Manual Taller CRF1100

2020
CRF11OOA/A4/D/D4
.,
HOW TO USE THIS MANUAL
A Few Words About Safety

Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
motorcycle 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 motorcycle.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of the motorcycle. Any error or oversight
while servicing a motorcycle can result in faulty operation, damage to the motorcycle, or injury to others.
AWARNING
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 or repair procedures. Only you can decide whether or not you should
perform a given task.
AWARNING
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 either 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 motorcycle up in the air. Any time you lift the motorcycle, 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.
61MKS00
How To Use This Manual
This manual describes the service procedures for the CRF11 OOA/A4/D/D4.
Sections 1,2 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may
be required to perform service described in the following sections.
Section 4 through 22 describe parts of the motorcycle, grouped according to location.
Follow the Maintenance Schedule recommendations to ensure that the motorcycle 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.
Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent
pages give detailed procedure.
Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI
section troubleshooting first.
...
r 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 judgment.
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 11\ and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
fj•f#(e§;j You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.
ffiw+i;WINI You CAN be KILLED or SERIOUSLy HURT if you don't follow instructions.
tiSW•O[l]a 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 [NOru:EJ 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: October, 2019
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.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.

~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1 ).
71
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
_.$1iii11
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
~
equivalent).
Example:
.
lI
Molykote® BR-2 plus manufactured by Dow Corning U.S.A. I
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or 1
equivalent).
Example: J
....'iii»t . Molykote® G-n Paste manufactured by Dow Corning U.S.A.
·l
. Pro Honda M-77 Assembly Paste (Moly) (U.S.A. only)
. Rocol ASP manufactured by Rocol Limited , U.K. j
. Moly Paste 500 manufactured by Sumico Lubricant, Japan l
,riisiat Use silicone grease.
I
~
c:,. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. l
..;1-.ru Apply sealant.
I Use Honda DOT 4 brake fluid . Use the recommended brake fluid unless otherwise specified.
l
1
8 Use fork or suspension fluid.

j
'l
•4
i''
I
I
I
j
CONTENTS
GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
PGM-FI SYSTEM
IGNITION SYSTEM
ELECTRIC STARTER
FUEL SYSTEM
..JI======================
~ COOLING SYSTEM
~!======================
1- LUBRICATION SYSTEM
(.)!======================
~ CYLINDER HEADNALVE/CAMSHAFT
~~====================
w ALTERNATOR/STARTER CLUTCH
zl======================
~ CLUTCH/GEARSHIFT LINKAGE (MT model)
w1======================
DUAL CLUTCH TRANSMISSION (DCT model)
CRANKCASE/TRANSMISSION/BALANCER
CRANKSHAFT/PISTON/CYLINDER
ENGINE REMOVAL/INSTALLATION
~ FRONT WHEEL/SUSPENSION/STEERING
UJ~====================
~ REAR WHEEL/SUSPENSION
:::c
o HYDRAULIC BRAKE
~ ANTI-LOCK BRAKE SYSTEM (ABS)
WU>-=====================
:::!!: - t-
~~ BATTERY/CHARGING SYSTEM
LL W
irl LIGHTS/METERS/SWITCHES/ELECTRONIC SUSPENSION
WIRING DIAGRAMS
INDEX
r
MEMO
1. GENERAL INFORMATION
SERVICE RULES .. ······ .. ························· 1-2 LUBRICATION & SEAL POINTS ............ 1-23
MODEL IDENTIFICATION ....................... 1-3 CABLE & HARNESS ROUTING ............. 1-25
SPECIFICATIONS··················· ··············· 1-5 EMISSION CONTROL SYSTEMS ........... 1-72
TORQUE VALUES ............................... 1-13 TECHNICAL FEATURES ...................... 1-75
L.
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design
specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners. J
:
4. Install new gaskets, 0-rings, cotter pins, and lock plates when reassembling .
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in '
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-26).
9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
ABS Anti-lock Brake System
A/F sensor Air/Fuel sensor
APS Accelerator Position Sensor J
BCU Body Control Unit
')
CAN Controller Area Network
CKP sensor Crankshaft Position sensor
OCT Dual Clutch Transmission
DLC Data Link Connector
OTC Diagnostic Trouble Code
ECM Engine Control Module
ECT sensor Engine Coolant Temperature sensor
ECV Exhaust Control Valve
ECVPOT Exhaust Control Valve Potentiometer
EGCA Exhaust Gas Control Actuator
EOP sensor Engine Oil Pressure sensor
EOP switch
EOT sensor
Engine Oil Pressure switch
Engine Oil Temperature sensor
•
EVAP Evaporative Emission
GP sensor Gear Position sensor
HSTC Honda Selectable Torque Control
IAT sensor Intake Air Temperature sensor
IMU Inertia Measurement Unit
MAP sensor Manifold Absolute Pressure sensor
MCS Motorcycle Communication System
MID Multi Information Display
MIL Malfunction Indicator Lamp
MT Manual Transmission
080 On-Board Diagnostic
PAIR Pulse Secondary Air Injection
PGM-FI Programmed Fuel Injection
scs Service Check Signal
scu Suspension Control Unit
TBW Throttle By Wire
TCM Transmission Control Module
TP sensor Throttle Position sensor
TR sensor Transmission Range sensor
VS sensor Vehicle Speed sensor
1-2
GENERAL INFORMATION
DESTINATION CODE
Throughout this manual, the following codes are used to identify individual models for each region.
DESTINATION CODE REGION
AC, IIAC 50-State, meets California
CM, IICM Canada
MODEL IDENTIFICATION
CRF1100D4 shown :
SERIAL NUMBERS/LABELS
The motorcycle Identification Number (V.1.N) [1] is stamped The engine serial number [1] is stamped on the crankcase as
on the right side of the steering head. shown .
The throttle body identification number [1] is stamped on the The color label [1], emission information labels [2]/[3] (CM
left side of the throttle body as shown. type only) are attached on the top side of the rear fender B.
When ordering color-coded parts, always specify the
designated color code.
1-3
GENERAL INFORMATION
TYPES
Manual Transmission (MT)
DUAL CLUTCH TRANSMISSION (OCT)
BIG FUEL TANK
TUBELESS TIRE
DESTINATION
TYPE CODE CORNERING LIGHT
CODE
ACCESSORY SOCKET
GRIP HEATER
ELECTRONIC
SUSPENSION
CRF1100A AC, IIAC, CM 0 - - - - - - -
CRF1100D AC, IIAC, IICM - 0 - - - - - -
CRF1100A4 IIAC, CM 0 - 0 0 0 0 0 0
CRF1100D4 IIAC, IICM - 0 0 0 0 0 0 0
1-4
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,330 mm (91 .7 in)
Overall width 960 mm (37.8 in)
Overall height CRF1100A/D 1,395 mm (54.9 in)
CRF1100A4/ Screen high
1,620 mm (63 .8 in)
D4 position
Screen low
1,560 mm (61.4 in)
position
Wheelbase 1,575 mm (62.0 in)
Seat height Standard
870 mm (34.3 in)
position
Low
850 mm (33.5 in)
position
Footpeg height 352 mm (13.9 in)
Ground clearance 250 mm (9 .8 in)
Curb weight CRF1100A 226 kg (498 lbs)
CRF1100D 236 kg (520 lbs)
CRF1100A4 240 kg (529 lbs)
CRF1100D4 250 kg (551 lbs)
Maximum weight capacity CRF1100A/D 206 kg (454 lbs)
CRF1100A4/D4 204 kg (450 lbs)
FRAME Frame type Semi double cradle
Front suspension Telescopic fork
Front axle travel 204 mm (8.0 in)
Rear suspension Swingarm
Rear axle travel 220 mm (8.7 in)
Front tire size 90/90-21 M/C 54H
Rear tire size 150/70R18M/C 70H
Front tire brand CRF1100A/D AX41TF G (BRIDGESTONE)
KAROO STREET (METZELER)
CRF1100A4/D4 AX41TF L (BRIDGESTONE)
Rear tire brand CRF1100A/D AX41TR G (BRIDGESTONE)
CRF1100A4/D4 AX41TR L (BRIDGESTONE)
Front brake Hydraulic double disc
Rear brake Hydraulic single disc
Caster angle 27.5°
Trail length 113 mm (4.4 in)
Fuel tank capacity CRF1100A/D 18.8 liters (4 .97 US gal, 4.14 Imp gal)
CRF11 OOA4/D4 24.8 liters (6 .55 US gal, 5.46 Imp gal)
ENGINE Cylinder arrangement 2 cylinders in-line, slant angle 22.5°
Bore and stroke 92 x 81.5 mm
(3.6 X 3.21 in)
Displacement 1,084 cm 3 (66.1 cu-in)
Compression ratio 10.1 : 1
Valve train Chain driven, OHC with valve lifter
and rocker arm
Intake opens at 1 mm (0.04 in) lift 2.5° BTDC
valve closes at 1 mm (0.04 in) lift 42 .5° ABDC
Exhaust opens at 1 mm (0.04 in) lift 41 ° BBDC
valve closes at 1 mm (0.04 in) lift 7.5° ATDC
Lubrication system Forced pressure and dry sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper element
Engine dry weight MT model 66.4 kg (146.4 lbs)
OCT model 74.9kg(165.1 lbs)
Firing order 1-2
1-5
GENERAL INFORMATION
ITEM SPECIFICATIONS
FUEL Type PGM-FI
DELIVERY Throttle bore
46 mm (1.8 in)
SYSTEM
DRIVE TRAIN Clutch system Multi-plate, wet
(MT model) Clutch operation system Cable operating
Transmission Constant mesh, 6-speeds
Primary reduction 1.717 (79/46)
Final reduction 2.625 (42/16)
Gear 1st 2.866 (43/15)
ratio 2nd 1.888 (34/18)
3rd 1.480 (37/25)
4th 1.230 (32/26)
5th 1.064 (33/31)
6th 0.972 (35/36)
Gearshift pattern Left foot operated return system,
1-N-2-3-4-5-6
DRIVE TRAIN Clutch system 2 Multi-plate wet clutches
(OCT model) Clutch operation system Automatic
Transmission Constant mesh, 6-speeds
Primary reduction 1.863 (82/44)
Final reduction 2.625 (42/16)
Gear 1st 2.562 (41/16)
ratio 2nd 1.761 (37/21)
3rd 1.375 (33/24)
4th 1.133 (34/30)
5th 0.972 (36/37)
6th 0.882 (30/34)
Gearshift pattern Automatic and electric shift (left hand
operated) return system,
N-1-2-3-4-5-6
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier FET shorted/triple phase full wave
rectification
Lighting system Battery
PGM-FI SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
IAT sensor resistance (at 40°C/104°F) 1.0 - 1.3 kO
Fuel injector resistance (at 20°C/68°F) 11 - 130
NF sensor heater resistance (at room temperature) 3.6-6.0 0
EVAP purge control solenoid valve resistance
30-34 0
(at 20°C/68°F)
PAIR control solenoid valve resistance (at 20°C/68°F) 24 - 28 0
ECT sensor resistance I 40°C (104°F) 1.0 - 1.3 kO
I 100°C (212°F) 0.14 - 0.18k0
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Spark plug SILMAR8A9S (NGK)
Spark plug gap 0.8 - 0.9 mm (0.03 - 0.04 in)
Ignition coil primary peak voltage 100 V minimum
Ignition timing ("F"mark) 10° BTDC at idle
1-6
GENERAL INFORMATION
FUEL SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identification number GNJ1A
Engine idle speed 1,250 ± 100 r/min
Fuel pressure at idle 324 - 367 kPa (3.3 - 3.7 kgf/cm2 , 47 - 53 psi)
Fuel pump flow (at 12 V) 319 cm, (10.8 US oz, 11 .2 Imp oz) minimum/10 seconds
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 1.81 liters (1 .91 US qt, 1.59 Imp qt)
Reserve tank 0.33 liter (0.35 US qt, 0.29 Imp qt)
Radiator cap relief pressure 108 -137 kPa (1 .1 -1.4 kgf/cm' , 16 - 20 psi)
Thermostat Begin to open 80 - 84°C (176 - 183°F)
Fully open 95°C (203°F)
Valve lift 8 mm (0.3 in) minimum
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene
glycol antifreeze containing corrosion protection inhibitors
Standard coolant concentration 1: 1 mixture with distilled water
LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil MT model After draining 3.9 liters (4.1 US qt, 3.4 Imp qt) -
capacity After draining/engine oil
filter change
4.0 liters (4.2 US qt, 3.5 Imp qt) -
After disassembly 4.8 liters (5.1 US qt, 4 .2 Imp qt) -
DCTmodel After draining 4.0 liters (4.2 US qt, 3.5 Imp qt) -
After draining/engine oil
4.2 liters (4.4 US qt, 3.7 Imp qt) -
filter/clutch oil filter change
After disassembly 5.2 liters (5.5 US qt, 4.6 Imp qt) -
Recommended engine oil Pro Honda GN4 4-stroke oil (U .S.A. &
Canada) or equivalent motorcycle oil
API service classification: SG or higher -
JASO T903 standard: MA
Viscosity: SAE 1OW-30
Oil pressure (at oil filter cartridge) 614 kPa (6.3 kgf/cm 2 , 89 psi)
-
at 5,000 r/min (80°C/176°F)
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
1-7
GENERAL INFORMATION
CYLINDER HEADNALVE/CAMSHAFT SPECIFICATIONS
Unit: mm (in)
Cylinder compression at 500 r/min 1.4 MPa (14.3 kgf/cm 2 , 203 psi) -
Valve IN Between valve lifter and cam
0.16 ± 0.03 (0.006 ± 0.001) -
clearance lobe
EX Between rocker arm roller
0.23 ± 0.02 (0.009 ± 0.001) -
and cam lobe
Between valve and adjusting
0.30 ± 0.03 (0.012 ± 0.001) -
screw
Valve, valve Valve stem O.D. IN 5.475 - 5.490 (0.2156 - 0.2161) 5.465 (0.2152)
guide EX 5.465 - 5.480 (0.2152 - 0.2157) 5.455 (0.2148)
Valve guide I.D. IN/EX 5.500 - 5.512 (0.2165 - 0.2170) 5.552 (0.2186)
Valve guide projection IN 12.9 -13.2 (0.51 - 0.52) -
above cylinder head EX 15.1-15.4 (0.59-0.61) -
Valve seat width IN 1.1 - 1.3 (0.04 - 0.05) 1.5 (0.06)
EX 1.3 - 1.5 (0.05 - 0.06) 1.9 (0.07)
Valve spring Free length IN 41.23 (1.623) 40.41 (1 .591 )
EX 40.93 (1.611) 40.11 (1.579)
Valve lifter Valve lifter 0 .0 . IN 31 .978 - 31.993 (1 .2590 - 1.2596) 31.97 (1.259)
Valve lifter bore I.D. IN 32.010 - 32.026 (1.2602 - 1.2609) 32.04 (1.261)
Rocker arm Arm 1.0. EX 12.000 -12.018 (0.4724 - 0.4731) 12.05 (0.474)
Shaft 0 .0 . EX 11.977 - 11.990 (0.4715 - 0.4720) -
Camshaft Cam lobe height IN 42.180 - 42.340 (1.6606 - 1.6669) 42.15 (1.659)
EX 42.282 - 42.442 (1.6646 - 1.6709) 42.25 (1.663)
Oil clearance 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
Cylinder head warpage - 0.10 (0.004)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit: mm (in)
Starter driven gear boss I O.D. 57.749 - 57.768 (2.2736 - 2.2743) -
I I.D. 44.000 - 44.016 (1.7323 - 1.7329) -
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (MT model)

Unit: mm (in)
Clutch lever freeplay 10 - 20 (0.4 - 0.8) -
Clutch Spring free length 45.0 (1.77) 44.1 (1 .74)
Disc thickness 2.72 - 2.88 (0.107 - 0.113) 2.5 (0.1 0)
Plate warpage - 0.20 (0.008)
Primary driven gear I.D. 41.958 - 41 .983 (1 .6519 - 1.6529) - J
Clutch outer guide O.D. 34.975 - 34.991 (1 .3770 - 1.3776) -
I.D. 28.000 - 28.021 (1 .1024 - 1.1032) -
Mainshaft 0 .0. at clutch outer guide 27.967-27.980 (1.1 011 - 1.1016) -
DUAL CLUTCH TRANSMISSION SPECIFICATIONS (DCT model)

Unit: mm (in)
Clutch initial clearance 0.70 - 0.90 (0.028 - 0.035) 1.3 (0.05)
EOT sensor resistance (20°C/68°F) 2.5-2.8 kO -
1-8
GENERAL INFORMATION
CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS
MT model:
Unit: mm (in)
Transmission Gear I.D. M5, M6 31 .000 - 31.025 (1.2205 -1.2215) -
C1 25.000 - 25.021 (0.9843 - 0.9851) -
C2, C3, C4 33.000 - 33.025 (1.2992 - 1.3002) -
Gear bushing M5 30.955- 30.980 (1 .2187 -1 .2197) -
O.D. M6 30.950 - 30.975 (1 .2185 - 1.2195) -
C1 24.959 - 24.980 (0.9826 - 0.9835) -
C2 32.955 - 32.980 (1 .2974 -1 .2984) -
C3, C4 32.950 - 32.975 (1 .2972 - 1.2982) -
Gear bushing I.D. M5 27.985-28.006 (1 .1018-1.1026) -
C1 21 .985 - 22.006 (0.8655- 0.8664) -
C2 29.985 - 30.006 (1 .1805 - 1.1813) -
Mainshaft O.D. at M5 27.967-27.980 (1.1011-1 .1016) -
Countershaft at C1 21.987 - 22.000 (0.8656 - 0.8661) -
O.D. at C2 29.967 - 29.980 (1.1798 - 1.1803) -
Shift fork, Fork I.D. 12.000-12.018 (0.4724- 0.4731) -
fork shaft Claw thickness 5.93 - 6.00 (0.233 - 0.236) 5.83 (0.230)
Shift fork shaft O.D. 11.957 - 11.968 (0.4707 - 0.4712) -
. DCT model:
Unit: mm (in)
Transmission Gear I.D. M5 35.000 - 35.025 (1 .3780 - 1.3789) -
M6 43.000 - 43.025 (1 .6929 - 1.6939) -
C1 35.000 - 35.025 (1.3780 - 1.3789) -
C2 25.000 - 25.021 (0.9843 - 0.9851) -
C3, C4 33.000 - 33.025 (1 .2992 - 1.3002) -
Gear bushing O.D. M5 34.950 - 34.975 (1 .3760 - 1.3770) -
M6 42.950 - 42.975 (1 .6909 - 1.6919) -
C1 34.950 - 34.975 (1 .3760 - 1.3770) -
C2 24.959 - 24.980 (0.9826 - 0.9835) -
C3, C4 32.950 - 32.975 (1 .2972 - 1.2982) -
Gear bushing I.D. M5 32.000 - 32.025 (1 .2598 - 1.2608) -
M6 40.007 - 40.028 (1 .5751 - 1.5759) -
C1 30.000-30.021 (1 .1811-1 .1819) -
C2 21.985 - 22 .006 (0 .8655 - 0.8664) -
Inner mainshaft O.D. M5 31 .957 - 31 .970 (1.2581 - 1.2587) -
Outer mainshaft O.D. M6 39.975 - 39.991 (1 .5738 - 1.5744) -
Countershaft O.D. C1 29.967 - 29.980 (1 .1798 - 1.1803) -
C2 21 .987 - 22.000 (0.8656 - 0.8661) -
Shift fork I.D. 12.000-12.018 (0.4724- 0.4731) -
Claw thickness 5.93 - 6.00 (0.233 - 0.236) 5.83 (0.230)
Shaft O.D. 11 .957 - 11.968 (0.4707 - 0.4712) -
1-9
GENERAL INFORMATION
CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS
Unit: mm (in)
Crankshaft Connecting rod side clearance 0.05 - 0.25 (0 .002 - 0.010) 0.35 (0.014)
Runout - 0.03 (0.001)
Main journal bearing oil clearance 0.019 - 0.038 (0.0007 - 0.0015) 0.05 (0.002)
Crankpin bearing oil clearance 0.027 - 0.045 (0.0011 - 0.0018) 0.065 (0.0026)
Cylinder I.D. 92.000 - 92.015 (3.6220 - 3.6226) 92.10 (3.626)
Piston, Piston 0.0. at 14.0 mm (0.55 in) from
91 .975 - 91 .985 (3.6211 - 3.6214) 91.89 (3.618)
piston pin, bottom
piston ring Piston pin hole 1.0. 22.002 - 22.008 (0.8662 - 0.8665) 22.02 (0 .867)
Piston pin 0.0. 21.994 - 22.000 (0.8659 - 0.8661) 21.98 (0.865)
Piston ring end gap Top 0.185 - 0.235 (0.0073 - 0.0093) 0.335 (0.0132)
Second 0.400 - 0.550 (0.0157 - 0.0217) 0.650 (0.0256)
Oil (side rail) 0.100 - 0.350 (0.0039 - 0.0138) 0.550 (0.0217)
Piston ring-to-ring Top 0.015- 0.045 (0.0006- 0.0018) -
groove clearance Second 0.015 - 0.050 (0.0006 - 0.0020) -
Connecting rod small end 1.0. 22.026 - 22.040 (0.8672 - 0.8677) 22.050 (0.8681)
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT J
Cold tire Up to 90 kg (200 lbs) load 225 kPa -
pressure (2.25 kgf/cm 2 , 33 psi)
Up to maximum weight capacity 225 kPa
-
(2.25 kgf/cm 2 , 33 psi)
Axle runout - 0.2 (0.01)
Wheel rim Radial - 1.0(0.04)
runout Axial - 1.0 (0.04)
Wheel balance weight 60 g (2 .1 oz)
-
max.
Fork Spring free Conventional suspension model 433.7 (17 .07) 425.0 (16 .73)
length Electronic MT model 412.0 (16 .22) 403.8 (15.90)
suspension
model OCT model 415.0 (16.34) 406.7 (16.01)
Recommended fork fluid Fork Fluid (viscosity: 1OW) -
Fluid level Conventional suspension model 93 (3.7) -
Electronic suspension model R: 139 (5.5)
-
L: 69 (2 .7)
Fluid capacity Conventional suspension model 708 ± 2.5 cm"
(23.9 ± 0.1 us oz, -
24.9 ± 0.1 Imp oz)
Electronic suspension model R: 637 ± 2.5 cm 3
(21 .5 ± 0.1 US OZ ,
22.4 ± 0.1 Imp oz)
-
L: 664 ± 2.5 cm 3
(22.5 ± 0.1 us oz,
23.4 ± 0.1 Imp oz)
CRF1100A Pre-load adjuster standard position 2 turns from the full soft
-
position
Rebound damping adjuster 2 3/4 turns from full hard
-
standard position position
Compression damping adjuster 9 clicks from full hard
-
CRF1100D Pre-load adjuster standard position 5 turns from the full soft
-
position
Rebound damping adjuster 2 3/4 turns from full hard
-
Compression damping adjuster 9 clicks from full hard
-
1-10
GENERAL INFORMATION
REAR WHEEL/SUSPENSION SPECIFICATIONS
Unit: mm (in)
Cold tire Up to 90 kg (200 lbs) load 250 kPa
-
pressure (2.50 kgf/cm 2 , 36 psi)
Up to maximum weight capacity 280 kPa
-
(2.80 kgf/cm 2 , 41 psi)
Axle runout - 0.2 (0.01)
Wheel rim runout I Radial - 1.0 (0.04)
I Axial - 1.0 (0.04)
Wheel balance weight 60 g (2 .1 oz)
-
max.
Drive Slack 35-45(1.4-1 .8) -
chain Size/link DID: 525HV3-124LE -
Shock Pre-load adjuster standard position 7 clicks from full soft
absorber position (first click is "O" -
position)
Rebound damping adjuster standard position 8 clicks from full hard
-
position
Compression damping adjuster standard position 12 clicks from full hard
-
position
HYDRAULIC BRAKE SPECIFICATIONS

