Professional Documents
Culture Documents
XR190L
1. General Information
4. Electrical System
A Few Words About Safety ···················· 1-2 SPECIAL TOOL LIST····························· 1-16
How To Use This Manual························ 1-3 CABLE & HARNESS ROUTING ············ 1-17
1-1
GENERAL INFORMATION
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
1-2
GENERAL INFORMATION
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided
safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,
or CAUTION. These signal words mean:
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.
1-3
GENERAL INFORMATION
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required
pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.
INSTRUCTION SYMBOL
Check the part for an inspection. Measure the part for an inspection.
1-4
GENERAL INFORMATION
MODEL IDENTIFICATION
• Model name: XR190L-H
Code/Type Destination
LA Latin America
PE Peru
CL Chile
DK General KILO
1-5
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
DIMENSIONS Overall length 2,075 mm
Overall width 812 mm
Overall height 1,124 mm
Wheelbase 1,351 mm
Seat height 835 mm
Footpeg height 300 mm
Ground clearance 242 mm
Curb weight 133 kg
Maximum weight capacity 155 kg
FRAME Frame type Semi double cradle type
Front suspension Telescopic fork
Front wheel travel 161.5 mm
Rear suspension Swingarm
Rear wheel travel 147 mm
Front tire size 90/90 -19M/C 52P
Rear tire size 110/90 - 17M/C 60P
Front tire brand C6559F (CHENG SHIN)
Rear tire brand C6559 (CHENG SHIN)
Front brake Hydraulic single disc
Rear brake Mechanical leading trailing
Caster angle 26° 12’
Trail length 95.9 mm
Fuel tank capacity 12.0 liter
Fuel tank reserve capacity 3.9 liter
ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical
Bore and stroke 61.000 x 63.096 mm
Displacement 184.43 cm3
Compression ratio 9.5 : 1
Valve train Chain driven OHC with rocker arm
Intake valve opens 10° BTDC at 1 mm lift
closes 30° ABDC at 1 mm lift
Exhaust valve opens 35° BBDC at 1 mm lift
closes 0° ATDC at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper filter
Engine dry weight 29.5 kg
Emission control system Crankcase emission control system
Three-way catalytic converter
FUEL SYSTEM Type PGM-FI (Programmed Fuel Injection)
Throttle bore 30 mm
1-6
GENERAL INFORMATION
ITEM SPECIFICATION
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission 5 speeds
Primary reduction 3.136 (69/22)
Final reduction 3.000 (48/16)
Gear ratio 1st 2.785 (39/14)
2nd 1.789 (34/19)
3rd 1.368 (26/19)
4th 1.090 (24/22)
5th 0.928 (26/28)
Gearshift pattern Left foot operated return system
1-N-2-3-4-5
ELECTRICAL Ignition system Full transistorized
Starting system Electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR opened, single phase half-wave rectification
Lighting system Alternator
ITEM SPECIFICATIONS
Throttle body identification number GQ1QA
Idle speed 1,400 ± 100 rpm
Throttle grip freeplay 2 – 6 mm
Fuel pressure at idle 294 kPa
Fuel pump flow (at 12 V) 58.6 cm3 minimum/10 seconds
LUBRICATION SYSTEM
Unit: mm
ITEM STANDARD LIMIT
Engine oil capacity After draining 1.0 liter –
After disassembly 1.2 liter –
Recommended engine oil Honda “4-stroke motorcycle oil” or an
equivalent motor oil.
API service classification: SG or higher –
JASO T903 standard: MA
Viscosity: SAE 10W-30
Oil pump rotor Tip clearance 0.15 0.20
1-7
GENERAL INFORMATION
CYLINDER HEAD
Unit: mm
ITEM STANDARD LIMIT
Cylinder compression 1,402 kPa at 650 rpm –
Valve clearance IN 0.08 ± 0.02 –
EX 0.24 ± 0.02 –
Camshaft Cam lobe height IN 34.249 – 34.489 34.219
EX 34.079 – 34.319 34.049
Rocker arm, Rocker arm shaft O.D.
IN/EX 9.988 – 10.000 –
rocker arm shaft
Valve, Valve stem O.D. IN 4.975 – 4.990 4.965
valve guide EX 4.955 – 4.970 4.945
Valve guide I.D. IN/EX 5.000 – 5.012 –
Valve guide projection
IN/EX 16.8 – 17.0 –
above cylinder head
Valve seat width IN 1.2 – 1.4 1.8
EX 1.0 – 1.2 1.6
Valve spring free length INNER 35.59 34.88
OUTER 39.46 38.67
Cylinder head warpage – 0.05
CYLINDER/PISTON
Unit: mm
ITEM STANDARD LIMIT
Cylinder I.D. 61.00 – 61.01 61.10
Warpage – 0.10
Piston Piston O.D. 60.981 – 60.997 at 13 mm from bottom of
60.900
skirt
Piston pin bore I.D. 14.002 – 14.008 14.020
Piston pin O.D. 13.994 – 14.000 13.980
Piston rings Piston ring end gap Top 0.07 – 0.17 0.27
Second 0.17 – 0.32 0.42
Oil (side rail) 0.10 – 0.35 0.55
Piston ring-to-ring Top 0.015 – 0.045 –
groove clearance Second 0.015 – 0.045 –
CLUTCH/GEARSHIFT LINKAGE
Unit: mm
ITEM STANDARD LIMIT
Clutch lever freeplay 10 – 20 –
Clutch Disc thickness 2.92 – 3.08 2.70
Plate warpage – 0.15
Spring free length 40.5 39.5
Primary driven gear I.D. 23.000 – 23.021 –
Clutch outer guide O.D. 22.959 – 22.980 –
