, 17-01, 17-02, 18-01, 18-02,
18-05, 18-06, 33-02, 35-01, 35-03 or 35-04

LM U
indicated?

RA O A
YES – Replace the EPS ECU with a known good
one (page 25-29), and recheck.
NO – Perform the troubleshooting for the
indicated DTC (page 25-11).

AB N
DTC 18-03: EPS ECU INTERNAL

-C O
CIRCUIT (CURRENT SENSOR STUCK

L. US
LOW) (INITIAL DIAGNOSIS)

• Before starting the troubleshooting, check for loose

S. N O
or poor contact of the following connectors, and
recheck the EPS indicator (page 25-6).
– EPS ECU 2P (Gray)
– EPS motor 2P (Gray)
R.
RS IÓ

1. EPS ECU System Inspection

1. Erase the DTC (page 25-7).
TO UC

2. Start the engine.

3. Fully turn the handlebar to the left or right and
hold it 10 seconds.
MO RIB

4. Check the EPS indicator.

Does the EPS indicator come on?
YES – GO TO STEP 2.
AL ST

NO – Intermittent failure
2. Motor Line Open Circuit Inspection
BR DI

Turn the ignition switch OFF.

Disconnect the EPS ECU 2P (Gray) connector
Bl
CA SU

(page 25-29). R
Check for continuity between the wire harness side
EPS ECU 2P (Gray) connector [1] terminals.
Connection: Black – Red
24 O

Is there continuity?
-20 BID

YES – Replace the EPS ECU with a known good

one (page 25-29), and recheck.
NO – GO TO STEP 3.
-07 HI

[1]
28 O
PR

25-18
dummyhead

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

3. Motor Open Circuit Inspection
Disconnect the EPS motor 2P (Gray) connector
[1] R Bl
(page 25-14).
Check for continuity between the motor side 2P

S. O
connector [1] terminals.
Connection: Red – Black

L.
S AD
Is there continuity?

R.
YES – Open circuit in the Red or Black wire

OR RIZ
NO – Replace the EPS unit with a new one
(page 17-27), and recheck.

OT TO
LM U
DTC 18-04: EPS ECU INTERNAL

RA O A
CIRCUIT (CURRENT SENSOR STUCK
LOW) (REGULAR DIAGNOSIS)
Refer to DTC 18-03 (page 25-18).

AB N
DTC 21-01: ABNORMAL MOTOR

-C O
TERMINAL VOLTAGE (INITIAL

L. US
DIAGNOSIS)
Refer to DTC 18-03 (page 25-18).
S. N O
DTC 21-02: ABNORMAL MOTOR
TERMINAL VOLTAGE (REGULAR
DIAGNOSIS)
R.
RS IÓ

Refer to DTC 18-03 (page 25-18).

TO UC

DTC 21-03: OPEN IN THE MOTOR

HARNESS (REGULAR DIAGNOSIS)
MO RIB

Refer to DTC 18-03 (page 25-18).

DTC 22-01: FAILURE TO INITIALIZE

AL ST

THE TORQUE SENSOR (INITIAL

DIAGNOSIS)
BR DI

• The EPS ECU stores the torque sensor neutral

position. The torque sensor must be initialized
CA SU

whenever the EPS unit, the EPS ECU, etc is

serviced (page 25-9).
• Refer to torque sensor neutral position information
for detail of the initialization parts (page 25-6).
24 O

1. Initializing Torque Sensor

-20 BID

Perform the torque sensor initialization (page 25-

9)and check the EPS indicator.
Does the EPS indicator come on?
-07 HI

YES – Check the DTC (page 25-6)and perform

the troubleshooting for the indicated DTC
28 O

(page 25-11).
PR

NO – Intermittent failure

25-19
 dummyhead

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

DTC 23-01: LOW/HIGH VOLTAGE FOR
THE TORQUE SENSOR (VT1 AND VT2)
(REGULAR DIAGNOSIS)

S. O
• Before starting the troubleshooting, check for loose

L.
S AD
or poor contact of the following connectors.
– EPS ECU 21P (Gray)

R.
– torque sensor 3P (Gray)

OR RIZ
1. EPS ECU System Inspection
1. Erase the DTC (page 25-7).
2. Start the engine.

OT TO
3. Fully turn the handlebar to the left or right and
hold it 10 seconds.
4. Check the EPS indicator.

LM U
Does the EPS indicator come on?

RA O A
YES – GO TO STEP 2.
NO – Intermittent failure
2. Torque Sensor Line Short Circuit Inspection

AB N
Turn the ignition switch OFF.
[1]
Disconnect the EPS ECU 21P (Gray) connector

-C O
(page 25-29).
Measure the resistance between the wire harness

L. US
side EPS ECU 21P (Gray) connector [1] terminals.
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
S. N O
Connection: C1 – C2 C1
C1 – C3
C2 – C3 C3
R.
RS IÓ

Is the resistance less than 10 Ω (at 20°C/68°F)? C2

YES – GO TO STEP 3.
TO UC

NO – GO TO STEP 4.
3. Torque Sensor Coil Short Circuit Inspection
MO RIB

Remove the left center mudguard (page 2-5).

Disconnect the torque sensor 3P (Gray) connector
[1].
AL ST
BR DI
CA SU
24 O

[1]
-20 BID
-07 HI
28 O
PR

25-20
dummyhead

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

Measure the resistance between the torque sensor
side connector [1] terminals in the EPS unit.
Connection: A – B
A–C

S. O
B–C B

L.
S AD
Is the resistance less than 10 Ω (at 20°C/68°F)?

R.
YES – Replace the EPS unit with a new one
(page 17-27), and recheck (short circuit in

OR RIZ
the torque sensor coil).
C A
NO – • Short circuit in the Yellow/red and
Green/orange wires

OT TO
• Short circuit in the Yellow/red and
White/blue wires [1]
• Short circuit in the Green/orange and

LM U
White/blue wires
4. Torque Sensor Line Ground Short Circuit

RA O A
Inspection
Check for continuity between the wire harness side
C1 C3 [1]
EPS ECU 21P (Gray) connector [1] terminals and

AB N
ground.
TOOL:

-C O
Test probe, 2 pack 07ZAJ-RDJA110

L. US
Connection: C1 – Ground
C3 – Ground
Is there continuity?
S. N O
YES – GO TO STEP 5.
NO – GO TO STEP 6.
R.
RS IÓ

5. Torque Sensor Coil Ground Short Circuit

TO UC

Inspection
Check for continuity between the torque sensor side
connector [1] terminals in the EPS unit and ground. C A
MO RIB

Connection: A – Ground
C – Ground
Is there continuity?
AL ST

YES – Replace the EPS unit with a new one

(page 17-27), and recheck (short circuit in
the torque sensor coil).
BR DI

NO – • Short circuit in the Yellow/red wire

• Short circuit in the White/blue wire
CA SU

[1]
24 O
-20 BID
-07 HI
28 O
PR

25-21
 dummyhead

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

6. Torque Sensor Line Open Circuit Inspection
Check for continuity between the wire harness side G/O
EPS ECU 21P (Gray) connector [1] and torque Y/R
sensor 3P (Gray) connector [2] terminals. W/Bu

S. O
TOOL:

L.
S AD
Test probe, 2 pack 07ZAJ-RDJA110

R.
Connection: C1 – Yellow/red [2]
C2 – Green/orange C2

OR RIZ
C3 – White/blue
C3
Is there continuity? C1

OT TO
YES – GO TO STEP 7.
NO – • Open circuit in the Yellow/red wire [1]
• Open circuit in the Green/orange wire

LM U
• Open circuit in the White/blue wire

RA O A
7. Torque Sensor Open Circuit Inspection
Measure the resistance between the torque sensor
side connector [1] terminals in the EPS unit.

AB N
Connection: A – B [1]
B
B–C

-C O
Is the resistance within 10 – 40 Ω (20°C/68°F)? A

L. US
YES – Replace the EPS ECU with a known good
one (page 25-29), and recheck.
NO – Replace the EPS unit with a new one
(page 17-27), and recheck (open circuit in
S. N O
the torque sensor coil).
C
R.
RS IÓ

DTC 23-02: TORQUE SENSOR (VT3

DIFFERENTIAL AMPLIFICATION
TO UC

FUNCTION) (REGULAR DIAGNOSIS)

MO RIB

• Before starting the troubleshooting, check for loose

or poor contact of the following connectors.
– EPS ECU 21P (Gray)
– torque sensor 3P (Gray)
AL ST

1. EPS ECU System Inspection

1. Erase the DTC (page 25-7).
BR DI

2. Start the engine.

3. Fully turn the handlebar to the left or right and
hold it 10 seconds.
CA SU

4. Check the EPS indicator.

Does the EPS indicator come on?
YES – GO TO STEP 2.
24 O

NO – Intermittent failure
-20 BID

2. Recheck DTC
Check the DTC (page 25-6).
Is DTC 23-02 indicated?
-07 HI

YES – Replace the EPS ECU with a known good

one (page 25-29), and recheck.
28 O

NO – Perform the troubleshooting for the

PR

indicated DTC (page 25-11).

25-22
dummyhead

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

DTC 23-03: TORQUE SENSOR
(VT1, VT2 RAPID CHANGE) (REGULAR
DIAGNOSIS)
Refer to DTC 23-01 (page 25-20).

S. O
L.
S AD
DTC 23-04: TORQUE SENSOR

R.
(TEMPERATURE SENSOR) (REGULAR
DIAGNOSIS)

OR RIZ
Refer to DTC 23-01 (page 25-20).

OT TO
DTC 23-05: TORQUE SENSOR
(SENSOR COIL) (REGULAR
DIAGNOSIS)

LM U
Refer to DTC 23-01 (page 25-20).

RA O A
DTC 24-01: ENGINE SPEED SIGNAL
(REGULAR DIAGNOSIS)

AB N
-C O
• Before starting the troubleshooting, check for loose
or poor contact of the following connectors, and

L. US
recheck the EPS indicator (page 25-6).
– EPS ECU 21P (Gray)
– PCM/ECM 33P (Black)
S. N O
1. CKP Sensor Signal Line Open Circuit Inspection
Turn the ignition switch OFF.
[1]
Disconnect the EPS ECU 21P (Gray) connector
(page 25-29)and PCM/ECM 33P (Black) connector
R.
RS IÓ

(page 4-42).
Check for continuity between the wire harness side
EPS ECU 21P (Gray) connector [1] and PCM/ECM
TO UC

33P (Black) connector [2] terminals.

TOOL: C20
A20
Test probe, 2 pack 07ZAJ-RDJA110
MO RIB

Connection: C20 (EPS ECU) – A20 (PCM/ECM)

Is there continuity?
AL ST

YES – GO TO STEP 2. [2]

NO – Open circuit in the Blue/black wire
BR DI

2. CKP Sensor Signal Line Short Circuit Inspection

Check for continuity between the wire harness side
CA SU

[1]
EPS ECU 21P (Gray) connector [1] terminal and
ground.
TOOL:
24 O

Test probe, 2 pack 07ZAJ-RDJA110

-20 BID

Connection: C20 – Ground

Is there continuity?
YES – Short circuit in the Blue/black wire C20
-07 HI

NO – Replace the EPS ECU with a known good

one (page 25-29), and recheck.
28 O
PR

25-23
 dummyhead

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

DTC 31-01: LOW/HIGH IG1-TERMINAL
VOLTAGE (INITIAL DIAGNOSIS)

Before starting the troubleshooting, check the following

S. O
items:

L.
S AD
– Check for loose or poor contact of the EPS ECU 21P
(Gray) connector, and recheck the EPS indicator

R.
(page 25-6).

OR RIZ
– Check for blown IGN fuse (20 A).
– Check the battery condition (page 22-5). (A fully
charged battery must be used.)