Unit: mm (in)
Front Specified brake fluid Honda DOT 4 brake fluid -
• Brake disc thickness 4.3 - 4.5 (0.17 - 0.18) 3.5 (0.14)
Brake disc warpage - 0.30 (0 .012)
Master cylinder I.D. 14.000 -14.043 (0.5512 - 0.5529) -
Master piston O.D. 13.957 - 13.984 (0.5495 - 0.5506) -
Caliper cylinder Upper 30.230 - 30.280 (1 .1902 - 1.1921) -
I.D . Lower 27.000 - 27.050 (1.0630 - 1.0650) -
Caliper piston Upper 30.148 - 30.198 (1 .1869 - 1.1889) -

O.D. Lower 26.918 - 26.968 (1 .0598 - 1.0617) -
Rear Specified brake fluid Honda DOT 4 brake fluid -
Master cylinder push rod length 73.0 - 75.0 (2.87 - 2.95) -
Brake disc thickness 6.0 ± 0.2 (0.24 ± 0.008) 5.0 (0.20)
Brake disc warpage - 0.30 (0.012)
Master cylinder I.D. 12.700-12.743 (0 .5000- 0.5017) -
Master piston O.D. 12.657 -12.684 (0.4983 - 0.4994) -
Caliper cylinder I.D. 38.18 - 38.23 (1 .503 - 1.505) -
Caliper piston O.D. 38.098 - 38.148 (1.4999 - 1.5019) -
BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Battery Type HY110
Capacity 12 V - 6.0 Ah (20 HR)
Current leakage 0.4 mA max.
Voltage I Fully charged 13.5-14.0 V
(20°C/68°F) I Needs charging Below 10.8 V
Alternator Capacity 0.49 kW/5,000 r/min
Charging coil resistance (20°C/68°F) 0.1-1.00
1-11
GENERAL INFORMATION
LIGHTS/METERS/SWITCH ES SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight Hi LED
Lo LED
Cornering light (CRF11 OOA4/D4) LED
Brake/taillight LED
Front turn signal lighUposition light LED
Rear turn signal light LED
License light LED
Instrument light LED
ABS indicator LED
Auto cruise set indicator LED
Auto cruise ON indicator LED
Fuel reserve indicator LED
High beam indicator LED
Coolant temperature indicator LED
Low oil pressure indicator (MT model) LED
MIL LED
Neutral indicator LED
Parking brake indicator (OCT model) LED
Rear ABS indicator LED
Suspension indicator
LED
(CRF11 OOA4/D4)
Torque control indicator LED
Torque control OFF indicator LED
Turn signal indicator LED
Fuse Main fuse 30A
Main2 fuse 30A
Fl fuse 15 A
ABS-M fuse 30A
DCT-M fuse (OCT model) 30A
Sub fuse 20 A X 2, 15 A X 2, 10 A X 9
Open air temperature sensor resistance (25°C/77°F) 4.9- 5.1 kO
Fuel level CRF1100A/D Full 6-10 n
sensor Empty 434-446 n
resistance CRF11 OOA4/D4 Full 6-10 n
Empty 328-338 n
Grip heater resistance (25°C/77°F)
1.7-2.10
(CRF1100A4/D4)
1
1-12
GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4 .2 (0.4, 3.1)
6 mm bolt (Include SH flange bolt) 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
and nut 6 mm flange bolt (Include NSHF) 12 (1.2, 9)
8 mm bolt and nut 22 (2.2, 16) and nut
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

FRAME BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Tank front cover screw 2 5 0.42 (0.04, 0.3)
Windscreen screw 4 5 0.42 (0.04, 0.3)
(CRF1100A/D)
Windscreen screw 6 5 0.42 (0.04, 0.3)
(CRF1100A4/04)
Lock plate mounting bolt 4 4 1.8 (0.2, 1.3)
(CRF1100A4/D4)
Front side reflector nut 2 5 1.8 (0.2, 1.3)
Skid plate bolt A 3 8 26.0 (2.7, 19)
Skid plate bolt B (CRF11 OOA4/D4) 1 6 12.0 (1 .2, 9)
Left rear cover bolt 2 6 12 (1.2, 9)
Clutch EOP sensor cover socket bolt 2 6 10 (1.0, 7)
Right rear engine cover bolt 2 6 10 (1.0, 7)
Left main step bracket bolt 2 10 35 (3.6, 26)
Sidestand switch bolt 1 6 10 (1.0, 7) ALOC bolt: replace with a
new one.
Right main step bracket upper bolt 1 12 69 (7.0, 51)
Right main step bracket lower bolt 1 8 32 (3.3, 24)
Pillion step bracket bolt 4 8 32 (3 .3, 24)
Rear side inner cover screw A 2 5 0.42 (0.04, 0 .3)
Pannier bracket bolt A/B (CRF11 OOA4/D4) 4 8 35 (3.6, 26)
Rear carrier bolt (CRF1100A4/D4) 2 8 35 (3.6, 26)
Rear side reflector nut 2 6 1.8 (0.2, 1.3) Self-lock nut
Rear reflector nut 1 5 1.8 (0.2, 1.3)
Seat rail bolt 4 10 44 (4.5, 32)
Rear master cylinder reservoir mounting 1 6 10 (1 .0, 7)
bolt
Catalyst cover bolt (CRF1100A/D) 4 6 9.0 (0.9, 6.6)
Exhaust pipe cover B bolt 4 6 9.0 (0.9, 6.6)
(CRF1100A4/04)
Exhaust outer cover bolt 1 6 9.0 (0.9, 6.6)
Exhaust pipe cover C bolt 3 6 9.0 (0.9, 6.6)
Muffler band bolt 2 8 17(1.7, 13)
Valve guide cover bolt 2 5 5.2 (0.5, 3.8)
Muffler cover screw 1 6 9.0 (0.9, 6.6)
Spark arrester bolt 6 6 9.0 (0.9, 6.6)
Tail cap cover bolt 3 6 9.0 (0.9, 6.6)
Exhaust pipe cover band screw 2 - 2.8 (0.3, 2.1) Worm screw
Exhaust pipe cover B stay bolt 1 6 9.0 (0.9, 6.6)
(CRF1100A4/D4)
Exhaust pipe joint nut 4 8 20 (2.0, 15)
Exhaust pipe stud bolt 4 8 - See page 2-54
Sidestand pivot bolt 1 10 10 (1 .0, 7) See page 2-55
Sidestand pivot nut 1 10 42 (4.3, 31) See page 2-55
1-13
GENERAL INFORMATION
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
Air cleaner element mounting screw 4 5 1.1(0.1, 0.8) Tapping screw
Air cleaner cover screw 6 5 1.1 (0 .1, 0.8) Tapping screw
Spark plug 4 10 22 (2.2 , 16)
Valve adjusting screw lock nut 4 5 10 (1.0, 7) Apply engine oil to the threads
and seating surface.
Timing hole cap 1 14 6.0 (0.6, 4.4) Apply grease to the threads.
Crankshaft hole cap 1 30 8.0 (0.8, 5.9) Apply grease to the threads .
Engine oil drain bolt 2 12 30 (3.1, 22)
Oil filter boss (crankcase side) 1 20 - Apply locking agent to the
threads.
See page 3-13 '
Engine oil filter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads.
Clutch oil filter cover bolt 2 6 12(1 .2, 9)
(OCT model)
Rear axle nut 1 18 100 (10 .2, 74) Self-lock nut
Drive chain adjuster lock nut 2 8 27 (2 .8, 20) UBS-nut
Drive sprocket bolt 1 10 54 (5.5, 40)
Driven sprocket nut 5 12 100 (10.2, 74) Apply engine oil to the threads
Self-lock nut
Parking brake adjuster lock nut 1 8 17.2 (1 .8, 13)
(OCT model)
Front spoke (CRF11 OOA/D) 36 BC 3.5 3.7 (0.4, 2.7)
Front spoke (CRF1100A4/D4) 40 BC4.0 5.0 (0.5, 3.7) Replace with a new one.
Rear spoke (CRF11 OOA/D) 32 BC 3.5 3.7 (0.4 , 2.7)
Rear spoke (CRF1100A4/D4) 36 BC 3.5 5.0 (0.5 , 3.7) Replace with a new one.
PGM-FI SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
IMU mounting bolUwasher 2 6 6.0 (0.6, 4.4)
A/F sensor 2 12 24.5 (2.5, 18)
IAT sensor mounting screw 2 5 1.1 (0.1, 0.8)
ECT sensor 1 10 12(1 .2, 9)
Rear master cylinder reservoir 1 6 10 (1 .0, 7)
mounting bolt
GP sensor mounting bolt (MT model) 1 6 12 (1 .2, 9)
Shift spindle switch 1 10 12 (1 .2, 9) Apply engine oil to the threads
Shift spindle switch terminal nut 1 4 1.7 (0.2, 1.3)
CKP sensor bolt 1 6 12 (1 .2, 9)
IGNITION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Timing hole cap 1 14 6.0 (0.6, 4.4) Apply grease to the threads.
ELECTRIC STARTER
THREAD TORQUE
ITEM Q'TY REMARKS
Starter motor cable terminal nuU 1 6 10 (1.0, 7)
washer
Starter motor setting bolt 2 5 4.9 (0 .5, 3.6)
Negative brush screw/washer 1 5 3.7 (0.4 , 2.7)
1-14
GENERAL INFORMATION
FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Fuel filler cap bolt 3 4 1.8 (0.2, 1.3)
Front cross plate bolt 4 6 12 (1.2, 9)
Fuel pump/reserve sensor terminal 2 4 1.0(0.1,0.7)
screw
Fuel pump unit mounting nut 6 6 12(1.2,9) See page 7-13
Connecting hose band screw 2 4 - See page 7-16
Insulator band screw 2 5 - See page 7-17
Fuel injector assembly mounting bolt 4 5 5.1 (0.5, 3.8)
MAP sensor screw/washer 1 6 4.9 (0.5, 3.6)
PAIR reed valve cover bolt 2 6 12 (1.2, 9)
COOLING SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Coolant drain bolt 1 6 13 (1.3, 10)
Thermostat cover bolt 2 6 12(1.2,9)
Water hose band screw 6 - - See page 8-9
Fan motor shroud bolt 6 6 8.5 (0.9, 6.3)
Cooling fan mounting nut 2 3 1.0 (0.1, 0. 7) Apply locking agent to the threads.
Fan motor mounting screw 6 5 2.7 (0.3, 2.0)
Water pump cover bolt 4 6 13 (1.3, 10) Apply locking agent to the threads.
(*1) See page 1-23
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Engine oil filter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads.
Oil pump mounting bolt 3 6 16 (1.6, 12)
Flange bolt 6 6 12(1 .2,9)
Sealing bolt (22 mm) 1 22 30 (3.1, 22) Apply locking agent to the threads.
Sealing bolt (24 mm) (DCT model) 1 24 30 (3.1, 22) Apply locking agent to the threads.
Oil pump driven gear set plate bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
(*1) See page 1-23
CYLINDER HEADNALVE/CAMSHAFT
THREAD TORQUE
ITEM Q'TY REMARKS
Cylinder head cover bolt 3 6 10 (1.0, 7)
Rocker arm shaft bolt 2 6 12 (1.2, 9) Apply engine oil to the threads and
seating surface.
Rocker arm shaft stopper bolt 1 14 18(1.8,13)
Camshaft holder bolt 6 6 12 (1.2, 9) Apply engine oil to the threads and
seating surface.
.' Cam sprocket bolt 2 7 20 (2.0, 15) Apply locking agent to the threads.
(*2) See page 1-23
/ Cam chain tensioner pivot bolt 1 8 23 (2.3, 17) Apply locking agent to the threads.
(*1) See page 1-23
/ Cylinder head bolt/washer 6 12 83 (8.5, 61) Apply molybdenum oil solution to
the threads and seating surface.
Apply engine oil to the washer.
Front head engine hanger bolt 1 8 32 (3.3, 24)
(right side)
Front head engine hanger bolt 2 8 32 (3.3, 24)
(left side)
Insulator mounting bolt 4 6 12 (1.2, 9)
1-15
GENERAL INFORMATION
ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. {mm) N·m {kgf·m, lbf·ft)
Alternator cover bolt 12 6 12 (1.2, 9)
Stator bolt 5 6 12 (1 .2, 9) Apply locking agent to the threads.
(*1) See page 1-23
Flywheel mounting bolt 1 12 137 (14.0, 101) Apply engine oil to the threads and
seating surface.
Starter clutch torx bolt 6 8 29 (3.0, 21) Apply locking agent to the threads.
(*2) See page 1-23
CLUTCH/GEARSHIFT LINKAGE {MT model)

THREAD TORQUE
ITEM Q'TY REMARKS
DIA. {mm) N·m {kgf·m, lbf·ft)
Right crankcase cover bolt 15 6 12 (1 .2, 9)
Clutch center lock nut 1 25 128 (13.1 , 94) Apply engine oil to the threads and
seating surface.
Stake.
Clutch set plate bolt 3 6 12 (1.2, 9)
Primary drive gear bolt 1 10 103 (10.5, 76) Apply engine oil to the threads and
seating surface.
Shift drum stopper arm pivot bolt 1 6 12 (1 .2, 9) Apply locking agent to the threads.
(* 1) See page 1-23
Shift drum center bolt 1 8 23 (2.3, 17) Apply locking agent to the threads.
(*2) See page 1-23
Gearshift spindle set plate bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
(*1) See page 1-23
Gearshift spindle cover bolt 2 6 12 (1 .2, 9)
Gearshift pedal pivot bolt 1 8 27 (2 .8, 20)
Clutch lever pivot bolt 1 6 1.0 (0.1, 0.7)
Clutch lever pivot nut 1 6 5.9 (0.6, 4.4) Self-lock nut
Clutch switch mounting screw 1 3 1.5 (0.2, 1.1) Apply locking agent to the threads.
Clutch cruise cancel switch 1 3 1.5 (0.2, 1.1) Apply locking agent to the threads.
mounting screw
1-16
GENERAL INFORMATION
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf-ft)
Feed pipe guide plate bolt 2 5 5.0 (0.5, 3.7)
Feed pipe cover bolt 3 6 12 (1 .2, 9)
Right crankcase cover bolt 15 6 12 (1.2, 9)
Water pipe bolt 2 6 12 (1.2, 9)
Clutch EOP sensor wire stay bolt 2 6 12 (1.2, 9)
Shift spindle angle sensor bolt 1 6 12 (1.2, 9)
Linear solenoid valve body cover 4 6 12 (1.2, 9)
bolt
Linear solenoid valve stopper plate 1 6 12 (1 .2, 9) Apply locking agent to the threads.
bolt (*1) See page 1-23
Linear solenoid valve body mounting 4 6 12 (1.2, 9)
bolt
Primary drive gear nut 1 22 118 (12 .0, 87) Apply engine oil to the threads and
seating surface.
Left-hand thread
Reduction gear cover torx bolt 3 6 14 (1.4, 10)
Shift control motor mounting torx bolt 3 6 14 (1 .4, 10)
Shift control motor cover bolt 2 6 12 (1 .2, 9)
Shift drum center bolt 1 8 31 (3.2, 23) Apply locking agent to the threads.
(*2) See page 1-23
Drum shifter guide plate/drum shifter 2 6 12 (1.2, 9) Apply locking agent to the threads.
assembly mounting bolt (*1) See page 1-23
TR sensor mounting bolt 1 6 12 (1.2, 9)
No.1/No.2 clutch EOP sensor 2 10 20 (2.0, 15)
Clutch line EOP sensor 1 10 20 (2.0, 15)
EOT sensor 1 10 15 (1 .5, 11) Apply engine oil to the threads and
seating surface.
EOP sensor 1 10 22 (2.2, 16)
Neutral switch 1 10 12 (1.2, 9) Apply engine oil to the threads and
seating surface.
Neutral switch terminal nut 1 4 1.7 (0.2, 1.3)
THREAD TORQUE
ITEM Q'TY REMARKS
Front balancer bearing set plate bolt 3 6 12 (1.2, 9) Apply locking agent to the threads.
r Front balancer shaft bolt 1 10 103 (1 0.5, 76)

(*1) See page 1-23
Apply engine oil to the threads and
t seating surface.
I Rear balancer shaft holder bolt 3 8 29 (3.0, 21)
t Mainshaft bearing set plate bolt 3 6 12 (1.2, 9) Apply locking agent to the threads.
J (*1) See page 1-23
Shift drum bearing setting bolU 2 6 12 (1.2, 9) Apply locking agent to the threads.
washer (*1) See page 1-23
Crankcase main journal bolt 6 10 43 (4.4, 32) Apply molybdenum oil solution to
Crankcase 10 mm bolt 1 10 39 (4.0, 29)
r
r
Crankcase 8 mm bolt 9 8 24 (2.4, 18)
t
l CRANKSHAFT/PISTON/CYLINDER
t THREAD TORQUE
t ITEM Q'TY
REMARKS
t
I
Crankpin bearing cap bolt (new) 4 9 22 (2.2, 16) + 120° Apply engine oil to the threads and
seating surface.
Replace with a new one.
Crankcase main journal bolt 6 10 43 (4.4, 32) Apply molybdenum oil solution to
Crankpin bearing cap bolt 4 9 22 (2.2, 16) + 90° Apply engine oil to the threads and
(retightening) seating surface.
1-17
GENERAL INFORMATION
ENGINE REMOVAUINSTALLATION
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbHt)
Right front lower engine hanger bolt 1 8 32 (3 .3, 24)
{short)
Right front lower engine hanger bolt 1 8 32 (3.3, 24)
(long)
Rear engine upper hanger bolt 2 6 12 (1.2, 9)
Swingarm pivot nut 1 16 80 (8.2, 59) Apply engine oil to the threads and
seating surface.
Self-lock nut
Rear lower nut 1 10 44 (4 .5, 32)
Front lower nut 1 10 44 (4.5, 32)
Front engine hanger nut (8 mm) 2 8 32 (3.3, 24)
Front engine hanger nut (10 mm) 1 10 44 (4.5, 32)
Front head engine hanger bolt 1 8 32 (3 .3, 24)
(right side)
Front head engine hanger bolt 2 8 32 (3 .3, 24)
(left side)
Rear upper nut 1 8 32 (3 .3, 24)
Drive sprocket bolt 1 10 54 (5 .5, 40)
Clutch EOP sensor wire stay bolt 2 6 12 (1 .2, 9)
Alternator cover bolt 12 6 12 (1 .2, 9)
FRONT WHEEUSUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
Handlebar upper holder bolt 4 8 32 (3.3, 24)
Right handlebar switch screw 2 5 2.5 (0.3, 1.8)
Front master cylinder holder bolt 2 6 9.8 (1.0 , 7.2)
Left handlebar switch screw 2 5 2.5 (0 .3, 1.8)
Handlebar weight bolt 2 18 55 (5.6, 41) ALOC bolt: replace with a new one.
Handlebar lower holder nut 2 10 39 (4.0, 29)
Front brake disc bolt 12 6 20 (2 .0, 15) ALOC bolt: replace with a new one .
(CRF1100A/D)
Pulser ring bolt 3 5 7.0 (0 .7, 5.2) ALOC bolt: replace with a new one.
(CRF1100A/D)
Front spoke (CRF11 OOA/D) 36 BC 3.5 3.7 (0.4, 2.7)
Front brake disc bolt 10 6 20 (2 .0, 15) ALOC bolt: replace with a new one. J
(CRF1100A4/D4)
Pulser ring bolt 5 5 7.0 (0.7, 5.2) ALOC bolt: replace with a new one.
(CRF11 OOA4/D4)
Front spoke (CRF11 OOA4/D4) 40 BC4.0 5.0 (0.5, 3.7) Replace with a new one.
Front tire valve nut 1 8V1 6.5 (0.7, 4.8)
(CRF1100A4/D4)
Front axle nut 1 16 65 (6 .6, 48)
Front axle holder pinch bolt 4 8 22 (2 .2, 16)
Front brake caliper mounting bolt 4 10 45 (4.6, 33) ALOC bolt: replace with a new one.
Fork center bolt 2 - 34 (3.5, 25)
(conventional suspension model)
Fork center bolt (electronic 1 - 20 (2.0 , 15) Apply locking agent to the threads.
suspension model left side)
Fork damper lock nut 2 10 20 (2 .0, 15)
(conventional suspension model)
Fork damper lock nut (electron ic 1 10 20 (2 .0, 15)
Fork bolt 2 - 35 (3.6 , 26)
Suspension solenoid (electronic 1 - 15(1 .5, 11)
Inner fork bolt (electronic 1 - 90 (9 .2, 66)
suspension model right side)
Fork bottom bridge pinch bolt 4 8 25 (2.5 , 18)
Fork top bridge pinch bolt 4 8 22 (2.2, 16)
Steering stem adjusting nut 1 26 15(1 .5,11) See page 17-51
Steering stem nut 1 24 100 (10.2, 74) See page 17-51
1-18
GENERAL INFORMATION
REAR WHEEUSUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
Rear axle nut 1 18 100 (10 .2, 74) Self-lock nut
Rear brake disc bolt 4 8 42 (4.3, 31) ALOC bolt: replace with a new
(CRF1100ND) one.
Rear brake disc bolt 5 8 42 (4.3, 31) ALOC bolt: replace with a new
(CRF1100A4/D4) one.
Driven sprocket nut 5 12 100 (10.2, 74) Apply engine oil to the threads and
seating surface.
Self-lock nut
Pulser ring bolt 4 5 7.0 (0.7, 5.2) ALOC bolt: replace with a new
(CRF1100ND) one.
Pulser ring bolt (CRF1100A4/D4) 3 5 7.0 (0.7, 5.2) ALOC bolt: replace with a new
one.
Rear spoke (CRF1100ND) 32 BC 3.5 3.7 (0.4, 2.7)
Rear spoke (CRF11 OOA4/D4) 36 BC 3.5 5.0 (0.5, 3.7) Replace with a new one.
Shock absorber upper nut 1 10 54 (5.5, 40) Self-lock nut
Shock absorber lower nut 1 10 44 (4.5, 32) Self-lock nut
Rear cushion connecting rod nut 1 10 54 (5.5, 40) Self-lock nut
Suspension solenoid 1 - 15 (1.5, 11)
(electronic suspension model}
Rear master cylinder mounting bolt 2 6 14 (1.4, 10)
(electronic suspension model}
Rear master cylinder reservoir 1 6 10 (1.0, 7)
mounting bolt
(electronic suspension model)
Brake hose guide screw 2 5 1.2 (0.1, 0.9) ALOC screw: replace with a new
one.
Brake hose clamp screw 1 5 1.2 (0.1, 0.9) ALOC screw: replace with a new
one.
Cushion arm nut 1 10 74 (7.5, 55) Self-lock nut
Front cushion connecting rod nut 1 10 44 (4.5, 32) Apply engine oil to the threads and
seating surface.
Self-lock nut
Drive chain slider screw 4 5 4.2 (0.4, 3.1) ALOC screw: replace with a new
., Drive chain guard bolt 2 6 10 (1 .0, 7)

one.
Swingarm pivot nut 1 16 80 (8.2, 59) Apply engine oil to the threads and
seating surface.
Self-lock nut
f 1-19
GENERAL INFORMATION
HYDRAULIC BRAKE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbMt)
Brake caliper bleed valve 3 8 5.4 (0.6, 4.0)
Front master cylinder reservoir cap 2 4 1.5(0.2, 1.1)
screw
Rear master cylinder reservoir cap 2 4 1.5(0.2,1 .1)
screw
Rear master cylinder reservoir 1 6 10 (1 .0, 7)
mounting bolt
Front brake caliper mounting bolt 4 10 45 (4.6, 33) ALOC bolt: replace with a new
one.
Rear brake caliper mounting bolt 1 8 22 (2 .2, 16) ALOC bolt: replace with a new
one.
Rear brake pad pin 1 10 17(1 .7, 13)
Parking brake caliper mounting bolt 2 8 30 (3.1, 22) ALOC bolt: replace with a new
(OCT model) one.
Parking brake pad pin 2 8 17.2 (1 .8, 13) ALOC bolt: replace with a new
(OCT model) one.
Drive chain guard bolt 2 6 10 (1 .0, 7)
(OCT model)
Parking brake caliper cover bolt 2 6 9.0 (0.9, 6.6)
(OCT model)
Front master cylinder holder bolt 2 6 9.8 (1 .0, 7.2)
Oil bolt 5 10 34 (3.5, 25)
Front brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
Front brake lever pivot nut 1 6 5.9 (0.6 , 4.4)
Front brake switch mounting screw 1 4 1.2 (0.1, 0.9)
Rear master cylinder mounting bolt 2 6 14(1.4, 10)
Rear master cylinder connector 1 4 1.5 (0 .2, 1.1) Apply locking agent to the threads .
screw (*1) See page 1-23
Rear master cylinder push rod lock 1 8 17.2 (1 .8, 13)
nut
Front brake caliper assembly tone 6 8 27 (2 .8, 20) Apply locking agent to the threads.
bolt
Rear brake caliper pin bolt
Parking brake stopper stay HEX bolt
1
1
12
4
27 (2 .8, 20)
2.3 (0.2, 1.7)
.j
;
(OCT model)
Parking brake stopper stay flange 1 6 11 .9 (1 .2, 9)
bolt (OCT model) J
Parking brake lock lever pivot bolt 1 6 6.9 (0 .7, 5.1 )
(OCT model) •
;
Parking brake lever pivot bolt 1 6 1.0 (0 .1, 0.7)
(OCT model}
Parking brake lever pivot nut 1 6 5.9 (0.6, 4.4)
(OCT model)
Parking brake switch mounting 1 4 1.2(0.1, 0.9) Apply locking agent to the threads .
screw (OCT model)
Parking brake caliper pin bolt 1 8 22 (2 .2, 16) Apply locking agent to the threads.
(OCT model)
Parking brake adjuster lock nut 1 8 17.2 (1 .8, 13)
(OCT model)
ANTI-LOCK BRAKE SYSTEM (ABS)

THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbMt)
Brake hose guide screw 2 5 1.2(0.1, 0.9) ALOC screw: replace with a new ;
one.
Brake hose clamp screw 1 5 1.2 (0 .1, 0.9) ALOC screw: replace with a new
one.
Oil bolt 5 10 34 (3.5, 25)
Brake pipe joint nut 4 10 14 (1.4, 10) Apply brake fluid to the threads .
1-20
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES
THREAD TORQUE
ITEM Q'TY REMARKS
License light bolt 2 4 2.0 (0.2, 1.5)
Meter/MID screw 7 5 1.0 (0.1, 0.7)
Open air temperature sensor screw 1 4 1.2 (0.1, 0.9)
EOP switch (MT model} 1 PT 1/8 12 (1 .2, 9) Apply sealant to the threads.
See page 22-25
EOP switch terminal bolt/washer 1 4 2.0 (0.2, 1.5)
(MT model}
Ignition switch mounting bolt 2 8 26 (2.7, 19) Replace with a new one.
Left handlebar switch screw 2 5 2.5 (0.3, 1.8)
Right handlebar switch screw 2 5 2.5 (0.3, 1.8)
Front master cylinder holder bolt 2 6 9.8 (1 .0, 7.2)
Neutral switch (MT model) 1 10 12 (1.2, 9) Apply engine oil to the thread and
seating surface.
Neutral switch terminal nut 1 4 1.7 (0.2, 1.3)
(MT model}
Left main step bracket bolt 2 10 35 (3.6, 26)
Sidestand switch bolt 1 6 10(1 .0,7) ALOC bolt: replace with a new
one.
OTHERS
THREAD TORQUE
ITEM Q'TY REMARKS
Front cowl stay nut 2 8 32 (3.3, 24)
MAP sensor stay mounting screw/ 1 5 4.2 (0.4, 3.1)
washer
Cylinder head sealing bolt 2 18 27 (2.8, 20) Apply locking agent to the threads.
Oil pan sealing bolt (14 mm) (DCT 1 14 18(1.8,13) Apply locking agent to the threads.
model) Coating width: 5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
0.04 in) from bolt end
Oil pan sealing bolt (16 mm) 1 16 23 (2.3, 17) Apply locking agent to the threads.
Coating width : 5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
Oil pan sealing bolt (20 mm) 1 20 45 (4.6, 33) Apply locking agent to the threads.
Coating width: 5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
Gearshift spindle return spring pin 1 8 23 (2.3, 17)
Right crankcase cover sealing bolt 5 6 10 (1.0,7)
(6 mm) (DCT model}
Right crankcase cover sealing bolt 4 10 12(1 .2,9)
(10 mm) (DCT model}
Right crankcase cover sealing bolt 1 12 16(1.6,12)
(12 mm) (DCT model)
Right crankcase cover orifice 1 - 2.0 (0.2, 1.5)
(DCT model)
Upper crankcase sealing bolt (8 mm) 1 8 23 (2.3, 17) Apply locking agent to the threads.
Coating width: 5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
Lower crankcase sealing bolt 1 10 12 (1.2, 9) Apply locking agent to the threads.
(10 mm) (DCT model) Coating width : 4.5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
(18 mm) Coating width: 5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
(22 mm) Coating width: 4.5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
1-21
GENERAL INFORMATION
*1: Apply locking agent to the threads as shown.
Do not apply this area.
The bolt shown is typical.
*2: Apply locking agent to the threads as shown .
6.5 ± 1.0 mm
(0 .26 ± 0.04 in) ... ~
1
ij -1-~ - ~ Apply this area .
The bolt shown is typical.
1-22
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Sealant Crankcase mating surface See page 14-27
(TB 12078 manufactured Alternator cover mating surface See page 11-5
by ThreeBond or an CKP sensor wire grommet See page 11-5
equivalent) Right crankcase cover mating surface MT model : See page 12-7
DCT model: See page 13-44
Linear solenoid valve wire grommet See page 13-48
Sealant Cylinder head cover packing See page 10-7
(TB5211 C manufactured
by ThreeBond, KE45T
manufactured by Shin-Etsu
Silicone or an equivalent)
Molybdenum oil solution Rocker arm sliding area and thrust surface
(a mixture of 1/2 engine oil Rocker arm shaft outer surface
and 1/2 molybdenum Camshaft journals, cam lobes, and thrust surface
disulfide grease) Valve stem sliding area and stem end
Starter reduction gear shaft outer surfaces
Clutch outer guide entire surface (MT model)
Primary driven gear teeth and clutch outer sliding surface
(MT model)
Judder spring and judder spring seat entire surface
(MT model)
Primary driven gear teeth, friction springs, and boss sliding
area (dual clutch assembly, DCT model)
Rear balancer washer seating surface
Rear balancer thrust spring sliding surface
Oil pump driven gear shaft outer surface
Oil pump driven gear needle bearing roller surface
Each transmission bushing and collar inner/outer surface
Each transmission needle bearing inner/outer surface
Each transmission spline bushing outer surface
M3, M4, CS, C6 gear (shift fork grooves and spline area)
Shift fork shaft outer surface
Main journal bearing sliding surface
Crankshaft thrust surface
Crankpin bearing sliding surface
Connecting rod small end inner surface
Piston pin outer surface
Engine oil Valve adjusting screw threads
Oil strainer seal ring entire surface
Starter one-way clutch sliding surface
Clutch friction discs entire surface (MT model)
Dual clutch assembly 0-ring entire surface (OCT model)
Piston pin hole inner surface
Piston sliding surface
Piston ring groove
Piston ring entire surface
Each bearing rolling area and contact surface
Each gear teeth and rotating surface
Each 0-ring entire surface (except water seal)
Other rotating area and sliding surface
Lithium based multi- Each oil seal lips
purpose grease NLGI #2 or
equivalent
Locking agent Crank pulser plate bolt threads Coating width :
(* 1) See page 1-23
Cam chain guide plate bolt threads Coating width:
(* 1) See page 1-23
UNIREX N3 manufactured Right crankcase inner cover bolt threads (OCT model) Coating width:
by ExxonMobil or (* 1) See page 1-23
equivalent Shift reduction gear teeth and journal (OCT model) 2-4 g (0 .07 - 0.14 oz)
1-23
GENERAL INFORMATION
FRAME
MATERIAL LOCATION REMARKS
Urea based multi-purpose Steering head bearing rolling contact surface 3 - 5 g (0.1 - 0.2 oz)
extreme pressure grease Steering head dust seal lips
NLGI #2 (EXCELITE EP2
manufactured by KYODO
YUSHI CO. , LTD. or
equivalent)
Lithium based multi- Seat catch hook sliding area
purpose grease NLGI #2 or Gearshift pedal pivot sliding area (grease groove)
equivalent (MT model)
Wheel dust seal lips
Rear wheel hub 0-ring (driven flange side)
Rear brake middle arm pivot sliding surface
Parking brake stopper stay teeth and lock lever pivot sliding
surface (DCT model}
Parking brake lever pivot sliding surface (DCT model)
Clutch lever pivot sliding area (MT model)
Throttle pipe-to-APS contacting area See page 17-10
Molybdenum disulfide Sidestand collar outer surface
grease (containing more Sidestand pivot sliding surface
than 3% molybdenum Swingarm pivot dust seal lips
disulfide, NLGI #2 or Swingarm pivot needle bearings
equivalent) Cushion arm dust seal lips
Cushion arm needle bearings
Cushion connecting rod needle bearings
Honda Bond A or Pro Left handlebar grip rubber matching surface
Honda Handgrip Cement (CRF1100ND)
(U.S.A. only) Left grip heater matching surface (CRF1100A4/D4) 1.0 g (0.04 oz) minimum
ThreeBond 1521 or an Rear brake pad retainer mating surface
equivalent
Silicone grease Front brake lever pivot bolts sliding surface 0.10 g (0.004 oz) minimum
Front brake lever-to-master piston contacting area 0.10 g (0.004 oz) minimum
Rear master cylinder push rod sliding surface 0.10 g (0.004 oz) minimum
Rear master cylinder push rod boot fitting area 0.10 g (0 .004 oz) minimum
Rear brake pad pin stopper ring
Brake caliper dust seals
Rear brake caliper sleeve sliding area 0.4 g (0.01 oz) minimum
Rear brake caliper pin bolt sliding surface 0.4 g (0 .01 oz) minimum
Parking brake shaft threads (DCT model} 0.4 g (0.01 oz) minimum
Parking brake push rod rolling surface (OCT model} 0.4 g (0.01 oz) minimum
Parking brake piston sliding surface (DCT model) 0.4 g (0.01 oz) minimum
Parking brake shaft boot lips (OCT model) 0.4 g (0.01 oz) minimum
Parking brake caliper pin boots inside (DCT model) 0.4 g (0.01 oz) minimum
Parking brake caliper bracket pin boot inside 0.4 g (0.01 oz) minimum
(OCT model}
Honda DOT 4 brake fluid Brake master piston and cups
Brake caliper piston
Brake caliper piston seals
Rear master cylinder reservoir hose joint 0-ring
Fork fluid Fork cap 0-ring
Fork dust seal and oil seal lips
Honda HP Chain Lube or Drive chain whole surface
an equivalent
Locking agent Main step rubber bolt
1-24
GENERAL INFORMATION
CABLE & HARNESS ROUTING
CRF1100A/D:
FRONT SUB HARNESS
FRONT SUB HARNESS
MID 7P CONNECTOR
GPS CONNECTOR
METER 20P
CONNECTOR
FRONT SUB HARNESS
~
I
GPS
FRONT SUB HARNESS

(to open air temperature sensor)
USB WIRE
FRONT SUB HARNESS

(to right front turn signal light)
1-25
GENERAL INFORMATION
CRF11 OOA4/D4:
FRONT SUB HARNESS
FRONT SUB HARNESS

(to left turn signal light)
GPS CONNECTOR
USB CONNECTOR
FRONT SUB HARNESS
GPSWIRE
GPS
FRONT SUB HARNESS

(to open air temperature sensor)
USBWIRE
FRONT SUB HARNESS

(to right front turn signal light)
1-26
GENERAL INFORMATION
CRF1100A/D:
OPEN AIR TEMPERATURE SENSOR RIGHT FRONT TURN SIGNAL LIGHT

2P (Black) CONNECTOR 2P (Orange) CONNECTOR
CRF11 OOA4/D4:
OPEN AIR TEMPERATURE SENSOR

2P (Black) CONNECTOR
RIGHT FRONT TURN SIGNAL LIGHT

2P (Orange) CONNECTOR
1-27
GENERAL INFORMATION
CRF1100A/D:
HEADLIGHT 6P CONNECTOR
CRF11 OOA4/D4:
CORNERING LIGHT
6P CONNECTOR
J
I
FRONT SUB HARNESS

(to headlight)
FRONT SUB HARNESS

(to cornering light)
1-28
GENERAL INFORMATION
CRF1100A/D:
ACCESSORY SOCKET (option)

2P CONNECTOR
FRONT SUB HARNESS 3

LEFT FRONT TURN SIGNAL LIGHT FRONT SUB HARNESS 2

2P (Light blue) CONNECTOR 4P (Black) CONNECTOR
CRF11 OOA4/D4:
ACCESSORY SOCKET
2P CONNECTOR
FRONT SUB HARNESS 3

LEFT FRONT TURN SIGNAL LIGHT

2P (Light blue) CONNECTOR
'!'.
r
I
r FRONT SUB HARNESS FRONT SUB HARNESS 2
1-29
GENERAL INFORMATION
CRF1100A/D:
FRONT BRAKE HOSE A
MT model : CLUTCH CABLE

OCT model: PARKING BRAKE CABLE
I
OCT model : PARKING BRAKE CABLE
LEFT HANDLEBAR SWITCH

WIRE
• Front
RIGHT HANDLEBAR SWITCH WIRE

(Grip APS)
1-30
GENERAL INFORMATION
CRF11 OOA4/D4:
FRONT BRAKE HOSE A

DCT model: PARKING BRAKE CABLE
DCT model : PARKING BRAKE CABLE

WIRE • Front
r•
• Front
RIGHT GRIP
HEATER WIRE

(Grip APS)
1-31
GENERAL INFORMATION
MT model:
White paint
LEFT HANDLEBAR
SWITCH WIRE
LEFT GRIP HEATER WIRE
5 mm (0.2 in)+ - - - -~
maximum
There is the white paint mark on the clutch j

switch connector (Black/green wire side). l
j
J
•
CRUISE CANCEL SWITCH 'l

1
1
~
l
1-32
GENERAL INFORMATION
OCT model:
White paint
LEFT HANDLEBAR
SWITCH WIRE
LEFT GRIP HEATER WIRE

5 mm (0.2 in)
maximum
PARKING BRAKE SWITCH
1-33
GENERAL INFORMATION
Install the wire band by

aligning with the front /
brake switch end.
5m;m~;/
max7 FRONT BRAKE SWITCH
RIGHT HANDLEBAR ~--...:~ ~~ CONNECTORS
SWITCH WIRE
RIGHT GRIP HEATER WIRE CRUISE CANCEL

SWITCH CONNECTORS
1-34
GENERAL INFORMATION
CRF11 OOA/D:
LEFT HANDLEBAR SWITCH WIRE
RIGHT HANDLEBAR
SWITCH WIRE (Grip APS) - - -----!l,L,4,. LEFT GRIP HEATER (option)
2P CONNECTOR
f
Front
RIGHT HANDLEBAR
'"
" SWITCH WIRE (Grip APS)
1-35
GENERAL INFORMATION
CRF11 OOA4/D4:
LEFT GRIP HEATER

2P CONNECTOR
FRONT SUSPENSION SOLENOID WIRE LEFT GRIP HEATER WIRE
FRONT SUSPENSION SOLENOID

2P CONNECTOR
FRONT SUSPENSION STROKE

SENSOR WIRE
l
RIGHT HANDLEBAR~~ - . .~ ~
SWITCH WIRES l
RIGHT GRIP
HEATER WIRE
J
FRONT SUSPENSION
STROKE SENSOR
2P CONNECTOR
l
J
J
l
j
FRONT SUSPENSION l
STROKE SENSOR WIRE J
RIGHT HANDLEBAR
'l
j
SWITCH WIRE
GRIP HEATER WIRE

j
RIGHT HANDLEBAR
SWITCH WIRE
(Grip APS)
FRONT BRAKE HOSE A
LEFT GRIP HEATER

2P CONNECTOR
FRONT SUSPENSION
STROKE SENSOR
2P CONNECTOR
FRONT SUSPENSION
SOLENOID 2P CONNECTOR
1-36
GENERAL INFORMATION
,
I
I
r FRONT BRAKE HOSE D
!
I
I
FRONT WHEEL SPEED
, SENSOR WIRE
I
FRONT WHEEL SPEED
f SENSOR WIRE
r, FRONT
BRAKE
' HOSED
HORN CONNECTORS
FRONT WHEEL SPEED

SENSOR WIRE
1-37
GENERAL INFORMATION
FRONT WHEEL SPEED SENSOR WIRE
..
Front
FRONT WHEEL SPEED

SENSOR WIRE
FRONT WHEEL SPEED

SENSOR WIRE
FRONT BRAKE HOSE D
J
j
1-38
GENERAL INFORMATION
FRONT BRAKE HOSE D
1-39
GENERAL INFORMATION
LEFT HANDLEBAR
SWITCH 8P CONNECTOR
LEFT HANDLEBAR
SWITCH 12P CONNECTOR
LEFT HANDLEBAR
SWITCH WIRE
GROUND TERMINAL
IGNITION SWITCH
WIRE
1-40
GENERAL INFORMATION
LEFT FAN MOTOR 2P CONNECTOR
LEFT RADIATOR SHROUD
LEFT NF AIR CLEANER

SENSOR WIRE HOUSING
MAIN WIRE
HARNESS MAIN WIRE HARNESS
ECT SENSOR 2P
(Black) CONNECTOR
"
.
1'
£ >' ' ' ' ,AIR CLEANER
,, DRAIN HOSE
No.2-2 SPARK PLUG CAP

LEFT NF SENSOR
LEFT NF SENSOR
4P CONNECTOR
1-41
GENERAL INFORMATION
OCT model shown:
MT model: CLUTCH CABLE

J
l
J
l
LINEAR SOLENOID VALVE
WIRE (OCT model)
MAIN WIRE
~ ARNESS
t
"r~
· ~
RIGHT A/F SENSOR
1-42
GENERAL INFORMATION
OCT model shown : RIGHT GRIP HEATER

2P CONNECTOR
GRIP APS 8P CONNECTOR RIGHT HANDLEBAR SWITCH

4P CONNECTOR
(Brake/cruise cancel switch)
(Black) CONNECTOR
(OCT model)
----
LINEAR SOLENOID VALVE 4P ....___
~ ~,;---l-- RIGHT HANDLEBAR SWITCH

12P CONNECTOR
RIGHT NF SENSOR
4P CONNECTOR
RIGHT FAN MOTOR WIRE
''
LINEAR SOLENOID VALVE WIRE
' (OCT model)
MAIN WIRE HARNESS

(OCT model)
RIGHT RADIATOR
SHROUD
No.2-2 SPARK PLUG WIRE
SIPHON HOSE
MAIN WIRE HARNESS

(OCT model)
LINEAR SOLENOID VALVE WIRE

(OCT model)
1-43
GENERAL INFORMATION
FRONT BRAKE HOSE A

FRONT BRAKE PIPE B
RADIATOR HOSE A
FRONT BRAKE PIPE C
RIGHT HANDLEBAR
SWITCH WIRE
FRONT BRAKE PIPE B
RIGHT HANDLEBAR
SWITCH WIRE (Grip APS)
RIGHT GRIP HEATER WIRE

(CRF1100A4/D4)
1-44
GENERAL INFORMATION
RADIATOR HOSE A
10 - 14 mm
(0.4 - 0.6 in) -'----------\--------c........
f Lower
Left
•
SIPHON HOSE
f Lower
1-45
GENERAL INFORMATION
LOWER RADIATOR HOSE

RADIATOR HOSE B
•
Lower
1-46
GENERAL INFORMATION
IOCT model :
BYPASS HOSE
goo
I'
45° • Lower
Insert the bypass hose

until the indent mark. of
the joint pipe.

until the indent mark of
the water pipe.

the joint pipe.
the joint pipe .
goo
45°
I• Lower
BYPASS HOSE
1-47
GENERAL INFORMATION
FRONT WHEEL SPEED SENSOR

PAIR CONTROL SOLENOID

VALVE 2P (Black) CONNECTOR

OCT model: PARKING BRAKE
CABLE
AIR SUPPLY HOSE
IATSENSOR Front
2P (Blue) t
CONNECTOR
. . Lower
TBW MOTOR 2P . _.::wi,u

CONNECTOR AIR SUCTION HOSE
IGNITION SWITCH 4P IGNITION SUB HARNESS

(Brown) CONNECTOR 6P CONNECTOR
I
l
1
1-48
GENERAL INFORMATION
IGNITION SUB HARNESS

6P CONNECTOR
No.2-1 IGNITION COIL

WIRES (Black tube) No.2-2 IGNITION COIL (Green tube)
MAIN WIRE HARNESS
No.2-2 IGNITION COIL WIRES (Green tube)
MAIN WIRE HARNESS


WIRES (Black tube)
No.1 -2 IGNITION COIL WIRES (Green tube)

6P CONNECTOR
1-49
GENERAL INFORMATION
MAIN WIRE HARNESS
FRAME
CRANKCASE BREATHER HOSE AIR SUPPLY HOSE

5 mm (0.2 in) maximum
•
Front
AIR CLEANER
DRAIN HOSE
No.2-2 SPARK PLUG CAP No.1-1 SPARK PLUG CAP
No.2-1 SPARK PLUG CAP
1-50
GENERAL INFORMATION
MT model:
ALTERNATOR WIRE
UPPER RADIATOR HOSE
MAIN WIRE HARNESS
MAIN WIRE HARNESS
..•
(to VS sensor)
~
Rear
SIDESTAND
SWITCH WIRE
SENSOR 3P (Black)
Left CONNECTOR
I[ 45°
SIDESTAND
t SWITCH WIRE
Ir
,
I
,r
r
HARNESS
I
~ SHIFT STROKE
I
SENSOR (option)
4P CONNECTOR
CKP SENSOR 3P (Gray)

CONNECTOR
, EOP SWITCH
r
!
RADIATOR RESERVE TANK
SIDESTAND SWITCH WIRE DRAIN HOSE
t
I
FUEL TANK DRAIN HOSE
II
1-51
GENERAL INFORMATION
DCT model:
UPPER RADIATOR HOSE
..•
Rear
Left
VS SENSOR 3P (Black)
CONNECTOR
OUTER MAINSHAFT SENSOR

45°
J
j
GEAR CHANGE
SWITCH (option )
3P (Black)
CONNECTOR
l
SIDESTAND
SWITCH WIRE
CKP SENSOR 3P (Gray)
CONNECTOR
SH IFT CONTROL
MOTOR 2P (Black)
CONNECTOR
EVAP CANISTER DRAIN HOSE

SIDESTAND SWITCH WIRE DRAIN HOSE
ALTERNATOR WIRE
Install the wire band in
position as shown .
EOP SENSOR 3P
Put the wire band end
(Black) CONNECTOR
inside the frame . I J
1-52
GENERAL INFORMATION
\ EVAP CANISTER DRAIN HOSE
White paint
Align the paint marks with
the crankcase mating
surface.
RADIATOR RESERVE
TANK DRAIN HOSE
White paint
EVAP CANISTER DRAIN HOSE
SIPHON HOSE
RADIATOR RESERVE
TANK DRAIN HOSE
1-53
GENERAL INFORMATION
MT model:
RADIATOR HOSE B
•
. . Front
45°
CLUTCH CABLE
FUSE BOX 4P CONNECTOR
STARTER RELA y SWITCH

BATTERY
POSITIVE(+)
CABLE
SIPHON HOSE
j
.
1-54
GENERAL INFORMATION
DCT model:
RADIATOR HOSE B
+
•
PARKING BRAKE CABLE Front
Right
STARTER RELAY SWITCH '

No.1 CLUTCH EOP

SENSOR 3P (Gray)
CONNECTOR
No.2CLUTCHEOPSENSOR
/ 3P (Gray) CONNECTOR
EOT SENSOR 2P CLUTCH LINE EOP

(Black) CONNECTOR SENSOR3PCONNECTOR
1-55
GENERAL INFORMATION
OCT model shown:
MAP SENSOR 3P
(Black) CONNECTOR
TBW UNIT6P
CONNECTOR
FUEL FEED
HOSE
MAIN WIRE
HARNESS
FUEL TANK
DRAIN HOSE
,...._~"'---FUELLEVELSENSOR2P
(Black) CONNECTOR
FUEL PUMP
EVAP PURGE CONTROL
UNIT 3P (Black)
SOLENOID VALVE 2P (Black)
CONNECTOR
CONNECTOR
PARKING BRAKE CABLE

