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    VTR1000 SP-1 Owner's manual & Parts List

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    VTR1000 SP-1 Owner's manual & Parts List

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    71 views267 pages

    HRC Manual

    Uploaded by

    dcapito4017
    VTR1000 SP-1 Owner's manual & Parts List

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    HONDA RACING OWNER’S MANUAL PARTS LIST 2000-¥TR1000 SP-1 & Fogording to fit ports ated inte parts we san @ for those purchasing VTR1000SP-1 kit parts Important sat ans prohibit operation of is vile oxcept nan orgie acing or compettiveaven pon a lsed course whic is enduro under the 2 fs reognoea sanctioning body or pom “This anal should bs considered 8 permanent prt of he motteal nd should resin wth the motocyle whe reso Safety Messages 1 safety and the sly of eter is vory important. We have provided ‘orn yess man oon he Re VI SP ‘Sot messages pacadea by acne set rbd ‘ord BANGER, WARDGING, CAUTION, Ps PS ach message ti you what th hazards what cannappen and what you You WL be ALLED oe SERIOUSLY HURT You CAN be KILLED or SEROUSLY HURT You CAN be HURT if you don't foow Damage Prevention Messages ‘You wi alae ss otharimportant messapes hat aroprecaded by te word NOTICE | ‘our HRC VIRION SP. or other propety can HRC VTR1000 SP-1 nual ‘Owner's Mat Contents 1. Operating Hstvtton estore [sie Operation Coole Spectators Stree bat ovcaton & Sal Pointe Cable Somes: Routing Wiring Dagar 2. Service And Maintenance eve recon ‘Warming repecon Spang ‘ve Clearance Eng oh Dine chain Bina ca oer Bake System ten Storie Fla Essauet pantie Fear Suspension eae 4 Lenton Systm 2 | Sen nematon 2 | Digranentressire Rett Vale 5 i Tae 5 Fue Systm aoe eterna Fut Lneirapecon a2 | lel Tanuel Pump 32 | Bist Pump tay 33 | Banning Sorsor 33) | BARoMAP Senoor To | at senoe Fo | Gr Pate conerator Fi | | eeteener Si | TeSenor ES | Lew tEngne conor meaue) Bi | vents 6. Coating Systm Serve Itormaion ‘ouseancatng. Syme Mastation boing System napacton fasion Water Fumo Engine Removalnstaiation Engine Hanger Tighaning Sequence Set | a opnderHaseivatve on ae ae ‘rovbieansoung Eomenat emavat vine ead Remova Gvlinde Hea Ouassemby ‘ate Seat inspecting (GVlinde Head Aecombly ying: Heed ntatton meet reatlton eam eee an 9. Cateh/Georshit Linkage Semis ttormation ‘Foubienooing ton eter ying Gltch Save cer teh Back Torus Limiter ‘Geant kage Primary rive Gear 10, Aernatr/Starter Catch ‘Sense Inormaton {rouiseneatng ‘Ararat Stator ‘Torque LimierSarter ete Gest ‘1 crankcase Transmission Senses Information ‘eubiesheging Grantee Separation Crankesse Combineton 12 Crantaatyiston/ylinder Serie lfornation Sebesnactng Cranes Ree SSfSrr Main Jouns Bearing ranean Searing Pataayinger 15. Front wheat suspenson/Statng Serce information ‘Roumieanconng Fore Sterng Stem “4. Roar Whoal/Sispenson Sere Information ‘Fousesnoatng tapers Linkage Snoce Absorber Singam 15. Bate System Senie Information ‘rovoieanonng rao Pad Repacament Fron Sake Cape ear sre Cale From Master Cynder ouraser cyinger ‘Sens information Troubsshootng Coolant Temperature MeterSencor Stenorzngina Stop Swen “1. Machine Setting Serie lformation Pater Sot 168 363 ie 1 ptins! Transmission Gear Seroe mation Engine Pevormance Kt Frame Pecermance Kt Erankense homing Fame Meshing Shmgarm Mostyng im To The New Owner Br seocng SHARC roadauer VTANEOD SP ws your os mathine, you nave sce yourel in 9 Sin (uanadfamivot owners sna ders ‘The Vis «nah patormance racing machine ut Wotied i caagetson use oy sgmranced nes “his now racers caigned tobe a competsive as posse Bat meoreyle acing t= ahlaly Uemanding sperma regis mere han ja fing ‘rcbalcondon and be ell ade atthe est Botetin resus, wove agent on your pivsea! Ennstonng and practice Naquent “I purpoen of thie Manali o ely ensure tat {You Bbtnn the grones posal ststacton from Journow VIR ronaraser Importance Of Proper Preparation Proper precompatiionprepartion a rele sr obi asntal order shy ad the clei of Tnemotoreae. ny errr oversight made oy he ee fotag platen or snrcing onto Wien dps damapeto smack. rej oie, Parts Availability (der for the parts tnd oe concentrated cing ‘he rearon.soyou need fo pan your pare orders fail Ye prevent aes In srt pace sven ose page 33, How To Use This Manual Tne purpote ofthis Owners Manual is 10 help neue that you belo egrets posse eat ‘Seon tom your aw Whose seston, Sou ules in compton {yu lant 60 ay sen on your VT, section 3 Cereb stancard mantenonee sod sections ¢ Fosow the Msintananoe Schau recommendation (page's taonsore at your TR fe trays nponk Sperting conan, 1. Operating Instructions Fuel Coolant Basic Operation Controls 12 13 15 1-1 Operating Instructions 1 RADIATOR CAP (oy AiR BLEED BOLT Coolant 1-2 pac | Basic Operation ‘enor motor by pushing Operating Instructions Operating Instructions (oy TACHOMETER Warming-up The Engine radure Saganciana Machine TNonce Mest roan procedure halo eeu | te opetetie os osnng ese ca NOTICE Tribe fo ingerant snd sepa components | Sones fora ne ne anging more than necessary ot | Seonarsndsonteia te elem peoparbrese | engnestiewe.”” ns we “unmmen and inp the machine sation: | When ding anew machin, operate he machine 35 tho 1200 min’ pre Vy the anpne ra toe asemum of 6000 min’ | Next 20 outa Mo abwt® mint laut wat | "Ergin van of 860 min om) 1-4 Operating Instructions (2) UPPER LEVEL LINE . ae v INCREASE Controls ten Operating Instructions OF at (SV ADWUSTER TA Operating Instructions ‘Toa gore pea can itd canio te To edjst the gearahit psa! hight: ‘Shining pats 1-0P anas-00WN score moan mani ‘Standard setting: th noth bach rom mama nonce 17 2. Service Data Specifications Service Data Torque