OT TO
1. IG1 Line Open Circuit Inspection
Turn the ignition switch OFF.
[1] C7
Disconnect the EPS ECU 21P (Gray) connector

LM U
(page 25-29).
Turn the ignition switch ON.

RA O A
Measure the voltage between the wire harness side
EPS ECU 21P (Gray) connector [1] terminal and
ground.
TOOL:

AB N
Test probe, 2 pack 07ZAJ-RDJA110

-C O
Connection: C7 (+) – Ground (–)

L. US
Is there battery voltage?
YES – GO TO STEP 2.
NO – Open circuit in the Black/red wire
S. N O
2. Battery Inspection
Perform the Battery/Charging System
troubleshooting (page 22-3).
R.
RS IÓ

Is the battery and charging system in good

condition?
TO UC

YES – Replace the EPS ECU with a known good

one (page 25-29), and recheck.
NO – Repair the battery/charging system.
MO RIB

DTC 31-02: LOW/HIGH IG1-TERMINAL

VOLTAGE (REGULAR DIAGNOSIS)
AL ST

Refer to DTC 31-01 (page 25-24).

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

25-24
dummyhead

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

DTC 32-01: LOW/HIGH VBU VOLTAGE
(REGULAR DIAGNOSIS)

S. O
Before starting the troubleshooting, check the following
items:

L.
S AD
– Check for loose or poor contact of the EPS ECU 2P
(Brown) connector, and recheck the EPS indicator

R.
(page 25-6).

OR RIZ
– Check for blown EPS fuse (30 A)
– Check the battery condition (page 22-5). (A fully
charged battery must be used.)
1. EPS ECU +B Line Open Circuit Inspection

OT TO
Disconnect the EPS ECU 2P (Brown) connector
(page 25-29). FM2: Bl [1]
Measure the voltage between the wire harness side FA2: W/R

LM U
EPS ECU 2P (Brown) connector [1] terminal and

RA O A
ground.
Connection: FM2: Black (+) – Ground (–)
FA2: White/red (+) – Ground (–)

AB N
Is there battery voltage?
YES – GO TO STEP 2.

-C O
NO – • FM2: Open circuit in the Black wire

L. US
• FA2: Open circuit in the White/red wire

2. Battery Inspection
S. N O
Perform the Battery/Charging System
troubleshooting (page 22-3).
Is the battery and charging system in good
R.
RS IÓ

condition?
YES – Replace the EPS ECU with a known good
TO UC

one (page 25-29), and recheck.

NO – Repair the battery/charging system.
MO RIB
AL ST
BR DI
CA SU
24 O
-20 BID
-07 HI
28 O
PR

25-25
 dummyhead

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

EPS INDICATOR CIRCUIT INSPECTION
EPS INDICATOR DOES NOT COME ON

S. O
• Under normal conditions, the EPS indicator comes

L.
S AD
on when the ignition switch is turned ON, then goes
off after starting the engine.

R.
• Before starting the troubleshooting, check for loose
or poor contact of the following connectors, and

OR RIZ
recheck the EPS indicator.
– combination meter 16P
– front sub-wire harness 8P (Gray)

OT TO
– EPS ECU 21P (Gray)
1. Combination Meter Inspection
Check the combination meter initial operation (page

LM U
23-6).

RA O A
Does the combination meter operate properly?
YES – GO TO STEP 2.
NO – Check the combination meter power/

AB N
ground lines (page 23-7).
2. EPS ECU Inspection (Short Circuit inspection)

-C O
Turn the ignition switch OFF.

L. US
Disconnect the EPS ECU 21P (Gray) connector
(page 25-29).
Turn the ignition switch ON.
Check the EPS indicator.
S. N O
Does the indicator come on?
YES – Replace the EPS ECU with a known good
one (page 25-29), and recheck.
R.
RS IÓ

NO – GO TO STEP 3.
3. Indicator Line Short Circuit inspection
TO UC

Turn the ignition switch OFF.

[1] Y/G
Disconnect the combination meter 16P connector
(page 23-6).
MO RIB

Check the for continuity between the wire harness

side 16P (Black) connector [1] terminal and ground.
Connection: Yellow/green – Ground
AL ST

Is there continuity?
YES – Short circuit in the Yellow/green wire
BR DI

NO – Replace the combination meter with a

known good one (page 23-6).
CA SU
24 O
-20 BID
-07 HI
28 O
PR

25-26
dummyhead

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

EPS INDICATOR DOES NOT GO OFF,
AND NO DTCs ARE STORED

S. O
• Under normal conditions, the EPS indicator comes
on when the ignition switch is turned ON, then goes

L.
S AD
off after starting the engine.
• Before starting the troubleshooting check the

R.
following items, and recheck the EPS indicator.

OR RIZ
– Check for loose or poor contact of the following
connectors:
– EPS ECU 21P (Gray)
– EPS ECU 2P (Brown)

OT TO
– combination meter 16P
– front sub-wire harness 8P (Gray)
– Check the battery condition (page 22-5). (A fully
charged battery must be used.)

LM U
1. Fuse Inspection

RA O A
Check the EPS fuse (30 A) and IGN fuse (20 A).
Are the fuses OK?

AB N
YES – GO TO STEP 2.
NO – Replace the fuse and recheck. If the fuse

-C O
is blown, check for short to ground in this
fuse circuit.

L. US
2. Recheck DTC
Check the DTC (page 25-6).
S. N O
Are there any DTCs?
YES – Perform the troubleshooting for the
indicated DTC (page 25-11).
NO – GO TO STEP 3.
R.
RS IÓ

3. Indicator Operation Check (Indicator Line Open

Circuit Inspection)
TO UC

Turn the ignition switch OFF.

[1]
Disconnect the EPS ECU 21P (Gray) connector
(page 25-29).
MO RIB

Ground the wire harness side 21P (Gray) connector C5

[1] terminal with a jumper wire.
TOOL:
AL ST

Test probe, 2 pack 07ZAJ-RDJA110

Connection: C5 – Ground
BR DI

Turn the ignition switch ON.

Check the EPS indicator.
CA SU

Does the indicator go off?

YES – Recheck for loose or poor contact of the
21P (Gray) connector. If it is OK, replace
24 O

the EPS ECU with a known good one

(page 25-29), and recheck.
-20 BID

NO – GO TO STEP 4.
-07 HI
28 O
PR

25-27
 dummyhead

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

4. Indicator Line Open Circuit Inspection
Turn the ignition switch OFF.
Disconnect the combination meter 16P connector C5
(page 23-6). Y/G

S. O
Check for continuity between the wire harness side
16P (Black) connector [1] and 21P (Gray) connector

L.
S AD
[2] terminals.

R.
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110

OR RIZ
Connection: Yellow/green – C5
Is there continuity?

OT TO
YES – GO TO STEP 5.
NO – Open circuit in the Yellow/green wire [1] [2]

LM U
5. SCS Line Short Circuit Inspection

RA O A
Disconnect the PCM/ECM 33P (Gray) connector
(page 4-42). C9 [1]
Check for continuity between the wire harness side
21P (Gray) connector [1] terminal and ground.

AB N
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110

-C O
Connection: C9 (+) – Ground (–)

L. US
Is there continuity?
YES – Short circuit in the Brown/red wire.
S. N O
NO – GO TO STEP 6.
R.
6. IG1 Line Open Circuit Inspection
RS IÓ

Turn the ignition switch ON.

[1] C7
Measure the voltage between the wire harness side
TO UC

EPS ECU 21P (Gray) connector [1] terminal and

ground.
TOOL:
MO RIB

Test probe, 2 pack 07ZAJ-RDJA110

Connection: C7 (+) – Ground (–)

AL ST

Is there battery voltage?

YES – GO TO STEP 7.
BR DI

NO – Open circuit in the Black/red wire

CA SU

7. EPS ECU +B Line Open Circuit Inspection

Turn the ignition switch OFF.
FM2: Bl [1]
Disconnect the EPS ECU 2P (Brown) connector
24 O

(page 25-29). FA2: W/R

Measure the voltage between the wire harness side
-20 BID

2P (Brown) connector [1] terminal and ground.

Connection: FM2: Black (+) – Ground (–)
FA2: White/red (+) – Ground (–)
-07 HI

Is there battery voltage?

28 O

YES – GO TO STEP 8.
NO – • FM2: Open circuit in the Black wire
PR

• FA2: Open circuit in the White/red wire

25-28
dummyhead

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

8. EPS ECU PG Line Open Circuit Inspection
Check for continuity between the wire harness side
[1] Green
EPS ECU 2P (Brown) connector [1] terminal and
ground.

S. O
Connection: Green – Ground

L.
S AD
Is there continuity?

R.
YES – GO TO STEP 9.

OR RIZ
NO – Open circuit in the Green wire

OT TO
LM U
9. Battery Inspection

RA O A
Perform the Battery/Charging System
troubleshooting (page 22-3).
Is the battery and charging system in good

AB N
condition?
YES – Recheck for loose or poor contact of the

-C O
combination meter 16P connector, front
sub-wire harness 8P (Gray) connector,

L. US
EPS ECU 21P (Gray) connector and EPS
ECU 2P (Brown). If they are OK, replace
the EPS ECU with a known good one
(page 25-29), and recheck.
S. N O
NO – Repair the battery/charging system.

EPS ECU
R.
RS IÓ

REMOVAL/INSTALLATION
TO UC

Remove the right following:

[3]
– trim clips [1]
MO RIB

– bolts [2]
– EPS ECU holder [3]
AL ST
BR DI
CA SU

[2] [1]

Remove the EPS ECU [1] from the stays on the EPS
24 O

[4] [5] [2]

ECU holder [2].
-20 BID

Disconnect the following connectors:

– EPS ECU 21P (Gray) [3]
– EPS ECU 2P (Gray) [4]
– EPS ECU 2P (Brown) [5]
-07 HI

Installation is in the reverse order of removal.

