You are on page 1of 128

Shop Manual

AFS110KSF/MSF/KDF/MCF

1. General Information

2. Fuel & Engine

3. Frame & Chassis

4. Electrical System

This book is Specific Shop Manual.


Refer to “Basic Shop Manual” for basic and
common maintenance instructions. AFS110KSF/MSF/KDF/MCF-J (2018)
1. GENERAL INFORMATION

A Few Words About Safety ················ 1-2 SPECIAL TOOL LIST ························ 1-15

How To Use This Manual ··················· 1-3 CABLE & HARNESS ROUTING ·········· 1-16

MODEL IDENTIFICATION ··················· 1-5 TECHNICAL FEATURE ····················· 1-25

SPECIFICATIONS······························ 1-6 MAINTENANCE SCHEDULE ·············· 1-26

TORQUE VALUE ·····························1-12

1-1
GENERAL INFORMATION

A Few Words About Safety


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.

For Your Customer’s Safety


Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

Improper service or repairs can create an unsafe


condition that can cause your customer to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.

For Your Safety


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

Failure to properly follow instructions and


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

Important Safety Precautions


Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

1-2
GENERAL INFORMATION

How To Use This Manual


This manual is "Spec (Specific)" Service Manual. The service and repair information for this model is described in this
manual as specific information. Refer to “Basic" Service Manual for basic/common service information and
instructions.
Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the
break-in period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided
safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,
or CAUTION. These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

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

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

• Instructions – how to service this vehicle correctly and safely.

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 BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF
APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY
TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,
MOTOR SCOOTERS OR ATVS.

© Honda Motor Co., Ltd.


SERVICE PUBLICATION OFFICE
Date of Issue: May, 2017

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

Removal or Disassembly procedure. Installation or Assembly procedure.


Disconnect the connector. Connect the connector.

Order of installation/assembly with a point of


Order of removal/disassembly with a point of note.
note.

Tighten specified torque. Replace with a new one before assembly.

Check the part for an inspection. Measure the part for an inspection.

Turn ignition switch to OFF. Turn ignition switch to ON.

Start the engine. Measure a resistance or check continuity.

Measure a voltage. Measure an ampere.

Refer to “Basic” Service Manual for the instruc-


Use the Honda special tool.
tion.

LUBRICATION AND SEAL SYMBOL


Apply molybdenum oil solution (mixture of an
Use the recommend engine oil. engine oil and molybdenum grease in a ration of
1:1).
Apply a specified grease. Use a multi-purpose
Apply a liquid sealant.
grease unless otherwise specified.

Apply a locking agent. Use a medium strength


Use DOT 3 or DOT 4 brake fluid.
one unless otherwise specified.

Use a specified fork oil or suspension fluid.

1-4
GENERAL INFORMATION

MODEL IDENTIFICATION
• Model name: AFS110KSF/MSF/KDF/MCF
• Destination: Thailand, Laos, and Asia direct

TYPE FRONT DISC FRONT DRUM SPOKE WHEEL CAST WHEEL NONE-SHUTTER KEY
AFS110KSF O – O – –
AFS110MSF O – O – –
AFS110KDF – O O – O
AFS110MCF O – – O –

AFS110MCF shown:

VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER

1-5
GENERAL INFORMATION

SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1,919 mm
Overall width KDF/ MCF 696 mm
KSF/ MSF 709 mm
Overall height 1,080 mm
Wheelbase 1,227 mm
Seat height 760 mm
Footpeg height 272 mm
Ground clearance 135 mm
Curb weight KDF/ KSF 95 kg
MSF 97 kg
MCF 98 kg
FRAME Frame type Back bone type
Front suspension Telescopic fork
Front axle travel 81 mm
Rear suspension Swingarm
Rear axle travel 82 mm
Front tire size 70/90 – 17 M/C 38P
Rear tire size 80/90 – 17 M/C 50P
Front tire brand NF63B Z (IRC), V357F (VEE)
Rear tire brand NR78Y D (IRC), V357RE (VEE)
Front brake KSF/MSF/ Hydraulic disc
MCF
KDF Mechanical leading trailing
Rear brake Mechanical leading trailing
Caster angle 26° 30’
Trail length 68 mm
Fuel tank capacity 3.7 liters
ENGINE Bore and stroke 50.000 x 55.597 mm
Displacement 109.17 cm3
Compression ratio 9.3 : 1
Valve train 2 valve, chain driven SOHC
Intake opens at 1 mm lift 5° BTDC
valve closes at 1 mm lift 30° ABDC
Exhaust opens at 1 mm lift 34° BBDC
valve closes at 1 mm lift 0° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper element
Engine dry weight KDF/ KSF 20.5 kg
MSF/ MCF 22.2 kg
Cylinder arrangement Single cylinder inclined 80° from vertical
FUEL SYSTEM Type PGM-FI
Throttle bore 22 mm

1-6
GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Automatic centrifugal type
Transmission Constant mesh, 4-speed
Primary reduction 4.059 (69/17)
Final reduction 2.642 (37/14)
Gear ratio 1st 2.615 (34/13)
2nd 1.555 (28/18)
3rd 1.136 (25/22)
4th 0.916 (22/24)
Gearshift pattern Left foot operated return system (rotary system;
only when the motorcycle is not running)
- N - 1 - 2 - 3 - 4 (- N)
ELECTRICAL Ignition system Full transistorized ignition
Starting system KDF/ KSF Kickstarter
MSF/ MCF Kickstarter with electric starter motor
Charging system Single phase output alternator
Regulator/rectifier Semiconductor type
Lighting system Alternator

FUEL & ENGINE SPECIFICATIONS


FUEL SYSTEM

ITEM SPECIFICATIONS
Throttle body identification number GQRQB
Idle air screw standard opening 2 turns out from fully seated position
Engine idle speed 1,400 ± 100 rpm
Throttle grip free play 2 – 6 mm
Fuel pressure at idle 263 – 316 kPa
Fuel pump flow (at 12 V) 82 cm3 minimum/10 seconds
EOT sensor resistance 20°C 2.5 – 2.8 kΩ
100°C 0.21 – 0.22 kΩ
IAT sensor resistance (20°C) 1 – 4 kΩ
Fuel injector resistance (20°C) 11 – 13 Ω
LUBRICATION SYSTEM
Unit: mm
ITEM STANDARD LIMIT
Engine oil capacity After draining 0.8 liter –
After disassembly 1.0 liter –
Recommended engine oil Honda "4-stroke motorcycle oil" or an
equivalent motor oil.
API service classification: SG or higher –
JASO T903 standard: MA
Viscosity: SAE 10W-30
Oil pump rotor Tip clearance – 0.15
Body clearance 0.15 – 0.21 0.26
Side clearance 0.03 – 0.09 0.15
CYLINDER HEAD/VALVES
Unit: mm
ITEM STANDARD LIMIT
Cylinder compression 0.8 MPa at 600 rpm –
Cylinder head warpage – 0.05
Valve clearance IN 0.10 ± 0.02 –
EX 0.15 ± 0.02 –
Valve stem O.D. IN 4.975 – 4.990 4.965
EX 4.955 – 4.970 4.945

1-7
GENERAL INFORMATION
ITEM STANDARD LIMIT
Valve guide I.D. IN/EX 5.000 – 5.012 5.03
Valve guide projection IN/EX 9.1 – 9.3 –
Valve seat width IN/EX 0.9 – 1.1 1.6
Valve spring free length IN/EX 30.62 29.7
Stem-to-guide clearance IN 0.010 – 0.037 0.065
EX 0.030 – 0.057 0.085
Camshaft Cam lobe height IN 32.204 – 32.424 32.18
EX 32.033 – 32.253 32.01
Cam chain Push rod O.D. 11.985 – 12.000 11.94
tensioner Spring free length 111.3 109.0
CYLINDER/PISTON
Unit: mm
ITEM STANDARD LIMIT
Cylinder I.D. 50.005 – 50.015 50.05
Out-of-round – 0.10
Taper – 0.10
Warpage – 0.05
Piston, Piston O.D. 49.980 – 49.995 at 10 mm from
49.91
piston rings, bottom of skirt
piston pin Piston pin bore I.D. 13.002 – 13.008 13.03
Piston pin O.D. 12.994 – 13.000 12.98
Piston-to-piston pin clearance 0.002 – 0.014 0.075
Piston ring-to-ring groove Top 0.015 – 0.045 0.09
clearance Second 0.015 – 0.045 0.09
Piston ring end gap Top 0.10 – 0.25 0.50
(Riken) Second 0.10 – 0.25 0.50
Oil (side rail) 0.20 – 0.70 1.10
Piston ring end gap Top 0.10 – 0.25 0.50
(Teikoku) Second 0.10 – 0.25 0.50
Oil (side rail) 0.10 – 0.35 0.80
Connecting rod small end I.D. 13.016 – 13.034 13.05
Connecting rod-to-piston pin clearance 0.016 – 0.040 0.07
Cylinder-to-piston clearance 0.010 – 0.035 0.10
CRANKSHAFT/TRANSMISSION/KICKSTARTER
Unit: mm
ITEM STANDARD LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.35 0.60
Connecting rod radial clearance 0 – 0.008 0.05
Runout – 0.10
Transmission Gear I.D. M2, M3 17.000 – 17.018 17.04
C1 18.000 – 18.018 18.04
C4 20.000 – 20.021 20.04
Bushing O.D. C1 17.966 – 17.984 17.94
Bushing I.D. C1 15.000 – 15.018 15.04
Gear-to-bushing clearance C1 0.016 – 0.052 0.10
Mainshaft O.D. at M3 16.966 – 16.984 16.95
Countershaft O.D. at C1
14.966 – 14.984 14.95
bushing
Gear-to-shaft clearance M3 0.016 – 0.052 0.09
Bushing-to-shaft clear-
C1 0.016 – 0.052 0.09
ance

1-8
GENERAL INFORMATION
ITEM STANDARD LIMIT
Shift fork/ Shift Shift fork I.D. 34.075 – 34.100 34.14
drum Shift fork claw thickness 4.85 – 4.95 4.60
Shift drum O.D. Left 23.940 – 23.980 23.92
Right 33.950 – 33.975 33.93
Kickstarter Pinion I.D. 20.000 – 20.021 20.08
Spindle O.D. 19.959 – 19.980 19.94
CLUTCH/GEARSHIFT LINKAGE
Unit: mm
ITEM STANDARD LIMIT
Manual clutch Disc thickness 2.00 – 2.20 1.82
Plate warpage – 0.20
Clutch spring free height 5.01 4.63
Primary driven gear I.D. 23.000 – 23.021 23.07
Clutch outer guide I.D. 16.991 – 17.009 17.049
O.D. 22.959 – 22.980 22.940
Mainshaft O.D. at clutch outer guide 16.966 – 16.984 16.87
Centrifugal Clutch drum I.D. 104.0 – 104.2 104.3
clutch Clutch weight lining thickness 1.5 1.0
One-way clutch drum I.D. 42.000 – 42.020 42.04
One-way clutch roller O.D. 4.990 – 5.000 4.97
Primary drive gear I.D. 19.030 – 19.058 19.11
Crankshaft O.D. at primary drive gear 18.967 – 18.980 18.92
ALTERNATOR/STARTER CLUTCH
Unit: mm
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss O.D. 45.660 – 45.673 45.642
FRAME & CHASSIS SPECIFICATIONS
FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm
ITEM STANDARD SERVICE LIMIT
Cold tire pressure Driver only 200 kPa –
Driver and passenger 200 kPa –
Axle runout – 0.2
Wheel rim runout Radial – 2.0
Axial – 2.0
Fork Spring free length KDF 293 281.3
KSF/MSF/MCF 294.3 282.5
Pipe runout – 0.2
Recommended fork KDF CN3# –
fluid KSF/MSF/MCF Honda Ultra Cushion Oil 10W –
Fluid level KDF 93 –
KSF/MSF/MCF 78 –
Fluid capacity KDF 61 ± 1 cm3 –
KSF/MSF/MCF 62 ± 1 cm3 –
Brake Brake drum I.D. 110.0 – 110.2 –
Brake lever freeplay 10 – 20 –

1-9
GENERAL INFORMATION
REAR WHEEL/BRAKE/SUSPENSION
Unit: mm
ITEM STANDARD SERVICE LIMIT
Cold tire pressure Driver only 225 kPa –
Driver and passenger 280 kPa –
Axle runout – 0.2
Wheel rim runout Radial – 2.0
Axial – 2.0
Drive chain Size/link RK420SL – 104RJ –
DID420AD2 – 104RB –
KMC420JB – 104 –
Slack 20 – 30 –
Brake Brake drum I.D. 110.0 – 110.2 111.0
Brake pedal freeplay 20 – 30 –
HYDRAULIC BRAKE
Unit: mm
ITEM STANDARD SERVICE LIMIT
Recommended brake fluid DOT 3 or 4 –
Brake disc thickness 3.3 – 3.7 3.0
Brake disc runout – 0.30
Master cylinder I.D. 11.000 – 11.043 11.055
Master piston O.D. 10.957 – 10.984 10.945
Caliper cylinder I.D. 33.96 – 34.01 34.02
Caliper piston O.D. 33.878 – 33.928 33.87