Values Tools Lubrication & Seal Points Cable & Harness Routing Wiring Diagram 22 23 2-10 20 214 2.22 Service Data Spectcations in echoes Si = rca ae en wings tata = ase nae | Hed seed ae pseu cele nen oe ‘Wa atrpae wt book ren Soy weian ress Tramenstsion Bepeed conatant mesh em sapesen neon wei ok aa | vzaven toraeea mea | acm Pedal nme ‘ignition systern Computer-contolies digital transtoried co Sena Samos mee te vse eng cor ‘ioe pe opto Dapaceers Ege ay wont roc 12m ‘7h e250 Stator wpe nae ae 22 ‘Service Data “bein St | ‘Speci eine i ot pump ‘Tp chatance ‘Sorra eosgten 00min mio) Tot to Seen 1. Sbmm'ij 19-99 nH stlae 2th (egten 5 pw ate ‘oan Satan 2-3 Service Data Chae outer ude 1D. ‘apr inabaraaoe 40) | 12616 178 (010-045 0040002) = = eel ; SS sas = ance AN | 022 £0.02 10.000 + 0.00081 _ ‘Starter driven gear Dove 0.0. | 87.749 - 67.760 (2.2736~ 2.2743), — cnmnatee” |iia-carn'ice | | PERI. [one amaencaoes | — Spamewion | — | | gas [Sotieateos) = cetera ccetee =a ee oe eats oe = Me ‘om aoss ecooe-aoozs) | — eee annoy = lle ‘cimeneen | = ap zi owt ie = 24 Service Data t com -aoesioou-cone | — ‘Front uspancon cyt ‘coms_-nooopane soon Nivogengos pure | SERPs tem’) = commana tn, | amon on | Conenon euro vom ahs _ 25 Service Data { = Sen oy co Spon rants wana | | Fore Sate actress | 64-88 021~0221 so1zm inte A Sate anc out = ae a00e Chala ences eter com ‘eer /Oharig Stem avert sone Oa mas = tiwychamea | .0-ta2va0cen) — (reedenogng) | Sxow 123 aces = Chapa calresiance | o2-o5 a0 = onion Sytem ‘ert Spetetoue ton | Dee Hcun = 2-6 ‘Service Data Torque Values standard Engine i | ne wo GS | atta | wenden | Mame Smt ade si0s.35) Cricrebonivanertin | «| v0 | _cria.an | nas mm dt wna. Comareterrsatigay | «| 30 | Soesone | awa rum sone toe.n mvceusrecangsia | | rue | tenaa | nwa ‘mm sce anc taeg bat Sm) sion Oren op i] e | soem | news Sm tenet dt tna orowicnecowratnpeon| 1 | 8 | musi | nwa Notes: 1, Aoply sn engna oo te trends and senting sca. Gaincermesenigver | 2) ou | marie | ans 4 ley asa grin Seton Soe en page Sormemvoiaerarontar |e) 7 | mama | ma 4 onl stocng sport ne tans Crintertestowerae | @ | 8 | tenon 1 te nuang cing wie ter Sohtening | 8 | tensa | mms Bonin gre oe teste i] | snes | rows & ot Conmctomrostaninntonn |< | 0 | seepeoetza | howe Bol cont terse tngtoo] | 8 | Sempge ea | noe & Su camorrvonnesreat | 2 | 8 | aeiatan 18, betthand esas Eimgarianmaninatot | a | | wenaa 1 Roplymohvosnum dstie groase tothe theds Stpmpmomigeor | a] 8 | nae 12: end oon ot esas Sigwesarenrat | t] ok | amatm | nm 12 ovtentme pok ooh pecliedtrque tas, then eighten iio | Spam dren-eroteoon | 1 | 8 | tnt) | Rae especies trae Otter sons i] @ | dana | rows 1, Hsing no plug. Nohten tothe specie oaue ten eigen | in tar | 2 | Soxen ino ti petiesorve Aetenstmoninasiceavor| «| § | S530 Service Data Engine cont ame ES or] etm | tent w | Pans Leal v1] etm | seni | Pemts rmetimmse | og | Weosm [MT | | Mtoamtewstsome | 2] 6 | nan | sess Snseunoonanct | | 8 | eam | awa fndeowtoumpmeat | 2] 8 | 2ezie [nowt Ian poe nectar nacorseerinneat | 2 [6 | toraml [Nowst Prewetnewmrgre pt Rawie | | opens | ie | “emer | now Sucnocrmmrana | 1] 6 | woo! Exomturenmerth |e] 8 | gaat | Nott ourpustezmcownse | | re | eoam | nwa | | rowsnat ST | gee tncn Erol 2) M | aoa Foret a | mess | root ae Frontal erage @ | mea |naene Poumon spec @ | sassy | au eer Fourteen tf 8 | asa en meneeyintesavon | 1] ow | teem Trwmourargoce = | 1 | 0 | aeasas | Noes ‘poe ete t] | Senon 28 ‘Service Data Lal (| aha | tem agama | POS ff amarsan | notes | auies.ay | nana «| spew ‘See page 7.2 for deta of me aninenenger tightening procedure. 29 Service Data Tools Soecit rwivcesarestet Common Bessie Teotnumier | Aopleaiy bac Toot mane Teo Seep ‘ere sion | Maser oindr aap ing |_| Fan press ao ior ase Figur chek ering omovor sa re cease | Sorermeteroewing |_| Fea rtd ‘r7s-ongon | Fre bot oningromeverheos1Omm | tvame-ceann | Siar motorseing | | Fy pur trasanonos | Fyne! Bot ‘ve pu omcner ta-svoed | ave goae ‘asin eover whe trrevanoiot_| Cntr baring faceranmie 8 tein | Song sem mee racer 370 mm cree aoezo0 Dosen bse ate-tonen | Scsig sem se Drache «247 recone Diner atacent ne teen ton? | Swingarm pot beng |_| Achmed 5288. rr aot00 wal aver sachment ‘rab. | Wate pum fen dver treeanoree | Steno being Dine ata 8 ‘atraeTou> | Seen stom oe Pa tor ree ana%c0 | Bons ination rekon, 2m riunateaone | Expire nae Pit 2m ‘opeecotoce | Berg inttnion Toinwinterinserion eat | Srymsaacrot0 | Toa tnt ‘eon ses trerananee | she rng Ecatesramess ‘romans | rome Seater 0 en ro. aneso0 Nranetoingconpese tater | Oreee-008 | mateandeanautane | | soseune 25mm iexas) | oreD-9rowo var cuter men 6) | erect | Fimaroreutors7smmtexsoy | e720. 2-10 ‘Service Data Lubrication & Seal Points asin wa Thnjomatot 0x28 | avo | att ioe sees sate [ame sen mag sangeten tte tone ene Steere oe Conmanyroveetteeissns | Enda ating bot nad Seer Cpu ect ening race | ta ig pe Satmercanii teaceana | ne cy | aoa nn Freleng | Teen | oeonig rt jee fue ca ce quar sh fk groove Kalen hate ter oatngatng Ginioteseweaing | mntssst —[tonoeacraie| [anton 2-11 rae Tacos <= =r = ———— a ae a =o fas ee erences Sea somreete | Sra | man || Ezra cae on | [Se corms ce a ea Sececcrn a fearon ae canescens ee ‘Singer acer satng Seiejanninanen Ea "an oe Sain oman Samoan pa Service Data Cable & Harness Routing o . 