I.D. 16.991 – 17.009 –
Mainshaft O.D. at clutch outer guide 16.966 – 16.984 –
ALTERNATOR/STARTER CLUTCH
Unit: mm
ITEM STANDARD LIMIT
Starter driven gear boss O.D. 45.660 – 45.673 –
Starter driven gear boss I.D. 29.000 – 29.021 –
1-8
GENERAL INFORMATION
CRANKSHAFT/TRANSMISSION/BALANCER
Unit: mm
ITEM STANDARD LIMIT
Connecting rod Side clearance 0.10 – 0.35 0.45
Radial clearance 0 – 0.008 0.05
Connecting rod small end I.D. 14.010 – 14.028 14.038
Crankshaft Runout – 0.03
Transmission Gear I.D. M4 20.000 – 20.018 –
M5 17.000 – 17.018 –
C1 20.500 – 20.521 –
C2 23.020 – 23.041 –
C3 20.020 – 20.038 –
Gear bushing O.D. C1 20.459 – 20.480 –
C2 22.984 – 23.005 –
Gear bushing I.D. C1 17.000 – 17.018 –
C2 20.020 – 20.041 –
Mainshaft O.D. at M4 19.968 – 19.980 –
at M5 16.968 – 16.980 –
Countershaft O.D. at C1 16.966 – 16.984 –
at C2 19.978 – 19.989 –
at C3 19.988 – 20.000 –
Shift fork, fork Fork I.D. 10.000 – 10.018 –
shaft Fork shaft O.D. 9.986 – 9.995 –
Claw thickness 4.93 – 5.00 4.83
1-9
GENERAL INFORMATION
BRAKE SYSTEM
Unit: mm
ITEM STANDARD LIMIT
Front Specified brake fluid DOT 3 or DOT 4 –
Brake disc thickness 3.8 – 4.2 3.5
Brake disc warpage – 0.3
Master cylinder I.D. 12.700 – 12.743 –
Master piston O.D. 12.657 – 12.684 –
Caliper cylinder I.D. 27.000 – 27.050 –
Caliper piston O.D. 26.918 – 26.968 –
Rear Pedal freeplay 20 – 30 –
Drum I.D. 110 111
ITEM SPECIFICATIONS
EOT sensor resistance (20°C) 2.5 – 2.8 kΩ
Fuel injector resistance (24°C) 11 – 13 Ω
IGNITION SYSTEM
ITEM SPECIFICATION
Spark plug CPR8EA-9 (NGK)
Spark plug gap 0.80 – 0.90 mm
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing ("F" mark) 8° BTDC at idle
BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS
Battery Type YTX7L-BS
Capacity 12 V – 6 Ah (10HR)/6.3 Ah (20HR)
Current leakage 0 mA
Voltage Fully charged 12.8 V minimum
(20°C) Needs charging Below 12.3 V
Charging current Normal 0.6 A/5 – 10 h
Quick 3 A/1 h
Alternator Capacity 0.165 kW/5,000 rpm
Charging coil resistance (20°C) 0.2 – 1.0 Ω
1-10
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES
ITEM SPECIFICATIONS
Bulbs Headlight Hi/Lo 12 V – 35/35 W
Brake/tail light 12 V – 21/5 W
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Position light 12 V – 5 W
License light 12 V – 5 W
Instrument light 1 12 V – 2 W
Instrument light 2 12 V – 1.7 W
High beam indicator 12 V – 1.7 W
Neutral indicator 12 V – 3.4 W
Turn signal indicator 12 V – 3.4 W
MIL 12 V – 3.4 W
Fuse Main fuse 15 A
Sub fuse 10 A x 2
Fuel level sensor resistance Full 6 – 10 Ω
Empty 90 – 100 Ω
1-11
GENERAL INFORMATION
TORQUE VALUE
• Each fastener should be tightened to the standard torque value except the fasteners specified torque value.
• Q’TY: Quantity, DIA: Thread diameter (mm), TRQ: Tightening torque (N·m)
STANDARD TIGHTENING TORQUE
FASTENER TYPE TRQ FASTENER TYPE TRQ
5 mm hex bolt and nut 5.2 5 mm screw 4.2
6 mm hex bolt and nut 10 6 mm screw 9.0
8 mm hex bolt and nut 22 6 mm flange bolt 12
10 mm hex bolt and nut 34 8 mm flange bolt and nut 27
12 mm hex bolt and nut 54 10 mm flange bolt and nut 39
FUEL PUMP UNIT
ITEM Q'TY DIA TRQ REMARKS
Fuel pump setting plate nut 4 6 12 2-4
AIR CLEANER
ITEM Q'TY DIA TRQ REMARKS
Air cleaner cover screw 4 5 1.0
Air cleaner element screw 4 5 1.0
Air cleaner cover separate screw 5 5 1.0
THROTTLE BODY
ITEM Q'TY DIA TRQ REMARKS
Throttle cable A lock nut (throttle body side) 1 6 4.5
Throttle cable B lock nut (throttle body side) 1 6 4.5
Insulator band screw 1 5 2.5
Insulator bolt 2 6 12
Sensor unit torx screw 3 5 3.4
IACV mounting torx screw 2 4 2.1
Throttle cable stay screw 2 5 3.4
Injector joint bolt 2 5 5.1
LUBRICATION SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Oil drain bolt 1 12 30
Oil pump cover screw 1 4 3.0
CYLINDER HEAD
ITEM Q'TY DIA TRQ REMARKS
Crankshaft hole cap 1 32 15 Apply grease.
Timing hole cap 1 14 10
Cam chain tensioner lifter plug 1 6 4.0
Cam sprocket bolt 2 5 9.0
Cylinder head nut 4 9 30 Apply engine oil.
Camshaft stopper bolt 1 6 12 Apply engine oil.
Rocker arm shaft stopper bolt 2 5 5.0
Valve adjusting screw lock nut 2 6 18 Apply engine oil.
Cylinder stud bolt 4 9 9.0
1-12
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE/BALANCER GEAR
ITEM Q'TY DIA TRQ REMARKS
Clutch center lock nut 1 14 83 Apply engine oil.
Shift drum stopper arm bolt 1 6 12 Apply locking agent.
Shift drum stopper plate bolt 1 6 12 Apply locking agent.
Gearshift return spring pin 1 8 22 Apply locking agent.
Clutch lifter plate bolt 4 6 12
Oil filter rotor lock nut 1 14 83 Apply engine oil.
Oil filter rotor cover screw 3 5 4.0
ALTERNATOR/STARTER CLUTCH
ITEM Q'TY DIA TRQ REMARKS
Starter clutch socket bolt 6 6 16 Apply locking agent.
Stator mounting bolt 3 6 12
Flywheel lock nut 1 14 74 Apply engine oil.