28 O

Perform the torque sensor initialization if the EPS ECU

replaced (page 25-9).
PR

[3] [1]

25-29
 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

26. WIRING DIAGRAMS

S. O
L.
S AD
R.
OR RIZ
OT TO
LM U
’14 TM1 model ···································· 26-2 '15 – '19 FA1 model ···························· 26-14

RA O A
’14 TE1 model····································· 26-3 '15 – '19 FA2 model ···························· 26-15

AB N
’14 FM1 model ···································· 26-4 '15 – '19 FA5 model ···························· 26-16

-C O
’14 FM2 model ···································· 26-5 '15 – '19 FA6 model ···························· 26-17

L. US
’14 FE1 model····································· 26-6
S. N O '20 – '21 TM model ····························· 26-18

’14 FA1 model ···································· 26-7 '20 – '21 FM models ···························· 26-19

’14 FA2 model ···································· 26-8 '20 – '21 TE/FE models························ 26-20
R.
RS IÓ

'15 – '19 TM1 model ····························· 26-9 '20 – '21 FA models ···························· 26-21
TO UC

'15 – '19 TE1 model ····························26-10 After '21 TM model ····························· 26-22
MO RIB

'15 – '19 FM1 model ····························26-11 After '21 FM models ··························· 26-23
AL ST

'15 – '19 FM2 model ····························26-12 After '21 TE/FE models ······················· 26-24
BR DI

'15 – '19 FE1 model ····························26-13 After '21 FA models···························· 26-25

CA SU
24 O
-20 BID

26
-07 HI
28 O
PR

26-1
dummyhead

D .L.
A WIRING DIAGRAMS
’14 TM1 model
WIRING DIAGRAMS

IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET
WELDING ALTERNATOR JOINT 5 MOTOR STARTER
(OPTION) ECM

R
RELAY SWITCH

T
JOINT 1 Y OPTION

FUEL SENDER

STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
U TO
JOINT CONNECTOR ANGLE

INH RLY
IACV 2B
IACV 1A

IACV 1B
IACV2A

TW IND

OR SW
K-LINE

WARN

Bl

Bl
Bl
WELDING

O2HT
MAIN
SENSOR

GP R

GP N
Y Y

IGN1

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
SCS

PCP
PG3

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
R N IND ST SW STOP

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
24P 3P R Bl RECTIFIER
W

O M

Bl/Bu

Bu/Bl

Lb/W
Br/W
Br/W
Br/W

Br/W

Bu/R

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
Lg/R
Lg/R
Lg/R

W/Bl

Gr/R

Lg/R
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

G/Bl

G/Bl

Bl/G

W/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Y/W

Bl/R

G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

G/Y
Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Gr
Gr

Gr
Lg

Gr
G

G
Y

Y
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G 12V 12AH GROUND

G
R
R
R
R
R
R

R
Y
Y
Y

Y/R
G
O RA
S B
U A
R/Bl 20A FAN
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT1
Bl Bl Bl Bl 20A IGN

O -C
BAT
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
NEUTRAL INDICATOR P 20A ACC
Bl/Br Bl/Br Bl/R

N .L.
W/Bl
12V 1.7W Lg/R Lg/R Lg/R

R/Y
REVERSE INDICATOR Bl/Br Bl/Br Bl/R R DIODE

IÓ.R
12V 1.7W Gr Gr Gr
ENGINE COOLANT
TEMPERATURE Bl/Br Bl/Br Bl/R FUSE BOX
INDICATOR Bu/R Bu/R Bu/R

C S
12V 1.7W
MIL Bl/Br Bl/Br Bl/R
12V 1.7W Br/W Br/W Br/W

U S FUEL INDICATOR Bl/Br Bl/Br Bl/R

IB R
12V 1.7W Bu Bu G/Y
10P

TR TO
LIGHTING/ G/Y
DIMMER/ IG Bl/W 8P G BRAKE/TAILLIGHT
ST Bu G Br
ENGINE BAT3 Bl/Br Bl/W Bl/W 3P
BAT4 Bl/R Bu Bu Bl
STOP/ TL Br G/Y G/Y

ISMO
HI Bu/Bl Y/R Y/R
STARTER LO W Bl/Br Bl/Br
SWITCH

DL REAR BRAKE
SWITCH
(LEVER)
G/Y
Bl/Br
Bl/R Bl/R

U A
Y/R
Bl/Br
Br Br
FRONT BRAKE G G

S R SWITCH
Bu/Bl
W
G

O AB
3P
Bu/Bl
W
Bu/Bl

G
W
G

ID C
Bu/Bl
W
G

HEADLIGHT

IB 24
(12V 35/35W X 2)

Bl/Bu

Bu/Bl

Lb/W
Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Bl/W
Gr/R

G/W
G/W
G/W
G/W
G/W
G/W

G/W

W/G
G/W

G/W

G/W

Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W

Bl/R

Bl/R
G/O
G/Y

G/Y
Y/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br
G

G
G
G
G

G
G
G
G
G

G
G
G
G
G
G
G
G
G
G

G
R

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Bu/Y
Lg/R
W/G
W/R
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
Y
FUEL PUMP
WELDING WELDING WELDING WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND
JOINT 6

R 07 1 2 3

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER
MAIN POWER FRAME GROUND
INHIBITOR GEAR POSITION 5 4

P -
3
RELAY FUEL PUMP 2
IGNITION
RELAY FAN
MAP
SWITCH 1
REAR UNIT SENSOR R N COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT
SWITCH
STARTER RELAY FUEL SENSOR IAT CKP SENSOR
(PEDAL)
SWITCH DIODE PUMP SENSOR FUEL INJECTOR
RELAY ENGINE FRAME
GROUND GROUND

LIGHTING REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE PULL
V VIOLET W WHITE
HI Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-2
 dummyhead

D L .
WIRING DIAGRAMS A .
’14 TE1 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET STARTER
WELDING (OPTION) PCM ALTERNATOR JOINT 5 MOTOR
RELAY SWITCH

T R
JOINT 1 Y U.S.A.: OPTION
Except U.S.A.: Standard

STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
U TO
ANGLE

SEN VB1
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
IACV2A

SFT UP
ANGLE
OR SW
K-LINE

Bl

Bl
Bl
WELDING

O2HT
MAIN
SENSOR

MOM

GP R

GP N
Y Y

IGN1
MOP

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
SCS

PCP
PG3
PVB

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
ST SW STOP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

W/Bu
Bl/Bu

Bu/Bl

Lb/W
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
W/Bl

Gr/R

Lg/R
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/R

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y
P/G

Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Lg

Gr
Bl
G

G
R

Y
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G U.S.A.: GROUND

G
R
R
R
R
R
R

R
Y
Y
Y
12V 12AH

Y/R
G
O RA
Except
U.S.A.:
12V 16AH

S B
U A
O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN
Bl/R

N .L.
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 V V P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
ENGINE IG Bl/W 14P

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

SWITCH Bl/Br

DL
Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bl/Bu

Bu/Bl

Lb/W

G/Bu
Br/W

Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

G/W
Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R

Bl/R

Bl/R
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W
G/O
G/Y

G/Y

G/Y
Y/G

P/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 6P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Br/W

Bu/Y
Lg/R

Bl/W
W/G
W/R

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING 2P WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND
JOINT 6

R 07
SHIFT
1 2 3

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER CONTROL
MAIN POWER FRAME GROUND
INHIBITOR MOTOR

P -
RELAY FUEL PUMP IGNITION
RELAY FAN
MAP
REAR UNIT SENSOR COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT GEAR POSITION 5 4
3
SWITCH 2
STARTER RELAY FUEL SENSOR IAT SWITCH 1
CKP SENSOR
(PEDAL) R N

SWITCH DIODE PUMP SENSOR VS FUEL INJECTOR

RELAY SENSOR ENGINE FRAME
GROUND GROUND
SHIFT SPINDLE
REAR BRAKE REAR BRAKE ANGLE SENSOR
LIGHTING DIMMER ENGINE STOP STARTER GEARSHIFT FRONT BRAKE
IGNITION SWITCH SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-3
dummyhead

D .L.
A WIRING DIAGRAMS
’14 FM1 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET STARTER
WELDING (OPTION) ECM ALTERNATOR JOINT 5 MOTOR
RELAY SWITCH

T R
JOINT 1 Y U.S.A.: OPTION
Except U.S.A.: Standard
Bl Bl

STOP SIG SW
DIODE BANK

CONDENSER
M-TXDRXD
U TO
ANGLE

SEN VB1
JOINT CONNECTOR

4WD SW

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
IACV2A

OR SW
K-LINE

Bl

Bl
Bl
WELDING

O2HT
SENSOR

MAIN
Y Y

GP R

GP N
IGN1

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
ST

SCS

PCP
PG3

PG1

PG2
FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
ST SW STOP

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

Bl/Bu

Bu/Bl

Lb/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
W/Bl

Gr/R

Lg/R
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

G/Bl

G/Bl

Bl/G

W/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y
P/G

Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Lg

Gr
G

G
Y

Y
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G U.S.A.: GROUND

G
R
R
R
R
R
R

R
Y
Y
Y
12V 12AH

Y/R
G
O RA
Except
U.S.A.:
12V 16AH

S B
U A
2WD/4WD SELECT SWITCH Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 V V P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11
12 8P
13 Gr

IB R
14
15
16
16P
LIGHTING/
8P
DIMMER/ IG Bl/W

TR TO
ST Bu G
ENGINE BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STOP/ TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
STARTER LO W Bl/Br Bl/Br Bl
SWITCH

REAR BRAKE
ISMO G/Y
Bl/Br

DL
SWITCH Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U ASWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bl/Bu

Bu/Bl

Lb/W
Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
G/O
G/Y

G/Y

G/Y
Y/G

P/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br
G

G
G
G
G

G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 3P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Bu/Y
Lg/R

Bl/W
W/G
W/R
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND
JOINT 6

R 07 1 2 3

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER
MAIN POWER FRAME GROUND
INHIBITOR GEAR POSITION 5 4

P -
3
RELAY FUEL PUMP 2
IGNITION
RELAY FAN
MAP
SWITCH 1
REAR UNIT SENSOR R N COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT
SWITCH
STARTER RELAY FUEL SENSOR IAT CKP SENSOR
(PEDAL)
SWITCH DIODE PUMP SENSOR VS FUEL INJECTOR
RELAY SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE PULL
V VIOLET W WHITE
HI Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-4
 dummyhead

D L .
WIRING DIAGRAMS A .
’14 FM2 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET STARTER
WELDING (OPTION) ECM ALTERNATOR JOINT 5 MOTOR
RELAY SWITCH

T R
JOINT 1 Y U.S.A.: OPTION
Except U.S.A.: Standard
TORQUE EPS

STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
M-TXDRXD
SENSOR MOTOR

U TO
EPS UNIT ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
IACV2A

TACHO
OR SW
K-LINE

Bl

Bl
Bl
WELDING

O2HT
MAIN
SENSOR

GP R

GP N
Y Y

IGN1

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
SCS

PCP
NEP
VSP
PG
+B
M-
M+
4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE

EPS IND
4WD INDI

PG3

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

T/S GND
A O

G
GND
OUT
K-LINE SCS ST SW STOP VSP

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
Bl

B-11

A-11
R

C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
VS2
VS1
R
4P 5P 33P Gr 33P Bl R G
REGULATOR/
21P 24P 3P R Bl
3P 2P 2P 2P RECTIFIER
W W

O M

Bl/Bu

Bu/Bl

Bu/Bl

Lb/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
W/Bl

Gr/R

Lg/R
2P

O/W
O/W
O/W
Br/R
Br/R
Br/R

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

G/Bl

G/Bl

Bl/G

W/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y
P/G
P/G
P/G

P/G

Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu

Bu
Gr
Lg

Gr
W/Bu

W/Bu

G
Bu/Bl

Y
Br/W
Br/R
O/W
Bl/R
G/O

G/O

P/G
Y/G
Y/R

Y/R
Bu
Bl

Bl
Bl
G
R

R
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G U.S.A.: GROUND

G
R
R
R
R
R
R

R
Y
Y
Y
12V 12AH

Y/R
G
O RA
Except
U.S.A.:
12V 16AH

S B R
Bl 40A

U A
2WD/4WD SELECT SWITCH Br/W
EPS FUSE

O -C
R/Bl 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 V V P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
EPS 6 Y/G Y/G Y/G
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
16
16P
LIGHTING/
DIMMER/ IG Bl/W 8P

TR TO
ST Bu G
ENGINE BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STOP/ TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
STARTER LO W Bl/Br Bl/Br Bl
SWITCH

REAR BRAKE
ISMO G/Y
Bl/Br

DL
SWITCH Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bl/Bu

Bu/Bl

Lb/W
Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
G/O
G/Y

G/Y

G/Y
Y/G

P/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br
G

G
G
G
G

G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 3P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Bu/Y
Lg/R