1) AEC (Gryheannectoe {2 orem te 2 acy (2 Tachometer F (ray eonnectoe (8) Bane angle aeesor 3 (Grown! connector (6) Catch nose [7 Tharma sono’ 2° (Grey connoctor 2-14 ‘Service Data 2-15 Service Data Service Data 2-17 Service Data Service Date Service Data 2-20 Service Data Service Data Wiring Diagram 2-22 3. Service And Maintenance Maintenance Schedule 32 Brake Fluid 3-13 Pre-ride Inspection 32 Brake Pad Wear 344 Warming-up Inspection 3-3 Brake System 3-14 ide Inspection 33 Clutch System/Clutch Fluid 3-15 After ride Inspection 33° Exhaust Pipe/Muffler 315 Replacement Parts 33 Front Suspension 3-15, Fuel Line 34 Fork 3.46 Spark Plug 3-4 Rear Suspension 3.46 Valve Clearance 3-5 Nuts, Bolts, Fasteners 347 Engine Oil/Oil Filter 3-7 Wheels And Tires 349 Cooling System 3-9 Handlebar And Steering Head Drive Chain 3-10 Bearings 2) Drive Chain Roller 3-12 Cleaning 321 Drive/Driven Sprocket 312 Storage a2 3-1 Service And Maintenance ‘Maintenance Schedule Perform previ nection a each schedules maintenance aviod PrmeomeraedttanseguseCubroate ar epiosmertf necesary CCisan, Festa, L: Luba eee amar “Tate Opeaton Spark Fog [esas on Engi 1 FR [nie ons exaust Vales — Pre-ride Inspection Moments before each ris to. walk srOund your {TPR SPs ana shac conciton PONS Impropery ssintining thie VIRIO00 SP-1 or {ang to cast ‘prim before ing can {fang ens yo cn seu Away perform a rede and Prorace spec {idntove every Hoe and caret sy robles ‘aie Songs Haier Sabon DIO every 5:00 18.100 ‘Cranin Bear [eyinder fag yar Sian Radiator Coen Gaaing Syste t Dive Csi SaaS Re aan 31a eh Fad [cies avery fate clue aus ane pe opis erring nin Suension t,o, Fatima Geka eos om bas oe FE ne ‘Coolant for proper love "SESS EE crt an iene ormarenc See tnd ane eee Re te a 1 Brive chan foreorec Sick and sdequtabres- Eueeremeco, 3-2 ‘Warming-up Inspection When warming-p the engne, check forthe lion "Bo not pov tne engine mere than necessary oF «Shs ort of and wate aks gin oro fw ites nl i Uperatng temperature an the tng reaponde othe Beate mth Ride Inspection Alter Ride Inspection Ata ing the VTA choc or he eiowing SGoar eontion of spre pag Sie fearon 1 Lease or missing ts an nuts Replacement Parts Parts Requitng Period Replacement Service And Maintenance Replscement interval Cave ea xnav valve Valve sping Piston pin TTansmission gar ton ot toh ies Cluch alte Every 5.00 ey 1,100 mi vary 3.00 9,100 i var 5.00 So 3.100 mi Every 1500 kr 909 mi Every 8.00 ke [3,100 mi) vary 5.00 tm [3,100 Every 5.000 km [3,100 Every 5.000 tm [3.100 Every 8000 tm [3.100 Every 4000 4m 250 mi Every race Darage or wear Drage, wear or bering Derage, wear o burning Darage, wear or burning Darage, wear or ming ‘ako ooa4e Wes Darago, wear or burg Looe beng War orturnng Baring Forum very 4.00 2.50 mi) Every 2.000 en 200 mb RA 35 Service And Maintenance (nFEELER GAUGE i ig vaeurren Measure he re yn valve carance by inset Maanar the rea ener valve clearance by ine Metre even wave errs 2 ma 0.08 = 0.008 in Ex: 0382 ogzimm om 20.008 m IN 022 = 002 wm 10.009 = 00089) 6038 sae mn ons £60 nt 3-6 Service And Maintenance Engine O1/Oit Filter Tongs Ultra GP Stroke OW (106-40) ‘Sromstor based recng alle are not recommended. ter vost shown nthe hr avery (2h ESeieh tea a hang te ej i nih ha nine ste codes ond rpid nn. ‘thot he sealing washer i 9 good condition and Torque: 29 Rem (20 tg, 22 0) Sow the neammend engine i soy ough ‘Shh het dnecembly 3-7 PBfaun ee Install the removes pare in the reverse order of Fite rankease with th recommenced i e8e Rernove ane card the i iter sing te spac 3-8 Service And Maintenance 1 UPPER RADIATOR [O)INSPECTION HOLE ‘QuEfriow ruse 2} Lowen RADIATOR aren tan Cooling System 2 3-9 Service And Maintenance 10) COOLANT TEMPERATURE METER (CO RADIATOR COVE ()ORWE CHAN SLACK Coolant Temperature Meter einen ner change rom chee te | Drive Chain ol ean aperars 8 CT A ‘eteptin | eenror ne horas. eer sere tare than replacment lar a ron. and proper aus et eee ate Bos ne ve Shi 3 winder shine rarerson ina neal tn ‘ney Seteeentsprciets Dv chain slack 26-26 mm (2.01.80) Rotate te woe and cack tance in 3-10 Service And Maintenance 3-11 Service And Maintenance (ome GaNRORER Cd an (ON man i) onve SeROCKET a Drive Chain Roller ‘ole and cols into te | Drive/Driven Sprockets Inepection rive Sororket Rep {cate te sive chain fay pose 310, Remove te bok ut, die Service And Maintenance (VBOCTSNUT (2}DRVEN SPROCKET Driven Sprocket Replcemont Torque 34 Rh 3.5 gem, 251864) Brake Fluid Front rake Mater Cylinder ‘Spectio brake it: APEOO 3-13 Service And Maintenance (0) BRAKE HOSE Brake Pad Wear Brake System Inepac the rate pds visually Refer to page 1-4 for Brake Lover Aust Flfr to fobs 08 ororns peas hegre jose Weiter pod is wear to the inietor, both pods must eveniaed Inspetion Da not avin the rake str in igh ui, Specie ea Mi: APGODonty Menthe cnr le oat wi a Servic nit: 0.5 (0.08) eae &8 mm (0.8 Refer to pages 1-S nd 13 for rmoval 3-14 Service And Maintenance ‘oy cuUToH Hose NIMUFFLERS”() EXHAUST PPE Clutch System/Cluteh Fluid Exhaust Pipe/Muffler Front Suspension i for lowe or sing Bal " ‘red he luton hea aystrn dutrmagon re csan ithe ths nat aengope prope lower 2 Check or dgneof il eskage. Damage otek teat orsponpy. sede ons yom | os of omer ico th exes sp bo] * nk tn stot ops re ou e Serato rack sgn ot elape + when you 6 new rat nyu ER 0 3-15 Service And Maintenance 4 1 COMPRESSION a OUTER Rear Suspension not 3-16 Service And Maintenance Service And Maintenance (9) REAR CALIPER GUNTING BOLTS i wHeeL 2 TRE "| wheels And Tires on {DAVE SPROCKET BOLT 1 CALIPER PAD PN CLP 3-19 Service And Maintenance oy wanoceoan (3) HANDLE LEVER Handlebars And Steering Head Ccreck te conto vee a ngs hs rota ear whos boa on aoe ei sonar pack be 3-20 Ser And Maintenance Cleaning Can your VIR regula to protect he surtoe te ‘parler Shae ner and oop rls serorgent cosh 3 iswashing ind to Od ‘Bacoloring seni High pressure water for at an damage centan Bar ofthe motores Fron oo ‘hes! nubs tne outa Dive chan Bre ae etch master ender sete tee secret See een eres eat ere eee eee Storage