CKP sensor mounting bolt 2 6 12 Apply locking agent.
Alternator harness stay bolt 1 6 12 Apply locking agent.
CRANKCASE/CRANKSHAFT/BALANCER
ITEM Q'TY DIA TRQ REMARKS
Mainshaft bearing setting plate bolt 2 6 12 Apply locking agent.
Push plug bolt 1 6 10 Apply locking agent.
Balancer driven gear lock nut 1 14 64 Apply engine oil.
Balancer nut 1 12 55 Apply engine oil.
ENGINE UNIT
ITEM Q'TY DIA TRQ REMARKS
Front engine hanger nut 3 8 35
Front lower engine hanger nut 1 8 35
Rear upper engine hanger nut 1 10 60
Rear lower engine hanger nut 1 10 60
Upper engine hanger nut 2 8 35
Drive sprocket bolt 2 6 12
SIDESTAND
ITEM Q'TY DIA TRQ REMARKS
Sidestand pivot bolt 1 10 10 3-12
Sidestand pivot nut 1 10 39 Self lock nut 3-12
EXHAUST PIPE/MUFFLER
ITEM Q'TY DIA TRQ REMARKS
Exhaust pipe stud bolt 2 8 11 3-13
Exhaust pipe joint cap nut 2 8 18
Muffler front protector bolt 3 6 14
Muffler protector socket bolt 1 6 10
Muffler band bolt 1 8 20
Exhaust pipe protector socket bolt 1 6 10
FRONT WHEEL
ITEM Q'TY DIA TRQ REMARKS
Front axle nut 1 12 44 Self lock nut
Front brake disc nut 5 6 15
1-13
GENERAL INFORMATION
FORK
ITEM Q'TY DIA TRQ REMARKS
Top bridge pinch bolt 2 8 22
Bottom bridge pinch bolt 4 8 32
Brake hose clamper bolt 2 6 12
Fork bolt 2 27 22
Fork socket bolt 2 8 20 Apply locking agent.
HANDLEBAR
ITEM Q'TY DIA TRQ REMARKS
Handlebar upper holder bolt 4 8 26
Clutch lever pivot bolt 1 6 1.0
Clutch lever pivot nut 1 6 5.9
Throttle cable A adjusting nut (grip side) 1 7 3.8
Throttle cable A lock nut (grip side) 1 10 3.0
Throttle cable B lock nut (grip side) 1 12 3.0
STEERING STEM
ITEM Q'TY DIA TRQ REMARKS
Steering stem nut 1 24 103
Steering stem adjusting nut 1 26 – 3-19
REAR WHEEL
ITEM Q'TY DIA TRQ REMARKS
Rear axle nut 1 16 93 Self lock nut
Driven sprocket nut 6 8 32 Self lock nut
REAR SUSPENSION
ITEM Q'TY DIA TRQ REMARKS
Shock absorber upper bolt 1 10 44
Shock absorber lower nut 1 10 44 Self lock nut
Swingarm pivot nut 1 14 88 Self lock nut
Drive chain slider screw 1 5 6.0
FRONT BRAKE
ITEM Q'TY DIA TRQ REMARKS
Front master cylinder reservoir cap screw 2 4 1.5
Front brake master cylinder holder bolt 2 6 12
Front brake hose oil bolt 2 10 34
Brake lever pivot bolt 1 6 1.0
Brake lever pivot nut 1 6 5.9
Front brake light switch screw 1 4 1.2
Front brake pad hanger pin 1 10 17
Front brake pad pin plug 1 10 2.5
Front brake caliper bolt 2 8 30 Pre-coated (ALOC) bolt,
replace with a new one.
Front brake caliper main slide pin 1 8 22 Apply locking agent.
Front brake caliper bleed valve 1 8 5.4
REAR BRAKE
ITEM Q'TY DIA TRQ REMARKS
Rear brake arm nut 1 6 10 Self lock nut
1-14
GENERAL INFORMATION
PGM-FI SYSTEM
ITEM Q'TY DIA TRQ REMARKS
EOT sensor 1 10 15 Apply engine oil.
O2 sensor 1 12 25
Bank angle sensor 2 6 5.8
IGNITION SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Spark plug 1 10 16
LIGHTING SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Turn signal light mounting nut 4 10 19
SPEEDOMETER
ITEM Q'TY DIA TRQ REMARKS
Meter screw 3 4 1.2
1-15
GENERAL INFORMATION
1-16
GENERAL INFORMATION
COMBINATION
SWITCH WIRE
RIGHT
HANDLEBAR
LEFT
SWITCH WIRE
HANDLEBAR
SWITCH WIRE
TURN
SIGNAL
LIGHT
WIRE MAIN WIRE
HARNESS
INSIDE BOOT CONNECTORS:
· LEFT HANDLEBAR 9P
MAIN WIRE · LEFT HANDLEBAR SWITCH WIRE
HARNESS
MAIN WIRE
HARNESS
1-17
GENERAL INFORMATION
THROTTLE
CABLE A
2 – 4 mm
THROTTLE
CABLE B
SPEEDOMETER
CABLE
1-18
GENERAL INFORMATION
INSIDE BOOT
CONNECTORS: BATTERY
· REAR BRAKE LIGHT SWITCH 2P NEGATIVE (–)
NEUTRAL
· ALTERNATOR 3P CABLE
SWITCH
· ALTERNATOR 2P WIRE
· NEUTRAL SWITCH WIRE
To be butted.