Bl/W
W/G
W/R
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND GND
JOINT 6

R 07 1 2 3 4

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER
MAIN POWER FRAME GROUND
INHIBITOR GEAR POSITION 5 4

P -
3
RELAY FUEL PUMP 2
IGNITION
RELAY FAN
MAP
SWITCH 1
REAR UNIT SENSOR R N COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT
SWITCH
STARTER RELAY FUEL SENSOR IAT CKP SENSOR
(PEDAL)
SWITCH DIODE PUMP SENSOR VS FUEL INJECTOR
RELAY SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE PULL
V VIOLET W WHITE
HI Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-5
dummyhead

D .L.
A WIRING DIAGRAMS
’14 FE1 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET STARTER
WELDING (OPTION) PCM ALTERNATOR JOINT 5 MOTOR
RELAY SWITCH

T R
JOINT 1 Y U.S.A.: OPTION
Except U.S.A.: Standard

STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
U TO
ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
IACV2A

SFT UP
ANGLE
OR SW
K-LINE

Bl

Bl
Bl
WELDING

O2HT
MAIN
SENSOR

MOM

GP R

GP N
Y Y

IGN1
MOP

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
SCS

PCP
PG3
PVB

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
ST SW STOP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

W/Bu
Bl/Bu

Bu/Bl

Lb/W
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
W/Bl

Gr/R

Lg/R
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/R

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y
P/G

Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Lg

Gr
Bl
G

G
R

Y
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G U.S.A.: GROUND

G
R
R
R
R
R
R

R
Y
Y
Y
12V 12AH

Y/R
G
O RA
Except
U.S.A.:
12V 16AH

S B
U A
2WD/4WD SELECT SWITCH Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 V V P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
ENGINE IG Bl/W 14P

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

SWITCH Bl/Br

DL
Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bl/Bu

Bu/Bl

Lb/W

G/Bu
Br/W

Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

G/W
Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R

Bl/R
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W

Bl/R
G/O
G/Y

G/Y

G/Y
Y/G

P/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 6P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Br/W

Bu/Y
Lg/R

Bl/W
W/G
W/R

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING 2P WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND
JOINT 6

R 07
SHIFT
1 2 3

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER CONTROL
MAIN POWER FRAME GROUND
INHIBITOR MOTOR

P -
RELAY FUEL PUMP IGNITION
RELAY FAN
MAP
REAR UNIT SENSOR COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT GEAR POSITION 5 4
3
SWITCH 2
STARTER RELAY FUEL SENSOR IAT SWITCH 1
CKP SENSOR
(PEDAL) R N

SWITCH DIODE PUMP SENSOR VS FUEL INJECTOR

RELAY SENSOR ENGINE FRAME
GROUND GROUND
SHIFT SPINDLE
REAR BRAKE REAR BRAKE ANGLE SENSOR
LIGHTING DIMMER ENGINE STOP STARTER GEARSHIFT FRONT BRAKE
IGNITION SWITCH SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-6
 dummyhead

D L .
WIRING DIAGRAMS A .
’14 FA1 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET
WELDING ALTERNATOR JOINT 5 MOTOR STARTER
(OPTION) PCM

R
RELAY SWITCH

T
JOINT 1 Y

STOPLAMP SW
OPTION

REVERSE SW
STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
SFT SOL A
U TO

AT ES SW
ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
FR VSP
IACV2A

SFT UP
ANGLE
OR SW
K-LINE

LIN_M
DP 3N

DP 5R
DP N4

DP 5N

DP N2

Bl

Bl
Bl
LIN_P
DP 12
DP 32

DP 54

DP 34
WELDING

O2HT
MAIN
SENSOR

MOM

DP N
Y Y

IGN1
MOP

TOIL
PRC

VCC
SCS

PCP
PG3
PVB

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
ST SW STOP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

W/Bu

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W

Br/W
Bu/R
Bu/Y

Bu/Y
Y/Bu

Br/Bl

Lg/R
W/Bl

Gr/R

Lg/R

Bl/W
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/Y

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R
Bl/Y

G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

G/Y
P/G

Y/G

Y/R
R/Y
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Lg

Gr

Lb
Bl
G

G
R

P
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G 12V 16AH GROUND

G
R
R
R
R
R
R

R
Y
Y
Y

Y/R
G
O RA
S B Bl/G
2P
Bl
Bl/R

U A
DRIVE MODE SELECT SWITCH Br/Bl Br/Bl

2WD/4WD SELECT SWITCH Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 V V P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
14P
ENGINE IG Bl/W

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

Bl/Br

DL
SWITCH Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G

G/Bu
Br/W

Br/W

Br/W

Bu/R

Br/W
Bu/Y

Bu/Y
Bl/Br

Y/Bu
Bl/W

Bl/W
Gr/R

Lg/R
G/W

G/W
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

W/G

G/W
Br/Y
R/W
G/Bl

G/Bl
W/Y

Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
Bl/Y

G/O
G/Y

G/Y

G/Y
Y/G

P/G

R/Y
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr

Lb
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 10P 6P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

W/Bu
Bu/W
Bu/Bl
Bu/G
Bu/R

Br/W

Bu/R

Bu/Y
Lg/R

Bl/W
W/G

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr

Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
2P WELDING WELDING WELDING WELDING
SHIFT JOINT 4 JOINT 2 JOINT 3 2P GND GND GND
JOINT 6

R 07
SHIFT 1 2 3
SOLENOID

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)

DP3N
DP12
DP32
DP5R
DPN4
DPN
DP54
DP5N
DP34
DPN2
STARTER 3P
MAIN POWER CONTROL
VALVE INHIBITOR FRAME GROUND
2P MOTOR

P -
RELAY FUEL PUMP IGNITION
DUAL RELAY FAN
MAP
SHIFT DRUM
FRONT REAR UNIT SENSOR COIL
CLUTCH PC MOTOR TP SENSOR POSITION SWITCH

28

G
SOLENOID VALVE VS BRAKE O2 SENSOR
ECT SENSOR UNIT REAR VS REVERSE
SENSOR SWITCH
STARTER RELAY FUEL SENSOR IAT SENSOR SWITCH CKP SENSOR
EOT SENSOR (PEDAL)
SWITCH DIODE PUMP SENSOR SHIFT SPINDLE FUEL INJECTOR
RELAY ANGLE SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING DIMMER ENGINE STOP STARTER GEARSHIFT FRONT BRAKE REAR BRAKE REAR BRAKE
IGNITION SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH
SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-7
dummyhead

D .L.
A WIRING DIAGRAMS
’14 FA2 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET
WELDING ALTERNATOR JOINT 5 MOTOR STARTER
(OPTION) PCM

R
RELAY SWITCH

T
JOINT 1 Y

STOPLAMP SW
OPTION
TORQUE EPS

REVERSE SW
STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
SENSOR MOTOR

SFT SOL A
U TO

AT ES SW
EPS UNIT ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
FR VSP
IACV2A

SFT UP
TACHO
ANGLE
OR SW
K-LINE

LIN_M
DP 3N

DP 5R
DP N4

DP 5N

DP N2

Bl

Bl
Bl
LIN_P
DP 12
DP 32

DP 54

DP 34
WELDING

O2HT
MAIN
SENSOR

MOM

DP N
Y Y

IGN1
MOP

TOIL
PRC

VCC
SCS

PCP
NEP
VSP
PG
+B
M-
M+
4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE

EPS IND
4WD INDI

PG3
PVB

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

T/S GND
A O

G
GND
OUT
K-LINE SCS ST SW STOP VSP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
Bl

B-11

A-11
R

C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
VS2
VS1
R
4P 5P 33P Gr 33P Bl R G
REGULATOR/
21P 24P 3P R Bl
3P 2P 2P 2P RECTIFIER
W W

O M

W/Bu

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl

Bu/Bl
Bu/G
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W
Bu/R
Bu/Y

Bu/Y
Y/Bu

Br/Bl

Lg/R
W/Bl

Gr/R

Lg/R

Bl/W
2P

O/W
O/W
O/W
Br/R
Br/R
Br/R

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/Y

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
Bl/Y

G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

G/Y
P/G
P/G
P/G

P/G

Y/G

Y/R
R/Y
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu

Bu
Gr
Lg

Gr

Lb
Bl
W/Bu

W/Bu

G
Bu/Bl

P
Br/W
Br/R
O/W
W/R

Bl/R
G/O

G/O

P/G
Y/G
Y/R

Y/R
Bu
Bl

Bl
G
R

R
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G 12V 16AH GROUND

G
R
R
R
R
R
R

R
Y
Y
Y

Y/R
G
O RA
R
W/R 40A

EPS FUSE

S B Bl/G
2P
Bl
Bl/R

U A
DRIVE MODE SELECT SWITCH Br/Bl Br/Bl

2WD/4WD SELECT SWITCH Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
DC
P P P Bl/Br
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 V V P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
EPS 6 Y/G Y/G Y/G
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
ENGINE IG Bl/W 14P

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

Bl/Br
SWITCH

DL
Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G

G/Bu
Br/W

Br/W

Br/W

Bu/R

Br/W
Bu/Y

Bu/Y
Bl/Br

Y/Bu
Bl/W

Bl/W
Gr/R

Lg/R
G/W

G/W
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

W/G

G/W
Br/Y
R/W
G/Bl

G/Bl
W/Y

Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
Bl/Y

G/O
G/Y

G/Y

G/Y
Y/G

P/G

R/Y
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr

Lb
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 10P 6P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

W/Bu
Bu/W
Bu/Bl
Bu/G
Bu/R

Br/W

Bu/R

Bu/Y
Lg/R

Bl/W
W/G

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr

Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
2P 2P WELDING WELDING WELDING 2P WELDING
SHIFT Br Bl JOINT 4 JOINT 2 JOINT 3 GND GND GND GND
JOINT 6

R 07
SHIFT
SOLENOID 1 2 3 4

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)

DP3N
DP12
DP32
DP5R
DPN4
DPN
DP54
DP5N
DP34
DPN2
STARTER 3P
CONTROL
VALVE MAIN POWER FRAME GROUND
INHIBITOR 2P MOTOR

P -
RELAY FUEL PUMP IGNITION
DUAL RELAY FAN
MAP
SHIFT DRUM
FRONT REAR UNIT SENSOR COIL
CLUTCH PC MOTOR TP SENSOR POSITION SWITCH

28

G
SOLENOID VALVE VS BRAKE O2 SENSOR
ECT SENSOR UNIT REAR VS REVERSE
SENSOR SWITCH
STARTER RELAY FUEL SENSOR IAT SENSOR SWITCH CKP SENSOR
EOT SENSOR (PEDAL)
SWITCH DIODE PUMP SENSOR SHIFT SPINDLE FUEL INJECTOR
RELAY ANGLE SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING GEARSHIFT REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-8
 dummyhead

D L .
WIRING DIAGRAMS A .
'15 – '19 TM1 model IZS.R
R ACCESSORY U.S.A.: OPTION

O S
Except U.S.A.: Standard
SOCKET
WELDING ALTERNATOR STARTER
(OPTION) ECM WELDING STARTER

R
RELAY SWITCH

T
JOINT 1 Y JOINT 5 MOTOR

FUEL SENDER

STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
U TO
JOINT CONNECTOR ANGLE