Exanded storage, such a for wines toques that [BEFORE storing your VIR nornise, have repairs nay be forgotten by he time your VFR romoves From sorge Preparing The Moree For Storage 1 Sample am a par of your VER, Wash 2, Bran the fl fom he Setar ino #0 apor0¥ed ‘teoine container PN EEE + Stop engine and keap heat, parks, and me | Remove the lower cate howato in cooan. Oran coca ty teint ows ‘treat re dove ein Femeve the spat plug ad pout tbl spoon Ge" 0 emi ofiean ening smote eyendar Wr the spac log grounds crank Bo ena6 Enver test drsbute he 6, Disgonect the batery termina, and remove the battery an tae in coat place, 7. Series tyne posing ic ot stgeton tne Int he eno tei recommenced prescue Fe your icon the manicure cen or 1. Stut ast the muffs outlet. Then fo 9 naienonnteon eeina, OF Rama Fron Storage 1 Upcover anc clan your fing sclera than & months 2. Uncover ins endef the mur and emove the ‘age ters mut oes our ison cole sowiy ita the Chargettetatery and eal 3-21 ‘Memo ubrication System ‘Service Information Troubleshooting Oil Strainer/Pressure Relief Valve 4-2 41 Oil Pump 43 41 Oil Cooler 44 Oil Tank 45 Service Information + Theol pump can be sored with he engine Barlores wth the engine ol Sana, « Bineing ted ing tho uo, te + Hany portion ofthe a pump fe wor Boyan the “pwnd orn tet toptace te of Pum 9 neeamby + Bertha ol pum has bao inst + Soasecian Sor engine and oi ker senves chock Troubleshooting Engine ol ove! 120 low. Ot onsumeion 2 Baers tah ‘orn piston igs 5 Imre ees ton to 1 Wor valve guide o ma Iaggeso galery or metering once 1 incre beng eed ‘i contantnation OiLemulefestion| blown esinr band gasket Em of wat + clogged ot aie 1 Maco ot bens ured il Steainer/Pressure Relief Valve Lubrication System Lubrication System VOM COOLER, Oil Cooler Lubrication System ‘ ‘ H}LODKRG we.) 8017S {9 COVER-TEOIL CATCH TANK HOSE i} OL COOLER Guan decade it Tank ernave ethane body ipa 5-16 45 aa 5. Fuel System (Programmed Fuel Inject Service Information 5-2 Bank Angle Sensor 51 Fuel System Troubleshooting 5-2: BARO/MAP Sensor 52 ‘System Location 53 IAT Sensor 513 PGN-Fl Troubleshooting 5-4 Cam Pulse Generator 513 PGM-Fl Self-diagnosis Malfunction ECT Sensor 53 Indicator Lamp Failure Codes. 55 tp sensor aan Fuel Ling Inspection 5-6 ECM (Engine Control Module) 5-15 enero 5-7 Throttle Body/Air Box 5-16 Fuel Tank/Fuel pump 58 Fuel Pump Relay 5-10 Fuol System (Programmed Fuel Injection) Servi + Wot ina wal erate, Sling low relne ie sored eat cause oe ar expason + Bevel apty orca alte corier ta wn malyadenu + Bnvnot snap the atte vate from fall an to fil "sloae after the tore cable nas” been «Salient ee are wh ap « ‘he inate pore shor the trot boar as beer + Bo'not spy excessive fore tothe te pe on ho rete sy whe moving or ating te tre oe + Botte dang te tots oo may uso + Fovent at and debi or entering etre ore, fslfeed te ane cura tus, clean the {ing compresses se + Ththetttie ry rest ot leg + Boor eke’ ne me pare a nd sows ofthe ote body Coen. ot ‘Ghia he an cute tle wa ae vave + Bolo uth ef parp bags under te «he. programmed fuel injection sytem is Seiad ort ih “Sel gran Sytor {orgs ola te sit Oragnonte Procedures Tomes) the prblan + When onecking the PMA, ebay fellow the ftepe m the voubletoatng fw chr sve VTA Information +The Pon yates rove tn ate ne ‘won thee sary rouble inte syst When ry atmormsity dest b the setisgnons ‘ution runing capa fe eered by sing {tof numrcalvaive af astuston preset h setae in the sated program mep. hm Ioltyi stead our hjctors andor te {lon ed cam ules gonartor the a sate Tone tion stops the engine fom the standeoit of + For PONE! system locaton, se pags 5. 1 Ritauny PEM syste ten fits to pocty ‘onesie or coroded connor. Chack hate {Senenngbtererocenting. : fon port ase the lagton of the, Oops ei ow neon spn esa + Belov canning the ful tube, roan the {eterna connate bane St + Kael ne eng meer van mt «staal ester for PEMA sytor spoction Fuel System Troubleshooting Engin cranks bt won't stort Peete eogged ue te = Blogged fal metor or = Pnchad or clogged uel fed hose = Gagged a beter 1 uly fa ecto 5 No sparc st pli Engine tal ar ost ough ting ouretad tue aaa noes 1 at containatddotaoraeg 1 leak saat 1 Reta fel tan bactnor 1 heausteg starter vee Synchronization 1 Ras gnton system tse seton 18) ‘Bazeiing or misting ring aceertion fet fntion system ne saton 18) Poor performance (veaity and poor fel eon + Pindhad or cogged ue eed hose {Fat fgntion sytem fan ston 16) Fuel System (Programmed Fuel Injection) PGI-FI Troubleshooting the FGM # matantion indleator imp tights Tig the engine op sv RUN. {Tivo mofeton iar lamp si hte ater {wvarcondesonormaly is ostecea bye 2 “pen the engine sop evi OFF 1 Shore erice chock connector using fomoer wie Turn tha angina sop etch to RUN ana note Tew mony tes tha naiuneson nds om Dine eve nes page “Tra anine stop atc OFF ond hoak | related gars foe next ge ‘move he Tmper vie Wom the seron check = “ura he engin stop sich RUN, and heat or Iratancion ndestor goes of fer few 2: et Sane eine |e ihe engine does not ar, heck or gnition puso fend andrea pan generar “The system is normal if the engine starts and {he auneon mestor imp docs px a Bea PGMFI Selfciagnosis Malfunction Indicator lamp Failure Codes + See VTR Service Manual for mafenetion nestor mp Snng function, 12 inks | «Open ay sho crn Nat a 1 hae dv net aad = Simone ehap TAP) oan ay Fly AP sence Foy cer sno | aoe or soo contas on? | Far agisreparas w emorconmatn ‘puang eee gy "Lone ere conta on1AT | v En prin nol Foamy 30 sensor Tens orpor conic hie | «Engin apes Fay whale opd ones ‘atin | «pn osetia 2 | Fat no eae rene | + Open or aon erin Neat gna spr normaly 5-5 Fuel System (Programmed Fuel Injection) i ReGX coven (a NEGaTI (8) SEALING WASHER, 6 re Fuel Line Inspection 2 emave the fa fee nerf belt and tach he fl Pevoure gauge with te fotowing Hones Genvine Benj ot, 12m Fart No. go08-FPe-En2 [cling wher em Pr Bez: oe 0 ( vACUUM TUBS nm bane bot 22 Nm (22 Kab, 16 emove te fl tanktront mounting bls ad ase te ee atiucione nn es te ma Fuel System (Programmed Fuel Injection) i] BANUO BOLTINEWY SEALING WASHERS “ Conner hotel pressure gauge Fuel Pump Flow Inspection Gonnge the batery negative cab ‘Strcto emain ites andres the ul potsure ‘Stondar 292 (0 tle, 57 pi ‘nd reintal nd ighten the orginal uel tbe banio TORQUE: 22 Nem 224g, 1618) 5-7 Fuel System (Programmed Fuel Injection} AI FUEL RETURN TUBE mrecTORS ————~SC*Y CV BREATHER TUBE [NOTICE] ; fun ad —— Cea i srt a 2 oe ores I ms eaaer — Sooimsarsn, a et ow ste an sete. nsnc te | Dasa el pa concer rom he Ged fuel foes hoe andr fal retro ube | Bante he voter tothe each wire termine Tura the engine stop switch RUN, check fe voage iemoommace | Ree 5-8 Fuel System (Programmed Fuel Injection) pur bese mounting screws Ramove he tue pump ener and arg. Fenn ose neasery, move me bate sponge ore to seg wash 5-9 Fuel System (Programmed Fuel Inject a Ms fn) sovrswaashens | ote the ful tank Fuel Pump Relay | Ei ee moni to. en vetoes ota heal tnk ratio othe casa, | Tun tenn ema SUM ur the engine top swith OFF, Diatonmast ete pump oly 4P (lah connects Canna aah ee ron sealing wash “Fora 72 Nom (2.2 gh, 18 ‘Sect the et pomp wie coonectr. 5-10 Fuel System (Programmed Fuel Injection) (11 FUEL PUMP atLav CONNECTOR "NF FUEL PUMP RELAY CoNHECTOR eer Peep ne ses Bank Angle Sensor ‘rina of the ite harness cide connector and | termina eV ofthe wre harass side connactor and | ngpeeton es st iy fr sot creat | Yon angie op sno RUN Seppe tm motryae srae, . $d bank gl neo there no vot in| otagebercen he Sen ng anor 38 (ren) FFthara eo contuty, check for open ect ‘Standard Diclieg wre bree th cee, bank S11 Sen Monat for tl pump ey aar | WES) Green cate vow | ant angle sensor fom the 5-11 Fuel System (Programmed Fuel Injection! Foapinte land Grose Speen ne” BARO/MAP Sensor Cutout voltage inspection Mar BIT fs) —Ae2 ine standoa atmosph we sa level baesore the out Woe few te seated BAROIMAP Sensor Remevainstalaion Remove th nr box sven page 5) Disconneet the BAROIMP censor connector Ferme te cena and BSROIMAP Sensor fom the ttt bay bracket Inetalloon icin eevee order of removal 5-12 IAT Sensor ‘See VIR Service Maru fr IAT sancor ingestion. emovatnatalition i CAM PULSE GENERATOR Cam Pulse Generator emovaestataion foute te ca putea gonertor ice ropa on Fuel System (Programmed Fuel Injection) ECT Sensor Femovatitatotion Insta te ng sting wast ‘TORQUE: 231m (23 hgh, 17 bet Secure the wire nth 5-13 Fusl System (Programmed Fuel Injection) ‘Avot fly cose TP Sensor Inspection Cisconnst me ECM 22° (lac! and 22° (Light gry) ‘Ena th connactor fo 0080 or corrode ter: nacre ECU et Rarnas between MeEECM and “Taming engine sep ch RUN and meseure and Tecore te input veltaga oe fot Roasts fis uelng eign! mutimete Br aze Standart 45" 55V ine measurment i out of epeleaton check he {ote Peden Connton ofthe ECM muit-connoctor tape cel wre homes 2. Outgut-vatage inspection i hae ute ops fomibesogine Hop owt AUN and meseere ond "he cit ooe at he tenes connection: Bea ae2 Measuring contin “a tate fly open Ouaut_votaae Inston wth anole fully ‘ibe eoine son switch RUN and measure and Tecra Mean akage wit the take ay ose connector Beto a22 easing contin: vations tty eoses 4 Calulat elt comparison area meet he esa of hte ote ay opm assured npurvotage XD 824= Vo “Ina sensor normal ihe messuroment oupat otage messed instep? ie within TOV. the ioe ay loa ‘Th srr naa ne rte cose pak Toltage reuted in atop 2 in Rat Ve Using em araing meter Sect het the rete ofthe ‘eotetartuinge aot wmen te totes opened Continaty inspection ‘open and suppor the ont ond of el ak page Disconnect the ECM 22P Light grav connector and fhe T senor BP connec {oak for sonny Sateen the ECM nd TP ean 1 hare ene coninvity, hack the open oso 5-14 Fuel Systom (Programmed Fuel Injection) (2) 220 (gna CONNECTOR ehecne ECM (Engine Control Module} Ground ine Power inputine Done he EM 229 ack and 2 ahr | Check or crinay Beran th CM ext mae | Te acing op pth in UN fonnectors fannectr AiO taminal snd ground: between the | Heesue te vag Power/ground ine inspection | Sod grounds Son etn he AZZ tina "| Pees see te Cont the tet : | ti Fares and EC lee Serve Renna.” | Granite wr, Gren'and SrosnvSh wits, ee ene a se | fhe wins OK, check for the bank angle (to require 5-15 Fuel System (Programmed Fuel Injection) rn 7 4) BOLT Fuel System (Programmed Fuel Injection) . BBIFUEL FEO HOSE NUT Dissssemby Hols he ie stay ith 217 mm open end ween | seat te eyinger nea ints gots with ope o » | | NOTICE Frater pors ‘ater tho toto Seay hes" Geen | « Oo not ony excessive fre to he ue pine romovel + Risa nal the fal pipe nit whi removing the NOTICE | bolts and move the radiator Forward Loosen te nin sid into band errs "yrobronanon fi, Do nat old heft pip onthe ttle Body while removing to nots bo 5-17 Fuel System (Programmed Fuel Injection) SENSOR ta} IAT SENSOR SENSOR (4) TPSENSOR {a} PUELnaecron Fuel System [Programmed Fuel Injection) 5-19 Fuel System (Programmed Fuel Injection} cupee stay (EAL nupeen we "pause ah tho ae box sol rubbers “Torque 22 en 2.2 to 101 Tout (0.1 go 07 Sh Si te nut de sts for oof om ‘throttle body instalation. 5-20 Fuel System (Programmed Fuel Injection) Connect tahoe ct Syndr oad the alias and ful pipe says while {NAIR 80X-T0-01 CATCH TANK HOSE Tongue 1 Ni 0.1 kt, 0:7 ttt Install and gta the ar box mounting ol secure Cnt he ar oxo eaten tank tbe 5-21 Fuel System (Programmed Fuel Injection) (9) 14 (GRAY CONNECTOR. 