O2 SENSOR
2P CONNECTOR
ALTERNATOR
WIRE
EOT SENSOR
2P CONNECTOR DLC
ECM 33P
CONNECTOR
STARTER
MOTOR
CABLE
BATTERY
NEGATIVE (–)
CABLE
45° ± 5°
ALTERNATOR
WIRE
BATTERY
NEGATIVE (–)
CABLE
NEUTRAL
SWITCH WIRE
1-19
GENERAL INFORMATION
NEUTRAL
NEUTRAL
SWITCH WIRE
SWITCH WIRE
DRIVE
SPROCKET
COVER
NEUTRAL
SWITCH WIRE
DRIVE
SPROCKET
COVER
DRIVE
SPROCKET
COVER
CKP SENSOR
WIRE
ALTERNATOR
WIRE
1-20
GENERAL INFORMATION
IGNITION COIL
WIRE
1-21
GENERAL INFORMATION
MAIN WIRE
HARNESS
INJECTOR 2P
CONNECTOR
MAIN WIRE
HARNESS
IACV 4P
CONNECTOR
MAIN WIRE
HARNESS
TURN SIGNAL
LIGHT WIRE
1-22
GENERAL INFORMATION
1-23
GENERAL INFORMATION
TECHNICAL FEATURES
FUEL PUMP SYSTEM WITH A FUEL FILTER BLOCKAGE REMINDER
FUNCTION
FUEL TANK
BREATHER FILTER
FUEL PUMP
FUEL LEVEL
BREATHER
PASSAGE
PUMP CHAMBER
To FUEL INJECTOR
FUEL FILTER
The fuel pump system of this model consists of the following components:
– Fuel pump chamber
– Fuel filter
– Breather passage
– Breather filter
Under normal condition, the fuel pump chamber sucks fuel through the fuel filter and then supplies it to the injector.
When the fuel filter is clogged, the fuel is sucked into the pump chamber through the breather passage in order to
keep the vehicle running. The breather filter is located in the upper inner side of fuel tank. When the fuel is consumed
to the point where the breather filter is exposed above the fuel level, a certain amount of air will be drawn into the
pump chamber via the breather filter and breather passage. This incoming air produces "a lack of fuel", which impairs
engine performance in order to notify the rider of the fuel filter blockage. This symptom works as a reminder for the
filter replacement.
This system eliminates the need of fuel filter replacement according to a fixed interval, as the rider will experience the
symptom and notice the filter blockage during vehicle usage.
The driveability remains normal as long as the fuel level in tank is maintained above the breather filter because no air
will be drawn into the pump chamber, even when the fuel filter is clogged.
If the fuel in tank is sufficient but such symptom as poor engine performance, lack of fuel, or engine start failure exist,
perform the fuel supply test.
1-24
GENERAL INFORMATION
MAINTENANCE SCHEDULE
• Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
• I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
• The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may
require more technical information and tools. Consult a dealer.
• Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this
manual.
1-25
MEMO
2. FUEL & ENGINE
2-1
FUEL & ENGINE
FUEL LINE
FUEL & ENGINE
• This vehicle uses resin for the part of materials in the fuel
feed hose. Do not bend or twist the fuel feed hose.
• Seat 3-4
• Fuel tank shroud 3-8
• Fuel pump 5P connector
• Let the engine idle until it stops.
2-2
FUEL & ENGINE
FUEL SUPPLY TEST
• If the fuel in tank is sufficient but such symptom as poor en-
gine performance, lack of fuel, or engine start failure exist,
perform the following.
– Perform the fuel pressure test. 2-3
– Fuel flow inspection if the fuel pressure is within specifi-
cation. 2-3
– Fuel flow inspection in the specified fuel quantity. 2-3
2-3
FUEL & ENGINE
12 N·m
2-4
FUEL & ENGINE
FUEL FILTER
G Y G
R Bl Y G
• To prevent dirt and debris from entering the fuel pump unit, always clean it before disassembly.
• Clean the fuel pump unit and fuel pump filter with clean gasoline. Never use commercially available
carburetor cleaners.
• Release the hooks from the stoppers by slightly spreading the hooks using the special tool.
Fuel pump case remover: 070MF-KVS0300
• Release the hooks from the stoppers by slightly spreading the hooks, and then turn the filter.
• Fuel filter for clogs or excessive damage
• If the fuel filter is clogged, replace it with a new one.
• Before installing the fuel pump filter, check the fuel pump unit for dirt. If necessary, clean the fuel pump unit
with compressed air. Do not blow into the fuel pump unit.
• If the R or Bl wire connector is disconnected, replace the fuel level sensor with a new one.
• Connect the fuel pump motor wires to the specified terminals.
• Make sure the "CLICK" when the fuel pump unit is assembled.
• Route the fuel pump motor wires and fuel level sensor wires to the guide and terminals properly.
2-5
FUEL & ENGINE
FUEL TANK
2-6
FUEL & ENGINE
AIR CLEANER
1.0 N·m
1.0 N·m
1.0 N·m
• Discard the air cleaner element in accordance with the maintenance schedule. 1-25
• Replace the element any time if it is excessively dirty or damaged.
• Seat 3-4
• Side cover 3-7
• Rear center cowl 3-5
• Battery box 3-11
2-7
FUEL & ENGINE
THROTTLE BODY
12 N·m
2.5 N·m
4.5 N·m
• Injector 2-11
• If the throttle body is replaced, perform the TP sensor reset procedure. 2-10
2-8
FUEL & ENGINE
3.4 N·m
[A]
2.1 N·m
3.4 N·m
• 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 fastener. Loosening or tightening it can cause throttle body malfunction.
Sensor unit
• Throttle body 2-8
• Install the sensor unit to the throttle body by aligning the clip of the sensor unit with the boss of the throttle
valve.
• Perform the TP sensor reset procedure. 2-10
IACV
• Throttle cable cover 2-8
• Turn the slide valve [A] clockwise until lightly seated on IACV.
• Align the slot in the set plate with the lug of the IACV.
• Align the slide valve groove with the pin.
• Check the IACV for wear or damage.
• The IACV operation can be checked visually as follows:
1. Connect the IACV 4P connector.
2. Turn ignition switch ON, check the slide valve operation.
2-9
FUEL & ENGINE
TP SENSOR RESET PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, TP sensor reset mode won’t start by follow-
ing the procedure below.
• Left side cover 3-7
• Connector cover from the DLC [A].
• Connect the special tool to the DLC.
SCS short connector: 070PZ-ZY30100
[A]
Y/Bu G/W
[B]
within 10 sec.
0.3 sec.
0.3 sec.
0.1 sec.
1.3 sec.
2-10
FUEL & ENGINE
INJECTOR
5.1 N·m
2-11
FUEL & ENGINE
LUBRICATION SYSTEM
SYSTEM DIAGRAM
OIL STRAINER
OIL PUMP
SCREEN
CENTRIFUGAL
OIL FILTER
2-12
FUEL & ENGINE
ENGINE OIL CHANGE
• Drain oil completely.
30 N·m
• Fill the crankcase with the recommended engine oil.