ELECTRICAL SYSTEM SPECIFICATIONS


IGNITION SYSTEM

ITEM SPECIFICATIONS
Spark plug CPR6EA – 9S (NGK) /U20EPR9S (DENSO)
Spark plug gap 0.80 – 0.90 mm
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 1.5 V minimum
Ignition timing 5° BTDC at idle speed
BATTERY/CHARGING SYSTEM

ITEM SPECIFICATIONS
Battery Type KSF/ KDF YTZ3/ FTZ3V
MSF/ MCF YTZ4V/ FTZ4V
Capacity YTZ3/ FTZ3V 12 V – 2.3–2.5 Ah (10HR)
YTZ4V/ FTZ4V 12 V – 3.0 Ah (20HR)
Current leakage 0.001 mA max.
Voltage Fully charged 13.0 – 13.2 V
Needs charging Below 12.4 V
Charging Normal 0.3 A/5 – 10 h
current Quick 3.0 A/0.5 h
Alternator Capacity 0.17 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 (High/Low) 12 V – 32/32 W
Position light KSF/MSF/MCF 12 V – 3.4 W x 2
Brake/tail light 12 V – 18/5 W
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Meter light 12 V – 1.7 W x 2
Turn signal indicator 12 V – 3.4 W x 2
High beam indicator 12 V – 1.7 W
Gear position indicator 12 V – 1.7 W x 4
Neutral indicator 12 V – 1.7 W
MIL 12 V – 1.7 W
Fuse Main 15 A
Sub 10 A

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
MAINTENANCE
ITEM Q'TY DIA TRQ REMARKS
Spark plug 1 10 16
Valve adjusting screw lock nut 2 5 9 Apply oil to the threads and
seating surface.
Engine oil drain bolt 1 12 24
Engine oil centrifugal filter cover bolt 3 5 5 Apply locking agent.
Throttle cable adjusting nut 1 6 4.5
Timing hole cap 1 14 6
Clutch adjusting lock nut 1 8 12
Air cleaner housing cover screw 5 5 1.1
Headlight aim adjusting bolt 1 4 2
Rear axle nut 1 12 59
FUEL SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Fuel tank mounting bolt 4 6 14
Injector mounting bolt 1 6 12
Fuel pump set plate nut 4 6 12 Î2-4
Throttle cable bracket screw 1 5 3.4
LUBRICATION SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Oil pump cover bolt 3 5 5
CYLINDER HEAD/VALVES
ITEM Q'TY DIA TRQ REMARKS
Cylinder head cover special bolt 2 6 10
Cylinder head cap nut 4 7 13 Apply oil to the threads and
seating surface.
Cam sprocket bolt 2 8 27 Apply oil to the threads and
seating surface.
Cam chain tensioner sealing bolt 1 14 22
Cam chain tensioner arm pivot bolt 1 8 16
Cam chain guide lower roller pivot bolt 1 6 10
Rocker arm shaft stopper bolt 2 6 5 Apply oil to the threads and
seating surface.
CYLINDER/PISTON
ITEM Q'TY DIA TRQ REMARKS
Cam chain guide roller pin bolt 1 8 10
Cylinder stud bolt 4 7 –

1-12
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE
ITEM Q'TY THREAD TRQ REMARKS
Shift drum stopper arm bolt 1 6 10 Apply locking agent: Î2-25
Shift return spring pin 1 8 30
Gearshift cam plate socket bolt 1 6 17 Apply locking agent: Î2-25
Centrifugal clutch lock nut 1 14 54 Apply oil to the threads and
seating surface.
Clutch center lock nut 1 14 54 Apply oil to the threads and
seating surface.
Clutch lifter plate bolt 4 6 12
ALTERNATOR
ITEM Q'TY DIA TRQ REMARKS
Flywheel nut 1 10 40 Apply oil to the threads and
seating surface.
Starter clutch outer mounting torx bolt 6 6 16 Apply locking agent.
ENGINE REMOVAL/INSTALLATION
ITEM Q'TY DIA TRQ REMARKS
Drive sprocket fixing plate bolt 2 6 12
Engine hanger nut 3 10 59
FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Exhaust pipe joint nut 2 8 27
Muffler cover bolt 2 6 10
Exhaust pipe stud bolt 2 6 – Î3-15
Throttle cable lock nut 1 6 3
1 10 3
Chain cover mounting bolt 1 6 7
CRANKSHAFT/TRANSMISSION/KICKSTARTER
ITEM Q'TY DIA TRQ REMARKS
Cam chain guide sprocket spindle 1 6 10
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
ITEM Q'TY DIA TRQ REMARKS
Front brake arm nut 1 6 10
Brake lever pivot bolt 1 5 1
Brake lever pivot nut 1 5 4.5
Handlebar weight screw 2 6 9
Steering stem lock nut 1 26 83 For tigthten sequence Î3-23
Steering stem top thread 1 26 25
Bottom bridge pinch bolt 4 10 64
Handlebar post nut 1 10 59 Self lock-nut
Front axle nut 1 12 59 Self lock-nut
Front brake disc socket bolt 4 8 42 Pre-coated (ALOC) bolt,
replace with a new one.
Fork socket bolt 2 8 20 Apply locking agent.
Fork cap bolt 2 20 22
Front spoke 36 BC2.9 3.2
Brake hose clamp bolt 1 6 12 Pre-coated (ALOC) bolt,
replace with a new one.

1-13
GENERAL INFORMATION
REAR WHEEL/BRAKE/SUSPENSION
ITEM Q'TY DIA TRQ REMARKS
Rear axle nut 1 12 59 Self lock-nut
Driven sprocket bolt 4 8 32 Self lock-nut
Driven flange stud bolt 4 8 – Î3-24
Rear brake stopper arm nut 2 8 22
Rear brake arm bolt 1 6 10 Self lock-nut
Shock absorber upper mounting bolt 2 10 24
Shock absorber lower mounting nut 2 10 24
Swingarm pivot nut 1 12 59
Rear spoke 36 BC3.2 3.2
BRAKE SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Caliper bleed valve 1 8 5.4
Pad pin 1 10 17
Caliper bracket pin bolt 1 8 17 Pre-coated (ALOC) bolt,
replace with a new one.
Caliper mounting bolt 2 8 30 Pre-coated (ALOC) bolt,
replace with a new one.
Brake hose oil bolt 2 10 34
Master cylinder reservoir cap screw 2 4 1.5
Front brake lever pivot bolt 1 6 1
Front brake lever pivot nut 1 6 5.9
Front brake light switch screw 1 4 1.2
Front brake hose clamp bolt 1 6 12 Pre-coated (ALOC) bolt,
replace with a new one.
PGM-FI SYSTEM
ITEM Q'TY DIA TRQ REMARKS
EOT sensor 1 10 14
O2 sensor 1 12 24.5
ELECTRIC STARTER
ITEM Q'TY DIA TRQ REMARKS
Starter motor case screw 3 5 4.2
Starter motor cable screw 1 4 2
LIGHTS/METERS/SWITCHES
ITEM Q'TY DIA TRQ REMARKS
Key shutter socket bolt 1 6 9 Pre-coated (ALOC) bolt,
replace with a new one.
Front turn signal light screw 4 5 1.1
Combination meter screw 3 5 1.1
OTHERS
ITEM Q'TY DIA TRQ REMARKS
Sidestand pivot bolt 1 10 18
Sidestand pivot nut 1 10 44

1-14
GENERAL INFORMATION

SPECIAL TOOL LIST


TITLE TOOL No TOOL NAME
MAINTENANCE 07708-0030400 Valve adjusting wrench
07709-0010001 Timing cap wrench
FUEL SYSTEM 07406-0040004 Fuel pressure gauge
07ZAJ-S5A0111 Pressure gauge manifold
07ZAJ-S5A0130 Hose attachment, 6 mm/9 mm
07ZAJ-S5A0120 Hose attachment, 9 mm/9 mm
07ZAJ-S5A0150 Attachment joint, 6 mm/9 mm
PGM-FI SYSTEM 070PZ-ZY30100 SCS connector
07ZAJ-RDJA110 Test probe
FRXM17 (Snap on) Flare nut socket
IGNITION SYSTEM 07HGJ-0020100 Peak voltage adaptor
07ZAJ-RDJA110 Test probe
07709-0010001 Timing cap wrench
CYLINDER HEAD/VALVE/CAMSHAFT 07725-0030000 Universal holder
07757-0010000 Valve spring compressor
07959-KM30101 Valve spring compressor attachment
07942-MA60000 Valve guide driver 5.0 mm
07743-0020000 Valve guide adjusting driver
07984-MA60001 Valve guide reamer, 5.0 mm
DRIVETRAIN/FINAL REDUCTION 07716-0020100 Lock nut wrench, 20 x 24 mm
07716-0020500 Extension bar
07HMB-HB70100 Clutch center holder
07725-0030000 Universal holder
ALTERNATOR/STARTER CLUTCH 07725-0040001 Flywheel holder
07KMC-HE00100 Flywheel puller, 30 mm
FRONT WHEEL/SUSPENSION/ 07746-0050300 Bearing remover head, 12 mm
STEERING 07746-0050100 Bearing remover shaft
07749-0010000 Driver
07746-0010100 Attachment, 32 x 35 mm
07746-0040200 Pilot, 12 mm
07748-0010001 Oil seal remover
07746-0010200 Attachment, 37 x 40 mm
07916-KM10000 Socket wrench
07916-3710101 Steering stem socket
07GMD-KS40100 Ball race remover shaft
07948-4630100 Ball race remover, 34.5 mm
07947-KA20200 Fork seal driver attachment, 35.2 mm
07946-3710701 Bearing driver attachment
07947-SB00200 Oil seal driver, 53.5 mm
REAR WHEEL/SUSPENSION 07746-0050300 Bearing remover head, 12 mm
07746-0050100 Bearing remover shaft
07749-0010000 Driver
07746-0010200 Attachment, 37 x 40 mm
07746-0040200 Pilot, 12 mm
07746-0040400 Pilot, 17 mm
HYDRAULIC BRAKE 07914-SA50001 Snap ring pliers
BATTERY/CHARGING SYSTEM BM-210 Battery tester
LIGHT/METERS/SWITCHES 07ZAJ-RDJA110 Test probe
07HGJ-0020100 Peak voltage adaptor

1-15
dummyhead

GENERAL INFORMATION

CABLE & HARNESS ROUTING


DRUM BRAKE TYPE

HEADLIGHT 9P
CONNECTOR

LEFT HANDLEBAR DIMMER SWITCH 3P


FRONT BRAKE LIGHT SWITCH WIRE CONNECTOR
SWITCH WIRE

FRONT BRAKE CABLE


HORN SWITCH 2P
(BLACK) CONNECTOR

TURN SIGNAL LIGHT


SWITCH 3P (RED)
SPEEDOMETER CONNECTOR
THROTTLE CABLE
CABLE
COMBINATION
SPEEDOMETER METER SUB
CABLE HARNESS

FRONT BRAKE CABLE

HORN WIRE

FRONT BRAKE CABLE

IGNITION SWITCH
4P CONNECTOR

COMBINATION METER
SUB HARNESS

CONNECTORS:
– COMBINATION METER 9P CONNECTOR
– COMBINATION METER 6P CONNECTOR

1-16
dummyhead

GENERAL INFORMATION
DISC BRAKE TYPE

FRONT BRAKE HOSE

LEFT HANDLEBAR
FRONT BRAKE LIGHT
SWITCH WIRE
SWITCH WIRE

HEADLIGHT 9P DIMMER SWITCH 3P


CONNECTOR CONNECTOR

STARTER SWITCH 3P
(Black) CONNECTOR HORN SWITCH 2P
(ELECTRIC STARTER (BLACK) CONNECTOR
TYPE ONLY)