2 GROMMET Appiy a locking aget tothe ai funnel mounting 5-22 6. Cooling System Service Information Troubleshooting System Illustration 61 Cooling System Inspection 63 61 Radiator 63 62 Water Pump 65 ‘Service Information + HeSenvcing tha system, chock for aks wth 3 Troubleshooting 1 uty ator cap uly radii’ cop 1 Damaged or catarrntoa owas 62 Cooling System 6-3 Cooling System 11) THERMOSENSOR CONNECTOR (GV LOVER RADIATOR MOUNTING BOLTS | UPpen pabiaron MOUNTING soLT (@ Urren nabiavoA Hose (1) WATER JONT HOSEPRE anne the water ont fom the einde Blok. ‘BitaySteriace eater pint sons how one Cooling System [Shia Ove Gean pour Water Pump lnepecton tack isp leforson ofestge ois not sated sere Bish ae asta oops Remove the wate ur ting bt sr er ase 0°) amaue te bots an at rakeate cov move the dowel sins ara Ong Amave he wot mare ed oe 6-5 Cooling System PUMP COVER 2} JOINT HOSE ‘gmaren sony coutango.ames i bOweL PINS Assembly Insta the sight erankeae cova while tring the saa 1 eee cover maine =| een en the oon rst se doa i. shinee 6-6 7. Engine Removal/Installation Service Information Engine Removal/Installation mm 72 ‘Service Information Ing tot fk mt, use 9 stectng bot type | tou nthe specie seuonce. you mtake terove weno 2 Inches long. "The tse mat | toe sgntaning orgs or eaguenen,loocan a Bo'not overghten he ook nt Tae ‘Throttie bogy Ipage 6-16 al fr eave onrecr seinen pulse gener Engine Removal/installation Engine Hanger Tightening Sequence oon ‘Aproy MOLYBDENUM SISULbe Grease rowre APELY MOLYBDENUM DISULADE GREASE swncagie PIVOT spur mouvaoenw bisuLrbe GREASE Pont: sry mowedenum, DisuLsibe GREASE ‘apeuy MoLvepeNuM ‘ApeLy MOLYBDENUM SISULADE GREASE Sisuusice a Engine Removal/Installation NOTICE ‘nen ing the look ut wrench for the aditing bat lek nu ase @ Jefecing bee type torque wench 20 Foca lang. Te lok rik eh {osaue arorch reading wi be lee ton te ore ily ode sk tthe snctcton the'tecding on the tog wrench. "Do tat over" Tighten meveek at Apply molybdenum dslise gresse to the at ‘movming tat hreass and rexing sraoef the ms snd washer Inston vie mo ean harge Bos 8 foo ‘neta th rght and ie saingam iat soja ing Bole ao thatthe toot the adhaing Bolts ‘Se nel protase mars 2 Insta al te engine manger ajuting Wot to ‘he fide mnuntng post or te nae, 2, Instn t engine in fh fees thon neal al {he engine hanger bake 4, Sate" eningarm Between the frame anc {nai ntal to swingarm pve Bk rom the 5: Maman ho point asusting bot othe spec ted toraue, then tghtan the pene D adjusting Tongue: 10 Hem (1.0 gh, 7 ete ‘ijing bos, “Tighten fhe poet Causing Bot ack nto the ratfiod torque san tighten the point Dsus ‘tg bt ook nu tothe specie ort, oot Toek out wench orvma-waaot00 ‘Kcusk anv (0 bot, 42 By Ea teaaing 8 Nh tt Enon, 99 a) ater te pit Changer a to spec Tongue: $9 Nr (6.0 gh, 2 6) ‘igen the pont O hanger nut to te seciog “Tongue: 46 Nam (45 kgf, 35 ft) tighten the sont ¢adusing bt ock nut tg the apeded fraue han tighten the pint B dating bok ok toe Seaton toga “oot Tongue: tusk 5 nm 0 Kom, 43 Sea Yeading: 8 Nn. Ram, 38 Stntne pit Changer itt sei “Torque: $9 em 60 kati. 3 Wt) tighten the pot © nange ut othe spied “Tongue: Na 45 gto 35 ‘Titten thesia sda ofthe point 8 hanger Bot tothe sped tore, ‘onque: 89 Nam 6.0 kgf 2 6) Handtighen then sde ofthe point assting tent Tighten the lt si fo point 8 aeusting bolt Top nut to the pected ore. ekisk 9 ten 6.0 kot. 4 et Seale vening: 63 Nom at kom, 99 at 16 Tonten elt ie of he pnt Thespecied orev. Torque 58 Nim [0 kg, 421 an antl i oth nk adoing onthe it sd othe poi cui bot Toe mut wrench o7vitA.tog0%00 Toraue ‘Retin: Nam G0 kab, 4 ‘Seale ruaig: 8 fn 58 na ‘ohn he ight side of the pot K hanger ut eine sesie trgue Torque 58 Nem [60 kg, 431 Tghtn th lah sae of the swingarm ple ‘Shsting bot tate spectestraues Tigntan the sight sae of the swingarm piv ‘a aang te sdusng bok US wroch SEB my tun: 69 Ne 2.0 ktm, It ‘Seale racing: 6 Rom 6.3 eon, 4 Tight the lh side of the swingarm phot “Torque: 15 Nem 15 gh, HHA) Engine Removal/Installation Sot at ck ao Sead tae. Rost 69m (0 kan, St mt Seale reading 62 Rom (Seam, 48 A Mitte pt nt tthe ape org Ta 8. Cylinder Head/Valves Service Information 81 Valve Seat Inspection/Refacing 8-5 Troubleshooting 81 Cylinder Head Assembly 87 Camshaft Removal 82 Cylinder Head Installation a8 Cylinder Head Removal 84 Camshaft Installation a8 Cylinder Head Disassembly 8-4 © Cam Gear Trait ant Information sm saremtling. mare and rete es : cosgmblod pats with leaning so ‘eet ana ty tem by bowing ter oh ‘ages mae cy hao Glan he ol as + Beare nt to damage tha mating sutoee inn remaing the oder Redo Troubleshooting Engin top-end probleme uly afct onane fe fo the topeand seth 9 sounding rod Seno et valve alusiment ing or demaced ender head gasket 120 igh vein akong ‘Sticking valve of roken valve spring Worn dareagad cam pe 8-1 Cylinder Head/Valves (ay BouTsavounTing RUBBER i} CYLINDER HEAD COVER Camshaft Removal erovethe ning hte op andl erakshat hole cap Ipage $3 Remove the evinger head mousing bots, mount: Inorutbore sn cover ‘Remove te inde hea packing fro te cover, o RK (Fr Mame Rear evtinder amshat te eankenat counteokse and alan ‘oar an te ye! wah the nox are Front elder cmshat Rotate_the ernkana,countrlocw/se and lian 1 ron the fas wth etd Path thee craneona coves roy NDexUNES “end ines on the cares must bo fs with the crite end ‘uracs and facing’ autwerd Se Shown Ifa ges ies are aig inward, rotate he crane {hak courtwlokones oe tum G60) nd fea the indes nee 8-2 Cylinder Head/Valves o. W)BOLT (2\CANM PULSE GENERATOR 101 BOUTS. (2) CAMSHAFT HOLDER A (9 VALVE U=TERS el CAMSHAPT HOLDER 8 Fer the rar olndercamenat removal, remove the | Remove