INH RLY
IACV 2B
IACV 1A

IACV 1B
IACV2A

TW IND

OR SW
K-LINE

WARN

Bl

Bl
Bl
WELDING

O2HT
MAIN
SENSOR

GP R

GP N
Y Y

IGN1

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
SCS

PCP
PG3

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
R N IND ST SW STOP

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
24P 3P R Bl RECTIFIER
W

O M

Bl/Bu

Bu/Bl

Lb/W
Br/W
Br/W
Br/W

Br/W

Bu/R

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
Lg/R
Lg/R
Lg/R

W/Bl

Gr/R

Lg/R
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

G/Bl

G/Bl

Bl/G

W/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Y/W

Bl/R

G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

G/Y
Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Gr
Gr

Gr
Lg

Gr
G

G
Y

Y
Bl
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G 12V 12AH GROUND

G
R
R
R
R
R
R

R
Y
Y
Y

Y/R
G
O RA
S B
U A
R/Bl 20A FAN
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT1
Bl Bl Bl Bl 20A IGN

O -C
BAT
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
NEUTRAL INDICATOR P 20A ACC
Bl/Br Bl/Br Bl/R

N .L.
W/Bl
12V 1.7W Lg/R Lg/R Lg/R

R/Y
REVERSE INDICATOR Bl/Br Bl/Br Bl/R R DIODE

IÓ.R
12V 1.7W Gr Gr Gr
ENGINE COOLANT
TEMPERATURE Bl/Br Bl/Br Bl/R FUSE BOX
INDICATOR Bu/R Bu/R Bu/R

C S
12V 1.7W
MIL Bl/Br Bl/Br Bl/R
12V 1.7W Br/W Br/W Br/W

U S
FUEL INDICATOR Bl/Br Bl/Br Bl/R

IB R
12V 1.7W Bu Bu G/Y
10P

TR TO
LIGHTING/ G/Y
DIMMER/ IG Bl/W 8P G BRAKE/TAILLIGHT
ST Bu G Br
ENGINE BAT3 Bl/Br Bl/W Bl/W 3P
BAT4 Bl/R Bu Bu Bl
STOP/ TL Br G/Y G/Y

ISMO
HI Bu/Bl Y/R Y/R
STARTER LO W Bl/Br Bl/Br
SWITCH

REAR BRAKE
SWITCH
(LEVER) DL G/Y
Bl/Br
Bl/R Bl/R

U A
Y/R
Bl/Br
Br Br
FRONT BRAKE G G

S R SWITCH
Bu/Bl
W
G

O AB
3P
Bu/Bl
W
Bu/Bl

G
W
G

ID C
Bu/Bl
W
G

HEADLIGHT

IB 24
(12V 35/35W X 2)

Bl/Bu

Bu/Bl

Lb/W
Br/W

Br/W
Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu
Lg/R

Lg/R
Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W

Bl/R

Bl/R
G/O
G/Y

G/Y
Y/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br
G

G
G
G
G

G
G
G
G
G

G
G
G
G
G
G
G
G
G
G

G
R

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Bu/Y
Lg/R
W/G
W/R
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
Y
FUEL PUMP
WELDING WELDING WELDING WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND
JOINT 6

R 07 1 2 3

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER
MAIN FRAME GROUND
INHIBITOR GEAR POSITION 5 4

P -
3
POWER FUEL PUMP 2
IGNITION
RELAY FAN
MAP
SWITCH 1
RELAY REAR UNIT SENSOR R N COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT
SWITCH
IN-GEAR STARTER RELAY FUEL SENSOR IAT CKP SENSOR
(PEDAL)
START DIODE SWITCH DIODE PUMP SENSOR FUEL INJECTOR
RELAY ENGINE FRAME
GROUND GROUND

LIGHTING REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE PULL
V VIOLET W WHITE
HI Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-9
dummyhead

D .L.
A WIRING DIAGRAMS
'15 – '19 TE1 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET STARTER
WELDING (OPTION) PCM ALTERNATOR JOINT 5 MOTOR
RELAY SWITCH

T R
JOINT 1 Y U.S.A.: OPTION
Except U.S.A.: Standard

STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
U TO
ANGLE

SEN VB1
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
IACV2A

SFT UP
ANGLE
OR SW
K-LINE

Bl

Bl
Bl
WELDING

O2HT
MAIN
SENSOR

MOM

GP R

GP N
Y Y

IGN1
MOP

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
SCS

PCP
PG3
PVB

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
ST SW STOP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

W/Bu
Bl/Bu

Bu/Bl

Lb/W
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
W/Bl

Gr/R

Lg/R
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/R

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y
P/G

Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Lg

Gr
Bl
G

G
R

Y
Bl
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G U.S.A.: GROUND

G
R
R
R
R
R
R

R
Y
Y
Y
12V 12AH

Y/R
G
O RA
Except
U.S.A.:
12V 16AH

S B
U A
O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN
Bl/R

N .L.
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 P P P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
ENGINE IG Bl/W 14P

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

SWITCH Bl/Br

DL
Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A
SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bl/Bu

Bu/Bl

Lb/W

G/Bu
Br/W

Br/W
Br/W

Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Lg/R

Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

G/W
Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R

Bl/R

Bl/R
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W
G/O
G/Y

G/Y

G/Y
Y/G

P/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 6P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Br/W

Bu/Y
Lg/R

Bl/W
W/G
W/R

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING 2P WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND
JOINT 6

R 07
SHIFT
1 2 3

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER CONTROL
MAIN FRAME GROUND
INHIBITOR MOTOR

P -
POWER FUEL PUMP IGNITION
RELAY FAN
MAP
RELAY REAR UNIT SENSOR COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT GEAR POSITION 5 4
3
SWITCH 2
IN-GEAR STARTER RELAY FUEL SENSOR IAT SWITCH 1
CKP SENSOR
(PEDAL) R N

START DIODE SWITCH DIODE PUMP SENSOR VS FUEL INJECTOR

RELAY SENSOR ENGINE FRAME
GROUND GROUND
SHIFT SPINDLE
REAR BRAKE REAR BRAKE ANGLE SENSOR
LIGHTING DIMMER ENGINE STOP STARTER GEARSHIFT FRONT BRAKE
IGNITION SWITCH SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-10
 dummyhead

D L .
WIRING DIAGRAMS A .
'15 – '19 FM1 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET STARTER
WELDING (OPTION) ECM ALTERNATOR JOINT 5 MOTOR
RELAY SWITCH

T R
JOINT 1 Y U.S.A.: OPTION
Except U.S.A.: Standard
Bl Bl

STOP SIG SW
DIODE BANK

CONDENSER
M-TXDRXD
U TO
ANGLE

SEN VB1
JOINT CONNECTOR

4WD SW

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
IACV2A

OR SW
K-LINE

Bl

Bl
Bl
WELDING

O2HT
SENSOR

MAIN
Y Y

GP R

GP N
IGN1

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
ST

SCS

PCP
PG3

PG1

PG2
FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
ST SW STOP

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

Bl/Bu

Bu/Bl

Lb/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
W/Bl

Gr/R

Lg/R
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

G/Bl

G/Bl

Bl/G

W/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y
P/G

Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Lg

Gr
G

G
Y

Y
Bl
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G U.S.A.: GROUND

G
R
R
R
R
R
R

R
Y
Y
Y
12V 12AH

Y/R
G
O RA
Except
U.S.A.:
12V 16AH

S B
2WD/4WD SELECT SWITCH
U A Br/W

O -C
R/Bl 20A FAN
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 P P P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11
12 8P
13 Gr

IB R
14
15
16
16P
LIGHTING/
8P
DIMMER/ IG Bl/W

TR TO
ST Bu G
ENGINE BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STOP/ TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
STARTER LO W Bl/Br Bl/Br Bl
SWITCH

REAR BRAKE
ISMO G/Y
Bl/Br

DL
SWITCH Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A
SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bl/Bu

Bu/Bl

Lb/W
Br/W

Br/W
Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Lg/R

Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
G/O
G/Y

G/Y

G/Y
Y/G

P/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br
G

G
G
G
G

G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 3P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Bu/Y
Lg/R

Bl/W
W/G
W/R
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND
JOINT 6

R 07 1 2 3

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER
MAIN FRAME GROUND
INHIBITOR GEAR POSITION 5 4

P -
3
POWER FUEL PUMP 2
IGNITION
RELAY FAN
MAP
SWITCH 1
RELAY REAR UNIT SENSOR R N COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT
SWITCH
IN-GEAR STARTER RELAY FUEL SENSOR IAT CKP SENSOR
(PEDAL)
START DIODE SWITCH DIODE PUMP SENSOR VS FUEL INJECTOR
RELAY SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE PULL
V VIOLET W WHITE
HI Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-11
dummyhead

D .L.
A WIRING DIAGRAMS
'15 – '19 FM2 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET STARTER
WELDING (OPTION) ECM ALTERNATOR JOINT 5 MOTOR
RELAY SWITCH

T R
JOINT 1 Y U.S.A.: OPTION
Except U.S.A.: Standard
TORQUE EPS

STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
M-TXDRXD
SENSOR MOTOR

U TO
EPS UNIT ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
IACV2A

TACHO
OR SW
K-LINE

Bl

Bl
Bl
WELDING

O2HT
MAIN
SENSOR

GP R

GP N
Y Y

IGN1

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
SCS

PCP
NEP
VSP
PG
+B
M-
M+
4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE

EPS IND
4WD INDI

PG3

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

T/S GND
A O

G
GND
OUT
K-LINE SCS ST SW STOP VSP

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
Bl

B-11

A-11
R

C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
VS2
VS1
R
4P 5P 33P Gr 33P Bl R G
REGULATOR/
21P 24P 3P R Bl
3P 2P 2P 2P RECTIFIER
W W

O M

Bl/Bu

Bu/Bl

Bu/Bl

Lb/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
W/Bl

Gr/R

Lg/R
2P

O/W
O/W
O/W
Br/R
Br/R
Br/R

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

G/Bl

G/Bl

Bl/G

W/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y
P/G
P/G
P/G

P/G

Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu

Bu
Gr
Lg

Gr
W/Bu

W/Bu

G
Bu/Bl

Y
Br/W
Br/R
O/W
Bl/R
G/O

G/O

P/G
Y/G
Y/R

Y/R
Bl

Bu
Bl

Bl
Bl
G
R

R
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G U.S.A.: GROUND

G
R
R
R
R
R
R

R
Y
Y
Y
12V 12AH

Y/R
G
O RA
Except
U.S.A.:
12V 16AH

S B R
Bl 40A

2WD/4WD SELECT SWITCH

U A Br/W
EPS FUSE

O -C
R/Bl 20A FAN
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 P P P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
EPS 6 Y/G Y/G Y/G
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
16
16P
LIGHTING/
DIMMER/ IG Bl/W 8P

TR TO
ST Bu G
ENGINE BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STOP/ TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
STARTER LO W Bl/Br Bl/Br Bl
SWITCH

REAR BRAKE
ISMO G/Y
Bl/Br

DL
SWITCH Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A
SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bl/Bu

Bu/Bl

Lb/W
Br/W

Br/W
Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Lg/R

Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
G/O
G/Y

G/Y

G/Y
Y/G

P/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br
G

G
G
G
G

G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 3P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Bu/Y
Lg/R