TURN SIGNAL LIGHT


SWITCH 3P (RED)
CONNECTOR
THROTTLE CABLE
COMBINATION
SPEEDOMETER METER SUB
SPEEDOMETER CABLE HARNESS
CABLE

HORN WIRE

FRONT BRAKE HOSE

IGNITION SWITCH FRONT BRAKE HOSE


4P CONNECTOR

SPEEDOMETER
CABLE
COMBINATION METER
SUB HARNESS

CONNECTORS:
– COMBINATION METER 9P CONNECTOR
– COMBINATION METER 6P CONNECTOR

1-17
dummyhead

GENERAL INFORMATION
DRUM BRAKE TYPE

THROTTLE CABLE

15°

FRONT BRAKE CABLE

FRONT BRAKE CABLE HANDLEBAR

SPEEDOMETER CABLE

COMBINATION METER
SUB HARNESS

COMBINATION METER
SUB HARNESS

FRONT BRAKE CABLE

SPEEDOMETER CABLE

COMBINATION METER
SUB HARNESS

1-18
dummyhead

GENERAL INFORMATION
DISC BRAKE TYPE

THROTTLE CABLE

15°

FRONT BRAKE HOSE

HANDLEBAR

FRONT BRAKE HOSE

SPEEDOMETER CABLE

COMBINATION METER
SUB HARNESS

COMBINATION METER
SUB HARNESS

COMBINATION METER
SUB HARNESS

SPEEDOMETER CABLE

1-19
dummyhead

GENERAL INFORMATION

DISC BRAKE TYPE SHOWN:

IGNITION SWITCH 4P
CONNECTOR

CONNECTORS:
– COMBINATION METER 9P CONNECTOR
– COMBINATION METER 6P CONNECTOR

MAIN WIRE HARNESS

FRONT BRAKE HOSE

TP SENSOR 3P
(BLACK) CONNECTOR

1-20
dummyhead

GENERAL INFORMATION

FUEL FEED HOSE

INJECTOR 2P (Black)
CONNECTOR

CRANKCASE
BREATHER HOSE

CKP SENSOR
CONNECTORS

DLC CONNECTOR

GEAR POSITION
SWITCH 6P
CONNECTOR

GEAR POSITION
CRANKCASE ALTERNATOR 2P
SWITCH WIRE
BREATHER HOSE CONNECTOR

EOT SENSOR 2P (Black) ALTERNATOR/CKP


CONNECTOR SENSOR WIRE

EOT SENSOR WIRE

1-21
dummyhead

GENERAL INFORMATION
KICKSTARTER TYPE
REGULATOR/ IGNITION COIL
RECTIFIER

MAIN WIRE HARNESS


TP SENSOR WIRE
O2 SENSOR
CONNECTOR

SPARK PLUG WIRE

BATTERY WIRE HARNESS


CONNECTORS

REAR BRAKE LIGHT


SWITCH CONNECTORS O2 SENSOR WIRE

ELECTRIC STARTER TYPE


REGULATOR/ IGNITION COIL
MAIN WIRE HARNESS
RECTIFIER

TP SENSOR WIRE
O2 SENSOR
CONNECTOR

SPARK PLUG WIRE


BATTERY WIRE HARNESS
CONNECTORS

REAR BRAKE LIGHT STARTER MOTOR O2 SENSOR WIRE


SWITCH CONNECTORS CONNECTOR

1-22
dummyhead

GENERAL INFORMATION

REAR BRAKE LIGHT 4P FUEL PUMP FUEL FEED HOSE


CONNECTOR

REAR BRAKE LIGHT FUEL PUMP WIRE ECM 33P CONNECTOR


SWITCH WIRE

1-23
dummyhead

GENERAL INFORMATION
KICKSTARTER TYPE

BATTERY
BATTERY SUB
HARNESS

SUB FUSE 10 A

BATTERY NEGATIVE (–) BATTERY POSITIVE (+)


MAIN FUSE 15 A TERMINAL TERMINAL

ELECTRIC STARTER TYPE

BATTERY
BATTERY SUB
HARNESS

STARTER RELAY

SUB FUSE 10 A

BATTERY NEGATIVE (–) BATTERY POSITIVE (+)


MAIN FUSE 15 A TERMINAL TERMINAL

1-24
GENERAL INFORMATION

TECHNICAL FEATURE
FUEL PUMP SYSTEM WITH A FUEL FILTER BLOCKAGE REMINDER FUNCTION

FUEL TANK
BREATHER FILTER

FUEL PUMP

FUEL LEVEL

BREATHER
PORTION
BREATHER
PASSAGE

PUMP CHAMBER

To FUEL INJECTOR

FUEL FILTER

: Air suction passage under fuel filter blockage

: Air discharge passage under normal fuel filter condition

: Fuel flow under normal fuel filter condition

The fuel pump system of this model consists of the following components:
– Fuel pump chamber
– Fuel filter
– Breather portion
– Breather passage
– Breather filter
Under normal condition, the fuel pump chamber sucks fuel through the fuel filter and then supplies it to the injector.
When the fuel filter is clogged, the fuel is sucked into the pump chamber through the breather passage in order to
keep the vehicle running. The breather filter is located in the upper inner side of fuel tank. When the fuel is consumed
to the point where the breather filter is exposed above the fuel level, a certain amount of air will be drawn into the
pump chamber via the breather filter and breather passage. This incoming air produces "a lack of fuel", which impairs
engine performance in order to notify the rider of the fuel filter blockage. This symptom works as a reminder for the
filter replacement.
This system eliminates the need of fuel filter replacement according to a fixed interval, as the rider will experience the
symptom and notice the filter blockage during vehicle usage.
The driveability remains normal as long as the fuel level in tank is maintained above the breather filter because no air
will be drawn into the pump chamber, even when the fuel filter is clogged.
If the fuel in tank is sufficient but such symptom as poor engine performance, lack of fuel, or engine start failure exist,
perform the fuel supply test.
If the fuel filter is replaced, the ECM must be initialized to avoid the rich of fuel.

1-25
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.

FREQUENCY (NOTE 1) REFER


ANNUAL REGULAR
ITEMS NOTE X1,000 km 1 6 12 18 24 30 36 TO
CHECK REPLACE
X1,000 mi 0.6 4 8 12 16 20 24 PAGE
* FUEL LINE I I I I I I I
* THROTTLE OPERATION I I I I I I I
* AIR CLEANER NOTE 2 R R Î2-7
CRANKCASE BREATHER NOTE 3 C C C C C C
SPARK PLUG I R I R I R Î4-14
* VALVE CLEARANCE I I I I I I Î2-18
ENGINE OIL R R R R R R R R Î2-15
** ENGINE OIL STRAINER C C C Î2-15
SCREEN
** ENGINE OIL CENTRIFUGAL C C C
FILTER
* ENGINE IDLE SPEED I I I I I I I I
DRIVE CHAIN EVERY 500 km (300 mi) I, L
BRAKE FLUID I I I I I I I
NOTE 4 2 years
(AFS110KSF/MSF/MCF)
BRAKE SHOES WEAR I I I I I I I
(AFS110KDF)
BRAKE SHOES/PADS WEAR I I I I I I I
(AFS110KSF/MSF/MCF)
BRAKE SYSTEM I I I I I I I I
BRAKE LIGHT SWITCH I I I I I I I
HEADLIGHT AIM I I I I I I I Î4-20
* CLUTCH SYSTEM I I I I I I I I
SIDESTAND I I I I I I I
* SUSPENSION I I I I I I I
* NUTS, BOLTS, FASTENERS I I I I I
** WHEELS/TIRES I I I I I I I
** STEERING HEAD BEARINGS I I I I
• * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
• ** In the interest of safety, we recommend these items be serviced only by a dealer.
• Honda recommends that a dealer should road test the vehicle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Replacement requires mechanical skill.

1-26
2. FUEL & ENGINE

FUEL LINE ······································· 2-2 CYLINDER/PISTON ·························· 2-24

FUEL PUMP UNIT······························ 2-4 CLUTCH/GEARSHIFT LINKAGE········· 2-25

FUEL TANK ······································ 2-6 ALTERNATOR/STARTER CLUTCH····· 2-32

AIR CLEANER ·································· 2-7 CRANKCASE/CRANKSHAFT············· 2-34

THROTTLE BODY ····························· 2-8 TRANSMISSION/KICKSTARTER ········ 2-35

LUBRICATION SYSTEM ····················2-14 ENGINE UNIT ·································· 2-38

CYLINDER HEAD ·····························2-18

2-1
FUEL & ENGINE

FUEL LINE
FUEL & ENGINE

• Do not bend or twist the fuel feed hose.


• Luggage box Î3-9
• Fuel pump cover Î2-6

• Fuel pump 5P connector

• Let the engine idle until it stops.

• Battery negative (–) cable Î4-19

• Do not use tools in removal. If the connector does not


move, alternately pull and push the connector until it
comes off easily.
• Check the fuel quick connect fitting for dirt, and clean if
necessary.
• Place a shop towel over the quick connect fitting.
• Push the retainer tab forward.
• Press down the retainer and disconnect the connector
from the fuel pump joint/injector joint.
• Check the retainer condition and replace it if necessary.
• To prevent damage and keep foreign matter out, cover the
disconnected connector and pipe end with the plastic
bags.
• Press the connector onto the fuel pump joint/injector joint
until the retainer locks with a “CLICK”. If it is hard to
connect, put a small amount of engine oil on the pipe end.
• Make sure the connection is secure; check visually and by
pulling the connector.
• After installing the removed parts, turn the ignition switch
ON. (Do not start the engine.)
The fuel pump will run for about 2 seconds, and fuel
pressure will rise. Repeat 2 or 3 times, and check that
there is no leakage in the fuel supply system.

2-2
FUEL & ENGINE
FUEL SUPPLY TEST
• If the fuel in tank is sufficient but such symptom as poor
engine performance, lack of fuel, or engine start failure
exist, perform the following.
• Perform the fuel pressure test. Î2-3
If the fuel pressure is within specification, perform the fuel
flow inspection. Î2-3
• Perform the fuel flow inspection in the specified fuel
quantity. Î2-3

FUEL PRESSURE TEST


• Quick connect fitting (fuel pump side)
[A]
[B]
• Attach the fuel pressure gauge, attachments and manifold.
[A] Fuel pressure gauge: 07406-0040004
[B] Pressure gauge manifold: 07ZAJ-S5A0111
[D]
[C] Hose attachment, 9 mm/9 mm: 07ZAJ-S5A0120
[D] Hose attachment, 6 mm/9 mm: 07ZAJ-S5A0130
[C] [E] Attachment joint, 6 mm/9 mm: 07ZAJ-S5A0150

• Temporarily connect the positive cable and negative cable


to the battery and fuel pump 5P connector.
Start the engine and let it idle, and read the fuel pressure.
from FUEL PUMP Standard: 263 – 316 kPa
• If the fuel pressure is higher than specified, replace the fuel
pump assembly. Î2-4
• If the fuel pressure is lower than specified, inspect the
following.
– Fuel line leaking
[E] – Any erratic swing or vibration of the gauge needle in the
pressure gauge reading.
to INJECTOR • If the needle swings or vibrates, replace the fuel filter.
(fuel feed hose)
Î2-5
• If the needle does not swing or vibrate, replace the fuel
pump unit. Î2-4

FUEL FLOW INSPECTION


• Quick connect fitting (injector side)
from FUEL PUMP
• Place the end of the hose into an approved gasoline
container. Wipe off spilled out gasoline.
• The fuel pump operates for 2 seconds. Repeat 5 times to
meet the total measuring time.
Standard: 82 cm3 minimum/10 seconds
• If fuel flow is less than specified, inspect the following:
– Clogged fuel hose
– Fuel pump unit
– Clogged fuel filter
• Adjust the fuel in the tank until the left side of fuel gauge
needle is positioned between the specified range [A], and
inspect the fuel flow.
[A]
SPECIFIED RANGE: Middle of third segment - Right
end of red band.
• If the fuel flow is above specification, check for other
malfunctioning parts.
• If the fuel flow is under specification, replace the fuel filter.
Î2-5

2-3
FUEL & ENGINE

FUEL PUMP UNIT

12 N·m

• Fuel pump cover Î2-6


• Fuel pump side quick connect fitting Î2-2
• Loosen the nuts in a crisscross pattern in several steps.
• Carefully remove the fuel pump unit from the fuel tank to prevent damage the fuel level sensor.
• Apply 1 g maximum of engine oil to the O-ring and install it to the fuel pump unit.
• Tighten the fuel pump set plate nuts in the specified sequence as shown.
• Fuel clog or excessively damaged.

• Fuel pump malfunction and inspection.