te camshaft holder Halts, carshat holder} Ramove the valve irs and shims bat and cam pulse goreatr prevent damaging Bo not tory remove the dowel ine from the | + Be caret oto cage the value ie orimagne| 8-3 Cylinder Head/Valves QZ cn yauve som Cylinder Head Disassembly Remove the sparkplug tom the ein: head fs pee 6:2) ring smprssor and ache frome front and anime veoge Mt Ovi | Tike erina compressor 57-s010000 [Nome Fmove te gost ne doe! i. ‘Sines ing ere eto soma te ashe hog the spike and ve rat fr BA Cylinder Head/Valves Valve Seat Inspection/Refacing | 8-5 Cylinder Head/Valves R68 Cylinder Head/Valves (SNE Shit SE 10 STENSEAL _ {@)INNEROUTER sea Cylinder Head Assembly 8-7 Cylinder Head/Valves VALVE UFTERS Cylinder Head Installation Camshaft Installation the caoon deposte cotine | Aepiy mobdenum cau ato the outer surace rata te dowel pine shins env iter int the va ter BB Ar aa (BINDER a Rotte the crankteltcourteroctuice and align thers on te ea wh non Cheat tat te rer eylindor at TOC using 2 dl ‘The camshat has he folowing idetfeation mare FN Front ever inthe cmshat REX: Frontend exaust comet [BRIN Ror onder ike eae [REX: Ror onder exhaust sarah ‘spl molyadenum dui ol tothe camshaft [uml oe apinasrnend ae comenae Holset, (orivoex uns Set the rear evlnder ick ard exeustcamhatie wth the evande head surace ara cing outward 8-9 Cylinder Hoad/Valves l 6 LT r (GTIDENTICATION MARKS (INTAKE CAMSHAFT. I) CHAUST CAMSHAFT | 1) “FT” MARK (3 Camisuart Hoven & (mex aan (2) CAMEHAFT HOLDER 8 () BOLTS “camshaft holder A hes the following idenetion | instal the carat holder Bie ts proper lcaton. | Rotate the crankset curerlchyiea 1-4 tne ‘rar IPE ‘Sane holeer Ain thew rope lors: | 0? and align te FT markon the wet with {AGeoih ke"sN lave mah aenpto te intake | Ye ax mast onthe lterontzasa covet Front eyinder intake camshat holder | sie. EE, Front vinden arate nati | Appi ll tothe sands an sting crtaee of he | Chek tat the Fon elder st TOC using 9 da {Ri Ror oping enka cama hele ima olser bot aun. RE; Rae cfnder oheustcamahaf holder) insta bots and ghen them ne rscross pat fonin ora eps Inetall she font ender amahats and eamsnat Molin the sh rocco flr theo i Ran Cylinder Head/Valves 2 < Install he eyinée had packing into he eyindr oa over groove ‘Apply Thee ond S21%C of KEASC to the vine TAPP SETIC OR KERR (a) crLnbeR Heao cover (2) BOLTSMOUNTING RUSBER ‘natal the ore head cover {taal the mounting rubbers wth thelr “UP mark naa ee ter need mounting bot. {ight the leh side cylin Need coves bot Fst, ‘han eather bot tothe specie orave Tore 10 (1.0 hg, 7s) Cam Geer Train Femove he clint mead (pape 8 eave fe am peta sting ot nd set 8-11 Cylinder Head/Valves Service Information Troubleshooting Clutch Master cylinder Clutch Slave Cylinder 94 Clutch 93 9-1 Back Torque Limiter 913, 9-2 Gearshift Linkage a7 93 Primary Drive Gear 97 Service Information rtaled ne me = SBio or BUT brake fuid is vend forthe fyateue clutch ana reforre to ae cc ia they are noe ompatie + Spa uch rake) fui wil avery demage ‘te las pane and pinged seas. Sr eo arf to some ber pars, 9 arf wor + Never alow consents (it, wate, 6) t {etimtoan open vero = Boa nea soon ns ben opens, ne Sytem must bo bee «= Regine alecoty vs! and te soo i - {ise haven stron cutehangeger a ‘ir baiives fay a ete speticaly otro. SGope onthe machine sepa wih clteh er avec inept he ranemsson oi lve Sloe Sarsing the sts ater ‘This mathnde cueh ts ocuppod tock torus liter" Alwaye agus the back trae ltr laanever th cuton diss and ate” a ‘eoares ‘Troubleshooting ose 1 Boge Sac on, » Battech a aen REST ire (lute stipe when aeelernng £"Sicing icon + Sige mat yam 1 Weak ete spring “Tepe tes ecsorue ite | soa ‘lteh wi nt aengage oF machine craps with itch deegaae Stetingpeton Eater dit tt amare etch | Gis tne pace Ha toate imprage al went 1 Santa fon en fork shaft o hilt ok low 1 Damon shit dram ea groove 1 Lecce sper plat bt Bemaged geen spine “Worn safc atppes St 1 Weal Seton shar etn sping Bomage sit drum cam groove * Damefes ar tent mito 1 Worm gee engagement dogs of sls Gears roa! wal not tar Seat ofbrouengemehit sini eure sng + Bomtgeashit sends 9-1 Clutch/Gearshift Linkage ronson, uate rower newrotnose Reb os EDR a EE cvs Clutch Master Cynder apenas dr ttt, Slr | tan ena en tant ee rt ono [NOTICE | al eras oa th sass 0 nermeayen Torque 34 Nh (2 kgf, 25 ne, slate or ber toi. ever the dof ne 9-2 Clutch/Gearshift Linkage ¥ 5 Clutch Slave Cylinder The cue slave oy clutch espe 65) 9-3 Cluteh/Gearshift Linkage Ger holde (0 UFTER CaM PLATE (a euurew cenes femove th cach das and ats Rermove ha ete trem plate and catch ents, a4 Clutch/Gearshift Linkage 9-5 Clutch/Gearshift Linkage veuuren ose ‘uel lace ane pats a ela (page 22 teats ERSSEe te for oa heat the plate warpage oh tae pl wing eplce the cltch ioe ae plate 9 et Dinaysaajst the Sack tomue tor heen the ‘teh tes and potas aeroplooe age 12). On Clutch/Gearshift Linkage te tor wear or danape 9-7 Cluteh/Gearshitt Linkage L (9 UFTER ROD aR Clutch/Gearshift Linkage (OUTER GUE 2) AWE senooxe PeSiam_ i DAVEN SenockeT fangs Taig ne rnicase, driven sprockat as a set with the index fines on the thon spree facing Sivan spreket while pushing nthe Guten outer Arosa sere lla sven prot | Tune 3 oan ven sect at 0 te erat ale wa soa road ter {ergo ater naling he cach outer “Tongue: 5 Nor (35 gto, 1 6) 9-9 Clutch/Gearshitt Linkage tp ewures ‘ie dutch dices ontcaton color pin, | Install he cue center @ wile agnng ls bosses Cte ae 2500 Whe cing the sun somer nt ve cluch “Gran pina (wide segments) Besson wes sheratey sare cut ie cten de 9170 1A i ia ited Iarow segments Insta te on se 2500 AY on each ens in PRESSURE PLATE Cock thate the utah contr is insti socure Ieemo