Bl/W
W/G
W/R
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND GND
JOINT 6

R 07 1 2 3 4

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER
MAIN FRAME GROUND
INHIBITOR GEAR POSITION 5 4

P -
3
POWER FUEL PUMP 2
IGNITION
RELAY FAN
MAP
SWITCH 1
RELAY REAR UNIT SENSOR R N COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT
SWITCH
IN-GEAR STARTER RELAY FUEL SENSOR IAT CKP SENSOR
(PEDAL)
START DIODE SWITCH DIODE PUMP SENSOR VS FUEL INJECTOR
RELAY SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE PULL
V VIOLET W WHITE
HI Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-12
 dummyhead

D L .
WIRING DIAGRAMS A .
'15 – '19 FE1 model IZS.R
R ACCESSORY

S
WELDING STARTER

O
SOCKET STARTER
WELDING (OPTION) PCM ALTERNATOR JOINT 5 MOTOR
RELAY SWITCH

T R
JOINT 1 Y U.S.A.: OPTION
Except U.S.A.: Standard

STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
U TO
ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
IACV2A

SFT UP
ANGLE
OR SW
K-LINE

Bl

Bl
Bl
WELDING

O2HT
MAIN
SENSOR

MOM

GP R

GP N
Y Y

IGN1
MOP

GP 2
GP 3
GP 1

GP 5

GP 4
PRC

VCC
SCS

PCP
PG3
PVB

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
ST SW STOP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

W/Bu
Bl/Bu

Bu/Bl

Lb/W
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W
Bu/Y
Y/Bu

Lg/R
W/Bl

Gr/R

Lg/R
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/R

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y
P/G

Y/G

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Lg

Gr
Bl
G

G
R

Y
Bl
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G U.S.A.: GROUND

G
R
R
R
R
R
R

R
Y
Y
Y
12V 12AH

Y/R
G
O RA
Except
U.S.A.:
12V 16AH

S B
2WD/4WD SELECT SWITCH
U A Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 P P P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
ENGINE IG Bl/W 14P

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

SWITCH Bl/Br

DL
Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A
SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bl/Bu

Bu/Bl

Lb/W

G/Bu
Br/W

Br/W
Br/W

Br/W

Br/W

Bu/Y
Bl/Br

Y/Bu

Lg/R
Lg/R

Bl/W
Gr/R

W/G
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

G/W
Br/Y

W/R
R/W
G/Bl

G/Bl
Bl/R

Bl/R
Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Y/W

Bl/R
G/O
G/Y

G/Y

G/Y
Y/G

P/G
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
H 0
4P
2P 4P 2P 2P 2P 5P Bl 8P 6P 2P 2P
4P

FUEL LEVEL SENSOR

Bl

O -2

Lb/W

Br/W

Bu/Y
Lg/R

Bl/W
W/G
W/R

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr
Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING 2P WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND
JOINT 6

R 07
SHIFT
1 2 3

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
STARTER CONTROL
MAIN POWER FRAME GROUND
INHIBITOR MOTOR

P -
RELAY FUEL PUMP IGNITION
RELAY FAN
MAP
REAR UNIT SENSOR COIL
MOTOR TP SENSOR

28

G
BRAKE O2 SENSOR
ECT SENSOR UNIT GEAR POSITION 5 4
3
SWITCH 2
IN-GEAR STARTER RELAY FUEL SENSOR IAT SWITCH 1
CKP SENSOR
(PEDAL) R N
START DIODE SWITCH DIODE PUMP SENSOR VS FUEL INJECTOR
RELAY SENSOR ENGINE FRAME
GROUND GROUND
SHIFT SPINDLE
REAR BRAKE REAR BRAKE ANGLE SENSOR
LIGHTING DIMMER ENGINE STOP STARTER GEARSHIFT FRONT BRAKE
IGNITION SWITCH SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-13
dummyhead

D .L.
A WIRING DIAGRAMS
'15 – '19 FA1 model IZS.R
R ACCESSORY U.S.A.: OPTION

O S
Except U.S.A.: Standard
SOCKET
WELDING ALTERNATOR STARTER
(OPTION) PCM WELDING STARTER

R
RELAY SWITCH

T
JOINT 1 Y JOINT 5 MOTOR

STOPLAMP SW

REVERSE SW
STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
SFT SOL A
U TO

AT ES SW
ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
FR VSP
IACV2A

SFT UP
ANGLE
OR SW
K-LINE

LIN_M
DP 3N

DP 5R
DP N4

DP 5N

DP N2

Bl

Bl
Bl
LIN_P
DP 12
DP 32

DP 54

DP 34
WELDING

O2HT
MAIN
SENSOR

MOM

DP N
Y Y

IGN1
MOP

TOIL
PRC

VCC
SCS

PCP
PG3
PVB

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

A O

G
GND
OUT
ST SW STOP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

W/Bu

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W

Br/W
Bu/R
Bu/Y

Bu/Y
Y/Bu

Br/Bl

Lg/R
W/Bl

Gr/R

Lg/R

Bl/W
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/Y

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R
Bl/Y

G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

G/Y
P/G

Y/G

Y/R
R/Y
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu
Gr
Lg

Gr

Lb
Bl
G

G
R

P
Bl
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G 12V 16AH GROUND

G
R
R
R
R
R
R

R
Y
Y
Y

Y/R
G
O RA
S B Bl/G
2P
Bl
Bl/R

U A
DRIVE MODE SELECT SWITCH Br/Bl Br/Bl

2WD/4WD SELECT SWITCH Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 P P P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
14P
ENGINE IG Bl/W

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

Bl/Br

DL
SWITCH Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A
SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24
Br/W
G

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G

G/Bu
Br/W

Br/W
Br/W

Br/W

Bu/R

Br/W
Bu/Y

Bu/Y
Bl/Br

Y/Bu
Bl/W

Lg/R

Bl/W
Gr/R

Lg/R
G/W

G/W
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

W/G

G/W
Br/Y
R/W
G/Bl

G/Bl
W/Y

Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
Bl/Y

G/O
G/Y

G/Y

G/Y
Y/G

P/G

R/Y
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr

Lb
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
SHIFT

H 0 SOLENOID 4P
2P 4P 2P 2P 2P 5P Bl 10P 6P 2P 2P
4P
VALVE

FUEL LEVEL SENSOR

Bl
2P

O -2

W/Bu
Bu/W
Bu/Bl
Bu/G
Bu/R

Br/W

Bu/R

Bu/Y
Lg/R

Bl/W
W/G

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr

Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING WELDING
DUAL JOINT 4 JOINT 2 JOINT 3 2P GND GND GND
JOINT 6

R 07
SHIFT 1 2 3
CLUTCH PC

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)

DP3N
DP12
DP32
DP5R
DPN4
DPN
DP54
DP5N
DP34
DPN2
STARTER 3P
MAIN POWER CONTROL
SOLENOID VALVE INHIBITOR FRAME GROUND
2P MOTOR

P -
RELAY FUEL PUMP IGNITION
RELAY FAN
MAP
SHIFT DRUM
FRONT REAR UNIT SENSOR COIL
MOTOR TP SENSOR POSITION SWITCH

28

G
VS BRAKE O2 SENSOR
ECT SENSOR UNIT REAR VS REVERSE
SENSOR SWITCH
IN-GEAR STARTER RELAY FUEL SENSOR IAT SENSOR SWITCH CKP SENSOR
EOT SENSOR (PEDAL)
START DIODE SWITCH DIODE PUMP SENSOR SHIFT SPINDLE FUEL INJECTOR
RELAY ANGLE SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING DIMMER ENGINE STOP STARTER GEARSHIFT FRONT BRAKE REAR BRAKE REAR BRAKE
IGNITION SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH
SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-14
 dummyhead

D L .
WIRING DIAGRAMS A .
'15 – '19 FA2 model IZS.R
R ACCESSORY U.S.A.: OPTION

O S
Except U.S.A.: Standard
SOCKET
WELDING ALTERNATOR STARTER
(OPTION) PCM WELDING STARTER

R
RELAY SWITCH

T
JOINT 1 Y JOINT 5 MOTOR

STOPLAMP SW
TORQUE EPS

REVERSE SW
STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
SENSOR MOTOR

SFT SOL A
U TO

AT ES SW
EPS UNIT ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
FR VSP
IACV2A

SFT UP
TACHO
ANGLE
OR SW
K-LINE

LIN_M
DP 3N

DP 5R
DP N4

DP 5N

DP N2

Bl

Bl
Bl
LIN_P
DP 12
DP 32

DP 54

DP 34
WELDING

O2HT
MAIN
SENSOR

MOM

DP N
Y Y

IGN1
MOP

TOIL
PRC

VCC
SCS

PCP
NEP
VSP
PG
+B
M-
M+
4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE

EPS IND
4WD INDI

PG3
PVB

PG1

PG2
ST

FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7 OR

W/Bl
2P

T/S GND
A O

G
GND
OUT
K-LINE SCS ST SW STOP VSP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
Bl

B-11

A-11
R

C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
VS2
VS1
R
4P 5P 33P Gr 33P Bl R G
REGULATOR/
21P 24P 3P R Bl
3P 2P 2P 2P RECTIFIER
W W

O M

W/Bu

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl

Bu/Bl
Bu/G
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W
Bu/R
Bu/Y

Bu/Y
Y/Bu

Br/Bl

Lg/R
W/Bl

Gr/R

Lg/R

Bl/W
2P

O/W
O/W
O/W
Br/R
Br/R
Br/R

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/Y

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
Bl/Y

G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

G/Y
P/G
P/G
P/G

P/G

Y/G

Y/R
R/Y
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu

Bu

Bu
Gr
Lg

Gr

Lb
Bl
W/Bu

W/Bu

G
Bu/Bl

P
Br/W
Br/R
O/W
W/R

Bl/R
G/O

G/O

P/G
Y/G
Y/R

Y/R
Bl

Bu
Bl

Bl
G
R

R
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G 12V 16AH GROUND

G
R
R
R
R
R
R

R
Y
Y
Y

Y/R
G
O RA
R
W/R 40A

EPS FUSE

S B Bl/G
2P
Bl
Bl/R

U A
DRIVE MODE SELECT SWITCH Br/Bl Br/Bl

2WD/4WD SELECT SWITCH Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 P P P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
EPS 6 Y/G Y/G Y/G
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
ENGINE IG Bl/W 14P

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

Bl/Br
SWITCH

DL
Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A
SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G

G/Bu
Br/W

Br/W

Br/W
Br/W

Br/W

Bu/R

Br/W
Bu/Y

Bu/Y
Bl/Br

Y/Bu
Bl/W

Lg/R

Bl/W
Gr/R

Lg/R
G/W

G/W
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

W/G

G/W
Br/Y
R/W
G/Bl

G/Bl
W/Y

Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
Bl/Y

G/O
G/Y

G/Y

G/Y
Y/G

P/G

R/Y
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr

Lb
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
H 0
4P
2P 2P 4P 2P 2P 2P 5P Bl 10P 6P 2P 2P
4P
SHIFT

FUEL LEVEL SENSOR

Br Bl

O -2
SOLENOID

W/Bu
Bu/W
Bu/Bl
Bu/G
Bu/R

Br/W

Bu/R

Bu/Y
Lg/R

Bl/W
W/G

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr

Gr
W
W
2P

Bl
VALVE

Bl

G
P
Y
FUEL PUMP
Bl WELDING WELDING WELDING 2P WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND GND
JOINT 6

R 07
SHIFT
1 2 3 4

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)

DP3N
DP12
DP32
DP5R
DPN4
DPN
DP54
DP5N
DP34
DPN2
STARTER 3P
CONTROL
MAIN POWER FRAME GROUND
DUAL INHIBITOR 2P MOTOR

P -
RELAY FUEL PUMP IGNITION
CLUTCH PC RELAY FAN
MAP
SHIFT DRUM
FRONT REAR UNIT SENSOR COIL
SOLENOID VALVE MOTOR TP SENSOR POSITION SWITCH