2-4
FUEL & ENGINE
FUEL FILTER

• Fuel pump unit Î2-4


• Release the hooks from the stoppers by slightly spreading the hooks.
• Turn the filter clockwise.
• Pull up the filter and remove it from the fuel pump.
• Align the triangle marks on the filter and fuel pump body.
• Turn the filter counterclockwise until the hooks are completely secured by the stoppers.
• If the fuel filter is changed, the ECM must be initialized.Î2-11

2-5
FUEL & ENGINE
FUEL TANK

14 N·m

• Body cover Î3-8


• Quick connect fitting (fuel pump side) Î2-2

2-6
FUEL & ENGINE
AIR CLEANER

1.1 N·m

• Discard the air cleaner element in accordance with the maintenance schedule. Î1-26
• Replace the element any time if it is excessively dirty or damaged.
• Lower side cover Î3-6

2-7
FUEL & ENGINE
THROTTLE BODY

• Lower side cover Î3-6


• Quick connect fitting (injector side) Î2-2
• TP Sensor reset procedure Î2-10

• Throttle body cleaning and inspection.

2-8
FUEL & ENGINE

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 remove the white painted screw and TP sensor. Removing them can cause throttle body malfunction.
• Do not loosen or tighten the white painted nut of the throttle drum. Loosening or tightening it can cause throttle body
malfunction.
• TP sensor reset procedure Î2-10

ENGINE IDLE SPEED ADJUSTMENT


• Start the engine and let it idle.
IDLE SPEED: 1,400 ± 100 rpm
• Idle air screw standard opening
STANDARD: 2 turns out from the fully seated position.

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.
• Lower side cover Î3-6
[A]
• Connector cover from the DLC [A]
• Connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100

[A]

• EOT sensor 2P connector [B]


• Short the EOT sensor terminals with jumper wire.
[B] Connection: Y/Bu – G/O

Y/Bu G/O

[B]
• Turn the ignition switch ON then disconnect the
jumper wire from the EOT sensor 2P connector within 10
seconds while the MIL is blinking (reset receiving pattern).
[B] • Check for the MIL blinks.
After disconnecting the jumper wire, the MIL should start
blinking. (reset completed pattern)
If the jumper wire is connected for more than 10 seconds,
the MIL will stay ON (unsuccessful pattern). Try again from
within 10 sec. the first.
• Check the engine idle speed.

Reset procedure and MIL blinking pattern

within 10 sec. 0.3 sec.


0.3 sec.
0.1 sec.

1.3 sec.

Reset receiving Reset completed

2-10
FUEL & ENGINE
ECM INITIALIZING PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, ECM initializing mode won’t start.
• Perform this procedure when any of the following fuel
related part is replaced with a new one.
[A] – Idle air screw
– Fuel pump/fuel filter
– Injector
– O2 sensor
• Perform this procedure when any of the following engine
part is replaced or is overhauled.
– Cylinder head
[A] – Valves/valve guides/valve seat
– Cylinder/piston/piston ring
• Center cover Î3-5
• Disconnect the dummy connector from the DLC [A] and
connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
• Open the throttle grip fully and hold.
• The MIL should come on and then start blinking rapidly.
Open and hold. Within 5 seconds after rapid blinking starts, close the
throttle grip and hold for more than 3 seconds.
• If the MIL does not start blinking rapidly, turn the ignition
switch OFF and try again.
• If you can not restart the procedure, recheck if the DTC is
not stored in ECM.
MIL ON Rapid blink • If the DTC is not stored but you still can not restart the
procedure, replace the ECM with a known-good one and
try again.
• When the ECM initializing is successful, the MIL will repeat
one short blink.
• If the successful pattern is indicated, turn the ignition
switch OFF.
Within 5 seconds after • If altitude is higher than 2,000 m, perform the altitude
rapid blink starts, close setting. Î2-12
and hold for more than • Check the engine idle speed.
3 seconds.

Successful pattern
(One short blink repeats)

2-11
FUEL & ENGINE
ALTITUDE SETTING
• Make sure that DTC is not stored in ECM. If stored, the
ECM cannot enter the setting mode.
• The setting will fail if the engine is started during the
procedure.
[A] • Select the appropriate MODE which meets the situation de-
scribed below.
MODE1: 0 – 2,000 m above sea level
MODE2: 2,000 – 2,500 m above sea level
MODE3: 2,500 – 3,500 m above sea level
MODE4: 3,500 m or higher above sea level
• Center cover Î3-5
[A] • Disconnect the dummy connector from the DLC [A] and
connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
Open
• Open the throttle grip fully and hold.
and • The MIL should come on and then start blinking rapidly.
hold. MODE1: Within 5 seconds after rapid blinking starts, close
the throttle grip and hold for more than 3 seconds.
MIL ON Rapid blink MODE2, 3, 4: Within 5 seconds after rapid blinking starts,
snap the throttle grip (close for 0.5 second/open for 0.5
second) as specified times, then close and hold for more
than 3 seconds.
MODE2: Snap 1 time
MODE3: Snap 2 times
MODE 1: MODE 2, 3, 4:
MODE4: Snap 3 times
Close 0.5 sec. • If the MIL does not start blinking rapidly, turn the ignition
Open 0.5 sec. switch OFF and try again.
Close and hold. • If you can not restart the procedure, recheck if the DTC is
not stored in the ECM.
• If the DTC is not stored but you still can not restart the
Within 5 seconds procedure, replace the ECM with a known-good one and
after rapid blink Within 5 seconds after rapid
try again.
starts, close and blink starts, snap (close 0.5 • The MIL will repeat the short blinks as the number of the se-
hold for more than sec./open 0.5 sec.), close and lected MODE.
3 seconds. hold for more than 3 seconds. • If the desired successful pattern is indicated, turn the
ignition switch OFF.
MODE 2: Snap 1 time • If the MIL starts blinking slowly during this step before
MODE 3: Snap 2 times successful pattern is indicated, turn the ignition switch OFF
MODE 4: Snap 3 times and try again.
Successful patterns (Short blinks repeat): • If the number of MIL blink and the number of desired MODE
is different, turn the ignition switch OFF and try again.
MODE 1: • Turn the idle air screw to the specified opening and check
the engine idle speed.
MODE 2:

MODE 3:

MODE 4:

2-12
FUEL & ENGINE
INJECTOR

• Lower side cover Î3-6


• Quick connect fitting (injector side) Î2-2

2-13
FUEL & ENGINE

LUBRICATION SYSTEM
SYSTEM DIAGRAM

OIL PUMP

OIL CENTRIFUGAL
FILTER

OIL STRAINER SCREEN

2-14
FUEL & ENGINE
ENGINE OIL LEVEL CHECK

• Let it idle for 3 - 5 minutes.


UPPER
• Wait for 2 - 3 minutes.

• Hold the motorcycle in an upright position.


LOWER • Remove the oil filler cap/dipstick and wipe off the oil from
the dipstick with a clean cloth.
• Insert the oil filler cap/dipstick without screwing it in,
remove it and check the oil level.
• If the oil level is below or near the lower level line on the
dipstick, add the recommended oil to the upper level.
• RECOMMENDED ENGINE OIL:
Honda “4-stroke motorcycle oil” or an equivalent mo-
tor oil.
API service classification: SG or higher
JASO T903 standard: MA
Viscosity: SAE 10W-30

ENGINE OIL CHANGE


• Remove the drain bolt and sealing washer. Drain oil
completely.
• Install the oil drain bolt with a new sealing washer and
tighten it to the specified torque.
• Fill the engine with the recommended engine oil.
• Check that the O-ring on the oil filler cap is in good
condition, and replace it if necessary.
• ENGINE OIL CAPACITY:
0.8 liter at draining
1.0 liter at disassembly

24 N·m

ENGINE OIL STRAINER SCREEN CHANGE


• Drain engine oil completely.
• Right crankcase cover Î2-25
• Install the oil strainer screen with its tapered side facing the
crankcase side and thinner edge facing up.

2-15
FUEL & ENGINE
ENGINE OIL CENTRIFUGAL FILTER CHANGE

5 N·m

• Drain engine oil completely.


• Right crankcase cover Î2-25
• Clean the oil centrifugal filter cover and inside of the drive plate.
• Install a new gasket with its sealed side facing the oil centrifugal filter cover.

2-16
FUEL & ENGINE
OIL PUMP

5 N·m

• Drain engine oil completely.


• Right crankcase cover Î2-25
• Install the oil pump shaft aligning the flat surface of the oil pump shaft and the inner rotor.
• Install the oil pump to the crankcase aligning the oil pump shaft groove with the cam chain guide sprocket
spindle.
• Oil pump inspection.

2-17
FUEL & ENGINE
CYLINDER HEAD
VALVE CLEARANCE
• Inspect and adjust the valve clearance while the engine is
cold (below 35 °C).
• Cylinder head cover Î3-6

• Remove the crankshaft hole cap and timing hole cap


Timing cap wrench: 07709-0010001
• Rotate the crankshaft counterclockwise until the "T" mark
on the flywheel is aligned with the index notch on the left
crankcase cover.
• Make sure that the piston is at TDC on the compression
stroke.
• Confirm the position by checking the slack in the rocker
arm. If there is no slack, turn the crankshaft again until the
correct position is obtained.

• Valve clearance (Insert a feeler gauge between the valve


adjusting screw and valve stem).
IN: 0.10 ± 0.02 mm, EX: 0.15 ± 0.02 mm
Valve adjusting wrench: 07708-0030400
9 N·m • Loosen the lock nut and turn the adjusting screw until
there is a slight drag on the feeler gauge.
• Hold the adjusting screw and tighten the lock nut.
• Recheck after tightening.

2-18
FUEL & ENGINE
CYLINDER HEAD COVER

10 N·m

• Lower side cover Î3-6


• Apply liquid sealant (TB1215 manufactured by Three Bond or equivalent) to the semicircular area of rub-
ber seal.

CAMSHAFT/ROCKER ARM
• Cylinder head cover Î2-19
• Left crankcase rear cover Î3-12
• Camchain tensioner sealing washer bolt.
• Set the piston to the TDC (Top Dead Center) on the
compression stroke.
• Turn the crankshaft counterclockwise until the index lines
on the cam sprocket is aligned with the top surface of the
cylinder head.
This position can be obtained by confirming that there is
slack in the rocker arms. If there is no slack, turn the crank-
shaft again until the correct position is obtained.

2-19
FUEL & ENGINE

27 N·m

• Remove the bolt, cam sprocket from the camshaft and cam chain off the cam sprocket.
• Hold the cam sprocket by using the special tool.
Universal holder: 07725-0030000
• Remove the camshaft from the cylinder head while holding the rocker arms to ease removal.
• Inspect cam sprocket, camshaft and camshaft bearings for damage, abnormal wear, deformation, burning or
clogs in oil passages.
• Measure each part according to cylinder head/valves specification. Replace any part if it is out of service limit.
• Install the camshaft into the cylinder head with its groove facing forward while holding the rocker arms to
ease installation.
• Install and tighten the cam sprocket bolt to specified torque.
• Camshaft inspection.

2-20
FUEL & ENGINE

13 N·m

• Inlet pipe Î2-8


• Exhausted pipe/muffler Î3-15
• Camshaft Î2-19
• Remove the cylinder head bolts.
• Loosen the cylinder head nuts in a crisscross pattern in several steps.

2-21
FUEL & ENGINE

9.1-9.3 mm

5 N·m

• Remove the valve cotters using the special tool.


Valve spring compressor: 07757-0010000
Valve spring compressor attachment: 07959-KM30101
• Ream the valve guide. Insert the reamer [1] from the combustion chamber side of the cylinder head and
always rotate the reamer clockwise.
Valve guide reamer, 5.0 mm: 07984-MA60001
• Support the cylinder head and drive the valve guides out of the cylinder head from the combustion
chamber side.
Valve guide driver, 5.0 mm: 07942-MA60000
• Drive new clips and valve guides into the cylinder head to the specified height from the cylinder head.
VALVE GUIDE PROJECTION: IN/EX: 9.1 – 9.3 mm
Valve guide adjusting driver: 07743-0020000
• Install the camshaft into the cylinder head with its groove facing up.
• Valve and valve spring inspection.
• Valve guide inspection.
• Valve seat inspection.

2-22
FUEL & ENGINE
CAM CHAIN TENSIONER

22 N·m

16 N·m

• Cylinder head cover Î2-19


• Alternator Î2-32
• Inspect tensioner spring length and push rod.

2-23
FUEL & ENGINE
CYLINDER/PISTON

176.0 ± 1.0 mm

• Cylinder head Î2-18


• Spread each piston ring and remove it by lifting up at a point opposite the gap.
• Carefully install the piston rings into the piston ring grooves with the markings facing up.
• Install the piston with the “IN” mark facing the intake side.
• Do not align the piston pin clip end gap with the piston cut-out.
• Piston and piston rings inspection.
• Cylinder inspection.

2-24
FUEL & ENGINE
CLUTCH/GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER

• Drain the engine oil


• Loosen bolts in criss cross pattern in several steps and remove them and guide.
• Check the kickstarter spindle oil seal is in good condition, replace if necessary.