3.0 N·m
• Align the cutouts of the oil pump drive shaft and inner rotor.
2-13
FUEL & ENGINE
CYLINDER HEAD
• The following services can be serviced with the engine installed in the frame.
VALVE CLEARANCE
• Inspect while the engine is cold (below 35°C).
10 N·m • Cylinder head cover 2-15
15 N·m
• The index lines on the cam sprocket are aligned with the
[B]
cylinder head tabs [A].
• Make sure that the mark [B] on the cam sprocket is in the
position shown (TDC).
If the cam sprocket mark is not in position shown, rotate
the crankshaft one full turn.
[A]
18 N·m
2-14
FUEL & ENGINE
CYLINDER HEAD COVER
2-15
FUEL & ENGINE
CAMSHAFT/ROCKER ARM
• Set the piston to the TDC on the compression stroke.
2-14
• Install the special tool into the tensioner body and turn the
tool clockwise until it stops. Hold the tensioner lifter by
pushing the tool while aligning the tabs of the tool with the
grooves of the tensioner lifter.
Tensioner stopper: 070MG-0010100
4.0 N·m
Intake:
[A]
9.0 N·m
5.0 N·m
12 N·m
Exhaust:
2-16
FUEL & ENGINE
30 N·m
7.4 – 12 mm
9.0 N·m
2-17
FUEL & ENGINE
2-18
FUEL & ENGINE
CAM CHAIN TENSIONER
• Install the special tool into the tensioner body and turn the
tool clockwise until it stops. Hold the tensioner lifter by
pushing the tool while aligning the tabs of the tool with the
grooves of the tensioner lifter.
Tensioner stopper: 070MG-0010100
4.0 N·m
2-19
FUEL & ENGINE
CYLINDER/PISTON
• This service can be serviced with the engine installed in the frame.
2-20
FUEL & ENGINE
CLUTCH/GEARSHIFT LINKAGE
1.0 mm
0.5 – 1.0 mm
2-21
FUEL & ENGINE
22 N·m
12 N·m
12 N·m
83 N·m
12 N·m
4.0 N·m
Each bearing
83 N·m
Each gear tooth
Coating width:
6.5 ± 1 mm from the tip
2-22
FUEL & ENGINE
[A]
[B]
2-23
FUEL & ENGINE
ALTERNATOR/STARTER CLUTCH
• This service can be serviced with the engine installed in the frame.
Clean.
74 N·m
2-24
FUEL & ENGINE
16 N·m
Coating width:
6.5 ± 1 mm from the tip
12 N·m 12 N·m
12 N·m
Coating width:
6.5 ± 1 mm from the tip
• Apply sealant (TB 1141G, 1215, 1207G, or equivalent) to the seating surface.
2-25
FUEL & ENGINE
CRANKCASE/CRANKSHAFT/BALANCER
Coating width:
[A] 64 N·m 6.5 ± 1 mm from the tip
Each bearing
Each gear tooth
[B]
1 – 2 cm3
[A]
10 N·m
[B]
55 N·m
2-26
FUEL & ENGINE
• Balancer inspection
47.5 mm 45.0 mm
2-27
FUEL & ENGINE
TRANSMISSION
Coating width:
6.5 ± 1 mm from the tip
Each bearing
Each gear tooth
R/L
C
12 N·m
0.5 – 1.0 mm
0.5 – 1.0 mm
2-28
FUEL & ENGINE
MAINSHAFT
• Transmission inspection
COUNTERSHAFT
• Transmission inspection
2-29
FUEL & ENGINE
• Hook the return spring to the hole of the kickstarter spindle, and then install the collar by aligning its cut-
out with the spring.
• Kickstarter inspection
2-30
FUEL & ENGINE
ENGINE UNIT
35 N·m
60 N·m
35 N·m
60 N·m
35 N·m
12 N·m
35 N·m
2-31
MEMO
3. FRAME & CHASSIS
3-1
FRAME & CHASSIS
BODY PANELS
FRAME & CHASSIS
[1]
[2]
[3]
[8]
[4]
[5]
[7]
[6]
[9]
[16]
[15]
[10]
[14]
[13]
[11]
[12]
3-2
FRAME & CHASSIS
REARVIEW MIRROR
FRONT COWL
3-3
FRAME & CHASSIS
FRONT FENDER
SEAT
3-4
FRAME & CHASSIS
REAR CENTER COWL
• Seat 3-4
REAR GRIP
3-5
FRAME & CHASSIS
REAR FENDER
CL only :
3-6
FRAME & CHASSIS
SIDE COVER
3-7
FRAME & CHASSIS
FUEL TANK SHROUD
CL only :
3-8
FRAME & CHASSIS
SHIFT CHANGE PEDAL
98 mm
3-9
FRAME & CHASSIS
BRAKE PEDAL
108 mm
3-10
FRAME & CHASSIS
BATTERY BOX
• Battery 4-28
• Seat 3-4
3-11
FRAME & CHASSIS
TOOL BOX
SIDESTAND
39 N·m
10 N·m
Sliding surface
• After tightening the pivot bolt to the specified torque, turn it 45 – 90 ° counterclockwise.
• When tightening the pivot nut, hold the pivot bolt securely.
3-12
FRAME & CHASSIS
EXHAUST PIPE/MUFFLER
14 N·m
10 N·m
20 N·m
21
.5
±1
.0
mm
11 N·m
10 N·m 18 N·m
• Muffler 3-13
3-13
FRAME & CHASSIS
FRONT WHEEL
44 N·m
• Wheel inspection
3-14
FRAME & CHASSIS
15 N·m
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive out the bearing from the wheel hub.
Bearing remover head, 12 mm: 07746-0050300
Bearing remover shaft: 07746-0050100
• Drive in a new bearing squarely with its marked side facing outside until it is fully seated.
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 12 mm: 07746-0040200
• Install the distance collar.
• Drive in a new bearing squarely with its marked side facing outside until it is seated on the distance collar.