28

G
VS BRAKE O2 SENSOR
ECT SENSOR UNIT REAR VS REVERSE
SENSOR SWITCH
IN-GEAR STARTER RELAY FUEL SENSOR IAT SENSOR SWITCH CKP SENSOR
EOT SENSOR (PEDAL)
START DIODE SWITCH DIODE PUMP SENSOR SHIFT SPINDLE FUEL INJECTOR
RELAY ANGLE SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING GEARSHIFT REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-15
dummyhead

D .L.
A WIRING DIAGRAMS
'15 – '19 FA5 model IZS.R
R ACCESSORY U.S.A.: OPTION

O S
Except U.S.A.: Standard
SOCKET
WELDING ALTERNATOR STARTER
(OPTION) PCM WELDING STARTER

R
RELAY SWITCH

T
JOINT 1 Y JOINT 5 MOTOR

STOPLAMP SW

REVERSE SW
STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
SFT SOL A
U TO

AT ES SW
ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
FR VSP
IACV2A

SFT UP
ANGLE
K-LINE

LIN_M
DP 3N

DP 5R
DP N4

DP 5N

DP N2

Bl

Bl
Bl
LIN_P
DP 12
DP 32

DP 54

DP 34
WELDING

O2HT
MAIN
SENSOR

MOM

DP N
Y Y

IGN1
MOP

TOIL
PRC

VCC
SCS

PCP
PG3
PVB

PG1

PG2
FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7

W/Bl
2P

A O

G
GND
OUT
ST STOP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
B-11

A-11
C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
4P 5P 33P Gr 33P Bl R G
REGULATOR/
12P 3P R Bl RECTIFIER
W

O M

W/Bu

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W

Br/W
Bu/R
Bu/Y

Bu/Y
Y/Bu

Br/Bl

Lg/R
W/Bl

Gr/R

Lg/R

Bl/W
2P

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W

Bl/G
G/Bl

G/Bl

W/Y

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
Bl/Y

G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

G/Y
P/G

Y/G

Y/R
R/Y
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu
Gr
Lg

Gr

Lb
Bl
G

G
R

P
Bl
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G 12V 16AH GROUND

G
R
R
R
R
R
R

R
Y
Y
Y

Y/R
G
O RA
S B Bl/G
2P
Bl
Bl/R

U A
DRIVE MODE SELECT SWITCH Br/Bl Br/Bl

2WD/4WD SELECT SWITCH Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 P P P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
6
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
14P
ENGINE IG Bl/W

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

Bl/Br
SWITCH

DL
Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A
SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24
Br/W
G

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G

G/Bu
Br/W

Br/W
Br/W

Br/W

Bu/R

Br/W
Bu/Y

Bu/Y
Bl/Br

Y/Bu
Bl/W

Lg/R

Bl/W
Gr/R

Lg/R
G/W

G/W
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

W/G

G/W
Br/Y
R/W
G/Bl

G/Bl
W/Y

Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
Bl/Y

G/O
G/Y

G/Y

G/Y
Y/G

P/G

R/Y
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr

Lb
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
SHIFT

H 0 SOLENOID 4P
2P 4P 2P 2P 2P 5P Bl 10P 6P 2P 2P
4P
VALVE

FUEL LEVEL SENSOR

Bl
2P

O -2

W/Bu
Bu/W
Bu/Bl
Bu/G
Bu/R

Br/W

Bu/R

Bu/Y
Lg/R

Bl/W
W/G

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr

Gr
W
W
Bl

Bl

G
P
Y
FUEL PUMP
WELDING WELDING WELDING WELDING
DUAL JOINT 4 JOINT 2 JOINT 3 2P GND GND GND
JOINT 6

R 07
SHIFT 1 2 3
CLUTCH PC

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)

DP3N
DP12
DP32
DP5R
DPN4
DPN
DP54
DP5N
DP34
DPN2
STARTER 3P
MAIN POWER CONTROL
SOLENOID VALVE INHIBITOR FRAME GROUND
2P MOTOR

P -
RELAY FUEL PUMP IGNITION
RELAY FAN
MAP
SHIFT DRUM
FRONT REAR UNIT SENSOR COIL
MOTOR TP SENSOR POSITION SWITCH

28

G
VS BRAKE O2 SENSOR
ECT SENSOR UNIT REAR VS REVERSE
SENSOR SWITCH
IN-GEAR STARTER RELAY FUEL SENSOR IAT SENSOR SWITCH CKP SENSOR
EOT SENSOR (PEDAL)
START DIODE SWITCH DIODE PUMP SENSOR SHIFT SPINDLE FUEL INJECTOR
RELAY ANGLE SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING GEARSHIFT REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-16
 dummyhead

D L .
WIRING DIAGRAMS A .
'15 – '19 FA6 model IZS.R
R ACCESSORY U.S.A.: OPTION

O S
Except U.S.A.: Standard
SOCKET
WELDING ALTERNATOR STARTER
(OPTION) PCM WELDING STARTER

R
RELAY SWITCH

T
JOINT 1 Y JOINT 5 MOTOR

STOPLAMP SW
TORQUE EPS

REVERSE SW
STOP SIG SW
Bl Bl
DIODE BANK

CONDENSER
SFT DOWN
M-TXDRXD
SENSOR MOTOR

SFT SOL A
U TO

AT ES SW
EPS UNIT ANGLE

SEN VB1
4WD SW
JOINT CONNECTOR

INH RLY
IACV 2B
IACV 1A

IACV 1B
RR VSP
FR VSP
IACV2A

SFT UP
TACHO
ANGLE
K-LINE

LIN_M
DP 3N

DP 5R
DP N4

DP 5N

DP N2

Bl

Bl
Bl
LIN_P
DP 12
DP 32

DP 54

DP 34
WELDING

O2HT
MAIN
SENSOR

MOM

DP N
Y Y

IGN1
MOP

TOIL
PRC

VCC
SCS

PCP
NEP
VSP
PG
+B
M-
M+
4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE

EPS IND
4WD INDI

PG3
PVB

PG1

PG2
FAN

FLR
R

TW
INJ

SG
PB

TH
LG

BA

O2
TA
JOINT 7

W/Bl
2P

T/S GND
A O

G
GND
OUT
K-LINE SCS ST STOP VSP R

Vcc

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12
B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-10
Bl

B-11

A-11
R

C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
VS2
VS1
R
4P 5P 33P Gr 33P Bl R G
REGULATOR/
21P 24P 3P R Bl
3P 2P 2P 2P RECTIFIER
W

O M

W/Bu

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl

Bu/Bl
Bu/G
G/Bu
Br/W
Br/W
Br/W
Br/W
Br/W

Br/W

Br/W

Br/W

Br/W
Bu/R
Bu/Y

Bu/Y
Y/Bu

Br/Bl

Lg/R
W/Bl

Gr/R

Lg/R

Bl/W
2P

O/W
O/W
O/W
Br/R
Br/R
Br/R

G/W

O/W
Br/R

Br/R

O/W

G/W

W/G
Br/Y
Bl/G

R/W
G/Bl

G/Bl

Bl/G

W/Y

W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

V/W

Bl/R

Bl/R
Bl/Y

G/O
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

G/Y
P/G
P/G
P/G

P/G

Y/G

Y/R
R/Y
Y/R
Y/R
Y/R

Y/R

Y/R

Y/R
Bu

Bu
Gr
Lg

Gr

Lb
Bl
W/Bu

W/Bu

G
Bu/Bl

P
Br/W
Br/R
O/W
W/R

Bl/R
G/O

G/O

P/G
Y/G
Y/R

Y/R
Bl

Bu
Bl

Bl
G
R

R
3P 3P

N L
Gr Bl 2P BATTERY ENGINE
G 12V 16AH GROUND

G
R
R
R
R
R
R

R
Y
Y
Y

Y/R
G
O RA
R
W/R 40A

EPS FUSE

S B Bl/G
2P
Bl
Bl/R

U A
DRIVE MODE SELECT SWITCH Br/Bl Br/Bl

2WD/4WD SELECT SWITCH Br/W

O -C
R 30A ES
R/W
R/Bl 10A MAIN 2
R R R R/Y
IGNITION BAT
BAT1
Bl Bl Bl Bl 20A IGN

N .L.
Bl/R
SWITCH BAT2
R/Bl R/Bl R/Bl P 10A LIGHT
P P P Bl/Br
DC
4P R 30A MAIN 1
R/Bl
P 20A ACC

IÓ.R
W/Bl
FUEL(+) 1 Y/W Y/W Y/W
FUEL(-) 2 G/Y G/Y G/Y
UART 3 P P P R/Y
SP 4 P/G P/G P/G R DIODE
5

C S
EPS 6 Y/G Y/G Y/G
IGN 7 Bl/R Bl/R Bl/R
COMBINATION BATT 8 R/Y R/Y R/Y
METER 9 FUSE BOX

U S
GND 10 G G G
11 8P
12
13 Gr

IB R
14
15
LIGHTING/ 16
16P
DIMMER/
ENGINE IG Bl/W 14P

TR TO
ST Bu G
STOP/ BAT3 Bl/Br Bl/W Bl/W G/Y
BAT4 Bl/R Bu Bu G BRAKE/TAILLIGHT
STARTER TL Br G/Y G/Y Br
HI Bu/Bl Y/R Y/R 3P
SWITCH LO W Bl/Br Bl/Br Bl
GEARSHIFT VCC Br/W Br/W Br/W

ISMO
S/D W/Y W/Y W/Y
SWITCH S/U W/Bu W/Bu W/Bu

REAR BRAKE G/Y

Bl/Br
SWITCH

DL
Bl/R Bl/R
(LEVER) Y/R
Bl/Br
Br Br
FRONT BRAKE G G

U A
SWITCH
Bu/Bl
W
G

S R Bu/Bl
W
3P

O AB
Bu/Bl

G
W
G

Bu/Bl
W
G

ID C
HEADLIGHT
(12V 35/35W X 2)

IB 24

Bu/W
Bl/Bu

Bu/Bl

Bu/Bl
Bu/G

G/Bu
Br/W

Br/W

Br/W
Br/W

Br/W

Bu/R

Br/W
Bu/Y

Bu/Y
Bl/Br

Y/Bu
Bl/W

Lg/R

Bl/W
Gr/R

Lg/R
G/W

G/W
G/W
G/W
G/W
G/W
G/W
G/W
G/W

G/W

G/W

G/W

G/W

W/G

G/W
Br/Y
R/W
G/Bl

G/Bl
W/Y

Bl/R
Bl/R
V/W
R/Bl

Bl/R
Bl/R

Bl/R

Bl/R

Y/W

Bl/R

Bl/R

Bl/R
Bl/Y

G/O
G/Y

G/Y

G/Y
Y/G

P/G

R/Y
Y/R

Y/R

Y/R
Bu
Bu
Bu

Bu
Gr

Lg

Gr

Lb
Br

Br

Bl
G

G
G
G
G
G

G
G
G
G
G

G
G
G
G
G
G
G
G
G
G
G

G
R

R
Y

Y
H 0
4P
2P 2P 4P 2P 2P 2P 5P Bl 10P 6P 2P 2P
4P
SHIFT

FUEL LEVEL SENSOR

Br Bl

O -2
SOLENOID

W/Bu
Bu/W
Bu/Bl
Bu/G
Bu/R

Br/W

Bu/R

Bu/Y
Lg/R

Bl/W
W/G

G/R
G/Y
G/Y

INJ
Bu

Bu
Gr

Gr
W
W
2P

Bl
VALVE

Bl

G
P
Y
FUEL PUMP
Bl WELDING WELDING WELDING 2P WELDING
JOINT 4 JOINT 2 JOINT 3 GND GND GND GND
JOINT 6

R 07
SHIFT
1 2 3 4

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)