• Install aligning clutch adjuster/lifter boss with the hole in the right crankcase cover.
• Adjust the clutch system lock nut after installing the right crankcase cover.

2-25
FUEL & ENGINE
CLUTCH

• Clutch system can be serviced with the engine installed on the frame.
• Right crankcase Î2-25
• Engine oil centrifugal filter cover Î2-16
• Remove the centrifugal lock nut using the special tool.
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar: 07716-0020500
Clutch center holder: 07HMB-HB70100
• Hold clutch lifter and remove the clutch center locknut using the special tool.
Universal holder: 07725-0030000
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar: 07716-0020500
• Remove the centrifugal clutch outer, manual clutch and the oil separator plate as an assembly.

2-26
FUEL & ENGINE

54 N·m

Align

54 N·m

• Align the cut-outs of the primary gear and sub gear as shown, then engage the primary drive/ driven gears.
Install the centrifugal clutch outer, manual clutch and the oil separator plate as an assembly.
• Install the clutch center lock nut. Hold the clutch plate and tighten the clutch center lock nut to specific
torque using the special tools.
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar: 07716-0020500
Clutch center holder: 07HMB-HB70100
• , Install the lock washer onto the crankshaft while align its inner tab with the groove of the clutch weight
assembly. Lock washer "OUT SIDE" mark facing out.

• Hold clutch lifter and install the clutch center locknut using the special tool.
Universal holder: 07725-0030000
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar: 07716-0020500
• Align the lock washer tab against the centrifugal clutch lock nut groove.

2-27
FUEL & ENGINE
CENTRIFUGAL CLUTCH

• Align spring retainer/ spring to the clutch outer while aligning the retainer groove with the pin.

• One way clutch inspection.

2-28
FUEL & ENGINE
MANUAL CLUTCH

4 Bolts type shown:

Turn 45°

12 N·m

• Align chamfered edge of spring seat with clutch lifter plate.


• Turn clutch spring seat about 45°.
• Manual clutch inspection.

2-29
FUEL & ENGINE

6 Bolts type shown:

Turn 45°

12 N·m

• Turn clutch spring seat about 45°.

• Manual clutch inspection.

2-30
FUEL & ENGINE
GEARSHIFT LINKAGE

Align

6.5±1 mm

17 N·m

10 N·m

6.5±1 mm
from tip

• Clutch Î2-26
• Gearshift pedal Î2-25
• Holding down the gearshift arm to ease the removal.
• Align the gearshift cam plate with stopper plate pins.
• Set the return spring end along with the crankcase wall.
• Gearshift pedal inspection.

2-31
FUEL & ENGINE
ALTERNATOR/STARTER CLUTCH
Align

Align
[B]

40 N·m

[A]

• Body cover Î3-8


• The alternator/stator can be serviced with the engine installed in the frame.
• Left crankcase rear cover Î3-12
• Hold the flywheel with the special tool for the nut removal.
[A] Flywheel holder: 07725-0040001
• Flywheel
[B] Flywheel puller, 30 mm: 07KMC-HE00100
• Inspect the gearshift spindle oil seal for deterioration or damage, replace if necessary.
If replacing the oil seal, install in it is fully seated.
• Install the flywheel onto the crankshaft by aligning the key way on the flywheel with the woodruff key.
• Install the starter reduction gear by aligning the starter drive gear and starter driven gear.

2-32
FUEL & ENGINE

16 N·m

• Left crankcase cover Î2-32

2-33
FUEL & ENGINE
CRANKCASE/CRANKSHAFT

10 mm

• Cylinder head Î2-18, Cylinder/pistonÎ2-24


Clutch/gearshift linkage Î2-25, Alternator/starter clutch Î2-32
• Remove the crankcase bolts in a crisscross pattern in 2 - 3 steps.
• Place the crankcase with the right crankcase facing down and separate.
• Replace the parts if there is exceeded the service limits.

• Install the mainshaft, countershaft and shift drum as an assembly.

• Crankshaft inspection.
• Connecting rod inspection.

2-34
FUEL & ENGINE
CRANKSHAFT RUNOUT INSPECTION
• Place the crankshaft on a stand of V-blocks and measure
the runout using a dial gauge.
• SERVICE LMIT: 0.10 mm

30 mm
46 mm 120 mm

TRANSMISSION/KICKSTARTER

• Separate the crankcase Î2-34


• Remove the mainshaft, countershaft and shift drum as an assembly.
• Install the mainshaft, countershaft and shift drum as an assembly.
• Rotate the shift drum to check the transmission operation.
Align the tip of the lock plate and shift drum groove.
Assembly the crankcase.

2-35
FUEL & ENGINE
MAINSHAFT

• Transmission inspection.

COUNTERSHAFT

• Transmission inspection.

2-36
FUEL & ENGINE
KICKSTARTER

• Kickstarter inspection.

2-37
FUEL & ENGINE
ENGINE UNIT

59 N·m

12 N·m

12 N·m

• Drain the engine oil


• Body cover Î3-8
• Left crankcase rear cover Î3-12
• Exhaust pipe/muffler Î3-15
• O2 sensor Î4-12
• EOT sensor 2P connector Î4-11
• Tighten the rear upper engine hanger nut, the rear lower engine hanger nut, the front engine hanger nut to
the specified torque.
• Rotate the fixing plate and align their bolt holes. Install and tighten the drive sprocket fixing plate bolts.

2-38
3. FRAME & CHASSIS

BODY PANELS ································ 3-2 STEERING STEM ····························· 3-23

CENTERSTAND ·······························3-14 REAR WHEEL ································· 3-24

SIDESTAND ····································3-15 REAR SUSPENSION ························ 3-26

EXHAUST PIPE/MUFFLER·················3-15 SWINGARM ···································· 3-26

FRONT WHEEL ································3-16 FRONT BRAKE································ 3-27

FORK ·············································3-19 REAR BRAKE ································· 3-30

HANDLEBAR ···································3-21

3-1
FRAME & CHASSIS

BODY PANELS
FRAME & CHASSIS

[1]

[2]

[12]
[4]

[9]

[11]

[5] [7] [10]

[8]
[3] [15]

[13]

[6]

[16]

[17] [14]

[1] Top handlebar cover Î3-3 [10] Front fender B Î3-7


[2] Front handlebar cover Î3-3 [11] Body cover Î3-8
[3] Rear handlebar cover Î3-4 [12] Luggage box Î3-9
[4] Front top cover Î3-4 [13] Rear fender Î3-10
[5] Center cover Î3-5 [14] Drive chain cover Î3-11
[6] Main pipe cover Î3-5 [15] Seat Î3-11
[7] Lower side cover Î3-6 [16] Footpeg bar Î3-12
[8] Grab railÎ3-6 [17] Passenger footpeg holder Î3-13
[9] Front fender A Î3-7

3-2
FRAME & CHASSIS
TOP HANDLEBAR COVER

• Rearview mirrors.

FRONT HANDLEBAR COVER

• Top handlebar coverÎ3-3.

3-3
FRAME & CHASSIS

REAR HANDLEBAR COVER


Disc brake type shown:

0 – 1.25 mm

• Front handlebar cover Î3-3


• Remove throttle cable from rear handlebar cover.

FRONT TOP COVER

3-4
FRAME & CHASSIS

CENTER COVER

MAIN PIPE COVER

• Front top cover Î3-4


• Center cover Î3-5

3-5
FRAME & CHASSIS
LOWER SIDE COVER

Left side shown:

• Main pipe cover Î3-5

GRAB RAIL

3-6
FRAME & CHASSIS
FRONT FENDER A

AFS110KDF

• Front top cover Î3-4

FRONT FENDER B

• Front fender A Î3-7


• Front wheel Î3-16

3-7
FRAME & CHASSIS
BODY COVER
Left side shown:

• Center cover Î3-5


• Grab rail Î3-6

Left side shown:

Right side shown:

3-8
FRAME & CHASSIS
LUGGAGE BOX

AFS110MSF/ MCF:

• Body cover Î3-8


• Battery Î4-19

3-9
FRAME & CHASSIS
REAR FENDER

• Luggage box Î3-9


• Release the ECM from the rear fender Î4-11
• Brake/ tail light unit Î4-20
• Fuel tank Î2-6

SEAT LOCK KEY CYLINDER

• Body cover Î3-8

3-10
FRAME & CHASSIS
DRIVE CHAIN COVER

SEAT

• Support the seat while removing the nuts.

3-11
FRAME & CHASSIS
LEFT CRANKCASE REAR COVER

FOOTPEG BAR

3-12
FRAME & CHASSIS
PASSENGER FOOTPEG HOLDER
Right side shown:

• Body cover Î3-8


• Muffler mounting nut, washer and mounting bolt Î3-15 (right side only)

BATTERY COVER

AFS110MSF/ MCF:

• Open the seat

3-13
FRAME & CHASSIS
CENTERSTAND

• Exhaust pipe/ muffler Î3-15

3-14
FRAME & CHASSIS
SIDESTAND

18 N·m
44 N·m

EXHAUST PIPE/MUFFLER

11 N·m

29.5 ± 1.0 mm

27 N·m

3-15
FRAME & CHASSIS
FRONT WHEEL
AFS110KSF/ MSF/ MCF:

59 N·m

13.0 ± 1.0 mm

• Align the speedometer gearbox grove with the boss on the fork leg.

3-16
FRAME & CHASSIS

AFS110KSF/ MSF/ MCF:

[B]

[A]
42 N·m

• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive the bearing out of the wheel hub.
Remover head, 12 mm: 07746-0050300
Bearing remover shaft: 07746-0050100
• Drive in a new left bearing [A] squarely with its marked side facing up until it is fully seated
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 12 mm: 07746-0040200
• Install the distance collar
• Drive in a new right bearing [B] squarely with its sealed side facing up until its inner race is seated on the
distance collar. (Pack all bearing cavities with grease.)
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 12 mm: 07746-0040200
• Wheel disassembly and inspection.

3-17
FRAME & CHASSIS

AFS110KDF:

59 N·m

10 ± 1.0 mm

• Align the brake panel slot with the left fork leg.

3-18
FRAME & CHASSIS
FORK

64 N·m

• Front fender B Î3-7


• Brake caliper Î3-28
• Loosen the lower bolts for fork removal.
• Install the fork pipe into the steering stem while aligning its groove with the upper pinch bolt hole.

3-19
FRAME & CHASSIS

78 mm
(KSF/MSFMCF)

93 mm (KDF)

22 N·m

(KDF)

20 N·m

• Remove the oil seal.


Oil seal remover: 07748-0010001 or equivalent commercially available.
• Drive in a new oil seal squarely with its marked side facing up until it is fully seated.
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
• Pour the specified amount of recommended fork fluid into the fork pipe.
RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W
FORK FLUID CAPACITY: AFS110KSF/MSF/MCF: 62 ± 1 cm3
AFS110KDF: 61 ± 1 cm3
• Compress the fork pipe fully and measure the fluid level from the top of the fork pipe.
FORK FLUID LEVEL: AFS110KSF/MSF/MCF: 78 mm
AFS110KDF: 93 mm
• Pull the fork pipe up and install the fork spring with its tapered side facing down.

• Fork disassembly and inspection.

3-20
FRAME & CHASSIS
HANDLEBAR
AFS110KSF/ MSF/ MCF:

9 N·m

59 N·m

FRONT REAR

• Rear handlebar cover Î3-4


• Main pipe cover Î3-5
• Turn the inner weight and hook the retainer tab with the hole in the handlebar.
• Install the brake master cylinder and holder with its "UP" mark facing up. Align the edge of the mating
surface with the punch mark on the handlebar
• Handlebar disassembly/assembly and inspection.

3-21
FRAME & CHASSIS

AFS110KDF:
9 N·m

1 N·m

4.5 N·m

59 N·m

FRONT REAR

• Rear handlebar cover Î3-4


• Main pipe cover Î3-5
• Turn the inner weight and hook the retainer tab with the hole in the handlebar.
• Check the identification marks when connecting the throttle cables and make sure that they are connected
properly. Check that the shaded parts are fully seated in the end of the slider holes.
• Handlebar disassembly/assembly and inspection.