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 12 mm: 07746-0040200
• Wheel disassembly and inspection
3-15
FRAME & CHASSIS
FORK
22 N·m
32 N·m
12 N·m
3-16
FRAME & CHASSIS
184 mm
22 N·m
20 N·m
LEFT RIGHT
3-17
FRAME & CHASSIS
HANDLEBAR
3.0 N·m
3.8 N·m
26 N·m
3.0 N·m
1.0 N·m
5.9 N·m
3-18
FRAME & CHASSIS
STEERING STEM
TOP BRIDGE
22 N·m
103 N·m
• Speedometer 4-34
• Handlebar 3-18
3-19
FRAME & CHASSIS
BOTTOM BRIDGE
[A]
3–5g
3–5g
3–5g
[B] [C] [D]
3–5g
[B] [C] [D]
• STEERING STEM:
[A] Lock nut wrench: 07916-KA50100
• STEERING STEM BEARING:
[B] Ball race remover set: 07953-MJ10000
• STEERING STEM BEARING:
[C] Driver: 07749-0010000
[D] Attachment 42 x 47 mm: 07746-0010300
• STEERING STEM:
[A] Lock nut wrench: 07916-KA50100
[E] Fork seal driver attachment: 07747-0010300
• Install the adjusting nut. Hold the steering stem and tighten the adjusting nut to the initial torque.
TORQUE: 5.0 N·m
• Turn the steering stem lock-to-lock several times to seat the bearing. Completely loosen the top thread.
• Tighten the steering stem adjusting nut to the specified torque using the special tool.
TORQUE: 5.0 N·m
• Steering disassembly/assembly and inspection
3-20
FRAME & CHASSIS
REAR WHEEL
93 N·m
• Wheel inspection
3-21
FRAME & CHASSIS
32 N·m
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive out the bearing from the wheel hub.
Remover head, 17 mm: 07746-0050500
Bearing remover shaft: 07746-0050100
• Drive in a new bearing squarely until it is fully seated.
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 17 mm: 07746-0040400
• Install the distance collar.
• Drive in a new bearing squarely with its marked side facing outside until it is seated on the distance collar.
Driver: 07749-0010000
Attachment, 42 x 47 mm: 07746-0010300
Pilot, 17 mm: 07746-0040400
• Wheel disassembly and inspection
3-22
FRAME & CHASSIS
REAR SUSPENSION
44 N·m
40 mm
44 N·m
• Left side cover 3-7
• If you dispose of the shock absorber, drill at the specified point as shown.
88 N·m
44 N·m
3-23
FRAME & CHASSIS
8 – 9 mm
6.0 N·m
FRONT BRAKE
BRAKE FLUID REPLACEMENT
1.5 N·m
Set line
• Fill the reservoir with brake fluid from a sealed container to the set line.
RECOMMENDED BRAKE FLUID: DOT 3 or DOT 4
3-24
FRAME & CHASSIS
BRAKE MASTER CYLINDER
12 N·m
34 N·m
• Install the brake master cylinder and holder with the "UP" mark facing up. Align the edge of the master
cylinder with the punch mark on the handlebar.
1.0 N·m
Silicone grease
Silicone grease
1.2 N·m
5.9 N·m
3-25
FRAME & CHASSIS
BRAKE CALIPER
BRAKE PAD REPLACEMENT
17 N·m
2.5 N·m
• Install brake pads so that they are set on the brake caliper bracket.
34 N·m
30 N·m
3-26
FRAME & CHASSIS
Silicone
5.4 N·m grease
Silicone
grease
22 N·m
Silicone
grease
REAR BRAKE
0.2 – 0.3 g
0.2 – 0.3 g
0.2 – 0.3 g
0.2 – 0.3 g
10 N·m
• Align the punch marks of the brake arm and brake cam.
3-27
MEMO
4. ELECTRICAL SYSTEM
4-1
ELECTRICAL SYSTEM
PGM-FI SYSTEM
ELECTRICAL SYSTEM
4-2
ELECTRICAL SYSTEM
PGM-FI SYSTEM LOCATION
FUEL PUMP
IGNITION SWITCH
INJECTOR
IACV
DLC
BANK ANGLE
SENSOR
O2 SENSOR
EOT SENSOR
CKP SENSOR
SENSOR UNIT:
· MAP SENSOR
· IAT SENSOR ECM
· TP SENSOR
4-3
ELECTRICAL SYSTEM
PGM-FI SYSTEM DIAGRAM
IGNITION
SWITCH
REGULATOR/
RECTIFIER
LOAD CUT
RELAY
BATTERY R Bl/R
Bl/G Bl/R
(33-2) Bl/R
Bl/R ECM PCR
1 IGP 7
(54-1,54-2) R/Bu
26 BA
BANK ANGLE Bl/O FUEL PUMP
SENSOR FFP 8
10A
Y/R
6 VCC INJ 16
P/Bl (12-1)
INJECTOR
SENSOR UNIT
(1-1,1-2) Lg/Y
Bl/R
SCS SHORT
27 PB Bu
MAP SENSOR SCS 15 CONNECTOR
Y
(8-1,8-2) Y
5 THL
K-LINE 30
TP SENSOR DLC
G/Bl
Gr/Bu LG 2
14 TA
(9-1,9-2)
IAT SENSOR Y/Bu
24 TO
(7-1,7-2) G/W
4 SG FI-IND 18
W/Bu Bl
EOT SENSOR
MIL
Br/W
IACV2A 20
Bu/Y Bu/W
12 IACV1A 21
PCP
CKP SENSOR W/Y IACV2B 31
Br/Bl IACV (29-1)
23 PCM
Bu/Bl
IACV1B 32
G
(21-1) Bl/W PG1 9
3 O2 G
PG2 10
O2 SENSOR
( ) : DTC
1 2 3 4 5 6 7 8 9 10 11
: Engine does not start
12 13 14 15 16 17 18 19 20 21 22
when detecting DTC
23 24 25 26 27 28 29 30 31 32 33
:Short terminals for
reading DTC
ECM 33P CONNECTOR
(ECM side of the male terminals)
4-4
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW VOLTAGE)
G/W Lg/Y
Lg/Y
5V
Y/R VCC
5V
Sensor unit PB ECM
Lg/Y
(MAP sensor)
SG
G/W
Yes ▼
Yes ▼
• Connection: Lg/Y (+) – G/W (–) Yes • Replace the sensor unit (MAP sensor) with a new
• Is the voltage within 3.80 – 5.25 V? ► one 2-8, and recheck.