(OCT model)
FUEL TANK BREATHER HOSE:

Route the fuel tank breather hose
between the frame and rear
engine upper hanger plate.
FRONT BRAKE PIPE C
FRONT BRAKE PIPE B
EVAP CANISTER-to-PURGE CONTROL

SOLENOID VALVE HOSE 4
IMU 4P (Black) CONNECTOR j

i
-
1
J
1
1-56
GENERAL INFORMATION
,...
MAP SENSOR
VACUUM HOSE
No.2 CYLINDER FUEL

No.1 CYLINDER FUEL INJECTOR 2P (Gray)
INJECTOR 2P (Gray) CONNECTOR
CONNECTOR
PURGE CONTROL SOLENOID
VALVE-to-THROTILE BODY
I HOSE
L
'
ECM 33P (Gray) CONNECTOR
ECM 39P (Black) CONNECTOR
1-57
GENERAL INFORMATION
9 mm (0.4 in)
FUEL TANK
DRAIN HOSE
FUEL LEVEL SENSOR 2P FUEL PUMP UNIT 3P

(Black) CONNECTOR (Black) CONNECTOR
BATTERY POSITIVE(+) CABLE FUSEBOX4PCONNECTOR
STARTER RELAY
SWITCH 4P (Black)
CONNECTOR
Fl RELAY
JUNCTION 1 24P JUNCTION 2 24P
(White) CONNECTOR (White) CONNECTOR
1-58
GENERAL INFORMATION
MAIN WIRE HARNESS
BATIERY POSITIVE(+) CABLE
BATIERY NEGATIVE(-) CABLE
- + Front
45°±10°
•
Right
1-59
GENERAL INFORMATION
MT model:
10° 10°
SIDESTAND SWITCH 2P
(Black) CONNECTOR
SHIFT STROKE SENSOR

(option) 4P CONNECTOR
SH IFT SPINDLE SWITCH
GP SENSOR 3P (Black)
CONNECTOR
NEUTRAL SWITCH
DCT model:
SIDESTAND SWITCH 2P
(Black) CONNECTOR
MAIN WIRE HARNESS
NEUTRAL SWITCH
SHIFT SPINDLE ANGLE
SENSOR 3P (Blue)
CONNECTOR
TR SENSOR 3P (Black) INNER MAINSHAFT SENSOR

CONNECTOR 3P (Black) CONNECTOR
1-60
GENERAL INFORMATION
CRF110004 shown:
FRONT BRAKE PIPE C
FRONT BRAKE PIPE B

EVAP CANISTER-to-PURGE
CONTROL SOLENOID VALVE HOSE
IMU 4P (Black)'CONNECTOR\
~ - -
'
r
r
r
rr
~
MAIN WIRE
HARNESS
BCU
REAR BRAKE
SWITCH 4P
CONNECTOR
BCU 39P (Black) CONNECTOR
1-61
GENERAL INFORMATION
CRF110004 shown:
J
j
TCM (OCT model)
TCM 33P (Gray) TCM 33P (Black)

CONNECTOR CONNECTOR
(OCT model) (OCT model)
EVAPCANISTER
DRAIN HOSE
ALTERNATOR
WIRE
I
MAIN WIRE HARNESS
EVAP CANISTER-to-PURGE CONTROL

SOLENOID VALVE HOSE
1-62
GENERAL INFORMATION
CRF1100D4 shown :
19°
t REAR SUSPENSION LEVEL
f ADJUSTER HOSE
[ (CRF1100A4/D4)
'
[
I
r
SIPHON
HOSE
MAIN WIRE
HARNESS
(to shift spindle
angle sensor)
~
(DCT model)
REARBRAKE
( r= HOSEA
MAIN WIRE HARNESS (to EOT sensor)

(DCT model)
r
t
'
r
1-63
GENERAL INFORMATION
CRF11 OOD4 shown :
MAIN WIRE HARNESS
FUEL TANK BREATHER HOSE
j
J
Up
t+ Front
ALTERNATOR WIRE
J
•
REAR SUSPENSION SOLENOID 2P CONNECTOR
1-64
GENERAL INFORMATION
REAR BRAKE HOSE B
,
,...
REAR BRAKE HOSE A
.
I
r ALTERNATOR WIRE
MAIN WIRE HARNESS
r.-
'
ABS MODULATOR 18P (Black) CONNECTOR
1-65
GENERAL INFORMATION
CRF11 OOD4 shown:
FRONT BRAKE PIPE C
REAR BRAKE SWITCH WIRE
REAR WHEEL SPEED SENSOR WIRE
EVAP CANISTER-to-PURGE \
CONTROL SOLENOID VALVE HOSE \
'., REAR SUSPENSION LEVEL

ALTERNATOR ADJUSTER HOSE
WIRE (CRF11 OOA4/D4)
MAIN WIRE
HARNESS
REAR WHEEL SPEED

SENSOR WIRE
........-LBAAKE HOSES
J
l
I
PARKING BRAKE CABLE
(OCT model)
j
FUEL TANK J
DRAIN HOSE
SIPHON HOSE
I
J
EVAP CANISTER
DRAIN HOSE
J
MAIN WIRE HARNESS (to EOT sensor) ,J
(OCT model)
RADIATOR RESERVE TANK DRAIN HOSE
•
1
1-66
GENERAL INFORMATION
MT model:
REAR WHEEL SPEED

SENSOR W IRE
REAR WHEEL SPEED

SENSOR WIRE
+Right
REAR BRAKE HOSE B
,.
+ Right
REAR BRAKE HOSE B
REAR WHEEL SPEED

SENSOR WIRE
REAR BRAKE HOSE B
REAR WHEEL SPEED

REAR BRAKE HOSE B SENSOR WIRE
REAR WHEEL SPEED

SENSOR WIRE
1-67
GENERAL INFORMATION
DCT model:
REAR BRAKE HOSE B
REAR WHEEL SPEED SENSOR WIRE
PARKING BRAKE CABLE
REAR WHEEL SPEED

SENSOR WIRE
+ Right
PARKING BRAKE CABLE
REAR BRAKE HOSE B
..Right
+ Right
+ Right
REAR WHEEL SPEED
SENSOR WIRE
REAR BRAKE HOSE B
REAR BRAKE
REAR WHEEL SPEED HOSES
REAR BRAKE HOSE B SENSOR WIRE
REAR WHEEL SPEED

SENSOR WIRE
1-68
GENERAL INFORMATION
CRF11 OOD4 shown :
POWER BOX
REAR SUSPENSION
POSITION SENSOR 3P
(Gray) CONNECTOR
ff""._.-. / (CRF11 OOA4/D4)
OCT RELAY
(OCT model)
SCU 48P (Black)
CONNECTOR
(CRF11 OOA4/D4)
REAR SUSPENSION
PRE-LOAD MOTOR
2P CONNECTOR
(CRF1100A4/D4)
ABS FSR+ FUSE BOX
MAIN WIRE
HARNESS
SEAT LOCK
CABLE
DLC
1-69
GENERAL INFORMATION
EGCA
EGCA 6P CONNECTOR EGCACABLEA
REGULATOR/RECTIFIER 3P (Black) CONNECTOR
LICENSE LIGHT 2P (White) CONNECTOR
LEFT TURN SIGNAL LIGHT 1 RIGHT TURN SIGNAL LIGHT

2P (Orange) CONNECTOR 2P (Light blue) CONNECTOR
'\
BRAKE/TAILLIGHT 3P (Black) CONNECTOR \
MAIN WIRE HARNESS
1-70
GENERAL INFORMATION
RIGHT REAR TURN SIGNAL LIGHT WIRE
LICENSE LIGHT WIRE
LEFT REAR TURN

SIGNAL LIGHT WIRE
I
~
1-71
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
EXHAUST EMISSION REQUIREMENT
The U.S. Environmental Protection Agency (EPA), California Air Resources Board (CARS) and Environment and Climate Change
Canada (ECCC) require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during
their useful life, when operated and maintained according to the instructions provided.
NOISE EMISSION REQUIREMENT

The EPA also requires that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or
3,730 miles (6,000 km) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions
provided.
WARRANTY COMPLIANCE
Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in
order to keep the emissions system warranty in effect.
SOURCE OF EMISSIONS
Fuel evaporation and the combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx), and hydrocarbons (HC).
The control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form
photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Uncontrolled fuel
evaporation also releases hydrocarbons to the atmosphere.
Honda Motor Co., Ltd. utilizes various systems (page 1-74) to reduce carbon monoxide, hydrocarbons and oxides of nitrogen.
CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body.
AIR CLEANER HOUSING
~ FRESH AIR
.,_ BLOW-BY GAS
1-72
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a pulse secondary air supply system, three-way catalytic converter and PGM-
FI system.
SECONDARY AIR SUPPLY SYSTEM
The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the
exhaust port by the function of the PAIR control solenoid valve.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and
carbon monoxide into relatively harmless carbon dioxide and water vapor.
The PAIR reed valve prevents reverse air flow through the system. The PAIR control solenoid valve is controlled by the ECM, and
the fresh air passage is opened/closed according the running condition (ECT/IAT/TP/MAP sensor and engine revolution).
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is
recommended .
AIR CLEANER HOUSING
PAIR CONTROL
f SOLENOID VALVE
r
rr
t
r
PAIR REED VALVE 0
<G== FRESH AIR

+a EXHAUST GAS
Three-way catalytic converter

This motorcycle is also equipped with three-way catalytic converter.
The three-way catalytic converter is in the exhaust system. Through chemical reactions, they convert HC, CO, and NOx in the
engine's exhaust to carbon dioxide (CO2), dinitrogen {N2), and water vapor.
No adjustment to these systems should be made although periodic inspection of the components is recommended .
1-73
GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM
This model complies with GARB evaporative emission requirements. Fuel vapor from the fuel tank is routed into the EVAP canister
where it is absorbed and stored while the engine is stopped. When the engine is running and the EVAP purge control solenoid
valve is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body.
FUEL TANK
EVAP CANISTER
~ EVAP PURGE CONTROL SOLENOID VALVE
\ ¢=, FRESH AIR

~ FUEL VAPOR
NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. Federal law prohibits, or Canadian provincial law may
prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person , other than for purposes of
maintenance, repair or replacement, of any device or element of design incorporated into any vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate customer or while it is in use; (2) the use of the vehicle after such device or element
of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Removing or disabling any emissions compliance component, or replacing any compliance component with a non-compliant
component.
FUEL PERMEATION EMISSION CONTROL SYSTEM

This motorcycle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency
(EPA), the California Air Resources Board (GARB), and Environment and Climate Change Canada (ECCC). The fuel tank, fuel
hoses, and fuel vapor charge hoses used on this motorcycle incorporate fuel permeation control technologies. Tampering with the
fuel tank, fuel hoses, or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is
prohibited by federal regulations.
1-74
GENERAL INFORMATION
TECHNICAL FEATURES
MOTORCYCLE BODY CONTROL WITH IMU
MOTORCYCLE BODY BEHAVIOR DETECTION WITH IMU
In the CRF11 OOA/A4/D/04, six-axis IMU is adopted .
The IMU measures longitudinal/side/vertical acceleration and roll/pitch/yaw angular velocity of the motorcycle.
The IMU and each control unit communicate each other through the CAN communication to calculate the motorcycle body attitude
information including fall determination.
Roll angular velocity

Longitudinal
acceleration
Side
acceleration
Pitch
angular
velocity
Vertical acceleration
!IMU 1- - - - - - - - - - - - - - - - - - ,
+ Motorcycle inertia 1
Motorcycle inertia I information (~AN) :

·1nforma t·10n (CAN) • for fall determination ,
1
t
ABS
t
- - - - - - - - - _.. ECM
MODULATOR
Brake pressure
control
Motorcycle attitude +
information (CAN) 1
I
r - - - _. 1 Motorcycle
~ - Moto~;cl; ;ttitu-d; - : - - - - , • attitude
information (CAN) : information Fall determination
t f (CAN) 1
Engine torque control
T
: ~;~~rol
Damping force
adjustment
~ ~h~i~g-c~n~r~I - ~ L - - - - -
I I
I I ~~-~-~
!BRAKES! ISUSPENSIONS
L---------------
~I~~~N~~I~~ ~I?~~ ~ ENGINE
CRF1100A4/D4: CRF11 OOA4/D4:
1-75
GENERAL INFORMATION
REAR LIFT MITIGATION
The CRF11 OONA4/D/D4 mitigates the rear wheel lift during braking using
the acceleration information from the IMU and the motorcycle speed Accelerations occur just after braking
information from the front and rear wheel speed sensors.
When it is determined that the front brake will be applied rapidly and the
rear lift will occur, this system reduces the front brake fluid pressure.
When it is determined that the rear lift behavior has subsided, it operates to
return the brake fluid pressure to normal.
Depending on the riding mode setting, this system behavior can be
changed for on-road or off-road .
•
Accelerations occur just before rear lift
BRAKE CONTROL SUITED FOR ESTIMATED BANK ANGLE

The CRF1100NA4/D/D4 calculates and estimates bank angle by the
acceleration information from the IMU and the speed information from the
front and rear wheel speed sensors , and controls the brake force depending ABS MODULATOR IMU
on the bank angle.
"'
Such a brake force control is enabled by varying the threshold, where the
ABS intervenes in the slip ratio of the front and rear wheels and the
deceleration of the motorcycle by reducing the brake pressure.
J
Even when sudden braking is applied during cornering, the braking force
can be generated while maintaining high stability.
Depending on the riding mode setting, this system behavior can be
changed for on-road or off-road.
REAR WHEEL FRONT WHEEL

SPEED SENSOR SPEED SENSOR
1-76
GENERAL INFORMATION
WHEELIE CONTROL
In this system, the ECM makes a wheelie determination based on the following information.
- Motorcycle speed signal from the front/rear wheel speed sensor
- Pitch angular velocity information from the IMU
If the ECM detects a wheelie state, the ECM engages the wheelie control to stabilize motorcycle behavior and reduce the
occurrence of wheelies.
The wheelie control level changes depending on the wheelie control level manually set.
REAR WHEEL SPEED SENSOR

,,
,,
,, ,, ,,
FRONT WHEEL
SPEED SENSOR
GEAR CHANGE MANAGEMENT BY BODY POSITION DETECTION (DCT model)

In the OCT model of this motorcycle, the body position information that is detected by the IMU is newly added to shift control during
cornering.
The current motorcycle position is calculated from the output signal of the IMU, and the AT shift table which is appropriately varied
to achieve AT shift timing closer to the rider's sensitivity.
Vertical acceleration
Longitudinal
Yaw angular acceleration
velocity
IMU
Side
acceleration
IProper AT shift timing
1-77
GENERAL INFORMATION
COOPERATION SYSTEM OF THE MID (WITH THE TOUCH SCREEN) AND SMARTPHONE
In this motorcycle, Apple CarPlay™ (music playback/voice call/email/navigation) can be used on the MID by connecting an iPhone
by wire.
Touch screen operation of the MID, handlebar switch operation, and voice operation with a smartphone/Bluetooth® headset are
possible.
• Functions that can be operated while riding:
- Map scaling
- Song selection
- Volume adjustment
- Telephone reception acceptance/rejection
- Riding mode change (at throttle fully closed)
NOTE:
• You can not operate the touch screen while riding .
By connecting a smartphone (including iPhone) to Bluetooth®, music can be played and voice calls can be made on the MID.
Also, the following functions can be executed from home screen:
- OTC read out: (page 4-7)
- Cornering light forcibly activate: (page 22-8)
- MID system software update: (page 22-22)
- Touchscreen calibration: (page 22-23)
Q Bluetooth® HEADSET
~ (riderside)
ECM
))) Q Bluetooth® HEADSET
~ (passenger side)
) '
BCU GPSANTENNA
-
HANDLEBAR
SWITCHES
METER
1-78
GENERAL INFORMATION
CORNERING LIGHT SYSTEM (CRF1100A4/D4)
The CRF11 OOA4/D4 is equipped with cornering light system.
If there is a problem with the cornering light system, the cornering light will turn off, and the low beam will illuminate.
NOTE:
• For cornering light system malfunctions, no notifications are made by the indicators or display.
• For cornering light system inspection: (page 22-8)
• For cornering light aim adjustment: (page 3-24)
BASIC OPERATION:
BCU: HEADLIGHT UNIT:
FRAME
Estimated bank angle CAN DATA
Lo BEAM ON
-:::: - IDETERMINATION
LIGHTING I
Hi BEAM ON
- IHEADLIGHT I
Motorcycle speed
- DRIVER
LEFT or RIGHT
::-
LIGHT 1
ILIGHTING LIGHT 2 ICORNERING I
CONTROL I - LIGHT DRIVER
LIGHT 3
Cornering light 1 Cornering light 2 Cornering light 3

turned ON turned ON turned ON
1-79
MEMO
' .
2. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION· .. ····················· 2-2 TOOL BOX ......................................... 2-26
TROUBLESHOOTING · · · ·· · · · ·· · · · · · · ·· · ·· · · ·· · ·· 2-2 LEFT REAR COVER · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-26
BODY PANEL LOCATIONS····················· 2-3 HEEL GUARD ..................................... 2-26
PILLION SEAT · · · · .. · .. · .. · .. · .. · · · · · · · · · · · · · · · · · · .. 2-5 CLUTCHEOPSENSORCOVER

(DCT model) ....................................... 2-27
MAIN SEAT · · · · · · · · · · · .. · · · · .. · ...... · .. · .. · .... · .. · · 2-5
RIGHT REAR ENGINE COVER .............. 2-27
TANK FRONT COVER .... · .. ·· .. · .. · .. · .... · .. · .. 2-6
MAIN STEP · · .. · ... · ·· .. · .. · · · .... · · · · .. · .. · ... · .. · 2-27
MIDDLE COWL ··· · · .............. ·· ................ 2-7
PILLION STEP · · · · .... · .. · · · ...... · · .. · ...... · .. · · 2-29
INNER COVER .. · ...... · .......... ·· .. · .. · .. ··· .. · .. 2-9
SEAT CATCH HOOK/SEAT LOCK
CYLINDER ......................................... 2-30
FRONT CENTER COWL .. · .................... 2-12
... REAR SIDE COWL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-30
FRONT SIDE COWL (CRF11 OOA/D) .. · .... · 2-13
FRONT LOWER COVER · · ............ · .. · .... · 2-14 REAR SIDE INNER COVER ................... 2-33
FRONT TURN SIGNAL COVER .. ·· .. · .... · .. 2-15 REAR SEAT UNDER COVER ................ 2-34
INNER PANEL COVER ......................... 2-17 REAR CENTER COWL ......................... 2-35
WINDSCREEN · .. · · · · · · · · · · · .... · .... · .. · .. · · · .. · · 2-18 PANNIER BRACKET (CRF1100A4/D4)···· 2-37
SCREEN ADJUST RAIL REAR CARRIER (CRF1100A4/D4) .......... 2-37

(CRF1100A4/D4) ................................. 2-19
MUD GUARD ...................................... 2-38
FRONT UPPER COVER ........................ 2-21
REAR FENDER A ................................ 2-38
KNUCKLE GUARD .............................. 2-22
REAR FENDER B ................................ 2-40
FRONT FENDER ................................. 2-23
SEAT RAIL ......................................... 2-43
TANK SIDE COVER (CRF1100A/D) ........ 2-24
MUFFLER/EXHAUST PIPE .... , ............... 2-45
SKID PLATE ....................................... 2-25
SIDESTAND .................................. ..... 2-54
2-1
SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels, exhaust system and sidestand.
• Always replace the exhaust pipe gaskets after removing the exhaust pipes from the engine.
• When installing the exhaust system, loosely install all of the exhaust pipe fasteners . Always tighten the exhaust clamps first,
then tighten the mounting fasteners . If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
• Always inspect the exhaust system for leaks after installation.
I j
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
2-2
BODY PANEL LOCATIONS
CRF1100A/D
[20] [21]
[5]
[29] [28] [27] [26] [25]

[1] Windscreen (page 2-18) [12] Main seat (page 2-5) [24] Rear fender B (page 2-40)
[2] Front upper cover (page 2-21) [13] Pillion seat (page 2-5) [25] Mud guard (page 2-38)
[3] Front center cowl (page 2-12) [14] Rear center cowl (page 2-35) [26] Rear side cowl (page 2-30)
[4] Front lower cover (page 2-14) [15] Tank side cover (page 2-24) [27] Seat catch hook/seat lock
[5] Front fender (page 2-23) [16] Middle cowl (page 2-7) cylinder (page 2-30)
[6] Skid plate (page 2-25) [17] Knuckle guard (page 2-22) [28] Sidestand (page 2-54)
[?] Inner cover (page 2-9) [18] Front turn signal cover (page 2-15) [29] Main step (page 2-27)
[8] Clutch EOP sensor cover (OCT model) [19] Front side cowl (page 2-13) [30] Heel guard (page 2-26)
(page 2-27) [20] Inner panel cover (page 2-17) [31] Left rear cover (page 2-26)
[9] Right rear engine cover (page 2-27) [21] Rear seat under cover (page 2-34) [32] Tool box (page 2-26)
[1 OJ Pillion step (page 2-29) [22] Rear side inner cover (page 2-33) [33] Seat rail (page 2-43)
[11] Muffler/exhaust pipe (page 2-45) [23] Rear fender A (page 2-38) [34] Tank front cover (page 2-6)
BODY PANEL REMOVAL CHART

This chart shows the removal order of the frame covers by following the arrow.
I [13] Pillion seat

~
r
[ [1] Windscreen [34] Tank front cover [10] Pillion step [23] Rear fender A
[3] Front center cowl [16] Middle cowl t------- [11] Muffler/exhaust pipe [12] Main seat
'----~--~----'
[20] Inner panel cover [15] Tank side cover [22] Rear side inner cover [26] Rear side cowl
[19] Front side cowl [2] Front upper cover [21] Rear seat under cover [14] Rear center cowl
I
t
[4] Front lower cover [18] Front turn signal cover [24] Rear fender 8 [33] Seat rail
[?] Inner cover [25] Mud guard
I [17] Knuckle guard 11 [6] Skid plate 11 [31] Left rear cover 11 [8] Clutch EOP sensor cover 11 [29] Main step 11 [28] Sidestand
I [5] Front fender 11 [32] Tool box 11 [30] Heel guard 11 [9] Right rear engine cover 11 [27] Seat catch hook/seat lock cylinder I
2-3
CRF11 OOA4/D4
[1] Windscreen (page 2-18) [13] Main seat (page 2-5) [26] Mud guard (page 2-38)
[2] Screen adjust rail (page 2-19) [14] Pillion seat (page 2-5) [27] Rear side cowl (page 2-30)
[3] Front upper cover (page 2-21) [15] Rear center cowl (page 2-35) [28] Seat catch hook/seat lock )
[4] Front center cowl (page 2-12) [16] Middle cowl (page 2-7) cylinder (page 2-30)
[5] Front lower cover (page 2-14) [17] Knuckle guard (page 2-22) [29] Sidestand (page 2-54)
[6] Front fender (page 2-23) [18] Front turn signal cover (page 2-15) [30] Main step (page 2-27)
[7] Skid plate (page 2-25) [19] Inner panel cover (page 2-17) [31] Heel guard (page 2-26)
[8] Inner cover (page 2-9) [20] Rear seat under cover (page 2-34) [32] Left rear cover (page 2-26)
[9] Clutch EOP sensor cover (DCT model) [21] Rear side inner cover (page 2-33) [33] Tool box (page 2-26)
(page 2-27) [22] Pannier bracket (page 2-37) [34] Seat rail (page 2-43)
[10] Right rear engine cover (page 2-27) [23] Rear carrier (page 2-37) [35] Tank front cover (page 2-6)
[11] Pillion step (page 2-29) [24] Rear fender A (page 2-38)
[12] Muffler/exhaust pipe (page 2-45) [25] Rear fender B (page 2-40)
BODY PANEL REMOVAL CHART

This chart shows the removal order of the frame covers by following the arrow.
(35] Tank front cover (11] Pillion step [24] Rear fender A [14] Pillion seat
~---------< (13] Main seat

(16] Middle cowl (12] Muffler/exhaust pipe
[22] Pannier bracket
[8] Inner cover (4] Front center cowl (27] Rear side cowl
(18] Front turn signal cover

(20] Rear seat
under cover
(19] Inner panel cover [5] Front lower

cover [15] Rear center cowl (23] Rear carrier
[2] Screen adjust rail [3] Front upper cover

(34] Seat rail
[1] Windscreen
(26] Mud guard
I (17] Knuckle guard 11 [7] Skid plate 11 [32] Left rear cover 11 [9] Clutch EOP sensor cover 11 [30] Main step 11 [29] Sidestand
I [6] Front fender 11 (33] Tool box II [31] Heel guard 11 [10] Right rear engine cover 11 (28] Seat catch hook/seat lock cylinder I
2-4
PILLION SEAT
REMOVAL/INSTALLATION
i
PILLION SEAT
r Unlock the pillion seat [1] using the ignition key [2].
[1 ) [3)
r~ Remove the pillion seat.
Installation is in the reverse order of removal.
NOTE:
• Align the pillion seat hooks [3] w ith the seat rail.
[2]
f
rl SEAT BELT {CRF1100A/D)
Remove the pillion seat (page 2-5).
Remove the bolts [1], washers [2], and seat belt [3].
MAIN SEAT
[2)
f Remove the main seat [1].