te cute iter cam plate by pusting the hoton comer | Clutch/Gearshift Linkage [@ Chutch/Gearshift Linkage het | Clutch/ Gearshift Linkage Back Torque Limiter ‘Troubleshooting + ack ora nite tects por oF doesnot eet ‘rms pa oes Gamanea brane pee fl and cinch coar tos 1 san ceosn ten ae Spee erin eda ge ah wrdonsnarnons Siting och ee anh + Back torque mar aessshly eter ess engine brake) Pressure plate if to age earnee neranihe remus [fn cmacabewwen apes. | pound cinoncotr 2800 piso ch cer toeiooe ‘ica kao WE eng ‘eee ho ae a pe tind as tas 9-13 Cluteh/Gearshitt Linkage ny cures ENTER 8 (a) CLUTCH CENTER GUIDE + Clutch Center Stroke Adustment Teeth car de eh th co Nonsense it exenced From th uth sorar 8 surge (Al Se sow Clutch/ Gearshift Linkage Oi (9 STROKE sa 2 2. Massena cach VC song thickness 6 Adjust me stoke by seacing me sous shim temo et + The osm a chs teritaion | Sheree ch roe sine 35mm 9-15 Clutch/Gearshift Linkage 4 Bicite he clutch spring inti rok () using Spectied stoke: 26-28 mm ae” 0 9 cwuren sums Asim sche by stig he teh sm ek fsteen ho sseutadrao, = ne mie © Gia stpseasiy ne ete inti teaon's mors tha the spied roe: Clutch/Gearshift Linkage Primary Drive Gear Ineation 9-17 Cluteh/Gearshift Linkage sh ie gear bolt 10. Alternator/Starter Clutch Service Information 10-1 Starter Clutch 10-4 Troubleshooting 10-1 Flywheel Installation 105 Alternator Stator 10-2 Torque Limiter/Starter Idle Gear 10-5 Flywheel Removal 10-4 Serves information Troubleshooting + ter 0 scion 16 for aerator ste ipo Meee 10-1 Alternator/Startor Clutch i2 Bours TWIT) CONNECTOR Alternator Stator framaved. Set ean i pot unde ode ie recommended oot spective (p dours, awe cane Remove the esrmator wie grormat fom the ate Fore the sola bolt ord stor wie came. Remove the socket batts an state ‘Resy's oseng agent tothe stator mowing bolt Rta and tpian the sr mounting soaker bots [Dita specie owe “TORQUE: 12 thm (1.2 ae OE) rsa te wr lr and ght the bl sere 10-2 Alternator/Starter Clutch 10-3 Alternator/Startor Clutch Flywheel Removal a wt eran 7725 0040000 (Eaivatoe som Aetr pur 127732002000 or (0) STARTER DAMEN GEAR Starter Clutch ‘chk ne operation ofthe anew clutch by tur ‘uo be Cet he ven gr courte. See VR Savin Manual estates ch inspacion 10-4 Alternator/Starter Clutch fire Torque Limiter/Starter Idle Gear TORQUE: 197 Nam (160 kg, 116 bt Flywheel Installation 10-5 Memo 11, Crankcase/Transmission Service Information 14-1 Transmission 113 Troubleshooting 11-1 Crankease Combination 114 Crankease Separation 12 Service Information Troubleshooting + Tha erankzace rust bo sparted 1 sve the achat (pogo 12.21 7 Pasting ode 25) ifocs hon serine + Boro aseorbing he crankeas halves, apy ‘nse to theming race, Wis 0 suc Satan through. + Tighton thei journal gry colores ote sing he ase agion Taken Nenad + REA? Sete anor So Excossive engin nese Wom sr amped eonsmision acre + them or damaged warsmission bearings ard to tt Eeneshiton 5 Damaged hit trum cam are i Tagen mee out of gu 1 Minders roa = 5 Baad um Sam rove Broken at deur stopper arm ‘be or bart hi fone 1 Moa o broken stopper rm return sping 1 Botan gsrsit spn rtun spring 11-1 Crankease/Transmission Remove the ssinnat baring set plat bolts and From ote ese lasen the the rm bate Note ha the ane rm bolthas the conser washer eh erin wih pone dom pata a8 sss emove em ftom te wer crorooe Loosen the main oural 10 opm ols Back and Crankease/Transmission ‘Transmission Remove thegowst pin Separate te canteat halves ipape 11-2, 1 vanamisson inepeton ‘geet an. ‘ptonltnemisson gears ermaton, pape spon etnove the thre dow png lng oe and Clean any sealant fom the crankcase mating sur 11-3 Crankease/Tr GRAY BOLTS Ws, 87.8) (2 BLACK BOLTS No.3.) epithe trots nt elo serene | Fura tone a 8 eas nr (G8 Same Bia seam oatentontgen tet NOTICE “Torque: 82 Nha (53 tigen 38 ric aioe + ove 1th tesco Crankease/Transmission Bape on stat — EMO RSTn 11-6 12. Crankshaft/Piston/Cylinder Service Information 12-1 Main Journal Bearing 123 Troubleshooting 12-1 Crankpin Bearing 12-4 Crankshaft 12-2 Piston/Cylinder 125 Service Information Troubleshooting case must be eapeate o service the ‘and journal 0.0. with a mito meter or cylinder Si Seance wor aaine damage + Then he 12-1 Crankshatt/Piston/Cylinder {1) APPLY MOLYBDENUM DISULFIDE OL tah Chanasaaer | Sar eon Crankshaft dep man na atid oh min ‘ed ond bearing cap, omove the cranks See VIR Service Manu for crankshaft inapectin, [Pains sures sndinsatbem [NoricE | NOTICE | {tang for measuring thw learance. + Yah th cane Sts Ua be asc 1 soi emaging the comacing rds epor 12-2 Crankshaft/Piston/Cylinder Journal Bearing Measure te crankshaft main jumal 0.0 using 3 aot the spotod ore a 12-3 Crankshaft/Piston/Cylinder IW CRANKPIN BEARINGS Crankpin Bearing [NOTICE Cran bestng selection ety natal ne boring cps aging he dows 1) CRANKPIN BEARING ‘oor ito the connasing rod tlk tess sn Fitton ina comnening fo basin 3 stops ar raat the spect tou Torque 20 Nem (20 khan, 6 864) to 29Nen (a0 kgm, 22 Be Fetter Caen the Gonnacing ro bots 80 dees seve then rar sn epee gan ‘Rete minum reading determine tho besng (ov wicno mereR From the messed besrng LO and main journal Speci of larnce: tions 0.68 mm (4018 -9.0022n) BEARING THICKNESS: EWetow: Thin 12-4 Crankshaft/Piston/Cylinder Piston/Cylinder ferove te pitcomacting rod seen rm | Paton Disnembepecion 12-5 Crankshatt/Piston/Cylinder «mere many zon connscrNs 90 {Side mans (a) SPACER [NOTICE | 1 gan a Crankshaft/Piston/ 0 (GT ERONT CONNECTING ROD [GVREAR CONNECTING ROD oy mane ilowroe Blan How Ary Le oe enmecingosamatend na | Eeaaanieenitcs | Gsute ton rd itoring wenn amarante piston tops fing te opponte

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