3-22
FRAME & CHASSIS
STEERING STEM

[B]

[A]

83 N·m

23 Balls

[C] [F] [G]

[C] [D] [H]

29 Balls

[E]

• Front fender Î3-7


• Fork Î3-19
• Handlebar Î3-21
• STEERING STEM:
[A] Steering stem socket: 07916-3710101, [B] Socket wrench: 07916-KM10000
• STEERING STEM BEARINGS
[C] Ball race remover shaft: 07GMD-KS40100, [D] Ball race remover, 34.5 mm: 07948-4630100
• STEERING STEM:
[A] Steering stem socket: 07916-3710101, [B] Socket wrench: 07916-KM10000
• STEERING STEM BEARINGS:
[E] Fork seal driver attachment, 35.2 mm: 07947-KA20200, [F] Driver: 07749-0010000
[G] Bearing driver attachment: 07946-3710701, [H] Oil seal driver, 53.5 mm: 07947-SB00200
• Install the top thread. Hold the steering stem and tighten the stem top thread to the initial torque using the
special tool.TORQUE: 25 N·m
• Turn the steering stem lock-to-lock several times to seat the bearing. Completely loosen the top thread.
• Tighten the top thread fully by hand while holding the steering stem, then turn and loosen the top thread
counterclockwise about 45 degrees.
• Hold the top thread using the pin spanner and tighten the steering stem lock nut to the specified torque.
TORQUE: 83 N·m
• Steering disassembly/assembly and inspection.

3-23
FRAME & CHASSIS
REAR WHEEL

59 N·m

22 N·m

• Drive chain case Î3-11


• Exhaust pipe/ muffler Î3-15

3-24
FRAME & CHASSIS

[B]

[A]

32 N·m

6 ± 1.0 mm

• Install the bearing remover head into the wheel bearing. From the opposite side, install the bearing remover
shaft and drive the bearing out of the wheel hub.
Bearing remover head, 12 mm: 07746-0050300
Bearing remover shaft: 07746-0050100
• Drive in a new right bearing [A] squarely with its sealed side facing up 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 left bearing [B] squarely with its sealed side facing up until it is fully seated.
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 12 mm: 07746-0040200
• Wheel disassembly and inspection.

3-25
FRAME & CHASSIS
REAR SUSPENSION

24 N·m

24 N·m

• Body cover Î3-8


• Exhausted pipe/ muffler Î3-15

SWINGARM

59 N·m

• Exhausted pipe/ muffler Î3-15


• Rear wheel Î3-24

3-26
FRAME & CHASSIS
FRONT BRAKE
FRONT BRAKE FLUID REPLACEMENT

• Turn the handlerbar until the reservoir is parallel to the ground before removing the reservoir cap.
• Connect a bleed hose to the bleed valve. Loosen the bleed valve and pump the brake lever until no more
fluid flows out of the bleed valve.
• Details instruction of the brake fluid replacement.

FRONT BRAKE MASTER CYLINDER

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.

3-27
FRAME & CHASSIS

1 N·m

5.9 N·m
1.2 N·m

• Remove the snap ring using the special tool.


Snap ring pliers: 07914-SA50001
• Master cylinder inspection.

FRONT BRAKE CALIPER


BRAKE PAD REPLACEMENT

17 N·m

• Install brake pads so that they are set on the brake caliper bracket and bracket pin.

3-28
FRAME & CHASSIS

30 N·m

34 N·m

• Caliper cylinder inspection.

5.4 N·m

3-29
FRAME & CHASSIS
REAR BRAKE
DRUM BRAKE

10 N·m

• Rear wheel Î3-24

3-30
4. ELECTRICAL SYSTEM

PGM-FI SYSTEM ······························· 4-2 LIGHTING SYSTEM ·························· 4-20

IGNITION SYSTEM ···························4-13 SPEEDOMETER ······························ 4-22

ELECTRICAL STARTER ····················4-15 ELECTRICAL COMPONENT ·············· 4-26

BATTERY/CHARGING SYSTEM ·········4-18

4-1
ELECTRICAL SYSTEM

PGM-FI SYSTEM
ELECTRICAL SYSTEM

• Refer to "Basic Shop manual" for the following information:


– PGM-FI technical feature and each sensor function.
– Symptom troubleshooting for the PGM-FI system.
– MCS (Motorcycle Communication System).

DTC CODE INDEX


DTC Function Failure Symptom/Fail-safe function Page
EOT sensor malfunction • Hard to start at a low temperature
7-1 Î4-5
• EOT sensor low voltage
EOT sensor malfunction • Hard to start at a low temperature
7-2 Î4-6
• EOT sensor high voltage
TP sensor malfunction • Poor engine acceleration
8-1 Î4-7
• TP sensor low voltage
TP sensor malfunction • Poor engine acceleration
8-2 Î4-8
• TP sensor high voltage
Injector malfunction • Engine does not start
12-1 Î4-9
• Injector, fuel pump and ignition coil shut down
21-1 O2 sensor malfunction • Engine operates normally Î4-10
ECM EEPROM malfunction • Engine stalls, hard to start, rough idling
• Self diagnosis data is not held
33-2 Î4-10
• Self diagnosis data cannot be erased with SCS
connector

4-2
ELECTRICAL SYSTEM
PGM-FI SYSTEM LOCATION

FUEL PUMP UNIT

TP SENSOR ECM

DLC

THROTTLE BODY

INJECTOR

EOT SENSOR

CKP SENSOR O2 SENSOR

4-3
ELECTRICAL SYSTEM
PGM-FI SYSTEM DIAGRAM
MAIN FUSE
R/Y
15 A R G

BATTERY
SUB FUSE
R/Y
10 A
W R/Y Bl/R Bl
REGULATOR/
RECTIFIER R R Bl/Bu
W
IGNITION
SWITCH

ALTERNATOR G

Bl/Bu
IGP 1

FL 8 Br FUEL PUMP

(8) Y
TP SENSOR G/O
5 THR INJECTOR (12)
4 TA P/G
INJ 16

MIL

Y/Bu W/Bu
24 TO WARN 18
(7)
EOT SENSOR

G/O Bu/Y
31 SG PCP 12
Y/R W/Y CKP
6 VCC PCM 23
SENSOR

(21) Bl Bl/O
3 O2
O2 SENSOR

ECM

Bu P/Bu
15 SCS IGPLS 11
Y
30 K-LINE

DLC
GEAR POSITION
SWITCH IGNITION COIL
Lg/R
29 NSW

2 LG 9 PG1 10 PG2
SPARK PLUG

G/Bl G G

A11 A1

Bl : BLACK Br : BROWN
Y: YELLOW O: ORANGE
Bu : BLUE Lb : LIGHT BLUE
G: GREEN Lg : LIGHT GREEN A22 A12
( ) : MIL number R: RED P: PINK
W: WHITE Gr : GRAY
A33 A23
: Engine does not start when detecting MIL
33P CONNECTOR A
: Short terminals for reading MIL (ECM side / male terminal)

4-4
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
DTC 7-1 (EOT SENSOR LOW VOLTAGE)

• Lower side cover Î3-6


• Luggage box Î3-9

EOT Sensor Diagram

EOT sensor 2P connector ECM 33P connector

G/O Y/Bu

G/O Y/Bu

5V

Y/Bu
TO-SENSOR
ECM
EOT sensor
SG2
G/O

1. EOT Sensor System Inspection

• Check the EOT sensor voltage with MCS. No


• Intermittent failure
• Is the voltage about 0 V indicated? ►

Yes ▼

2. EOT Sensor Inspection

• Check the EOT sensor voltage with MCS. No • Replace the EOT sensor with a new one Î4-11,
• Is the voltage about 0 V indicated? ► and recheck.

Yes ▼

3. EOT Sensor Output Line Inspection

• Check for a short circuit in Y/Bu wire.


• If there is no short circuit, replace the ECM with a
new one Î4-11, and recheck.

4-5
ELECTRICAL SYSTEM
DTC 7-2 (EOT SENSOR HIGH VOLTAGE)

• Lower side cover Î3-6


• Luggage box Î3-9

EOT Sensor Diagram

EOT sensor 2P connector ECM 33P connector

G/O Y/Bu

G/O Y/Bu

5V

Y/Bu
TO-SENSOR
ECM
EOT sensor
SG2
G/O

1. EOT Sensor System Inspection

• Check the EOT sensor voltage with MCS. No • Intermittent failure


• Is the voltage about 5 V indicated? ► • Loose or poor contact at the connector

Yes ▼

2. EOT Sensor Inspection

• Install the jumper wire between the terminals.


Connection: Y/Bu – G/O Yes • Replace the EOT sensor with a new one Î4-11,
• Check the EOT sensor voltage with MCS. ► and recheck.
• Is the voltage about 0 V indicated?

No ▼

3. EOT Sensor Output Line Inspection

• Check for an open circuit in Y/Bu and G/O wire.


• If there is no open circuit, replace the ECM with a
new one Î4-11, and recheck.

4-6
ELECTRICAL SYSTEM
DTC 8-1 (TP SENSOR LOW VOLTAGE)

• Main pipe cover Î3-5


• Luggage box Î3-9

TP Sensor Diagram

TP sensor 3P connector ECM 33P connector

Y/G Y/R Y/G G/O

G/O Y/R

5V
VCC
Y/R
THL
TP sensor Y/G ECM
SG1
G/O

1. TP Sensor System Inspection

• Check the TP sensor voltage with MCS. No • Intermittent failure


• Is the voltage about 0 V indicated? ► • Loose or poor contact at the connector

Yes ▼

2. TP Sensor Input Voltage Inspection

• Open or short circuit in Y/R wire


• Connection: Y/R (+) – G/O (–) No
• If there is no open or short circuit, replace the ECM
• Is the voltage within 4.75 – 5.25 V? ►
with a new one Î4-11, and recheck.

Yes ▼

3. TP Sensor Output Line Inspection

• Check for an open or short circuit in Y/G wire. Yes


• Faulty Y/G wire
• Is there open or short circuit? ►

No ▼

4. TP Sensor Inspection

• Replace the throttle body with a new one. Î2-8


• Erase the DTC’s.
• Check the TP sensor with MCS.
• If DTC 8-1 is indicated, replace the ECM with a
new one Î4-11, and recheck.

4-7
ELECTRICAL SYSTEM
DTC 8-2 (TP SENSOR HIGH VOLTAGE)

• Main pipe cover Î3-5


• Luggage box Î3-9

TP Sensor Diagram

TP sensor 3P connector ECM 33P connector

Y Y/R Y G/O

G/O Y/R

5V
VCC
Y/R
THL
TP sensor Y ECM
SG1
G/O

1. TP Sensor System Inspection

• Check the TP sensor voltage with MCS while


operating the throttle from fully closed to fully
• Check the TP sensor voltage with MCS when the
No opened.
throttle fully closed.
► • If the voltage is not increased continuously,
• Is the voltage about 5 V indicated?
replace the TP sensor with a new one Î2-8, and
recheck.

Yes ▼

2. TP Sensor Ground Line Inspection

• Check for an open circuit in G/O wire. Yes


• Faulty G/O wire
• Is there open circuit? ►

No ▼

3. TP Sensor Inspection

• Connection: G/O – Y No • Replace the TP sensor with a new one, and


• Is the resistance within 0.5 – 1.5 kΩ (20°C)? ► recheck.

Yes ▼

• Replace the ECM with a new one Î4-11, and


recheck.

4-8
ELECTRICAL SYSTEM
DTC 12-1 (INJECTOR)

• Lower side cover Î3-5


• Luggage box Î3-9

Injector Diagram

Injector 2P connector Injector 2P connector


ECM 33P connector
(Injector side) (Wire side)
P/G

A B Bl/Bu P/G

From ignition switch

Bl/Bu

Injector ECM
INJ
P/G

1. Fuel Injector System Inspection

• Check the fuel injector with MCS. No • Intermittent failure


• Is the DTC 12-1 indicated? ► • Loose or poor contact at the connector

Yes ▼

2. Fuel Injector Input Voltage Inspection

• Connection: Bl/Bu (+) – Ground (–) No


• Open circuit in Bl/Bu wire
• Does the battery voltage exist? ►

Yes ▼

3. Fuel Injector Signal Line Inspection

• Check an open or short circuit in P/G wire. Yes


• Faulty P/G wire
• Is there open or short circuit? ►

No ▼

4. Fuel Injector Resistance inspection

• Connection: A – B No
• Faulty fuel injector
• Is the resistance within 11 – 13 Ω (20°C)? ►

Yes ▼

• Replace the ECM with a new one Î4-11, and


recheck.

4-9
ELECTRICAL SYSTEM
DTC 21-1 (O2 SENSOR)

• Lower side cover Î3-6


• Luggage box Î3-9

O2 Sensor Diagram

O2 sensor 1P connector ECM 33P connector

Bl/O Bl/O

O2-SENSOR
Bl Bl/O
ECM
O2 sensor

1. O2 Sensor System Inspection

• Test-ride the vehicle and check the O2 sensor with


No • Intermittent failure
MCS.
► • Loose or poor contact at the connector
• Is the DTC 21-1 indicated?