NOTE: [1)
• Align the main seat hooks [2] with the fuel tank and
seat rail lugs.
l
rI
2-5
TANK FRONT COVER
CRF1100A/D
REMOVAUINSTALLATION j
Remove the following:
- Tank front cover screws [1]
- Socket bolts [2]
- Trim clips [3]
- Tank front cover [4]
- Well nut [5]
TORQUE:
Tank front cover screw:
0.42 N·m (0.04 kgf·m, 0.3 lbMt)
[5]
j
CRF11 OOA4/D4
REMOVAUINSTALLATION
Remove the following :
- Tank front cover screws [1]
-
-
-
Socket bolts [2]
Trim clips [3]
Tank front cover [4]
l
- Well nut [5] J
TORQUE:
Tank front cover screw:
0.42 N·m (0.04 kgf·m, 0.3 lbMt)
NOTE:
• Align the tank front cover hooks [6] with the middle
cowl slits.
2-6
MIDDLE COWL
CRF1100A/D
REMOVAUINSTALLATION
Remove the tank front cover (page 2-6).
Remove the trim clips [1] .
Release the bosses [2] from the grommets [3].
Remove the middle cowl [4] by releasing the tabs [5].
Right side shown:
I
~
I
[
''r
l [2] t'
f ''
t
''
'
,...
I
f
DISASSEMBLY/ASSEMBLY
Remove the middle cowl (page 2-7).
[1] [2] [3]
Remove the slide clips [1] and front side cover [2] from
the middle cowl [3].
r
I
r
2-7
Remove the slide clips [1] and front side plate [2] from
the front side cover [3]. (11~
[2]
CRF1100A4/D4
REMOVAUINSTALLATION
Remove the tank front cover (page 2-6).
Remove the socket bolt [1] and trim clips [2].
Release the bosses [3] from the grommets [4].
Remove the middle cowl [5] by releasing its tabs [6] .
Right side shown :
[3] ~ -
[4] [6] [2]
2-8
[3) [1)
Remove the following from the middle cowl [1]:
- Bolts [2]
- Front side plate [3]
Nuts [4]
/}
"
Remove the slide clips [1].
[6)
Release the middle cowl tabs [2] from the front side
cover slots [3].
Release the front side cover tabs [4] from the middle
cowl slots [5].
Remove the middle cowl [6] from the front side cover
[7].
Assembly is in the reverse order of disassembly.
INNER COVER
CRF1100A/D
REMOVAUINSTALLATION {LEFT SIDE)
Remove the front lower cover (page 2-14).
Release the following:
- Front sub harness 1 12P (Black) connector [1]
Front sub harness 2 4P (Black) connector [2]
Dummy connector [3]
2-9
Release the tab [1] of the air cleaner duct from the left
inner cover [2].
Remove the trim clip [3] and screws [4].
Remove the left inner cover.
REMOVAUINSTALLATION (RIGHT SIDE)

Remove the right middle cowl (page 2-7).
Release the dummy connector [1]. J
Release the tab [2] of the air cleaner duct from the right
..
inner cover [3].
Remove the trim clip [4] and screws [5] .
Remove the right inner cover.
2-10
CRF11 OOA4/D4
REMOVAUINSTALLATION (LEFT SIDE)
Remove the left middle cowl (page 2-8).
- Dummy connector [3]
Wire clip [4]
- Wire clamp [5]
Release the tab [1] of the air cleaner duct from the left
[1] [3]
inner cover [2].
Remove the left inner cover.
[4]
REMOVAUINSTALLATION (RIGHT SIDE)

- Open air temperature sensor 2P connector [1]
- Dummy connector [2]
- Wire clip [3]
Disconnect the open air temperature sensor 2P
connector.
,..
.
2-11
Release the tab [1] of the air cleaner duct from the right
inner cover [2].
Remove the right inner cover.
FRONT CENTER COWL 1

l
CRF1100A/D J
REMOVAUINSTALLATION
Remove the windscreen (page 2-18).
•l
Remove the socket bolts [1 J.
Release the tabs (2) and remove the front center cowl [3)
ll
(3] .
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[2] l
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2-12
CRF1100A4/D4
REMOVAUINSTALLATION
Remove the middle cowls (page 2-8).
[1 ] [2]
Release the bosses [1] and remove the front center I "\
cowl [2] . \

NOTE:
• Align the front center cowl tabs [3] with the headlight
unit lugs.
r
[3]
FRONT SIDE COWL (CRF1100A/D)

Remove the inner panel cover (page 2-17).
Left side shown:
Remove the trim clip [1].
r Remove the front side cowl [2] by releasing its tabs [3]
from the front turn signal cover and front lower cover. [2]
[3]
2-13
FRONT LOWER COVER
CRF1100A/D
REMOVAUINSTALLATION
Remove the front side cowl (page 2-13).
Remove the trim clips [1] and socket bolts [2], and front
lower cover [3] .
)'
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[3] [1 J J
_.
CRF11 OOA4/D4
REMOVAUINSTALLATION
Remove the middle cowls (page 2-8).
Remove the trim clip [1] and socket bolts [2], and front
lower cover [3].
[3] [1 J [2]
2-14
I DISASSEMBLY/ASSEMBLY
Remove the front lower cover (page 2-14 ).
I
Remove the slide clip [1] .
Remove the front spoiler [2] from the front lower cover
[3] .
( Assembly is in the reverse order of disassembly.
lt [2]
t FRONT TURN SIGNAL COVER

t CRF1100A/D
I
REMOVAUINSTALLATION
Remove the front side cowl (page 2-13).
Remove the socket bolt [1].
Release the front turn signal cover tab [2] from the front
lower cover.
Disconnect the front turn signal light 2P connector [3].
- Left side: 2P (Orange) connector
- Right side: 2P (Light blue) connector
I Disconnect the following connector [4] :

-
-
Left side: accessory socket (option) 2P connector
Right side: open air temperature sensor 2P
connector
Right side only: Disconnect the USB connector [5] .
f Right side shown :

[3] [5]
,•
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[2] [4]
2-15
Right side: Remove the USB socket [1] by releasing its tabs [2]
from the right front turn signal cover [3]. [3]
Remove the collar [4] .

NOTE :
• Install the USB socket as shown .
[1)
Right
[4]____a LRear
Jfil-
[1 J
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7; ]
[2) [4) [3)
CRF11 OOA4/D4
REMOVAUINSTALLATION
Remove the trim clip [1] and socket bolts [2] .
Disconnect the front turn signal light 2P connector [3] .
-
-
Left side: 2P (Orange) connector
Right side: 2P (Light blue) connector
t
)
Remove the front turn signal cover [4] .
Installation is in the reverse order of removal. 'l
NOTE:
Align the front turn signal cover groove [5] with the [2)
inner panel cover tab [6] .
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2-16
INNER PANEL COVER
CRF1100A/D
REMOVAUINSTALLATION
Remove the front center cowl (page 2-12).
Release the open air temperature sensor 2P connector
[1] .
Remove the right inner panel cover [4] by releasing its
boss [5] from the left inner panel cover grommet.

Remove the left inner panel cover [3].
[2]
2-17
CRF11 OOA4/04
REMOVAUINSTALLATION
Remove the front turn signal covers (page 2-16).
[3]
Release the accessory socket 2P connector [1] and
front sub harness 3 12P (Black) connector [2] from the
inner panel cover [3].
Disconnect the accessory socket 2P connector.
Release the inner panel cover tab [4] from the front
upper cover slot [5].
[1] [2]
Release the open air temperature 2P connector [1] from

the inner panel cover [2].
Release the inner panel cover tab [3] from the front I
upper cover slot [4].
Remove the USB socket [5] rearward by releasing its
tabs from the inner panel cover.
Release the cover [6]. J
Disconnect the USB connector [7].
Remove the inner panel cover.
NOTE:
• Align the USB connector tab [8] with the USB socket
'J
groove.
Install the USB socket with USB connector tab
facing up.
j
1
[1]
J
WINDSCREEN
CRF1100A/D
REMOVAUINSTALLATION
l
- Windscreen screws [1]
- Plastic washers A [2]
- Rubber washers [3] I
- Windscreen [4] j
Remove the well nuts [5] and plastic washers B [6].
..l
:
TORQUE:
Windscreen screw:
0.42 N·m (0.04 kgf·m, 0.3 lbf-ft)
l
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2-18
CRF1100A4/D4
REMOVAUINSTALLATION
- Windscreen screws [1]
- Plastic washers A [2]
- Rubber washers [3]
- Windscreen [4]
Remove the well nuts [5] and plastic washers B [6].
TORQUE:
Windscreen screw:
0.42 N·m (0.04 kgf·m, 0.3 lbMt)
SCREEN ADJUST RAIL

(CRF11 OOA4/D4)
NOTE:
• Do not apply grease to the screen adjust rail slide
portions .
•
ADJUSTMENT
If you feel that the windscreen does not move smoothly,
clean the slides.
If there is no improvement, perform an alignment of the
slide rails on both slides in the following procedure:
Loosen the screen adjust rail bolts [1 J with the
windscreen installed.
Retighten the screen adjust rail bolts securely.
If the condition still is not improved, replace the slider
guide and rail guide (page 2-20).
2-19
Remove the windscreen (page 2-19).
Remove the screen adjust rail bolts [1] and screen
adjust rail [2].
[1]
Left side shown:

LEVER SPRING
SCREEN ADJUST
BRACKET
~
SPRING PIN
LOCK LEVER
)
~£\_ ~~CK
~LATE
1
COLLARS
E-RINGS
SCREEN ADJUST - - -7 }.
RAIL WASHERS
LOCK PLATE MOUNTING BOLTS
1.8 N·m (0.2 kgf·m, 1.3 lbf·ft)
NOTE:
• Install the lever spring in the direction as shown.
• Install the lock plate with the chamfered edge facing
the screen adjust bracket side.
• Drive the spring pin into the lock lever until fully
seated.
2-20
FRONT UPPER COVER

CRF1100A/D
REMOVAUINSTALLATION
Remove the inner panel cover (page 2-17). [3]
Remove the trim clip [1] .
Remove the bolts [2] and front upper cover [3].
I
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11
Remove the front upper cover (page 2-21 ).
... Remove the bolts [1].
,
I
Remove the windscreen stays [2] and collars [3] .
Remove the front upper cover [4] by releasing its
bosses [5] from the stay [6].
r' -
... Installation is in the reverse order of removal.
,f
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[6]
[4]
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(3] [2] [5]
r CRF11 OOA4/D4
REMOVAUINSTALLATION
Remove the screen adjust rail (page 2-20).
Remove the front center cowl (page 2-13).
Release the bosses [2] and remove the front upper
cover [3] .
2-21
KNUCKLE GUARD
Remove the handlebar weight (page 17-14 ).
Left side shown:
- Screws [1]
- Knuckle guard B [2] (CRF11 OOA4/D4)
- Knuckle guard A [3]
- Well nuts [4]
- Plastic washers [5]
A
.•
[1] [2] [1]
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2-22 l
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FRONT FENDER
Remove the bolt [1] and brake hose clamp [2] from the
front fender.
Remove the socket bolts [3] and fender covers [4] .
Release the front wheel speed sensor wire grommet [5]
from the fender clamp.
Remove the socket bolts and front fender [6] .
Remove the collars A [7] and collars B [8] from the front
fender.
Remove the front side reflector nuts [9] and front side
reflectors [1 OJ from the front fender covers .
TORQUE:
Front side reflector nut:
1.8 N·m (0.2 kgf·m, 1.3 lbMt)
NOTE:
• Route the wire and hoses properly (page 1-26).
• Align the front side reflector boss with the front
' fender cover hole.
,,
,
r--
2-23
FRONT FENDER A
FRONT FENDER B
TANK SIDE COVER (CRF1100A/D)

Right side shown:
(4)
J
- Socket bolt A [1]
- Socket bolt B [2]
Release the tank side cover bosses [3] from the
grommets [4].
J
j
Remove the tank side cover [5] .
[5] [3] (1)
l
2-24
SKID PLATE
CRF1100A/D
REMOVAUINSTALLATION
[3]/[4]/[5] [8]
- Skid plate bolts A [1)
Washers [2]
Collars [3)
Grommets A [4)
Clip nuts [5)
Skid plate [6)
Grommets B [7)
TORQUE:
Skid plate bolt A:
26.0 N·m (2.7 kgf·m, 19 lbHt)
NOTE:
• Align the grommet B of the skid plate with the boss
[8) of the frame.
CRF11 OOA4/D4
REMOVAUINSTALLATION
[8]/[9]/[ 1OJ
- Skid plate bolt A [1)
- Washers A [2)
Clip nuts A [3]
Collars A [4)
- Grommets A [5)
r
I
- Skid plate bolts B [6)
- Washer B [7]
- Clip nut B [8]
- Collar B [9)
- Grommet B [10]
Skid plate [11]
- Grommet C [12)
TORQUE:
Skid plate bolt A:
26.0 N·m (2.7 kgf·m, 19 lbHt)
Skid plate bolt B:
12.0 N·m (1.2 kgf·m, 9 lbHt)
NOTE:
• Align the grommet C of the skid plate with the boss
. [13) of the frame .
[1] [11] [12]
2-25
TOOLBOX
Remove the socket bolts [1] and tool box [2].
NOTE:
• Align the tool box slots [3] with the battery box tabs
[4].
LEFT REAR COVER

MT model only: Remove the gearshift arm (page 12-23).
Remove the left rear cover bolts [1], left rear cover [2]
and drive chain guide plate [3].
Release the sidestand wire clip [4] and sidestand wire
[5] from the left rear cover.
TORQUE:
Left rear cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
NOTE:
• Align the chain guide plate holes with the left rear
cover bosses.
• Route the wires properly (page 1-26).
[1]
l ~
[5]//~
[4]
HEEL GUARD
Remove the socket bolt [1] and heel guard [2].
J
J
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2-26
CLUTCH EOP SENSOR COVER

(OCT model)
CRF110004: Remove the exhaust pipe cover B (page 2-45).
Remove the socket bolts [1] and release the clutch EOP
sensor cover boss [2].
Remove the clutch EOP sensor cover [3].
TORQUE:
Clutch EOP sensor cover socket bolt:
10 N·m (1 .0 kgf·m, 7 lbf-ft)
RIGHT REAR ENGINE COVER

, Remove the right rear engine cover bolts [1] and right
rear engine cover [2] .
TORQUE:
Right rear engine cover bolt:
10 N·m (1.0 kgf·m, 7 lbf-ft)
MAIN STEP
LEFT MAIN STEP BRACKET
' Remove the sidestand switch bolt [1] and sidestand
switch [2].
- i - =~:"""""'",:---,;;;:;-;::
[1 J [2]
2-27
Remove the left main step bracket bolts [1] and left
main step bracket [2].
For main step disassembly/assembly (page 2-29)

TORQUE:
Left main step bracket bolt:
35 N·m (3.6 kgf·m, 26 lbMt)
Sidestand switch bolt:
10 N·m (1 .0 kgf·m, 7 lbf·ft)
NOTE:
• Align the sidestand switch tab [1] with the sidestand
hole [2].
• Align the sidestand switch groove [3] with the return
spring holding pin [4].
• Replace the sidestand switch bolt [5] with a new ==-- - ' - - = - - - - - -- - - - - -- - - - - '
one.
RIGHT MAIN STEP BRACKET
Remove the exhaust pipe (page 2-50).
- Right main step bracket lower bolt [1]
- Right main step bracket upper bolt [2]
- Right main step bracket [3]
For main step disassembly/assembly (page 2-29)
TORQUE:
Right main step bracket upper bolt:
69 N·m (7.0 kgf·m, 51 lbMt)
Right main step bracket lower bolt:
32 N·m (3.3 kgf·m, 24 lbMt) [1)
2-28
Left side shown:

JOINTPIN ~ MAIN STEP BRACKET
MAIN STEP RUBBER
STEP RUBBER
SET PLATE
-COTTER PIN
MAIN STEP RETURN SPRING
,• MAIN STEP RUBBER BOLT ~
,I PILLION STEP
Remove the pillion step bracket bolts [1) and pillion step
Right side shown:
assembly [2).
TORQUE:
Pillion step bracket bolt:
32 N·m (3.3 kgf·m, 24 lbf·ft)
NOTE:
• Apply grease to the pillion step joint pin sliding area.
2-29
SEAT CATCH HOOK/SEAT LOCK
CYLINDER
SEAT CATCH HOOK
Remove the bolt [1].
Disconnect the seat lock cable [2] from the seat catch
hook [3] and remove the seat catch hook.
NOTE:
• Apply grease to the seat catch hook sliding area.
• Align the seat catch hook boss [4] with the seat rail
hole [5].
SEAT LOCK CYLINDER

Remove the left fender B cover (page 2-43).
Disconnect the seat lock cable [1] from the seat lock
cylinder [2].
Remove the lock spring [3], seat lock cylinder, and stay
[4].
NOTE:
• Align the seat lock cylinder lug [5] with the left fender
B cover groove [6] and stay groove [7].
[1] [7]
REAR SIDE COWL

CRF1100A/D
REMOVAUINSTALLATION
Remove the main seat (page 2-5).
[1]
Remove the trim clips [1] and socket bolt [2].
Remove the rear side cowl [3] by releasing its tabs [4]
from the rear side inner cover slots.
j
2-30
Remove the rear side cowl (page 2-30).
Remove the twist clip [1].
Remove the rear cowl lid (2) from the side cowl (3) .
Remove the trim clip [1) .
~
Remove the rear side cowl A (2) by releasing its tabs [3)
from the rear side cowl B [4).
[3)
2-31
CRF11 OOA4/D4
REMOVAUINSTALLATION
Remove the trim clips [1] and socket bolt [2].
Release the dual lock fastener [3] and rear side cowl
bosses [4] and remove the rear side cowl [5].
NOTE:
• Align the rear side cowl tabs [6] with the rear fender
B and rear fender B cover lugs.
Left side shown:

[1]
[5)
I ,."
I, ,.
[4)
2-32
REAR SIDE INNER COVER

CRF1100A/D
REMOVAUINSTALLATION
- Trim clips [1]
- Rear side inner cover screw A [2]
- Rear side inner cover screw B [3]
- Rear side inner cover [4]
TORQUE:
Rear side inner cover screw A:
0.42 N·m (0.04 kgf·m, 0.3 lbMt)
CRF1100A4/D4
REMOVAUINSTALLATION
- Trim clips [1]
- Rear side inner cover screw A [2]
- Rear side inner cover screw B [3]
- Rear side inner cover [4]
TORQUE:
Rear side inner cover screw A:
0.42 N·m (0.04 kgf·m, 0.3 lbMt)
NOTE:
• Align the rear side inner cover tabs [5] and slots [6]
with the rear side cowl slots and lugs.
Left side shown :
,.
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2-33
REAR SEAT UNDERCOVER
CRF1100A/D
Remove the rear side inner cover (page 2-33).
Left side shown :
Release the tank side cover boss (1) from the rear seat
under cover grommet (2).
Remove the socket bolts (3) and screw (4) .
Release the rear seat under cover tab (5) from the rear
fender B cover slot (6) . ·
Remove the rear seat under cover (7) .
Installation is in the reverse order of removal. I
I
J
(6)
CRF1100A4/D4 -
REMOVAL/INSTALLATION ,,J
Left side shown : J
Remove the socket bolt [1) and screw (2) .
l
Release the rear seat under cover grommet (3) from the
rear side cowl boss (4).
Release the rear seat under cover tab (5) from the rear
fender B cover slot (6) .
,'.----[2]
(3)
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Remove the rear seat under cover (7) . (4) 1../ ~

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1
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2-34
REAR CENTER COWL
CRF1100A/D
REMOVAUINSTALLATION
Release the tabs [1] from the rear fender B slots by
pulling the rear center cowl assembly [2] rearward.
Remove the rear center cowl assembly.
Remove the rear center cowl (page 2-35).
Release the tabs [1] by pulling the rear side cowls C [2]
r rearward.
' Remove the rear side cowls C from the rear center cowl
[3].
f
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2-35
CRF11 OOA4/D4
REMOVAUINSTALLATION
[2)
[1)
Remove the rear center cowl A [1] by releasing its tabs
[2] from the rear center cowl B slots.
,._
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I
Remove the tapping screws [1] .
Remove rear center cowl B [2] by releasing its tabs [3]
from the rear fender B slots.
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2-36
PANNIER BRACKET (CRF11 OOA4/D4)
- Pannier bracket bolt A [1]
- Pannier bracket bolt B [2]
Washers [3]
- Pannier bracket [4]
- Collars [5]
TORQUE:
Pannier bracket bolt A/8:
35 N·m (3.6 kgf·m, 26 lbMt)
(1)
REAR CARRIER (CRF11 OOA4/D4)

Remove the rear center cowl B (page 2-36).
(4)
- Pannier bracket bolts A [1]
- Washers [2]
- Rear carrier bolts [3]
- Rear carrier [4]
- Rear center rubbers [5]
TORQUE: [1)
Pannier bracket bolt A:
Lz
35 N·m (3.6 kgf·m, 26 lbMt)
Rear carrier bolt:
35 N·m (3.6 kgf·m, 26 lbf·ft)
"'-
I
2-37
MUD GUARD
- Trim clips [1]
- Socket bolts [2]
- Mud guard [3]
[2]
REAR FENDER A
REMOVAL/INSTALLATION •
t
,,.'
Release the connector cover [1] from the stay.
Disconnect the following :
- Right rear turn signal light 2P (Light blue) connector
[2]
-
-
License light 2P {White) connector (3]
Left rear turn signal light 2P (Orange) connector [4]
.
...

Bolts [1]
- Washers [2]
- Rear fender A (3]
- Collars [4]
Installation is in the reverse order of removal. '
NOTE:
'
..
~
2-38
TAPPING SCREWS
REAR REFLECTOR NUT
REAR FENDER STAY
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1.8 N·m (0.2 kgf·m, 1.3 lbf-ft)
REAR REFLECTOR
REAR SIDE REFLECTOR NUTS

.I
1.8 N·m (0.2 kgf-m, 1.3 lbf·ft)
STAYS
REAR SIDE REFLECTORS SOCKET BOLTS

,·
NOTE:
• Align the rear reflector boss with the rear fender A
hole.
• For rear turn signal light removal/installation (page
22-12)
• For license light removal/installation (page 22-13)
2-39
REAR FENDER B
CRF1100A/D
REMOVAUINSTALLATION
- Mud guard (page 2-38)
- Rear center cowl (page 2-35)
- Brake/taillight (page 22-13)
- Rear fender A (page 2-38)
Release the following from the rear fender B:
- Wire clamp [1]
- Sub fuse ABS FSR+ 20 A [2]
- DCT relay (DCT model) [3]
- Power box [4]
Release the EVAP canister mounting rubber [1] from

the rear fender B stay [2].