No ▼
4-5
ELECTRICAL SYSTEM
DTC 1-2 (MAP SENSOR HIGH VOLTAGE)
G/W Lg/Y
Lg/Y
5V
Y/R VCC
5V
Sensor unit PB ECM
Lg/Y
(MAP sensor)
SG
G/W
Yes ▼
No ▼
4-6
ELECTRICAL SYSTEM
DTC 7-1 (EOT SENSOR LOW VOLTAGE)
G/W
Y/Bu G/W
Y/Bu
5V
TO
Y/Bu
Yes ▼
• Check the EOT sensor voltage with MCS. No • Replace the EOT sensor with a new one 4-19,
• Is the voltage about 0 V indicated? ► and recheck.
Yes ▼
4-7
ELECTRICAL SYSTEM
DTC 7-2 (EOT SENSOR HIGH VOLTAGE)
G/W
Y/Bu G/W
Y/Bu
5V
TO
Y/Bu
Yes ▼
No ▼
4-8
ELECTRICAL SYSTEM
DTC 8-1 (TP SENSOR LOW VOLTAGE)
TP Sensor Diagram
Y/R Y G/W
G/W Y
Y/R
5V
VCC
Y/R
Sensor unit THL
(TP sensor) Y ECM
SG
G/W
Yes ▼
Yes ▼
No ▼
4. TP Sensor Inspection
4-9
ELECTRICAL SYSTEM
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
TP Sensor Diagram
Y/R Y G/W
G/W Y
Y/R
5V
VCC
Y/R
Sensor unit THL
(TP sensor) Y ECM
SG
G/W
Yes ▼
Yes ▼
3. TP Sensor Inspection
4-10
ELECTRICAL SYSTEM
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
G/W
Gr/Bu G/W
Gr/Bu
5V
TA
Gr/Bu
Sensor unit
(IAT sensor) ECM
G/W SG
Yes ▼
• Check the IAT sensor voltage with MCS. No • Replace the sensor unit (IAT sensor) with a new
• Is the voltage about 0 V indicated? ► one 2-8, and recheck.
Yes ▼
4-11
ELECTRICAL SYSTEM
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)
G/W
Gr/Bu G/W
Gr/Bu
5V
TA
Gr/Bu
Sensor unit
(IAT sensor) ECM
G/W SG
Yes ▼
No ▼
4-12
ELECTRICAL SYSTEM
DTC 12-1 (INJECTOR)
Injector Diagram
Injector 2P connector Injector 2P connector ECM 33P connector
(Injector side) (Wire side)
P/Bl
A B Bl/R P/Bl
From Battery
Bl/R
Injector ECM
INJ
P/Bl
Yes ▼
Yes ▼
No ▼
• Connection: A – B No
• Faulty fuel injector
• Is the resistance within 11 – 13 Ω (24 °C)? ►
Yes ▼
4-13
ELECTRICAL SYSTEM
DTC 21-1 (O2 SENSOR)
O2 Sensor Diagram
Bl/W
Bl/W
O2
Bl/W
ECM
O2 sensor
Yes ▼
No ▼
3. O2 Sensor Inspection
4-14
ELECTRICAL SYSTEM
DTC 29-1 (IACV)
IACV Diagram
A B C D
Bu/W Bu/Bl
Bu/Bl Br/Bl
Bu/W IACV1A
Bu/Bl IACV1B ECM
IACV
Br/W IACV2A
Br/Bl IACV2B
Yes ▼
No ▼
• Connection: A – D, B – C No
• Faulty IACV
• Is the resistance within 110 – 150 Ω (25 °C)? ►
Yes ▼
• Connection: A – B, C – D Yes
• Faulty IACV
• Is there continuity? ►
No ▼
4-15
ELECTRICAL SYSTEM
DTC 33-2 (EEPROM)
Yes ▼
4-16
ELECTRICAL SYSTEM
DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)
G/W
Y/R R/Bu
5V
VCC
Y/R 5V
Bank angle BANK ECM
R/Bu
sensor SG
G/W
• Check the bank angle sensor voltage with MCS. No • Intermittent failure
• Is the voltage about 0 V indicated? ► • Loose or poor contact at the connector
Yes ▼
Yes ▼
No ▼
4-17
ELECTRICAL SYSTEM
DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)
G/W
Y/R R/Bu
5V
VCC
Y/R 5V
Bank angle BANK ECM
R/Bu
sensor SG
G/W
• Check the bank angle sensor voltage with MCS. No • Intermittent failure
• Is the voltage about 5 V indicated? ► • Loose or poor contact at the connector
Yes ▼
Yes ▼
No ▼
4-18
ELECTRICAL SYSTEM
ECM
EOT SENSOR
15 N·m
4-19
ELECTRICAL SYSTEM
O2 SENSOR
25 N·m
5.8 N·m
4-20
ELECTRICAL SYSTEM
IGNITION SYSTEM
IGNITION SYSTEM LOCATION
IGNITION SWITCH
MAIN FUSE
15 A
ECM
IGNITION COIL
SPARK PLUG
FUSE BOX:
· 10 A
IGNITION
15 A SWITCH 10 A
R/Bu Bl/R
REGULATOR/
RECTIFIER
Bl/R
BATTERY
Bu/Y
CKP Bl/R
SENSOR ECM
W/Y P/Bu
G G
G/Bl IGNITION
COIL
SPARK
PLUG
4-21
ELECTRICAL SYSTEM
SPARK PLUG REPLACEMENT
• Spark plug inspection.