Yes ▼

2. O2 Sensor Circuit Inspection

• Check an open or short circuit in Bl/O wire. Yes


• Faulty Bl/O wire
• Is there open or short circuit? ►

No ▼

3. O2 Sensor Inspection

• Replace the O2 sensor with a new one. Î4-12


• Erase the DTC’s.
• Test-ride the vehicle and check the O2 sensor with
MCS.
• If DTC 21-1 is indicated, replace the ECM with a
new one Î4-11, and recheck.

DTC 33-2 (EEPROM)

1. EEPROM System Inspection

• Check the EEPROM with MCS. No


• Intermittent failure
• Is the DTC 33-2 indicated? ►

Yes ▼

• Replace the ECM with a new one Î4-11, and


recheck.

4-10
ELECTRICAL SYSTEM
ECM

• Luggage box Î3-9

• ECM power circuit and ground circuit inspection.

EOT SENSOR

14 N·m

• Drain the engine oil


• Lower side cover Î3-6
• EOT sensor inspection.

4-11
ELECTRICAL SYSTEM
O2 SENSOR

24.5 N·m

• Lower side cover Î3-6


• Remove the O2 sensor using the special tool.
Flare nut socket: FRXM17 (Snap on) or equivalent
• Notice of O2 sensor removal/installation.

4-12
ELECTRICAL SYSTEM

IGNITION SYSTEM
IGNITION SYSTEM LOCATION

IGNITION SWITCH

REGULATOR/RECTIFIER

IGNITION COIL BATTERY

ECM

SPARK PLUG

CKP SENSOR
MAIN FUSE 15A

IGNITION SYSTEM DIAGRAM


IGNITION SWITCH G: Green
R: Red
Bl/Bu W: White
MAIN FUSE
15 A Bl: Black
G R Y: Yellow
Bu: Blue

P/Bu
R/Y G R/W IGNITION COIL
BATTERY

RECGULATOR/
SPARK PLUG
RECTIFIER
Bl/Y

W/Y

Bu/Y

G/Bl G

CKP SENSOR
ECM

4-13
ELECTRICAL SYSTEM
SPARK PLUG REPLACEMENT
• Lower side cover Î3-5

16 N·m • Spark plug inspection.

INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE

• Refer to "Basic Shop Manual" for the detail information of


ignition coil primary peak voltage inspection.
• Support the vehicle with its centerstand on a level
surface.
• Lower side cover Î3-5
• Disconnect the spark plug cap from the spark plug.
• Connect a known-good spark plug to the spark plug cap
and ground it to the cylinder head as done in a spark test.
• With the ignition coil primary wires connected, connect
the peak voltage adaptor probes to the ignition coil
primary terminal and ground.
CONNECTION: Black/Yellow (+) – Ground (–)

• Check the initial voltage at this time.


STANDARD VOLTAGE: Battery voltage
• Crank the engine with the electric starter with the throttle
grip fully opened and measure the
ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum

IGNITION TIMING

• Timing hole cap


Timing cap wrench: 07709-0010001
• Warm the engine up to normal operating temperature.
• Connect the timing light to the spark plug wire.
• Start the engine and let it idle.
IDLE SPEED: 1,400 ± 100 rpm
• The ignition timing is correct if the index notch on the
left crankcase cover aligns with the "F" mark on the fly-
wheel.

4-14
ELECTRICAL SYSTEM

ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION

STARTER SWITCH

STARTER RELAY

BATTERY

IGNITION SWITCH

STARTER MOTOR

REGULATOR/RECTIFIER MAIN FUSE 15A

ELECTRICAL STARTER SYSTEM DIAGRAM

MAIN FUSE 15 A
R R/Y R

RECGULATOR/
RECTIFIER

STARTER
RELAY

G R
BATTERY
IGNITION SWITCH

Bl/Bu R

R/W
G: Green
Y/R G R: Red
STARTER W: White
SWITCH Bl: Black
STARTER MOTOR
Y: Yellow
Bu: Blue

4-15
ELECTRICAL SYSTEM
ELECTRICAL STARTER TROUBLESHOOTING
STARTER MOTOR DOES NOT TURN

• Main pipe cover Î3-5

• Loose or poor contacts of related terminal/connector


• Battery condition
• Burned fuse
• DTC (PGM-FI system)
Connector Diagram

Starter relay 5P connector


Y/R G

1. Starter Relay Switch Circuit inspection

• Inspect the following.


• Connection: Y/R (+) – G (–)
No – Ignition switch.
• Depress the starter button.
► – Starter switch.
• Does the battery voltage exist?
– Starter relay coil input circuit relate circuit.

Yes ▼

2. Starter Relay inspection

• Replace the starter relay with a new one, and • Faulty original starter relay.
Yes
recheck.

• Does the Starter motor turn?

No ▼

• Check a short or open circuit in starter motor


• If there is no faulty circuit, replace the Starter
motor with a new one Î4-17, and recheck.

4-16
ELECTRICAL SYSTEM
STARTER MOTOR

• Lower side cover Î3-6

1.2 N·m

• Starter motor inspection.

4-17
ELECTRICAL SYSTEM
BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEM LOCATION

REGULATOR/RECTIFIER

BATTERY

MAIN FUSE 15A

ALTERNATOR

BATTERY/CHARGING SYSTEM DIAGRAM

G: Green
To IGNITION SWITCH
R: Red
W: White
MAIN FUSE 15 A Y: Yellow

G R
To LIGHT
SWITCH

G R/Y R W Y
BATTERY

RECGULATOR/ R
RECTIFIER ALTERNATOR

• Battery/charging system information, troubleshooting and inspection.

4-18
ELECTRICAL SYSTEM
BATTERY

• Battery cover Î3-13

4-19
ELECTRICAL SYSTEM

LIGHTING SYSTEM

2 N·m

• Front handlebar cover Î3-3


• Headlight aim adjusting bolt Î4-22
• Clips

4-20
ELECTRICAL SYSTEM
BULB REPLACEMENT

• Front handlebar cover Î3-3

• Front handlebar cover Î3-3 • Front handlebar cover Î3-3

• Brake/ tail light Î4-20

4-21
ELECTRICAL SYSTEM
HEADLIGHT AIM

up

down

SPEEDOMETER

• Rear handlebar cover Î3-4

4-22
ELECTRICAL SYSTEM

4-23
ELECTRICAL SYSTEM

FUEL LEVEL SENSOR

Bl

• Fuel pump unit Î2-4

• Route the fuel level sensor wires into the guides properly.

4-24
ELECTRICAL SYSTEM
FUEL METER TROUBLESHOOTING
FUEL METER NEEDLE DOES NOT MOVE

• Fuel pump unit Î2-4

• Loose or poor contacts of related terminal/connector

FUEL UNIT 5P CONNECTOR

A (G) B (Y/W)
FULL

EMPTY Bl/Bu Ignition switch


G Ground
Y/W Fuel level sensor

1. Fuel Meter Circuit Inspection

• Check the G, Y/W and Bl/Bu wire. No • Faulty G, Y/W or Bl/Bu wire
• Is there no open or short circuit? ►

Yes ▼

2. Fuel Level Sensor Inspection

• Connection: A – B
No • Replace the fuel level sensor with a new one
• Standard: FULL 6 – 10 Ω, EMPTY 90 – 100 Ω
► Î4-24, and recheck.
• Does the Standard resistance exist?

Yes ▼

Replace the combination meter with a new one


Î4-22, and recheck.

4-25
ELECTRICAL SYSTEM

ELECTRICAL COMPONENT
IGNITION SWITCH

5.1 N·m

9 N·m

• Steering stem Î3-23

• Install the key shutter while aligning the grooves with the tabs.
• Install the ignition switch by aligning the boss and hole of the frame.

4-26
ELECTRICAL SYSTEM
GEAR POSITION SWITCH

• Left crankcase rear cover Î3-12

HORN

• Front top cover Î3-4

4-27
MEMO
INDEX
dummytext

INDEX
A Few Words About Safety······································1-2 FUEL TANK ·························································2-6
A

AIR CLEANER······················································2-7 GEAR POSITION SWITCH ··································· 4-27


G

ALTERNATOR/STARTER····································· 2-32 GEARSHIFT LINKAGE········································· 2-31


ALTITUDE SETTING ··········································· 2-12 HANDLEBAR ····················································· 3-21
H

BATTERY/CHARGING SYSTEM···························· 4-18 HORN······························································· 4-27


B

BODY PANELS ····················································3-2 How To Use This Manual ········································1-3


BULB REPLACEMENT ········································ 4-21 IGNITION SYSTEM ············································· 4-13
I

CABLE & HARNESS ROUTING ····························· 1-16 INJECTOR························································· 2-13


C

CENTERSTAND ················································· 3-14 LIGHTING SYSTEM ············································ 4-20


L

CENTRIFUGAL CLUTCH ····································· 2-28 LUBRICATION SYSTEM ······································ 2-14


CLUTCH/GEARSHIFT LINKAGE···························· 2-25 MAINTENANCE SCHEDULE································· 1-26
M

CRANKCASE/CRANKSHAFT ································ 2-34 MANUAL CLUTCH ·············································· 2-29


CYLINDER HEAD ··············································· 2-18 MODEL IDENTIFICATION ······································1-5
CYLINDER/PISTON ············································ 2-24 PGM-FI SYSTEM ··················································4-2
P

ECM INITIALIZING PROCEDURE ·························· 2-11 REAR BRAKE ···················································· 3-30


E R

ELECTRICAL COMPONENT ································· 4-26 REAR SUSPENTION ··········································· 3-26


ELECTRICAL STARTER ······································ 4-15 REAR WHEEL···················································· 3-24
ENGINE OIL CENTIFUGAL FILTER CHANGE·········· 2-16 SIDESTAND ······················································ 3-15
S

ENGINE OIL CHANGE ········································· 2-15 SPARK PLUG REPLACEMENT ····························· 4-14
ENGINE OIL LEVEL CHECK ································· 2-15 SPECIAL TOOL LIST··········································· 1-15
ENGINE OIL STRAINER SCREEN CHANGE ··········· 2-15 SPECIFICATIONS·················································1-6
ENGINE UNIT ···················································· 2-38 SPEEDOMETER················································· 4-22
EXHAUST PIPE/MUFFLER ··································· 3-15 STEERING STEM ··············································· 3-23
FORK ······························································· 3-19 TECHNICAL FEATURES······································ 1-25
F T

FRONT BRAKE ·················································· 3-27 THROTTLE BODY ················································2-8


FRONT WHEEL ·················································· 3-16 TORQUE VALUE ················································ 1-12
FUEL LEVEL SENSOR ········································ 4-24 TP SENSOR RESET PROCEDURE ······················· 2-10
FUEL LINE···························································2-2 TRANSMISSION/KICKSTARTER ··························· 2-35
FUEL PUMP UNIT·················································2-4 VALVE CLEARANCE··········································· 2-18
V

5-1
AFS110KSF-J (TH,LO,AD)

FRONT REAR
TURN STOP BRAKE
SIGNAL GROUND
LIGHT IGNITION LIGHT REGULATOR
RELAY SWITCH BATTERY
SWITCH SWITCH RECTIFIER 12V 3.0AH
O2 SUB MAIN
SENSOR

G
FUSE FUSE

BAT2

BAT1
VO2

VO1
10A 15A

Bl/Bu
Bl/R

G
6P

Bl

Bl
Bl
G/Y
Bl

G/Bl
2P

G
R/Y

R
Bl

W
G
R
Y
G
GR
Bl

Bl/R
R/Y

R/Y
R
Bl/Bu
Bl/R
Bl

Bl
Bl

Bl
G/Y
MIL INDICATOR

Bl
W/Bu 1P
12V 1.7W Bl
4P
Bl

METER LIGHT

Bl/Bu

Bl/O
G/Y
Bl/R

Bl
Y

Bl

Bl/R

R/Y
12V 1.7W

G
G

G/Y
Bl
METER LIGHT
12V 1.7W Y
G RIGHT REAR
GEAR POSITION TURN SIGNAL LIGHT

Bl/R

R/Y
12W 10W

G
INDICATOR
P
4TH 12V 1.7W
Bl Lb
G
W/Bu
3RD 12V 1.7W
Bl 9P
BRAKE/TAIL LIGHT
Bl Bl
Y Y
6P 12V 18W/5W
Bl/Bu Lb Lb
2ND 12V 1.7W Bl G G G
G G
P P G/Y G/Y G/Y
W/Bu W/Bu Y Y Y
Y/R
1ST 12V 1.7W Bl/Bu Bl/Bu O O
Bl
Y/R Y/R
Lg/R Lg/R
NEUTRAL Lg/R
G
12V 1.7W Bl
O
6P
HI BEAM Lb Lb
INDICATOR Bu G/Y G/Y LEFT REAR
G
12V 1.7W W/Bu W/Bu TURN SIGNAL LIGHT
O O 12V 10W
RIGHT TURN
Lb Y/W Y/W
SIGNAL INDICATOR G
12V 3.4W
LEFT TURN G
SIGNAL INDICATOR O
12V 3.4W
Bl
FUEL METER Y/W
G