- DLC [1]
- Wire clamps [2]
Disconnect the seat lock cable [3].
2-40
- Socket bolts A [1]
- Socket bolts B [2]
- Socket bolts C [3]
- Rear fender B [4]
NOTE:
• Place the rear fender B hooks [5] onto the seat rail.
[2] [1] [3] [4]
C RF11 OOA4/D4
REMOVAUINSTALLATION
Mud guard (page 2-38)
- Muffler (page 2-47)
- SCU (page 22-80)
- EVAP canister (page 7-23)
- Rear center cowl (page 2-36)
- Brake/taillight (page 22-13)
- Rear fender A (page 2-38)
- Wire clamp [1]
- Sub fuse ABS FSR+ 20 A [2]
- OCT relay (OCT model) [3]
- Power box [4]
rt
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2-41
- DLC [1]
- Wire clamps [2]
Disconnect the seat lock cable [3].
Release the rear suspension pre-load motor 2P

connector [1] and rear suspension position sensor 3P
(Gray) connector [2].

- Socket bolts A [1]
- Socket bolts B [2]
- Rear fender B [3]
NOTE:
~
• Place the rear fender B hooks [4] onto the seat rail.
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2-42
SEAT RAIL
• CRF1100A/D:
- Heel guard (page 2-26)
- Pillion steps (page 2-29)
- Seat catch hook (page 2-30)
- Regulator/rectifier (page 21-9)
- EGCA (page 4-70)
- ABS modulator (page 20-27)
- Rear fender B (page 2-40)
• CRF1100A4/D4:
- Heel guard (page 2-26)
- Pillion steps (page 2-29)
- Seat catch hook (page 2-30)
- Rear carrier (page 2-37)
- Regulator/rectifier (page 21-9)
- EGCA (page 4-70)
- ABS modulator (page 20-27)
- Rear suspension level adjuster bracket (page 18-
15)
- Rear fender B (page 2-41)
CRF1100A4/D4: Release the wire clip [2] .
Release the rear suspension solenoid 2P connector [3]
and disconnect it.
Remove the rear master cylinder reservoir mounting

bolt [1] and release the rear master cylinder reservoir
, [2].
NOTE:
• Keep the rear master cylinder reservoir upright to
prevent air from entering the hydraulic system.
,.
2-43
Seat rail bolts (short) [1]
- Seat rail bolts (long) [2]
- Washers [3]
- Nuts [4]
- Seat rail [5]
1
Remove the following from the seat rail [1 ]:

[5]
- Socket bolts [2]
~
- Left/right rear fender B covers [3]
- ABS modulator box [4]
- Collars [5]
TORQUE:
Seat rail bolt:
44 N·m (4.5 kgf·m, 32 lbf·ft)
Rear master cylinder reservoir mounting bolt:
10 N·m (1.0 kgf·m, 7 lbf·ft)
NOTE:
• Route the hose, wire, and cable properly (page 1-
fa
[2]
26).
• For IMU removal/installation (page 4-67) [4] [2] [1]
• For seat lock cylinder removal/installation (page 2-
30)
2-44
MUFFLER/EXHAUST PIPE
FRONT EXHAUST PIPE COVER
REMOVAUINSTALLATION {CRF1100A/D)
Remove the catalyst cover bolts [1] and washers [2] .
Fully loosen the exhaust pipe cover band screw [3] and
remove the catalyst cover [4] .
TORQUE:
Catalyst cover bolt:
9.0 N·m (0.9 kgf·m, 6.6 lbMt)
NOTE:
• Set the exhaust pipe cover band screw in position as
shown.
Up
Lleft
[4] I
~,/~,,...,------115'
-- -+--------
~ J 1s·
[3]
REMOVAUINSTALLATION (CRF11 OOA4/D4)

i
r Remove the exhaust pipe cover B bolts [1] and exhaust
pipe cover B [2].
Remove the grommet [3] .
TORQUE:
Exhaust pipe cover B bolt:
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
~
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2-45
REAR EXHAUST PIPE COVER
REMOVAUINSTALLATION
Remove the exhaust outer cover bolt [1].
Remove the exhaust outer cover [2] by releasing its [3]
slots [3] from the exhaust pipe cover C bosses [4].
Remove the grommet [5] .
[2]
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?
(1]
[5]
Remove the exhaust pipe cover C bolts [1] and exhaust

pipe cover C [2].
Remove the grommets [3].
TORQUE:
Exhaust outer cover bolt:
9.0 N·m (0.9 kgf·m, 6.6 lbHt)
Exhaust pipe cover C bolt:
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
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2-46
MUFFLER
MUFFLER REMOVAUINSTALLATION
Remove the right pillion step (page 2-29).
Remove the exhaust pipe cover C (page 2-46).
Remove the mud guard (page 2-38).
Turn the ignition switch OFF. [3]
~
Loosen the lock nut [1].
Fully slacken the EGCA cable by turning the adjusting . . 111
bolt [2] while holding the adjusting nut [3].
~[2]
0
Remove the valve guide cover bolts [1] and valve guide
cover [2]. [2]
Make sure that the ignition switch is turned OFF.

[1]
Loosen the lock nuts [3] and remove the cable joints [4]
J
from the valve guide body [5] of the muffler.
Disconnect EGCA cable B [6] from the valve cable
guide [7].
Turn the valve cable guide counterclockwise and
disconnect EGCA cable A [8].
[5]
[7]
2-47
Remove the mounting bolt [1], washer [2], and rubber
washer [3].
Release the EGCA cables [4] from the muffler mounting
collar [5] then remove the muffler mounting collar.
Loosen the muffler band bolts [6] then remove the
muffler [7] and gasket [8].
[1] [2] [3]
\_\~
[9]
[8).,

TORQUE:
Muffler band bolt:
17 N·m (1.7 kgf·m, 13 lbf·ft)
Valve guide cover bolt:
5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)
NOTE:
• Always replace the gasket with a new one.
• When installing the muffler, loosely install the
mounting bolt and tighten the muffler band bolts first
to the specified torque, and then tighten the
mounting bolt securely.
• Route the EGCA cables properly (page 1-26).
• Install the muffler band with its tab [9] is in position
as shown.
• After installing, adjust the EGCA cable freeplay
(page 3-17).
2-48
VALVE CABLE GUIDE REMOVAUINSTALLATION
Disconnect the EGCA cables (page 2-47).
Straighten the lock washer [1] tabs.
- Nut [2]
- Lock washer [3]-~
- Valve cable guide [3]
- Return spring [4]
NOTE:
• Hook the return spring ends to the muffler tab [5]
and valve cable guide groove [6] as shown .
• Align the flats in the valve cable guide hole with the
flats of the valve shaft properly.
• Note the positions of the valve cable guide tab [7]
t and muffler stopper tab [8].
• Replace the lock washer with a new one.
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MUFFLER DISASSEMBLY/ASSEMBLY
SPARK ARRESTER A
SPARK ARRESTER BOLTS
9.0 N·m (0.9 kgf·m, 6.6 lbf-ft) MUFFLER COVER SCREW
~
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
r•
TAILCAPCOVERBOLTS
9.0 N·m (0.9 kgf-m , 6.6 lbf-ft)
Ql
? RUBBER WASHER
~ "· l
I RUBBER WASHERS _ _ _ . . .""
L
! TAIL CAP COVER

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SPARK ARRESTER BOLTS

9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
f
t ~~ MUFFLER
r SPARK ARRESTER B
~
NOTE:
• Align the tail cap cover and muffler cover slots with
the muffler bosses.
2-49
EXHAUST PIPE REMOVAL
- Middle cowl (page 2-7)
- Exhaust pipe cover 8 (CRF11 OOA4/D4) (page 2-45)
- Muffler (page 2-47)
Open the clamp [1] and release the left A/F sensor wire
[2].
Disconnect the left A/F sensor 4P connector [3].
Release the wire clip [4].
Open the clamp [1] and release the right A/F sensor
wire [2].
Disconnect the right A/F sensor 4P connector [3].
NOTE:
• When disconnecting the linear solenoid 4P (Black)
connector and right A/F sensor 4P connector at the
same time, mark the main wire harness side
connectors to prevent the misconnection.
Release the wire clip [4] .
Remove the exhaust pipe mounting nut [1], collar [2],

washer [3], and bolt/washer [4].
Remove the exhaust pipe joint nuts [1], exhaust pipe .....- - - -
[2], and gaskets [3].
Remove the A/F sensors if necessary (page 4-67).
2-50
EXHAUST PIPE INSTALLATION
CRF1100D4 shown :
EXHAUST PIPE JOINT NUTS

20 N·m (2.0 kgf-m, 15 lbf-ft)
'
( EXHAUST PIPE COVER B
.t STAY BOLT*
9.0 N·m (0.9 kgf-m, 6.6 lbf-ft)
EXHAUST PIPE
COVER A
I *: CRF1100A4/D4 I
EXHAUST PIPE COVER BAND SCREWS
2.8 N·m (0.3 kgf·m, 2.1 lbf-ft)
Install the A/F sensors if they are removed (page 4-67).

CRF11 OOA4/D4 shown:
CRF1100A4/D4: Install the exhaust pipe cover B stay [1], rubber washer
[2], and exhaust pipe cover B stay bolt [3] and tighten
the bolt to the specified torque.
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TORQUE: 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
Loosely install the exhaust pipe cover A [4] and exhaust
I pipe cover bands [5].
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[5)
2-51
Install new gaskets [1] to the exhaust ports of the .....- - - -
cylinder head.
Loosely install the following :
Exhaust pipe [2]
- Exhaust pipe joint nuts [3]
- Washer [4]
- BolUwasher [5]
- Collar [6]
- Exhaust pipe mounting nut [7]
Loosely install the muffler and fasteners (page 2-47).
Tighten the exhaust pipe joint nuts to the specified
torque.
TORQUE:20 N·m (2.0 kgf·m, 15 lbMt)
Tighten the muffler band bolts [1] to the specified ,

torque.
TORQUE: 17 N·m (1 .7 kgf·m, 13 lbf·ft)
Tighten the exhaust pipe mounting nut [1] securely.
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2-52
Tighten the muffler mounting bolt [1] securely.
Tighten the exhaust pipe cover band screws [1] to the

specified torque. Up
TORQUE: 2.8 N·m (0.3 kgf·m, 2.1 lbf-ft)
NOTE:
Lleft
• Set the exhaust pipe cover band screws and
exhaust pipe cover A [2] in position as shown.
[2]
6.2 mm (0.24 in)
- ·H--41---
,.
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Connect the right NF sensor 4P connector (1].

Front
Install the wire clip [2].
Secure the right NF sensor wire [3] with the clamp [4]. LRight
2-53
Connect the left NF sensor 4P connector [1].
Install the wire clip [2).
Secure the left NF sensor wire [3) with the clamp [4) .
Adjust the EGCA cable freeplay (page 3-17).
Install the following :
- Front exhaust pipe cover (page 2-45)
- Exhaust outer cover (page 2-46)
- Middle cowl (page 2-7)
NOTE:
26).
STUD BOLT REPLACEMENT

Thread two nuts onto the stud and tighten them
together, and use a wrench on them to turn the stud bolt
out.
Install new stud bolts into the cylinder head.
After installing the stud bolts, check that the length from
the bolt head to the cylinder head surface is within
specification.
Install the exhaust pipe (page 2-51 ).
22.5 - 23.5 mm
(0.89 - 0.93 in )
SIDESTAND
REMOVAL
Remove the sidestand switch bolt [1] and sidestand F""........,,"'W""""""'"::r------;;;;= r-------,,,-,;;;
switch [2) .
[1 J [2]
Support the motorcycle securely using a hoist or

equivalent.
Remove the sidestand return spring [1] .
Remove the sidestand pivot nut [2] and bolt [3], then
remove the sidestand [4] and collar [5] .
2-54
INSTALLATION
Apply molybdenum disulfide grease to the sidestand
pivot bolt [1] sliding surface and collar [2] outer surface.
Install the sidestand [3] and collar.
Install and tighten the sidestand pivot bolt to the
specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbMt)
After tightening the pivot bolt, return the pivot bolt 45° to
goo.
Install and tighten the sidestand pivot nut [4] to the
specified torque while holding the sidestand pivot bolt.
TORQUE:42 N·m (4.3 kgf·m, 31 lbf·ft)
Install the sidestand return spring [5] in the direction as L . . __ _ _ _ _ _ _ __ ___L_ _ _ __ __J
shown.
Install the sidestand switch [1] and new sidestand
switch bolt [2].
Tighten the sidestand switch bolt to the specified
torque.
NOTE:
hole [4].
spring holding pin [6].
• Replace the sidestand switch bolt with a new one.
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2-55
MEMO
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3. MAINTENANCE
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SERVICE INFORMATION· .. ····················· 3-2 EXHAUST GAS CONTROL ACTUATOR

CABLE .............................................. 3-17
MAINTENANCE SCHEDULE · · · · · · · · · · · · · · · · · · · 3-3
DRIVE CHAIN · · · · · .. · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-18
FUEL LINE · ··· · ··· ···· · ·· · ·· · · ···· ··· ·· · ··· ··· ·· ..... 3-4
DRIVE CHAIN SLIDER · · · · .. · · .. · · · .. · · · · · · · · · · 3-21
THROTTLE OPERATION ........................ 3-4
BRAKE FLUID · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · .. · · · · 3-21
AIR CLEANER .. · · · · · · .. · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-5
BRAKE PADS WEAR··························· 3-22
CRANKCASE BREATHER · · · · · · · · · · · · · · · · · · · · · · 3-5
BRAKE SYSTEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-22
SPARK PLUG ··· · ···· .... ··· · ···· ··· ·· · ··· ·· · ·· ··· ·· 3-6
BRAKE LIGHT SWITCH························ 3-23
VALVE CLEARANCE ............................. 3-7
BRAKE LOCK OPERATION
ENGINE OIL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-11 (DCT model) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-23
ENGINE OIL FILTER ............................ 3-12 HEADLIGHT AIM································· 3-24
CLUTCH OIL FILTER (DCT model)········· 3-13 CLUTCH SYSTEM (MT model) · · · · · · · · · · · · .. 3-25
ENGINE IDLE SPEED ........................... 3-14 SIDESTAND ....................................... 3-26
RADIATOR COOLANT · · · · · · · · · · · · · · · · · · · · · · · · · 3-14 SUSPENSION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-26
COOLING SYSTEM······························ 3-15 SPARK ARRESTER····················· ... ····· 3-33
SECONDARY AIR SUPPLY SYSTEM···· .. 3-15 NUTS, BOLTS, FASTENERS················· 3-33
EVAPORATIVE EMISSION CONTROL WHEELS/TIRES·································· 3-33

SYSTEM · .. · .. · .. · · .. · · · .. · .. · · · · · · · · · · .... · .. · · · .. · 3-16
STEERING HEAD BEARINGS · · · · · · · · · · · · · · · 3-34
3-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
• Place the motorcycle on level surface before starting any work.
TOOLS
Valve adjusting wrench Tappet adjuster wrench, 3 mm Tappet lock nut wrench , 8 mm
07708-0030400 07908-3290100 (U.S.A. only) 07908-3290200 (U.S.A. only)
Not available in U.S.A.

Oil filter wrench Drive chain tool set
07HM-PJ70101 07HMH-MR10103
or 07AM-PLCA100 (U .S.A. only) or 07HMH-MR1010C (U .S.A. only)
3-2
MAINTENANCE
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.
FREQUENCY(NOTE1) REFER
REGULAR
ITEMS NOTE X 1,000 mi 0.6 4 8 12 16 20 24 TO
REPLACE
X 1,000 km 1.0 6.4 12.8 19.2 25.6 32.0 38.4 PAGE
* FUEL LINE I I I 3-4
* THROTTLE OPERATION I I I 3-4
AIR CLEANER NOTE2 R R 3-5
CRANKCASE BREATHER NOTE3 C C C C C C 3-5
Cl)
EVERY 16,000 mi (25,600 Km): I,
~ SPARK PLUG 3-6
w EVERY 32,000 mi (51,200 Km): R
t: * VALVE CLEARANCE I 3-7
0
w ENGINE OIL R R R R 1 year 3-11
I-
<( ENGINE OIL FILTER R R 3-12
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w CLUTCH OIL FILTER NOTES R R 3-13
0::: * ENGINE IDLE SPEED I I I 3-14
z RADIATOR COOLANT NOTE? I I I 3 years 3-14
0
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* COOLING SYSTEM I I I 3-15
SECONDARY AIR SUPPLY
~ * I 3-15
w SYSTEM
* EVAPORATIVE EMISSION
NOTE4 I 3-16
CONTROL SYSTEM
EXHAUST GAS CONTROL
** 3-17
ACTUATOR CABLE
DRIVE CHAIN NOTES EVERY 600 mi (1000 Km): L 3-18
Cl) DRIVE CHAIN SLIDER I I I I I 3-21
~
w BRAKE FLUID NOTE 7 I I I I I 2 years 3-21
t: BRAKE PADS WEAR I I I I I 3-22
0
w BRAKE SYSTEM I I 3-22
I- BRAKE LIGHT SWITCH I I 3-23
<(
...J
w * BRAKE LOCK OPERATION NOTES I I I I I 3-23
0::: HEADLIGHT AIM I I 3-24
z CLUTCH SYSTEM NOTE9 I I I I I 3-25
0
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SI DESTAND I I 3-26
* SUSPENSION I I 3-26
~
w * SPARK ARRESTER NOTE6 C C C C C C 3-33
z' * NUTS, BOLTS, FASTENERS NOTES I I I 3-33
0
z ** WHEELS/TIRES NOTES I I I I I I 3-33
** STEERING HEAD BEARINGS I I I 3-34
* 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.
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. 50 STATE (meets California)
5. Service more frequently when riding OFF-ROAD.
6. U.S.A. only.
7. Replacement requires mechanical skill.
8. OCT type only
9. Except OCT type
3-3
MAINTENANCE
FUEL LINE
CRF1100AID: Remove the following:
- Tank side cover (page 2-24)
- Rear seat under cover (page 2-34)
CRF1100A4/D4: Remove the middle cowl (page 2-8).
Remove the bolt [1] and washer [2].
Lift the fuel tank [3] by releasing its grooves [4) from the
mounting rubbers [5).
Support the fuel tank using a suitable support.
Check the fuel line [1) for deterioration, damage or

leakage. Replace the fuel line if necessary.
Also check the fuel line fittings for leakage.
Install the removed parts in the reverse order of
removal.
THROTTLE OPERATION
Check for smooth operation of the throttle grip [1] and
that it returns automatically to the fully closed position
from any open position.
Replace the right handlebar switch if the throttle
operation is not smooth (page 22-34 ).
3-4
MAINTENANCE
AIR CLEANER
NOTE:
• The viscous paper element type air cleaner can not
Right side shown:
be cleaned because the element contains a dust
adhesive.
• If the motorcycle is used in unusually wet or dusty
areas, more frequent inspections are required .
Release the tab [1) of the air duct from the inner cover.
Remove the screws [2).
Remove the air cleaner lid [3) from the air cleaner
"' housing by pulling it forward to release the tabs [4) .
r Remove the air cleaner element mounting screws [5]
and air cleaner element [6).
[ Replace the air cleaner element in accordance with the
MAINTENANCE SCHEDULE (page 3-3).
r
Also replace the air cleaner element any time if it is
I excessively dirty or damaged.
r removal.
I
TORQUE:
I Air cleaner element mounting screw:

1.1 N·m (0.1 kgf·m, 0.8 lbf-ft)
Air cleaner cover screw:
1.1 N·m (0.1 kgf·m, 0.8 lbf-ft)
(4) (3) (2) [1)
CRANKCASE BREATHER
Check the air cleaner housing drain hoses [1] .
NOTE:
• Service if the deposits level can be seen in the drain
hose.
If necessary, remove the drain plugs [2] from the drain
hoses and drain the deposits into a suitable container.
Reinstall the plugs securely.
3-5
MAINTENANCE
SPARK PLUG
NOTE:
• Clean around the spark plug base with compressed
air before removing the spark plug , and be sure that
no debris is allowed to enter the combustion
chamber.
Remove the ignition coil tray (page 5-10).
Remove the No.1-2 plug [1] using the equipped spark
) .
plug wrench .
Remove the No.2-2 plug in the same manner. .•.
Remove the No.1-1 plug using the equipped spark plug

wrench [1] .
Remove the No.2-1 plug in the same manner.
Inspect or replace the spark plugs as described in the
MAINTENANCE SCHEDULE (page 3-3).
Install and hand tighten the spark plug to the cylinder
head , then tighten the spark plug to the specified torque
using the spark plug wrench .
TORQUE:
Spark plug:
22 N·m (2.2 kgf·m, 16 lbMt)
NOTE:
• Replace new spark plugs as a set.
Install the ignition coil tray (page 5-10).
INSPECTION
Check the following and replace the spark plug if
[3] [2]
necessary.
- Insulator [1] for damage [1]
- Center electrode [2] and side electrode [3] for wear
- Coloration or burning condition
NOTE:
• This motorcycle's spark plugs are equ ipped with an
iridium center electrode. Do not clean the
electrodes.
If the electrodes are contaminated with accumulated
objects or dirt, replace the spark plug .
SPECIFIED SPARK PLUG: SILMAR8A9S (NGK)
3-6
MAINTENANCE
Check the gap between the center and side electrodes
[1)
with a wire type feeler gauge [1].
NOTE:
• To prevent damaging the iridium center electrode,
use a wire type feeler gauge to check the spark plug
gap.
X
Make sure that the <l> 1.0 mm (0.04 in) plug gauge can
not be inserted between the gap.
NOTE:
• Do not adjust the spark plug gap. If the gap is out of
specification, replace it with a new one.
VALVE CLEARANCE
NOTE:
• Inspect and adjust the valve clearance while the
engine is cold (below 35°/95°F).
Remove the cylinder head cover (page 10-5).
Remove the crankshaft hole cap [1] and the timing hole
cap [2].
Turn the crankshaft counterclockwise and align the "T1"

mark [1] on the flywheel with the index mark [2] of the
alternator cover.
Make sure that the index lines [3] on the cam sprocket
align with the upper surface of the cylinder head and
the punch mark [4] on the sprocket is visible.
If the punch mark is not visible, rotate the crankshaft
counterclockwise on full turn and realign the "T1" mark
with the index mark.
3-7
MAINTENANCE
Check the No.1 cylinder intake valve clearances by
inserting a feeler gauge [1] between the valve lifter and
cam lobe (page 1-8).
Adjust the valve clearance by changing the valve lifter
shim (page 3-10).
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Turn the crankshaft counterclockwise 270° and align
the "T2" mark [1] on the flywheel with the index mark [2]
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of the alternator cover. j
Make sure that the punch mark [3] on the cam sprocket
aligns with the upper surface of the cylinder head as
shown.
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Check the No.2 cylinder intake valve clearances by
inserting a feeler gauge [1] between the valve lifter and
l.
•
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cam lobe (page 1-8). '

Adjust the valve clearance by changing the valve lifter
shim (page 3-10).
3-8
MAINTENANCE
Check the No.2 cylinder exhaust valve clearances by
inserting a feeler gauge [1] between the rocker arm
roller and cam lobe (page 1-8).
Adjust the No.2 cylinder exhaust valve clearance by

loosening the lock nut [1) and turning the adjusting
screw [2) until there is a slight drag on the feeler gauge
[3].
TOOL:
Valve adjusting wrench (4) 07708-0030400
U.S.A. TOOLS:
Tappet adjuster wrench, 3 mm 07908-3290100
Tappet lock nut wrench, 8 mm 07908-3290200
Apply engine oil to the adjusting screw and lock nut

threads and seating surface.
Hold the adjusting screw and tighten the lock nut.
After tightening the lock nut, recheck the valve

clearance.
Rotate the crankshaft counterclockwise approximately
252.5° and align the "E1" mark [1] with the index mark
[2).
Make sure that the "t::,.'' mark [3] on the cam sprocket
align with the upper surface of the cylinder head as
shown.
3-9
MAINTENANCE
Check the No.1 cylinder exhaust valve clearances by
inserting a feeler gauge [1] between the locker arm
roller and cam lobe (page 1-8).
'
Adjust the No.1 cylinder exhaust valve clearance by
loosening the lock nut [1] and turning the adjusting
screw [2] until there is a slight drag on the feeler gauge
[3].
TOOL:
Valve adjusting wrench [4] 07708-0030400
U.S.A. TOOLS:
Tappet adjuster wrench, 3 mm 07908-3290100
Tappet lock nut wrench, 8 mm 07908-3290200 ;
I
Apply engine oil to the adjusting screw and lock nut