16 N·m
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
IGNITION TIMING
4-22
ELECTRICAL SYSTEM
ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION
IGNITION SWITCH STARTER SWITCH
CLUTCH SWITCH
MAIN FUSE 15 A
STARTER
RELAY SWITCH
STARTER MOTOR
G/R
Y/R
STARTER
Bl SWITCH
Lg/R
CLUTCH
SWITCH NEUTRAL
SWITCH
G
4-23
ELECTRICAL SYSTEM
ELECTRICAL STARTER TROUBLESHOOTING
STARTER MOTOR DOES NOT TURN
G/R Y/R
Yes ▼
Yes ▼
No ▼
4-24
ELECTRICAL SYSTEM
STARTER MOTOR
4-25
ELECTRICAL SYSTEM
NEUTRAL SWITCH
4-26
ELECTRICAL SYSTEM
BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEM LOCATION
IGNITION
SWITCH REGULATOR/
RECTIFIER
MAIN FUSE 15 A
ALTERNATOR
BATTERY
15 A
R W
ALTERNATOR
BATTERY
G
G
REGULATOR/
RECTIFIER
4-27
ELECTRICAL SYSTEM
BATTERY
LIGHTING SYSTEM
4-28
ELECTRICAL SYSTEM
19 N·m
4-29
ELECTRICAL SYSTEM
BULB REPLACEMENT
4-30
ELECTRICAL SYSTEM
4-31
ELECTRICAL SYSTEM
4-32
ELECTRICAL SYSTEM
HEADLIGHT AIM
Beam up
Beam down
4-33
ELECTRICAL SYSTEM
SPEEDOMETER
1.2 N·m
4-34
ELECTRICAL SYSTEM
FUEL LEVEL SENSOR
R
Bl Y G Bl
4-35
ELECTRICAL SYSTEM
FUEL METER TROUBLESHOOTING
FUEL METER NEEDLE DOES NOT MOVE
FULL
EMPTY
A B
No ▼
• Connection: A – B
No • Replace the fuel level sensor with a new one 4-35,
• Standard: FULL 6 – 10 Ω, EMPTY 90 – 100 Ω.
► and recheck.
• Does the standard resistance exist?
Yes ▼
4-36
ELECTRICAL SYSTEM
ELECTRICAL COMPONENT
IGNITION SWITCH
HORN
4-37
MEMO
INDEX
dummytext
INDEX
A Few Words About Safety ·············································1-2 HANDLEBAR································································ 3-18
A H
5-1
STARTER
MOTOR
FUSE BOX
SUB1 SUB2
STARTER
R
TURN DC-LOAD ECM
RELAY BANK
SIGNAL SWITCH CUT RELAY ANGLE REAR
IACV1B
IACV2B
IACV1A
IACV2A
BRAKE LIGHT
K-LINE
RELAY IGNITION
IGPLS
NLSW
FI IND
BANK
15A SENSOR
PCM
PCR
VCC
SWITCH
10A
10A
SCS
PCP
SWITCH
PG2
PG1
FFP
THL
IGP
INJ
SG
DLC
TO
PB
O2
LG
TA
-
-
BAT1
IACV
GND
R
OUT
Vcc
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
A-11
A- 9
A- 8
A- 7
A- 6
A- 5
A- 4
A- 3
A- 2
A- 1
4P
VO1
2P R 3P 4P 33P
Bl 4P
BATTERY R
12V 6Ah
Gr/Bu
Bu/W
Bu/W
W/Bu
Bu/Bl
Bu/Bl
R/Bu
R/Bu
R/Bu
Br/W
R/Bu
Br/W
Bu/Y
Br/Bl
Br/Bl
Y/Bu
P/Bu
Bl/W
Lg/Y
G/W
G/W
R/W
Bl/G
Bl/O
Bl/G
G/Bl
G/Bl
W/Y
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
P/Bl
G/R
G/R
G/R
G/Y
Y/R
Y/R
Y/R
Bu
Bu
Gr
Bl
Bl
Bl
Bl
G
G
R
R
Y
2P
Bl 2P
FRONT
G/Y
6P
Bl
BRAKE
LIGHT
R/Bu
R/W
SWITCH G/Y Bl Bl
G/Y G/Y
STARTER ST BAT
Y/R Y/R Y/R
SWITCH Bl/R Bl/R Bl/R
G/R 2P
Bl G/R
Lg/R
DIODE
FUEL METER Y/W
Lg/R
G/Bl
HI-BEAM IND Bu 9P Bl
12V 1.7W G Bl Bl LICENSE LIGHT
Y/W Y/W 12V 5W
FI IND Bl Bu Bu
12V 3.4W W/Bu W/Bu W/Bu G
Y
N IND Bl
12V 3.4W Lg/R Lg/R Lg/R
Y Y RIGHT REAR
TURN IND Lb TURN SIGNAL LIGHT
12V 3.4W O Lb Lb 12V 10W
O O
METER ILLUMI 2 Y G/Bl G/Bl 2P Lb
12V 1.7W G G G G G G
4P R Y Y
METER ILLUMI 1 Y Lb Lb
12V 2.0W G G BRAKE/TAIL LIGHT
G
G 12V 5W/21W
O O
G/Y G/Y G/Y
RIGHT FRONT G G G
TURN SIGNAL Lb Y Y Y
LIGHT G 3P
12V 10W LEFT REAR
TURN SIGNAL LIGHT
12V 10W
HEAD LIGHT
4P Bl G
12V 35W/35W Y Y O
Y/R
Y/R
Y/R
Bl Bl Bu
W W W
G G G
G
G
G
Lb Lb
POSITION Y O O
LIGHT
Gr/Bu
G
Lg/Y
Bl/W
G/W
Y/R
12V 5W
Bu/Y
Lg/R
W/Y
Y
W
G
LEFT FRONT 5P
2P
TURN SIGNAL O 3P 2P
Bl
LIGHT G
12V 10W
Gr/Bu
Bu/Y
W/Y
Lg/Y
G/W
Y/R
W
G
Y
9P Bl
L
TURN O O O
W
SIGNAL Gr Gr Gr
SWITCH R Lb Lb Lb
Bl G/R
LO W W W
DIMMER HL Y Y Y
SWITCH Bu Bu Bu
HI
G G
HO
HORN Lg Lg Lg
Bl/O
G/Bl
Bl/R
Y/W
SWITCH BAT
Bl Bl Bl
Gr/Bu
P/Bu
Lg/Y
G/W
G/W
G/W
G/W
G/W
G/W
G/W
G/Bl
G/Bl
R/W
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
P/Bl
Y/R
Y/R
W
Bl
G
G
G
G
Y/Bu
R
Y
Y
G/W
5P
Lg
CLUTCH Bl
SWITCH G
W
Bu/Y
Lg/R
2P 6P 2P
Bl/O
G/Bl
Bl/R
Y/W
O2 MAP
HORN NEUTRAL SENSOR SENSOR TP
W/Y
SWITCH SENSOR
IAT
G