W
G
RIGHT FRONT Lb 2P

W/Bu
Bl/Bu

Lg/R
Y/R
P
TURN SIGNAL LIGHT G
12 10W

Bu/Y
W/Y

W
G
6P
Bl
9P

W/Bu
Bl/Bu

Lg/R
Y/R
P
Lb Lb

Bu/Y
W/Y
Bl/Bu
Bu Bu Bu

P/G
HEAD LIGHT G G G

Bl/Bu

Bl/Bu
Y/W

P/Bu
12 32W/32W

Br
G

W
W W W
2P
O 5P

Bu/Y
O Bl
Bl 4 3
Y 2
Lg

1
N

W/Y
LEFT FRONT
Bu

Gr

Lg
Lb
W

Bl

Bl/Bu
Bl/Bu
O
Y

G
TURN SIGNAL LIGHT O
W/Bu
Bl/Bu
Bu/Y

P/Bu

Y/Bu

Lg/R

G/Bl

Bl/O
W/Y

G/O

G/O
P/G

Y/R

3P
Bu

3P 3P
Br

12 10W
G
G
Y

3P R Bl HORN INJECTOR
Bl/Bu

G/Bl

FUEL
Bu
Y

Y/Bu
HL

WL

BAT
LO
HI

W
WR

HO

G/O

G/O
Y/R

LEVEL
Y

4P 33P SENSOR F/P


R IGNITION GEAR
3P 2P
ALTERNATOR
FL
IGP
PCP
PCM
IGPLS
INJ

SG(TO)
TO
WARN
N SW
SG(THL)
LG
SCS
K-LINE
PG1
PG2
O2

THR
VCC

Bl Bl
COIL SWITCH
DIMMER TURN HORN FUEL PUMP POSITION
SWITCH SIGNAL SWITCH
VCC
THR
SG

BAT
HO

SWITCH DLC

ECM TP EOT
SENSOR SENSOR

SWITCH CONTINUITY

COMBINATION SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH

BAT1 VO1 BAT2 VO2 HL LO HI W WR WL HO BAT Bl Black Br Brown


Y Yellow O Orange
ON LO R FREE Bu Blue Lb Light Blue
G Green Lg Light Green
OFF (N) N PUSH R Red P Pink
W White Gr Gray
COLOR R Bl/Bu Bl/R Bl HI L COLOR Lg Bl

COLOR Y W Bu COLOR Gr Lb O TWO COLORED WIRE (EXAMPLE:YELLOW/RED)


AFS110KDF-J (TH,LO,AD)

FRONT
STOP REAR
TURN LIGHT
SIGNAL GROUND BRAKE
SWITCH IGNITION LIGHT REGULATOR
RELAY BATTERY
SWITCH SWITCH RECTIFIER 12V 3.0AH
O2 SUB MAIN
SENSOR

G
FUSE FUSE

BAT2

BAT1
10A 15A

VO2

VO1
Bl/Bu
Bl/R

G
6P

Bl

Bl
Bl
G/Y
Bl

G/Bl
2P

G
R/Y

R
Bl

W
G
R
Y
G
GR
Bl

Bl/R
R/Y

R/Y
R
Bl/Bu
Bl/R
Bl

Bl
Bl

Bl
MIL INDICATOR W/Bu 1P
4P
Bl Bl
12V 1.7W

Bl/Bu

Bl/O
G/Y
Bl/R

Bl
METER LIGHT Y

Bl

Bl/R

R/Y

G
12V 1.7W G

METER LIGHT Y
12V 1.7W G RIGHT REAR
TURN SIGNAL LIGHT

Bl/R

R/Y
GEAR POSITION 12W 10W

G
INDICATOR P
4TH 12V 1.7W Bl Lb
G
W/Bu
3RD 12V 1.7W Bl 9P
BRAKE/TAIL LIGHT
Bl Bl
Y Y
6P 12V 18W/5W
Bl/Bu Lb Lb
Bl G G G
2ND 12V 1.7W G G
P P G/Y G/Y G/Y
W/Bu W/Bu Y Y Y
Y/R O O
Bl/Bu Bl/Bu
1ST 12V 1.7W Bl
Y/R Y/R
Lg/R Lg/R
Lg/R
NEUTRAL Bl
G
12V 1.7W O
6P
Lb Lb
HI BEAM Bu G/Y G/Y LEFT REAR
INDICATOR G W/Bu W/Bu TURN SIGNAL LIGHT
12V 1.7W O O 12V 10W
RIGHT TURN Lb Y/W Y/W
G
SIGNAL INDICATOR
12V 3.4W
G
LEFT TURN O
SIGNAL INDICATOR
12V 3.4W
Bl
Y/W
FUEL METER
G

W
G
RIGHT FRONT Lb 2P

W/Bu
Bl/Bu

Lg/R
Y/R
P
TURN SIGNAL LIGHT G
12 10W

Bu/Y
W/Y

W
G
6P
POSITION LIGHT Y Bl
12V 3.4W G 9P

W/Bu
Bl/Bu

Lg/R
Y/R
P
Lb Lb

Bu/Y
W/Y
Bl/Bu
Bu Bu Bu

P/G
HEAD LIGHT G G G

Bl/Bu

Bl/Bu
Y/W

P/Bu
12 32W/32W

Br
G

W
W W W
2P
O 5P

Bu/Y
O Bl
Bl 4 3
Y 2
Lg

1
POSITION LIGHT G
12V 3.4W Y N

W/Y
LEFT FRONT
Bu

Gr

Lg
Lb
W

Bl

Bl/Bu
Bl/Bu
O
Y

G
TURN SIGNAL LIGHT O
W/Bu
Bl/Bu
Bu/Y

P/Bu

Y/Bu

Lg/R

G/Bl

Bl/O
W/Y

G/O

G/O
P/G

Y/R

3P
Bu

3P 3P
Br

12 10W
G
G
Y

3P R Bl HORN INJECTOR
Bl/Bu

G/Bl
Bu

FUEL
Y

Y/Bu
HL

WL

BAT
LO
HI

W
WR

HO

G/O

G/O
Y/R

LEVEL
Y

4P 33P SENSOR
F/P
R IGNITION ALTERNATOR GEAR
3P 2P
FL
IGP
PCP
PCM
IGPLS
INJ

SG(TO)
TO
WARN
N SW
SG(THL)
LG
SCS
K-LINE
PG1
PG2
O2

THR
VCC

Bl Bl
COIL SWITCH
DIMMER TURN HORN FUEL PUMP
POSITION
SWITCH SIGNAL SWITCH
VCC
THR
SG

BAT
HO

SWITCH DLC

ECM TP EOT
SENSOR SENSOR

SWITCH CONTINUITY

COMBINATION SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH

BAT1 VO1 BAT2 VO2 HL LO HI W WR WL HO BAT Bl Black Br Brown


Y Yellow O Orange
ON LO R FREE Bu Blue Lb Light Blue
G Green Lg Light Green
OFF (N) N PUSH R Red P Pink
W White Gr Gray
COLOR R Bl/Bu Bl/R Bl HI L COLOR Lg Bl

COLOR Y W Bu COLOR Gr Lb O TWO COLORED WIRE (EXAMPLE:YELLOW/RED)


AFS110MSF/MCF-J (TH,LO,AD)

FRONT
STOP STARTER REAR
TURN LIGHT SWITCH BRAKE
SIGNAL GROUND STARTER
SWITCH IGNITION LIGHT REGULATOR RELAY
RELAY SWITCH SWITCH RECTIFIER BATTERY
O2 SUB MAIN 12V 3.0AH
SENSOR

G
FUSE FUSE

BAT2

BAT1
10A 15A

VO2

VO1
3P
Bl 5P

Bl/Bu
Bl/R

G
6P

Bl

Bl
Bl
Y/R
G/Y

G
Bl

G/Bl
2P

Bl/Bu

W/R
Y/R
R/Y

R
G
Bl

W
G
R
Y
G
GR
Bl

R
R
Bl/R
R/Y

R/Y
R
Bl/Bu
Bl/R
Bl

Bl
Bl

Bl
MIL INDICATOR W/Bu 1P
4P
Bl Bl
12V 1.7W

Bl/Bu

Bl/O
G/Y
Bl/R

Bl
METER LIGHT Y

Bl

Bl/R

R/Y
12V 1.7W G
2P
METER LIGHT Y Bl
12V 1.7W G RIGHT REAR
TURN SIGNAL LIGHT

Bl/Bu

Bl/R

R/Y
Y/R
GEAR POSITION 12W 10W
INDICATOR P
4TH 12V 1.7W Bl Lb
G
W/Bu
3RD 12V 1.7W Bl 9P
BRAKE/TAIL LIGHT
Bl Bl
Y Y
6P 12V 18W/5W
Bl/Bu Lb Lb
Bl G G G
2ND 12V 1.7W G G
P P G/Y G/Y G/Y
W/Bu W/Bu Y Y Y
Y/R O O
Bl/Bu Bl/Bu
1ST 12V 1.7W Bl
Y/R Y/R
Lg/R Lg/R
Lg/R
NEUTRAL Bl
G
12V 1.7W O
6P
Lb Lb
HI BEAM Bu G/Y G/Y LEFT REAR
INDICATOR G W/Bu W/Bu TURN SIGNAL LIGHT
12V 1.7W O O 12V 10W
Y/R Y/R
RIGHT TURN Lb Y/W Y/W
G
SIGNAL INDICATOR
12V 3.4W
G
LEFT TURN O
SIGNAL INDICATOR
12V 3.4W
Bl
Y/W
FUEL METER
G

W
G
RIGHT FRONT Lb 2P

W/Bu
Bl/Bu

Lg/R
Y/R
P
TURN SIGNAL LIGHT G
12 10W

Bu/Y
W/Y

W
G
6P
POSITION LIGHT Y Bl
12V 3.4W G 9P

R/W
G

W/Bu
Bl/Bu

Lg/R
Y/R
P
Lb Lb

Bu/Y
W/Y
2P

Bl/Bu
Bu Bu Bu

P/G
HEAD LIGHT G G G

Bl/Bu

Bl/Bu
Y/W

P/Bu
12 32W/32W

Br
G

W
R/W
W W W

G
2P
O 5P

Bu/Y
O Bl
Bl 4 3
Y 2
Lg

1
POSITION LIGHT G
12V 3.4W Y N

W/Y
LEFT FRONT
Bu

Gr

Lg
Lb
W

Bl

Bl/Bu
Bl/Bu
O
Y

G
TURN SIGNAL LIGHT O
W/Bu
Bl/Bu
Bu/Y

P/Bu

Y/Bu

Lg/R

G/Bl

Bl/O
W/Y

G/O

G/O
P/G

Y/R

3P
Bu

3P 3P
Br

12 10W
G
G
Y

3P R Bl HORN INJECTOR
Bl/Bu

G/Bl
Bu

FUEL
Y

Y/Bu
HL

WL

BAT
LO
HI

W
WR

HO

G/O

G/O
Y/R

LEVEL
Y

4P 33P SENSOR
F/P
R IGNITION ALTERNATOR
3P 2P
GEAR
FL
IGP
PCP
PCM
IGPLS
INJ

SG(TO)
TO
WARN
N SW
SG(THL)
LG
SCS
K-LINE
PG1
PG2
O2

THR
VCC

Bl Bl
COIL SWITCH
DIMMER TURN HORN FUEL PUMP
SIGNAL POSITION
SWITCH SWITCH
VCC
THR
SG

STARTER
BAT
HO

SWITCH DLC
MOTOR

ECM TP EOT
SENSOR SENSOR

SWITCH CONTINUITY

COMBINATION SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH STARTER SWITCH

BAT1 VO1 BAT2 VO2 HL LO HI W WR WL HO BAT ST E Bl Black Br Brown


Y Yellow O Orange
ON LO R FREE FREE Bu Blue Lb Light Blue
G Green Lg Light Green
OFF (N) N PUSH PUSH R Red P Pink
W White Gr Gray
COLOR R Bl/Bu Bl/R Bl HI L COLOR Lg Bl COLOR Y/R G

COLOR Y W Bu COLOR Gr Lb O TWO COLORED WIRE (EXAMPLE:YELLOW/RED)


© Honda Motor Co.,Ltd. 2017 Book#: 82K58E0
Published by Honda Motor Co.,Ltd. A. 2017.05
Printed in Japan