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Hold the adjusting screw and tighten the lock nut.
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TORQUE:10 N·m (1.0 kgf·m, 7 lbHt)
J
After tightening the lock nut, recheck the valve
clearance. j
Coat new 0-rings [1] with engine oil and install them
into the timing hole cap [2] and crankshaft hole cap [3].
Apply grease to the threads of the timing hole and
crankshaft hole caps.
Install the timing hole and crankshaft hole caps, and
tighten them.
TORQUE:
Timing hole cap:
6.0 N·m (0.6 kgf·m, 4.4 lbMt)
Crankshaft hole cap:
8.0 N·m (0.8 kgf·m, 5.9 lbf·ft)
Install the cylinder head cover (page 10-7).
INTAKE VALVE CLEARANCE

ADJUSTMENT
Remove the valve lifter and shim (page 10-13).
[1 J
Clean the valve shim contact area in the valve lifter [1]
with compressed air.
•
-1
3-10
MAINTENANCE
Measure the shim [1] thickness and record it.
[1]
NOTE:
• Fifty-one different shim thicknesses are available in
increments of 0.025 mm (from 1.200 mm to 2.450
mm) .
•r
Calculate the new shim thickness using the equation

below.
.
.....
A= (B-C) + D
A: New shim thickness
B: Recorded valve clearance
C: Specified valve clearance
D: Old shim thickness
NOTE:
• Make sure of the correct shim thickness by
measuring the shim with the micrometer.
0000
1.80 mm 1.825 mm 1.85 mm 1.875 mm
• Reface the valve seat if carbon deposits result in a

calculated dimension of over 2.450 mm.
Install newly selected shims on the valve retainers.
Install the valve lifter and camshaft (page 10-16).
Rotate the crankshaft counterclockwise several times
and recheck the valve clearances.
ENGINE OIL
OIL LEVEL INSPECTION
Place the motorcycle on its sidestand.
Start the engine and let it idle for 3 - 5 minutes.
Stop the engine and wait 2 - 3 minutes.
Remove the dipstick [1] and wipe it clean.
Place the motorcycle on a level surface, and support it
in an upright position.
Insert the dipstick until it seats, but do not screw it in.
Check that the oil level is between the upper and lower
level lines on the dipstick.
If the level is below the lower level line [2], remove the
oil filler cap [3] and fill the crankcase with the
recommended oil up to the upper level line [4].
RECOMMENDED ENGINE OIL:
(
Pro Honda GN4 4-stroke oil (U.S.A. & Canada) or
equivalent motorcycle oil
API service classification: SG or higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
Check that the 0-rings [5] of the oil filler cap and
dipstick are in good condition, and replace them if
necessary.
Apply engine oil to the 0-rings.
Install the oil filler cap and dipstick.
3-11
MAINTENANCE
ENGINE OIL CHANGE
Remove the skid plate (page 2-25).
Warm up the engine.
Stop the engine and remove the oil filler cap and
dipstick.
Place an oil pan under the engine to catch the engine
oil, then remove the engine oil drain bolts [1] and
sealing washers [2] .
Drain the engine oil completely.
NOTE:
• Be sure to drain the engine oil from both drain holes.
Clean the drain bolts and install new sealing washers
onto the drain bolts.
Install and tighten the drain bolts to the specified torque.
TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)
Fill the engine with the recommended engine oil
(page 3-11 ).
ENGINE OIL CAPACITY:
MT model:
3.9 liters (4.1 US qt, 3.4 Imp qt) at draining
4.0 liters (4.2 US qt, 3.5 Imp qt) at oil filter change
4.8 liters (5.1 US qt, 4.2 Imp qt) at disassembly l
OCT model: I
4.0 liters (4.2 US qt, 3.5 Imp qt) at draining
4.2 liters (4.4 US qt, 3.7 Imp qt) at oil filter change
l
5.2 liters (5.5 US qt, 4.6 Imp qt) at disassembly ~
Check the engine oil level (page 3-11 ).
l
~'
Make sure that there are no oil leaks.
Install the skid plate (page 2-25).
ENGINE OIL FILTER

NOTE:
• OCT model:
Replace the clutch oil filter when the engine oil filter
is replaced.
Drain the engine oil (page 3-12).
.
-,
Remove and discard the oil filter cartridge [1] using the
special tool.
1J
I
TOOL:
Oil filter wrench 07HAA-PJ70101 or
07AAA-PL CA100
(U.S.A. only)
j
1
J
1
J
JI
j
3-12 j
MAINTENANCE
Check the oil filter boss [1] protrusion from the
~ Apply this area.
crankcase is within the specified length as shown.
6.5 ± 1.0 mm
SPECIFIED LENGTH: 15.5-16.5 mm (0.61 - 0.65 in) , (0 .26 ± 0.04 in)
[1]
NOTE:
If the oil filter boss is removed , apply locking agent
to the oil filter boss threads as shown and install it.
LJI.____..,
ff 15.5 - 16.5 mm
(0 .61 - 0.65 in)
Clean the oil filter attaching surface of the crankcase.

Apply engine oil to new oil filter cartridge threads and
;
0-ring.
Install and tighten the oil filter cartridge [1] to the
specified torque using the special tool.
TOOL:
07 AAA-PL CA 100
(U.S.A. only)

Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-12).
CLUTCH OIL FILTER (DCT model)

- NOTE:
• Replace the engine oil filter when the clutch oil filter
is replaced .
I NOTICE I
Ensure the model-specific engine oil filter is used.
Filters with a similar physical appearance may have
different flow characteristics. The use of such filters
could cause severe engine damage .
- Bolts [1]
- Clutch oil filter cover [2]
- 0-ring [3]
- Spring [4]
- Clutch oil filter [5]
Install a new clutch oil filter with the "OUT SIDE" mark
[6] facing outside.
. NOTE:
• Installing the oil filter backwards will result in severe
engine damage.
Apply engine oil to a new 0-ring and install it to the oil
filter cover.
Install the spring and oil filter cover.
Tighten the bolts to the specified torque.
, Fill the crankcase with the recommended engine oil and

check that there are no oil leaks (page 3- 12).
3-13
MAINTENANCE
ENGINE IDLE SPEED
IDLE SPEED INSPECTION
• The engine must be warm for accurate idle speed
inspection.
• This system eliminates the need for manual idle
speed adjustment compared to previous designs.
Start the engine and warm it up until the coolant
temperature rises to 80°C (176°F).
Stop the engine and connect a tachometer according to
the tachometer manufacturer's operating instructions.
Start the engine and let it idle. Check the idle speed.
ENGINE IDLE SPEED: )
1,250 ± 100 r/min
If the idle speed is out of the specification, check the
intake air leak or engine top-end problem (page 10-3).
RADIATOR COOLANT
Check the coolant level of the reserve tank with the
engine running at normal operating temperature.
The level should be between the "UPPER" [1] and
"LOWER" [2] level lines.
If necessary, add the recommended coolant.
RECOMMENDED ANTIFREEZE:
Pro Honda HP Coolant or an equivalent high
quality ethylene glycol antifreeze containing
corrosion protection inhibitors
RECOMMENDED MIXTURE:
1:1 mixture with distilled water
l
j
JJ
Remove the reserve tank cap [1] and add the coolant to •
I
the "UPPER" level line.
Reinstall the cap. J;
Check to see if there are any coolant leaks when the
coolant level decreases very rapidly.
If the reserve tank becomes completely empty, there is
a possibility of air getting into the cooling system.
Be sure to remove any air from the cooling system
(page 8-5).
3-14
MAINTENANCE
COOLING SYSTEM
Check the radiator air passages for clogging or
r damage.
I
Straighten bent fins, and remove insects, mud or other
obstructions with compressed air or low water pressure.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
Inspect the water hoses for cracks or deterioration, and
replace them if necessary.
Check the tightness of all water hose band screws
(page 8-9).

Remove the air cleaner housing (page 7-14).
[2]
Check the PAIR hoses for deterioration, damage or
loose connections.
Also , check that the hoses are not kinked, pinched or
cracked.
- Air suction hose [1] (between the air cleaner housing [1]
[2] and PAIR control solenoid valve [3])
- Air supply hose [4] (between the PAIR control
solenoid valve and cylinder head cover (5])
If the air suction/supply hoses show any signs of heat
damage, inspect the PAIR reed valves (page 7-21 ).
For secondary air supply system inspection (page 7-19)
r
¢=, FRESH AIR
~ EXHAUST GAS
3-15
[
MAINTENANCE
EVAPORATIVE EMISSION CONTROL
SYSTEM
Remove the BCU tray (page 22-52).
[1 J
Check the hoses between the fuel tank [1], EVAP
canister [2], EVAP purge control solenoid valve [3], and
throttle body [4] for deterioration, damage or loose
connection.
Also, check that the hoses are not kinked , pinched or
cracked .
Check the EVAP canister for cracks or other damage.
Refer to the CABLE & HARNESS ROUTING (page 1-
26) for hose connections and routing.
;
<:= FRESH AIR

- FUEL VAPOR
j
1
Open the fuel filler cap [1].
l
.J
Check the breather seal [2] in the fuel filler cap for
deterioration, cracks or damage. Replace it if
l
l
necessary.
NOTE:
• Always replace the breather seal with a new one
when the fuel filler cap is removed for service. -l
_J
]
j
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~
3-16
J
MAINTENANCE
EXHAUST GAS CONTROL ACTUATOR

CABLE
'' OPERATING INSPECTION
l Remove the following:
[2]
•• - Valve guide cover bolts [1]
- Valve guide cover [2]
[1]
~
•
[1]
'
I
r
f Short the DLC terminals using the special tool (page 4-

6).
f
~
Turn the ignition switch ON.
r The EGCA operates and the index line [1] on the valve
r cable guide tab should be aligned with the index groove
[2] of the valve guide body.
If the index line is not aligned with the index groove,
[ adjust the EGCA cable (page 3-1 7).

removal.
t'
•
CABLE ADJUSTMENT
[5]
Remove the valve guide cover (page 3-17).
Loosen the lock nut [1] .
Turn the adjusting bolt [2] to align the index line [3] with
the index groove [4] while holding the adjusting nut [5].
t Install the mud guard (page 2-38). [2]
lr
r
I..
r
f
,
f
3-17
.f
MAINTENANCE
DRIVE CHAIN
Amputation hazard . Never inspect or adjust the

drive chain while the engine is running .
DRIVE CHAIN SLACK INSPECTION

Turn the ignition switch OFF, support the motorcycle on
its sidestand, and shift the transmission into neutral.
Check the slack in the drive chain lower run midway
between the sprockets.
DRIVE CHAIN SLACK:
35-45 mm (1.4-1.8 in)
I NOTICE I
• Excessive chain slack, 60 mm (2.4 in) or more, may
damage the frame .
l
.;
,I
ADJUSTMENT
Loosen the rear axle nut [1] and drive chain adjuster
lock nuts [2].
Turn the drive chain adjusting bolts [3] on both sides an
equal number of turns until the correct drive chain slack
is obtained.
NOTE :
• Make sure that the adjusting plate index marks [4]
are in the same position on both sides.
Tighten the rear axle nut to the specified torque .
Seat the drive chain adjusting bolts snugly against the
adjusting plate [5] .
Tighten the drive chain adjuster lock nuts to the
specified torque while holding the drive chain adjusting
bolts.
Recheck the drive chain slack and free wheel rotation
(page 3-18).
Check the drive chain wear indicator label [6] attached
on the left swingarm.
If the adjusting plate index mark reaches red zone [7] of
the indicator label, replace the drive chain with a new
one (page 3-20).
3-18
MAINTENANCE
CLEANING AND LUBRICATION
Clean the drive chain [1] with a chain cleaner designed
specifically for 0-ring chains . Use a soft brush if the
drive chain is dirty.
I NOTICE I [1]
Do not use a steam cleaner, high pressure cleaner, wire

brush, volatile solvent such as gasoline and benzene,
abrasive cleaner or a chain cleaner NOT designed
specifically for 0-ring chains to clean the drive chain.
Inspect the drive chain for possible damage or wear.
Replace any drive chain that has damaged rollers,
loose fitting links, or otherwise appears unserviceable.
Be sure the drive chain has dried completely before L _ __ _ __ __
2_l__________
[ ____J
lubricating.
Lubricate the drive chain with drive chain lubricant [2].
[ RECOMMENDED LUBRICANT:
Honda HP Chain Lube or an equivalent
I NOTICE I
Do not use a chain lubricant NOT designed specifically
f for use with 0-ring chains to lubricate the drive chain.
Wipe off the excess oil or drive chain lubricant.
r
SPROCKET INSPECTION
Remove the left rear cover (page 2-26).
Inspect the drive and driven sprocket teeth for wear or
damage, replace if necessary.
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good condition, or
the replacement chain will wear rapidly.
I Check the drive sprocket bolt [1] and driven sprocket

nuts [2] on the drive and driven sprockets .
If any are loose, torque them.
TORQUE:
r Drive sprocket bolt:

54 N·m (5.5 kgf·m, 40 lbf·ft)
Driven sprocket nut:
100 N·m (10.2 kgf·m, 74 lbf·ft)
Install the left rear cover (page 2-26) .
I
3-19
MAINTENANCE
REPLACEMENT
This motorcycle uses a drive chain with a staked master
link.
Fully slacken the drive chain (page 3-18).
Remove the drive chain using the special tool.
NOTE: 1 LINK
• When using the special tool, follow the
manufacturer's instruction.
TOOL:
Drive chain tool set 07HMH-MR10103 or
07HMH-MR101 OC
(U.S.A. only)
124 LINKS
Remove the excess drive chain links from a new drive
chain with the drive chain tool set.
STANDARD LINKS: 124 LINKS
REPLACEMENT CHAIN
DID: 525HV3-130ZB
Insert a new master link [1] with new 0-rings [2] from J
the inside of the drive chain.
Install a new plate [3] and 0-rings with the identification
mark facing the outside.
•"
._...
(2)
(3)-~
lliliijjll
'
~
J
Assemble the master link, 0 -rings and plate.
TOOL:
Drive chain tool set 07HMH-MR10103 or
j
07HMH-MR101 OC J
(U.S.A. only)
5
NOTE: I
• Never reuse the old drive chain, master link, master "
l
link plate, or 0 -rings.
Make sure that the master link pins [1] are installed
[1 )
properly.
Measure the master link pin length projected from the
plate.
STANDARD LENGTH: 1.3-1.5 mm (0.05- 0.06 in)
.,
Stake the master link pins.
..
j
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J
-
J
J
J
Make sure that the pins are staked properly by l
[1)
measuring the diameter of the staked area using a slide
caliper [1 J. ,,~
) J
DIAMETER OF THE STAKED AREA: -,
5.50 - 5.80 mm (0.217 - 0.228 in)
:I
After staking, check the staked area of the master link
for cracks.
If there is any cracking, replace the master link, 0 -rings,
and plate.
j
i
1
J
J
3-20
MAINTENANCE
DRIVE CHAIN SLIDER
Check the drive chain slider for wear or damage.
The drive chain slider must be replaced if it is worn to
the wear limit indicator [1].
Refer to the swingarm DISASSEMBLY/ASSEMBLY for
drive chain slider replacing (page 18-26).
t BRAKE FLUID
l I NOTICE
Spilled fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE:
• Do not mix different types of fluid, as they are not
compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
• A low fluid level may be due to wear of the brake
pads. If the brake pads are worn, the caliper piston is
pushed out, and this accounts for a low reservoir
level. If the brake pads are not worn and the fluid
level is low, check entire system for leaks (page 3-
22).
FRONT BRAKE:
Turn the handlebar so that the reservoir is level and
check the front brake fluid reservoir level through the
sight glass [1].
If the level is near the lower level line [2], check the
brake pad wear (page 3-22).
REAR BRAKE:
Place the motorcycle on a level surface, and support it
in an upright position.
Check the rear brake fluid reservoir level.
If the level is near the lower level line [3], check the
brake pad wear (page 3-22).
f
l
3-21
MAINTENANCE
BRAKE PADS WEAR
INSPECTION
Check the brake pads for wear.
Front: Rear:
Replace the brake pads if either pad is worn to the
bottom of wear limit groove [1].
Refer to front brake pad replacement (page 19-8).
Refer to rear brake pad replacement (page 19-9).
[1] [1]
BRAKE SYSTEM
HYDRAULIC SYSTEM INSPECTION
Firmly apply the brake lever or pedal , and check that no
air has entered the system .
If the lever or pedal feels soft or spongy when operated ,
[1]
••
bleed the air from the system (page 19-6).
Inspect the brake hose [1] and fittings for deterioration ,
cracks, and signs of leakage.
Tighten any loose fittings .
Replace hoses and fittings as required .
I
BRAKE LEVER ADJUSTMENT

\
The distance between the brake lever and the grip can
be adjusted by turning the adjuster [1] .
NOTE:
• Align the "6'' mark [2] on the brake lever with the
index number on the adjuster.
j
'
l
3-22
MAINTENANCE
BRAKE LIGHT SWITCH

Adjust the rear brake switch [1] so that the brake light
comes on just prior to the brake actually being
engaged.
If the light fails to come on, adjust the switch so that the
light comes on at the proper time .
Hold the switch body and turn the adjuster [2] . Do not
turn the switch body.
NOTE:
[2]
• The front brake switch does not require adjustment.
[1]
BRAKE LOCK OPERATION

(DCT model)
INSPECTION
Support the motorcycle using a safety stand or hoist
and raise the rear wheel off the ground .
Unlock the parking brake lock lever [1] by pushing it
forward , then apply the parking brake lever [2] . Check
that the parking brake locked operation is functioning
properly.
ADJUSTMENT
Minor adjustment is made with the upper adjuster at the
parking brake lever.
Support the motorcycle using a safety stand or hoist
and raise the rear wheel off the ground.
Set the parking brake lever in one notch click.
Loosen the lock nut [1] and turn the adjuster [2] until
there is a slight drag while turning the rear wheel slowly.
NOTE:
• The adjuster may be damaged if it is positioned too
far out, leaving minimal thread engagement.
Tighten the lock nut while holding the adjuster.
If the adjuster is threaded out near its limit, turn the
adjuster all the way in and back out one turn , then
perform the adjustment at major adjuster as follows.
3-23
MAINTENANCE
Remove the parking brake caliper cover (page 19-10).
Set the parking brake lever in one notch click.
Loosen the lock nut [1].
Turn the rear wheel slowly by hand and turn the push
rod [2] until there is a slight drag .
Hold the push rod and tighten the nut to the specified
torque .
TORQUE:17.2 N·m (1.8 kgf·m, 13 lbHt)
Recheck the parking brake operation.
Install the parking brake caliper cover (page 19-12).
HEADLIGHT AIM
HEADLIGHT AIM
Place the motorcycle on a level surface.
Adjust the headlight beams vertically by turning the
vertical beam adjuster [1] on right side and left side.
NOTE:
• Adjust the headlight beam as specified by local laws
and regulations.
CORNERING LIGHT AIM

(CRF11 OOA4/D4)
NOTE:
• Before adjusting the cornering light aim, make sure
that the headlight aim is adjusted correctly (page 3-
24 ).
1. Place the motorcycle with the rider in an upright
position 10 m away from the aiming screen.
2. Record the position [1] where the motorcycle center
axis and Lo beam cut line intersect.
[2]
NOTE:
• The Lo beam cut line is 0.10 m below the headlight
mounting position [2] .
[1]
3-24
MAINTENANCE
3. Set the manually activating cornering light mode
(page 22-8).
Adjust the cornering light beam cut-off line to the
alignment point by turning the adjuster [1].
- Headlight mounting position [2]
Lo beam cut-off line [3]
- Motorcycle center axis and Lo beam cut-off line
intersect point [4]
Cornering light beam cut-off line [5]
Cornering light beam alignment point [6]
4. Operate the turn signal light switch to switch to the
opposite side.
Adjust the opposite side in the same manner.
5. Exit the manually activating cornering light mode.
NOTE: Right side shown:
[5]
• Adjust the cornering light beam as specified by local
laws and regulations. [2]
[3]
l \__ 0.10 m
CLUTCH SYSTEM (MT model)

Measure the clutch lever freeplay at the end of the
clutch lever.
FREEPLAY:10 - 20 mm (0.4- 0.8 in)
10-20 mm
I~ (0.4 - 0.8 in)
r
Minor adjustment is made with the upper adjuster at the
clutch lever.
NOTE:
• The adjuster may be damaged if it is positioned too
far out, leaving minimal thread engagement.
Loosen the lock nut [1] and turn the adjuster [2].
Recheck the clutch lever freeplay.
If the adjuster is threaded out near its limit and the
correct freeplay cannot be obtained, turn the adjuster all
the way in and back out one turn.
Tighten the lock nut while holding the adjuster.
3-25
MAINTENANCE
Major adjustment is made with the lower adjusting nut
[1] at the clutch lifter arm. I '-ieli!CillM!lll"'
Loosen the lock nut [2] and turn the adjusting nut to
adjust the freeplay.
Tighten the lock nut while holding the adjusting nut.
If proper freeplay cannot be obtained, or the clutch slips
during test ride, inspect the clutch (page 12-9).
SIDESTAND
Check the sidestand spring [1] for damage or loss of ~~~--lllliiii!LF-~~~-:::;:;:;;nnrnrmi-~7
tension .
Check the sidestand [2] for movement and lubricate the
sidestand pivot if necessary.
Check the sidestand ignition cut-off system:
••
Sit astride on the motorcycle and raise the J
sidestand.
- Start the engine with the transmission in neutral,
then , shift the transmission into gear (MT model:
with squeezing the clutch lever).
- Move the sidestand full down.
- The engine should stop as the sidestand is lowered.
If there is a problem with the system, check the
sidestand switch (page 22-46).
SUSPENSION J
FRONT SUSPENSION INSPECTION
Check the action of the forks by operating the front
brakes and compressing the front suspension several
times.
Check the entire assembly for signs of leaks, damage
or loose fasteners.
Replace the damaged components which cannot be
repaired .
NOTE:
• Loose, worn or damaged suspension parts impair
the motorcycle's stability and control.
Tighten all nuts and bolts.
Refer to the fork service (page 17-22).
3-26
MAINTENANCE
FRONT SUSPENSION ADJUSTMENT
(CONVENTIONAL SUSPENSION
model)
SPRING PRE-LOAD ADJUSTER
Spring pre-load can be adjusted by turning the adjuster
[1] .
TURN CLOCKWISE:
Increases the spring pre-load (harder)
TURN COUNTERCLOCKWISE:
Decreases the spring pre-load (softer)
ADJUSTABLE RANGE: 15 turns
STANDARD POSITION (from the full soft position):

CRF1100A: 2 turns
CRF11 OOD: 5 turns
REBOUND DAMPING ADJUSTER

Rebound damping can be adjusted by turning the
adjuster [1].
TURN CLOCKWISE:
Increases the damping force (harder)
Decreases the damping force (softer)
ADJUSTABLE RANGE: 3 - 4 turns
STANDARD POSITION (from full hard position):

CRF1100A/D: 2 3/4 turns
3-27
MAINTENANCE
COMPRESSION DAMPING ADJUSTER
Compression damping can be adjusted by turning the
adjuster [1].
TURN CLOCKWISE:
Decreases the damping force ,(softer)
ADJUSTABLE RANGE: 12 clicks or more