DP3N
DP12
DP32
DP5R
DPN4
DPN
DP54
DP5N
DP34
DPN2
STARTER 3P
CONTROL
MAIN POWER FRAME GROUND
DUAL INHIBITOR 2P MOTOR

P -
RELAY FUEL PUMP IGNITION
CLUTCH PC RELAY FAN
MAP
SHIFT DRUM
FRONT REAR UNIT SENSOR COIL
SOLENOID VALVE MOTOR TP SENSOR POSITION SWITCH

28

G
VS BRAKE O2 SENSOR
ECT SENSOR UNIT REAR VS REVERSE
SENSOR SWITCH
IN-GEAR STARTER RELAY FUEL SENSOR IAT SENSOR SWITCH CKP SENSOR
EOT SENSOR (PEDAL)
START DIODE SWITCH DIODE PUMP SENSOR SHIFT SPINDLE FUEL INJECTOR
RELAY ANGLE SENSOR ENGINE FRAME
GROUND GROUND

LIGHTING GEARSHIFT REAR BRAKE REAR BRAKE

IGNITION SWITCH DIMMER ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (LEVER) (PEDAL) Bl BLACK Br BROWN
STOP STOP STOP Bu BLUE G GREEN
BAT2 DC BAT1 BAT BAT3 TL (HL) (HL) LO HI BAT4 IG IG ST S/U VCC S/D VCC 12V 12V 12V
LAMP LAMP LAMP Gr GRAY Lb LIGHT BLUE
ON ON LO OFF FREE UP PUSH PUSH FREE Lg LIGHT GREEN O ORANGE
P PINK R RED
OFF OFF (N) RUN PUSH FREE FREE FREE PULL
V VIOLET W WHITE
HI DOWN Y YELLOW
TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-17
dummyhead

D .L.
A WIRING DIAGRAMS
'20 – '21 TM model IZS.R
R
O S ACCESSORY SOCKET
ECM

R
(OPTION)

T STARTER RELAY

FUEL SENDER

STOP SIG SW
LIGHTING SWITCH DIMMER SWITCH BANK REGULATOR/ WELDING SWITCH

U TO
IGNITION SWITCH JUNCTION 1 RECTIFIER JOINT 5

FUEL IND
STOP ANGLE

INH RLY
IACV 2B
IACV 1A

IACV 1B
IACV2A

TW IND

OR SW
K-LINE
CONDENSER

WARN
WELDING WELDING SENSOR

O2HT
SIGNAL

MAIN
BAT3 TL (HL) (HL) LO HI

GP R

GP N
IGN1
ST

GP 2
GP 3

GP 1

GP 5

GP 4
PRC

VCC
PCS

SCS

PCP
PG3

PG1

PG2
FAN

FLR
U.S.A.: OPTION Bl Bl Bl

TW
INJ

SG
JOINT 7 JOINT 1

PB

TH
LG

BA

O2
OR

TA
DIODE

W/Bl
A O
R N IND ST SW STOP
DLC

GND
Except U.S.A.: Standard

OUT
BAT2 DC BAT1 BAT

G
Vcc
Bl

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12

B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12

A-10
RBl Bl

B-11

A-11
AC type only

C-5
C-4
C-3
C-2
C-1

B-9
B-8
B-7
B-6
B-5
B-4
B-3
B-2
B-1

A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
ON LO
2P 3P 5P Bl 33P Gr 33P Bl 3P 3P STARTER
ON 24P Bl
OFF (N) W
4P Gr Bl MOTOR

O M

AC type only
R

G
R
Bl/Bu

Bu/Bl

Lb/W
Bu/R

Br/W
Br/W
Br/W
Br/W

Y/Bu

Bu/Y

Lg/R
Lg/R
Lg/R
Lg/R

Gr/R

Br/W
Br/W

Br/W

W/G
Br/R

O/W
G/Bl

G/Bl
O/Bl

W/R
Br/Y
V/W
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

Y/W

G/W
G/W

G/O
Bl/G
Bl/G

Bl/R
G/Y
G/Y
G/Y
G/Y
G/Y

G/Y

G/Y

Y/R
Y/R
Y/R
Y/R

Y/R

Y/R

Y/G
OFF

Bu
Bu
Bu
Bu

Gr
Gr
Lg
Gr
Gr
Gr

Bu

G
R

R
R
R
R
R
Y
Y
Y
G

Y
Y
G
HI

N L

Lg/R
Y/R
W/Bl
O/W
Br/R
2P ENGINE BATTERY

G
Bl 12V 16AH ENGINE
GROUND 2 GROUND 1

O RA

G
R
2P
REAR BRAKE REAR BRAKE G
ENGINE STOP STARTER SWITCH FRONT BRAKE
SWITCH SWITCH SWITCH SWITCH

Y/R
G
S B
(LEVER) (PEDAL)

BAT4 IG IG ST 12V STOP 12V STOP 12V STOP ALTERNATOR

LAMP LAMP LAMP

OFF FREE
U A PUSH PUSH FREE

RUN PUSH

O -C FREE FREE PULL

20A FAN

N .L.
R/Bl
R/W
R/Bl 10A MAIN 2
BAT1
R R R/Y
BAT Bl Bl Bl 20A IGN
IGNITION SWITCH Bl/R

IÓ.R
BAT2
R/Bl R/Bl P 10A LIGHT
DC P P Bl/Br
4P R 30A MAIN1
R/Bl
P 20A ACC
W/Bl

NEUTRAL INDICATOR
C S Bl/Br
Lg/R
Bl/R
Lg/R
R/Y

U S
R DIODE
REVERSE INDICATOR Bl/Br Bl/R
Gr Gr

IB R
FUSE BOX

ECT INDICATOR Bl/Br Bl/R

Bu/R Bu/R

TR TO
MIL INDICATOR Bl/Br Bl/R
Br/W Br/W

ISMO
FUEL INDICATOR Bl/Br Bl/R
Bu G/Y
10P
HANDLEBAR SWITCH Gr

DL
IG Bl/W G/Y
STARTER/LIGHTING/ ST Bu G BRAKE/TAILLIGHT
DIMMER/ BAT3 Bl/Br Bl/W Bl/W Br
BAT4 Bl/R Bu Bu
ENGINE STOP TL Br G/Y G/Y 3P
SWITCH HI Bu/Bl Y/R Y/R Bl

U A
LO W Bl/Br Bl/Br

REAR BRAKE SWITCH

S R G/Y

O AB
(LEVER) Bl/Br
Bl/R Bl/R
Y/R
FRONT BRAKE SWITCH Bl/Br
Br Br
G G

ID C
Bu/Bl Bu/Bl 8P
W W G
G G
3P

IB 24
Bu/Bl
W
G

HEADLIGHT

H 0
(12V 35/35W X 2)

O -2 ENGINE
GROUND
FRAME
GROUND

R 07
P -

Lb/W

Lg/R
W/G
W/R
Bu
Gr
Y
28
Br/W

Br/W
Br/W
Lg/R

Bl/W
Gr/R
Bl/R
Bl/R
R/Bl

Bl/R
Bl/R
V/W

Y/R

Y/R

Bu/Bl
Bl/Bu

Br/W
Bl/Br

Y/Bu
Bu
Bu
Bu

G/W
G/W
G/W

G/W
G/Bl

Br/Y
R/W
Bl/R

Y/W
Br

G/O

Y/G
G/Y

Y/R
G

Bu/Y
R

G/Bl
Bl/R

Bl/R
G/Y
Lg
Gr
Br
G

O/Bl
Bl/R
8P
Gr

AC type only
4P 5P
2P 2P Bl 2P 2P
G/W
G/W
G/W
G/W
G/W
Gr
G/W
2P 4P 4P 2P
G
G
G
G
G
G
G
G

2P Bl Bl Bl

Lb/W
Bl

Lg/R
W/G
W/R
Bl Bl Bl Gr

G
G
G
G
G
G
G
G

G
G
FUEL LEVEL SENSOR

Bu
Gr
Y
MAP SENSOR
IGNITION

Bu/Y
INJ
G/Y

TP SENSOR
FUEL PUMP
Bl BLACK Br BROWN

G
Bu
Gr
W
W
Bl

Bl

G
COIL
Bu BLUE G GREEN
5 43
IACV Gr GRAY Lb LIGHT BLUE

SNSR GND (-)

HEATER (+)
HEATER (-)
SNSR SIG (+)
IN-GEAR MAIN ECT 2
START POWER STARTER FUEL SENSOR R N1 Lg LIGHT GREEN O ORANGE
INHIBITOR PUMP WELDING WELDING WELDING WELDING
DIODE RELAY JOINT 4 JOINT 2 JOINT 3 SENSOR UNIT JOINT 6 P PINK R RED
(35 A) RELAY RELAY FAN GEAR POSITION CKP GND1 GND 3
REAR BRAKE SWITCH
SWITCH MOTOR SENSOR GND 2 V VIOLET W WHITE
STARTER RELAY O2 FUEL PUMP IAT ENGINE EVAP PURGE
SWITCH DIODE (PEDAL) SENSOR UNIT SENSOR GROUND Y YELLOW
FUEL INJECTOR CONTROL SOLENOID FRAME GROUND
VALVE TWO COLORED WIRE (EXAMPLE: YELLOW/RED)

26-18
 dummyhead

D L .
WIRING DIAGRAMS A .
'20 – '21 FM models IZS.R
R
O S ACCESSORY SOCKET
(OPTION) Not EPS type
Not EPS type

R
EPS type EPS type

T
EPS type EPS type ECM
EPS UNIT DLC STARTER RELAY

STOP SIG SW
REGULATOR/

U TO
SWITCH

M-TXDRXD
EPS EPS type JUNCTION 1 EPS type RECTIFIER
EPS ECU

SEN VB1
4WD SW
STOP

INH RLY
TORQUE MOTOR

IACV 2B
IACV 1A

IACV 1B
RR VSP
AC type only Not EPS type

IACV2A

TACHO
OR SW
BANK

K-LINE
WELDING CONDENSER

O2HT
MAIN
SIGNAL

GP R

GP N
SENSOR

IGN1
NEP
VSP
PG
+B
M-
M+

4WD INDO
VS2
T/S GND
VS1
IG1
SCS
K-LINE

EPS IND
4WD INDI

GP 2
GP 3

GP 1

GP 5

GP 4
W/Bl

PRC

VCC
PCS

SCS

PCP
PG3

PG1

PG2
FAN

FLR
A O
ST ANGLE Bl Bl

TW
INJ

SG
G

PB

TH
LG

BA

O2
JOINT 5 U.S.A.: OPTION

TA
WELDING K-LINE SCS ST OR STOP VSP DIODE WELDING SENSOR

T/S GND
SW Except U.S.A.: Standard

B-33
B-32
B-31
B-30
B-29
B-28
B-27
B-26
B-25
B-24
B-23
B-22
B-21
B-20
B-19
B-18
B-17
B-16
B-15
B-14
B-13
B-12

B-10

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19