CRF1100A/D: 9 clicks
~ [1]
REAR SUSPENSION INSPECTION

Check the action of the shock absorber by compressing
it several times.
Check the entire shock absorber assembly for signs of
leaks, damage or loose fasteners.
Replace damaged components which can not be
repaired .
NOTE:
• Loose, worn or damaged suspension parts impair
..
the motorcycle's stability and control.
Tighten all nuts and bolts.
Refer to shock absorber service (page 18-11 ).
Support the motorcycle securely and raise the rear
wheel off the ground.
Check for worn swingarm bearings by grabbing the rear
wheel and attempting to move the wheel side to side.
Replace the bearings if looseness is felt.
Refer to swingarm service (page 18-24 ).
REAR SUSPENSION ADJUSTMENT

model)
SPRING PRE-LOAD ADJUSTER
Spring pre-load can be adjusted by turning the adjuster
dial [1].
TURN CLOCKWISE:
Increases the spring pre-load (harder)
Decreases the spring pre-load (softer)
ADJUSTABLE RANGE: 35 clicks
STANDARD POSITION (from full soft position):

7 clicks (first click is "O" position)
3-28
MAINTENANCE
REBOUND DAMPING ADJUSTER
I NOTICE I
• Always start on fully hard when adjusting the
damping.
• Do not turn the adjuster screws more than the given
positions or the adjusters may be damaged.
Rebound damping can be adjusted by turning the
[1]
adjuster [1].
8
TURN CLOCKWISE:

8 clicks
COMPRESSION DAMPING ADJUSTER
I NOTICE I
• Always start on fully hard when adjusting the
damping.
• Do not turn the adjuster screws more than the given
positions or the adjusters may be damaged.
Compression damping can be adjusted by turning the
adjuster [1] .
TURN CLOCKWISE:
, Increases the damping force (harder)

12 clicks
.
,-
3-29
MAINTENANCE
ELECTRONIC SUSPENSION
ADJUSTMENT (ELECTRONIC
SUSPENSION model)
RIDING MODE SELECTING
Select the riding mode [1] by pushing the sel up switch
[2] and sel down switch [3].
NOTE:
When the riding mode is changed , rear spring
preload and front/rear suspension damping are
automatically selected to a setting corresponding to
the riding mode.
• The rear spring preload can be adjusted to any
setting in all riding modes (page 3-31 ).
• The front/rear suspension damping can be adjusted
to any setting in only "User 1" and "User 2" in "User
modes" (page 3-32).
(2)
(3)
'
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3-30
MAINTENANCE
REAR SPRING PRELOAD
NOTE:
• The rear spring preload can be adjusted to any
setting in all riding modes.
• The front spring preload is not adjustable.
1. Stop the motorcycle.
Pull and hold the page switch [1] or touch the "Clock
area" [2] of the MID.
Select the "Gold image display".
NOTE:
• Select the display in the following order to the Gold
image display:
"Settings" > "Display" > "Display Mode" > "TOUR"
Gold image display: /[2]

iii :.: pp
4 6 8 10
2. Select the "Page 4" [1] by using the sel up switch [2],
Page 4:
sel down switch [3], sel lefUright switch [4], ENT
switch [5] and back switch [6] or touch the MID.
Press the ENT switch. 6
I '
3. Select the "PRELOAD" [7] by using the sel up :ic lOOOrhnin

switch, sel down switch, ENT switch and back switch
or touch the MID.
Push the sel lefUright switch or touch the MID until
the desired value is displayed .
7
STANDARD POSITION: Rider only
NOTE:
• The electronic suspension allows the preload of the [7]
rear suspension to be adjusted in four levels
according to riding and load conditions. [2] [4]
"
[5]
[3] [6]
3-31
MAINTENANCE
FRONT/REAR SUSPENSION DAMPING
NOTE:
• The fronUrear suspension damping can be adjusted
to any setting in only "User 1" and "User 2" in "User
modes".
1. Stop the motorcycle.
[1]
Pull and hold the page switch [1] or touch the "Clock
area" [2] of the MIO.
6 8 10
... ,..""~o -~-

E i8 F
mph(.! H
•
2. Select the "User 1" [1 J or "User 2" [2] by using the
sel up switch [3] , sel down switch [4], sel lefUright
switch [5], ENT switch [6] and back switch [7] or
touch the MID.
NOTE:
• Select the display in the following order to the User 1
or User 2:
"Settings" > "Function" > "User Modes" > "User 1" or
"User 2"
3. Set the suspension settings to the desired value by
using the sel up switch , sel down switch, sel lefUright
switch, ENT switch and back switch or touch the J
MID. [2] l
STANDARD POSITION:
J
User 1
User2
Overall Front
OFFROAD STD
MEDIUM STD
Rear
STD
STD
[3] (5]
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NOTE:
• Push and hold the sel lefUright switch to advance the
figure fast.
[6]
[4] [7]
3-32
,~ SPARK ARRESTER
MAINTENANCE
I INSPECTION/CLEANING
Remove the spark arrester (without removing the
muffler from the exhaust pipe) (page 2-49).
Check the screen mesh and replace if necessary.
Use a soft brush to remove carbon deposits from the
spark arrester screen.
Be careful not to avoid damaging the spark arrester
screen.
The spark arrester must be free of breaks and holes,
and replace if necessary (page 2-49).
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NUTS,BOLTS,FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-13).
Check that all safety clips, hose clamps and cable stays
are in place and properly secured.
WHEELS/TIRES
Support the motorcycle securely and raise the front
Hold the front fork leg and move the front wheel
sideways forcefully to see if the wheel bearings are
worn.
For front wheel service (page 17-15).
Support the motorcycle securely and raise the rear
Hold the swingarm and move the rear wheel sideways
with force to see if the wheel moves and the driven
flange bearing is worn.
For rear wheel service (page 18-6).
Check the tire pressure with a tire pressure gauge when
the tires are cold .
- Front tire pressure (page 1-10)
- Rear tire pressure (page 1-11)
Check the tires for cuts, embedded nails, or other
damage.
Check the front and rear wheel for trueness.
Inspect the wheel rims and spokes for damage.
Tighten any loose spokes to the specified torque.
TORQUE:
CRF11 OOA/D (FRONT/REAR):
3.7 N·m (0.4 kgf·m, 2.7 lbMt)
CRF11 OOA4/D4 (FRONT/REAR):
5.0 N·m (0.5 kgf·m, 3.7 lbMt)
NOTE:
CRF1100A4/D4:
• Tighten the spokes with a ball point wrench.
• When removing the spokes replace them with new
ones.
3-33
i
MAINTENANCE t
STEERING HEAD BEARINGS

Support the motorcycle securely and raise the front
Ij
wheel off the ground .
l
Check that the handlebar moves freely from side to I
side. Make sure the control cables do not interfere with
the handlebar rotation .
If the handlebar moves unevenly, binds, or has vertical
l
movement, inspect the steering head bearings (page
17-47).
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3-34
4. PGM-FI SYSTEM
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SERVICE INFORMATION ........................ 4-2 IAT SENSOR ...................................... 4-69
SYSTEM LOCATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-3 ECT SENSOR · · · · · · · .. · .. · · · · · · · .. · · .. · · .. · · .. · · · · 4-69
PGM-FI TROUBLESHOOTING EGCA ................................................ 4-70

INFORMATION······································ 4-5
ECM .................................................. 4-71
PGM-FI SYMPTOM
TROUBLESHOOTING · .. · · · · · .. · · · .. · ............ 4-9 VS SENSOR ....................................... 4-73
PGM-FI SYSTEM DTC INDEX ................ 4-10 GP SENSOR (MT model)·· ................... · 4-73
PGM-FI SYSTEM DTC SHIFT SPINDLE SWITCH (MT model) ..... 4-74
TROUBLESHOOTING ...... · · · · .... · · .. · ...... · 4-16
GRIP APS .......................................... 4-74
MIL CIRCUIT TROUBLESHOOTING ....... 4-66
r IMU ................................................... 4-67 Fl RELAY · · .. · · · · · · · · · · · · · · · · · · · · · · .. · · · · · .... · · .. · · 4-75
I
r A/F SENSOR · .. · · .... · · · · · .. · · · · · · .. · · · · · · .. · .... · 4-67

TBW RELAY·· .. ·· .. ·· .. · .. · .. · .. ·· .. ···· .... ··· .. · 4-76
r SUB VB RELAY .................................. 4-77

MAP SENSOR .... ·· .. ·· .. ····· .. ··· .. ···· .. ·· .. ··· 4-68
r CKP SENSOR .. ··· .. ·· .. · .. · .... · .. ·· .... ·· .. ·· .. · 4-77

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4-1
•
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PGM-FI SYSTEM
SERVICE INFORMATION
GENERAL
• This section covers electrical system service of the PGM-FI system. For other service and fuel supply system, see Fuel System
section (page 7-2).
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
• The PGM-FI system is equipped with the Self-Diagnostic System (page 4-5). If the MIL lights or blinks, follow the Self-Diagnostic
Procedures to remedy the problem.
• When checking the PGM-FI, always follow the steps in the troubleshooting flow chart.
• If the TCM is replaced, perform the Clutch Initialize Learning Procedure (OCT model) (page 13-67).
• The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is any trouble
in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by making use of
the numerical values of a situation preset in the simulated program map.
It must be remembered, however, that when any abnormality is detected in an fuel injector, the fail-safe function stops the
engine to protect it from damage.
• For PGM-FI system location (page 4-3).
• For PGM-FI system diagrams: i
- MT model: (page 23-8)
- OCT model: (page 23-9) ;
• Use a digital tester for PGM-FI system inspection. 1
• The following color codes are used throughout this section.
Be= Beige Bl= Black Br= Brown Bu= Blue G = Green Gr= Gray
Lb= Light blue Lg = Light green 0 = Orange P = Pink R = Red V = Violet
W = White Y = Yellow
TOOLS
SCS service connector Test probe, 2 pack
070MZ-0010300 07ZAJ-RDJA 110
or 070MZ-001A300 (U.S.A. only)
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4-2
PGM-FI SYSTEM
SYSTEM LOCATION
MT model:
GRIPAPS
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MID I
DLC
POWER BOX
-TBW RELAY
- FAN RELAY
- FUEL RELAY
- SUB VB RELAY
FUEL
INJECTORS
EVAP PURGE
CONTROL
SOLENOID
VALVE
CKP SENSOR
EOP SWITCH
GP SENSOR
SHIFT SPINDLE SWITCH
NEUTRAL SWITCH
SIDESTAND SWITCH
4-3
PGM-FI SYSTEM
DCT model:
GRIPAPS
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MID
METER
-MIL POWER BOX
FUSE BOX
-TBW RELAY
- FAN RELAY
- FUEL RELAY
- SUB VB RELAY
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- TBW 10A
- Fl 15 A
- ST-MAG 10 A
- MAIN2 30 A
-METER 10A
-DCT-M 30 A
- HORN/STOP 10 A
-DIODE
PAIR CONTROL
SOLENOID VALVE
IGNITION COILS ---\"'~Ml._~ j

-;~~~;;;:;~~~ ==~~~r!;--~~~
FUEL
INJECTORS
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ECT SENSOR l
EVAP PURGE
CONTROL
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SOLENOID
VALVE
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CKP SENSOR
STARTER RELAY SWITCH

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- MAIN FUSE 30 A
TR SENSOR
NEUTRAL SWITCH
SIDESTAND SWITCH
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4-4
PGM-FI SYSTEM
PGM-FI TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on , check
for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting . If the MIL was on , but then went out,
the original problem may be intermittent.
Opens and Shorts
"Opens" and "Shorts" are common electrical terms . An open is a break in a wire or at a connection . A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With ECM
this can something mean something works, but not the way it's supposed to.
If the MIL has come on
Refer to DTC READOUT (page 4-6).
If the MIL did not stay on
If the MIL did not stay on , but there is a driveability problem , do the SYMPTOM TROUBLESHOOTING (page 4-9).
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The PGM-FI system is equipped with a self-d iagnostic system. When any abnormality occurs in the system, the ECM turns on the
MIL and stores a DTC in its erasable memory.
FAIL-SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system. When any abnormality is detected by the self-diagnosis function , running capability is maintained by pre-programed value
~ in the simulated program map. When any abnormality is detected in the fuel injector, the fail-safe function stops the engine to
' protect it from damage.
MIL Blink Pattern
• DTC can be read from the ECM memory by the MIL [1] blink pattern .
• The MIL will blink the current DTC by shorting SGS circuit (reading DTC
with DLC connector).
• When the ECM stores more than one DTC, the MIL will indicate them by
blinking in the order from the lowest number to highest number.
[1)
MIL Check
When the ignition switch is turned ON the MIL will stay on for a few seconds, then go off. If the MIL does not come on , troubleshoot
the MIL circuit (page 4-66).
CURRENT OTC/FREEZE OTC
The DTC is indicated in two ways according to the failure status.
• In case the ECM detects a current problem , the MIL will come on .
• In case the ECM does not detect any problem at present but has a problem stored in its memory, the MIL will not light. If it is
necessary to retrieve the past problem, readout the DTC by following the DTC readout procedure (page 4-6).
4-5
PGM-FI SYSTEM
MCS INFORMATION
• The MCS can readout the OTC, freeze data, current data, and other ECM condition .
How to connect the MCS
Turn the ignition switch OFF.
Remove the dummy connector from the OLC (page 4-6).
Connect the MCS to the OLC.
Turn the ignition switch ON and check the OTC and freeze data.
NOTE:
• Freeze data indicates the engine conditions when the malfunction was first detected.
OTC READOUT
Start the engine and check the MIL.
If the MIL stays on, connect the MCS to the OLC (page 4-6).
Read the OTC, freeze data and follow the OTC index (page 4-10).
To read the OTC by the MIL blinks, refer to the following procedure.
Reading OTC with the MIL
Remove the dummy connector [1] from the OLC.
Short the OLC terminals using a special tool.
TOOL:
SCS service connector (2) 070MZ-0010300 or
070MZ-001 A300
(U.S.A. only)
CONNECTION: Yellow - Green/blue
Turn the ignition switch ON, read , note the MIL blinks and refer to the OTC
index (page 4-10).
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4-6
PGM-FI SYSTEM
Reading DTC with the MID
1. Pull and hold the page switch [1] or touch the clock area [2] of the MID.
2. Select the "Settings", and then press the ENT switch [3].
Select the "Service" with pushing the sel left/right switch [4] or touch
screen , and then press the ENT switch.
Select the "DTC" [5], and then press the ENT switch.
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[4]
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3. Read the DTC [1].

. NOTE:
• For returning to the riding information, previous screen, or Home screen:
f - Pull the page switch
- Touch the return icon [2] on the touch screen of the MID
t
[2]
[1]
4-7
PGM-FI SYSTEM
ERASING STORED OTC
NOTE:
• When the ERASING OTC procedure is performed, the DTCs of OCT system are erased at the same time.
Erase the OTC with the MCS while the engine is stopped.
To erase the OTC without MCS, refer to the following procedure.
How to clear the DTC with SCS service connector j
1. Connect the SCS connector to the DLC (page 4-6). J
2. Turn the ignition switch ON.
3. Disconnect the SCS service connector [1] from the DLC [2].
Reconnect the SCS service connector to the DLC while the MIL stays
ON about 5 seconds (reset receiving pattern).
4. The stored OTC is erased if the MIL goes off and starts blinking
(successful pattern).
• The DLC must be jumped while the MIL light in ON. If not, the MIL will
not start blinking. In that case, turn the ignition switch OFF and try again.
• Note that the self-diagnostic memory cannot be erased if the ignition
switch is turned OFF before the MIL starts blinking.
CIRCUIT INSPECTION
• Always clean around and keep any foreign material away from the ECM ~§~~~=---
connector before disconnecting it.
• A faulty PGM-FI system is often related to poorly connected or corroded
terminals. Check those connections before proceeding.
• In testing at the ECM connector (wire harness side) terminal , always use
the test probe [1]. Insert the test probe into the connector terminal, then
attach the digital multimeter probe to the test probe.
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
The ECM connector terminals (wire harness side) are numbered as shown
WIRE HARNESS SIDE TERMINAL LAYOUT:
in the illustration.
- ECM 39P (Black) connector A [1]
- ECM 33P (Black) connector B [2] l
- ECM 33P (Gray) connector C [3] l
(1 )
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4-8
PGM-FI SYSTEM
PGM-FI SYMPTOM TROUBLESHOOTING
When the motorcycle has one of these symptoms, check if the OTC or MIL is blinking, then refer to the OTC index (page 4-10) and
begin the appropriate troubleshooting procedure. If there is no OTC stored in the ECM memory, do the diagnostic procedure for the
symptom, in the sequence listed below, until you find the cause.
Symptom Diagnosis procedure Also check for

Engine cranks, but won't start 1. Check the spark plug condition (page 3-6). . Contaminated/deteriorated fuel
(No OTC and MIL blinking) 2. Inspect the ignition system (page 5-7). . No fuel to fuel injector
3. Check the cylinder compression (page 10- - Clogged fuel filter
5). - Pinched or clogged fuel tank
breather hose
- Pinched or clogged fuel feed
...
hose
Faulty fuel injector
Intake air leak
Faulty IMU or related circuit
Engine cranks, but won't start 1. ECM power/ground circuits malfunction . Faulty Fl relay or related circuit
(No fuel pump operation sound (page 4-72) . Faulty engine stop switch or
when turning the ignition ON) 2. Check the fuel pump (page 7-8). related circuit
.
Engine stalls, hard to start,
rough idling
1. Check the idle speed (page 3-14 ).
2. Inspect the fuel supply system (page 7-4).
3. Inspect the battery charging system (page
.. Contaminated/deteriorated fuel
Intake air leak
Pinched or clogged fuel tank
21-8). breather hose
4. Inspect the ignition system (page 5-7). . Faulty ignition system
Afterburn when engine braking 1. Inspect the secondary air supply system
is used (page 7-19).
2. Inspect the ignition system (page 5-7).
Backfiring or misfiring during Inspect the ignition system (page 5-7).
acceleration
Poor performance (driveability) 1. Inspect the fuel supply system (page 7-4). . Faulty pressure regulator (fuel
and poor fuel economy 2. Inspect the air cleaner element (page 3-5). pump)
3. Inspect the ignition system (page 5-7). . Faulty fuel injector
r Idle speed is below
specifications or fast idle too low
1.
2.
Inspect the fuel supply system (page 7-4).
Check the idle speed (page 3-14 ).
(No OTC and MIL blinking) 3. Inspect the ignition system (page 5-7).
Idle speed is above 1. Check the idle speed (page 3-14 ). .. Faulty ignition system
r specifications or fast idle too
high (No OTC and MIL blinking)
2. Check the throttle operation (page 3-4 ).
.. Intake air leak
Engine top-end problem
Air cleaner condition
MIL never comes on at all 1. Check the CAN line circuit.
2. Inspect the meter (page 22-16).
MIL stays on, but no OTCs set
..
Inspect the MIL circuit (page 4-66).
OLC circuit malfunction
CAN line circuit malfunction
4-9
PGM-FI SYSTEM
PGM-FI SYSTEM DTC INDEX
NOTE:
• When using MCS, check the lighting or blinking state of the MIL and shift indicator, and then refer to OTC index.
• Follow the prior diagnosis notes before performing the troubleshooting, refer to the PRIOR DIAGNOSIS (page 4-16).
MID Detected
Shift
displays/ DIC Referto
OTC indicator OTC name
MIL (Driving page
blinks
blinks Cycle)
C0520 99 - 1 IMU Malfunction 4-17 \ .
A/F Sensor Heater Circuit Low
P0031 38 - 1
(Left A/F Sensor Heater Circuit Low Voltage)
A/F Sensor Heater Circuit High
P0032 38 - 1
(Left A/F Sensor Heater Circuit High Voltage)
4-17
A/F Sensor Heater Circuit Low
P0051 39 - 1
(Right A/F Sensor Heater Circuit Low Voltage)
A/F Sensor Heater Circuit High
P0052 39 - 1
(Right A/F Sensor Heater Circuit High Voltage)
A/F Sensor Heater Control Circuit Performance
Problem
POOD1 38 - 1
(Left A/F Sensor Heater Control Circuit Range/
performance)
4-19
A/F Sensor Heater Control Circuit Performance
Problem
POOD3 39 - 1
(Right A/F Sensor Heater Control Circuit Range/
performance)
MAP Sensor Circuit
P0105 1 - 2 4-19
(MAP Sensor Stuck)
- MAP Sensor Circuit Low
P0107 1 1
(MAP Sensor Circuit Low Voltage)
4-20
- MAP Sensor Circuit High
P0108 1 1
(MAP Sensor Circuit High Voltage)
IAT Sensor Circuit Low
P0112 9 - 1
(IAT Sensor Circuit Low Voltage)
4-21
IAT Sensor Circuit High
P0113 9 - 1
(IAT Sensor Circuit High Voltage)
ECT Sensor Circuit Low
P0117 7 - 1
(ECT Sensor Circuit Low Voltage)
4-22
- ECT Sensor Circuit High
P0118 7 1
(ECT Sensor Circuit High Voltage)
TP Sensor Circuit Low
P0122 71 - 1
(TP Sensor 1 Low Voltage)
4-24
TP Sensor Circuit High
P0123 71 - 1
(TP Sensor 1 High Voltage)
02/AF Sensor Circuit Low Voltage
P0131 36 - 1
(Left A/F Sensor Circuit Low Voltage)
4-25
02/AF Sensor Circuit High Voltage
P0132 36 - 1
(Left A/F Sensor Circuit High Voltage)
02/AF Sensor Circuit No Activity Detected
P0134 36 - 1 4-27
(Left A/F Sensor Circuit No Activity Detected)
02/AF Sensor Circuit Low Voltage
P0151 37 - 1
(Right A/F Sensor Circuit Low Voltage) I
4-25
P0152 37 - 1
02/AF Sensor Circuit High Voltage
(Right A/F Sensor Circuit High Voltage) 1
02/AF Sensor Circuit No Activity Detected
P0154 37 - 1
(Right A/F Sensor Circuit No Activity Detected)
4-27
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OCT model:
P0197 - 44 - EOT Sensor Circuit Low J
(EQT Sensor Low Voltage)
13-13 J
P0198 - 44 -
OCT model:
EOT Sensor Circuit High
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(EQT Sensor High Voltage)
Cylinder 1 Injector Circuit
P0201 12 - 1
(No. 1 (Left) Fuel Injector Malfunction)
4-27
Cylinder 2 Injector Circuit
P0202 13 - 1
(No. 2 (Right) Fuel Injector Malfunction)
4-10
PGM-FI SYSTEM
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DTC
MID
displays/
Mil
blinks
Shift
indicator
blinks
Detected
DIC
(Driving
Cycle)
DTC name
Referto
page
TP Sensor 2 Circuit low

P0222 72 - 1
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P0223 72 - 1
{TP Sensor 2 Low Voltage)
TP Sensor 2 Circuit High
(TP Sensor 2 High Voltage)
4-29
Ignition Coil 1 Primary Control Circuit Open

P0351 91 - 1 (No.1-1 (No.1 Cylinder Main) Ignition Coil Circuit
Malfunction)
P0352 92 - 1 (No.2-1 (No.2 Cylinder Main) Ignition Coil Circuit
Malfunction)
4-30
r P0353 93 - 1 (No.1-2 (No.1 Cylinder Sub) Ignition Coil Circuit
( Malfunction)
I P0354 94 - 1 (No.2-2 (No.2 Cylinder Sub) Ignition Coil Circuit
Malfunction)
AIR System Switching Valve Circuit
P0412 89 - 1 4-32
(PAIR Control Solenoid Valve Malfunction)
EVAP System Purge Control Valve Circuit
- 4-33
r P0443 88 1
(EVAP Purge Control Solenoid Valve Malfunction)
EX Pressure Control Valve
r P0479 35 - 2 4-34
(EGCA Motor Lock)
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EX Pressure Control Valve Intermittent
P048D 34 - 1
(EGCA Position Sensor Circuit Low)
4-35
EX Pressure Control Valve Position Sensor Circuit Low
P048E 34 - 1
(EGCA Position Sensor Circuit High)
MT model:
67 - 1 VSP Sensor 1 Malfunction
! P0500
67 67 1
(Front Wheel Speed Sensor Malfunction)
DCT model:
VSP Sensor 1 Malfunction
4-36
DCT model:
P0501 - 66 1 Vehicle Speed Sensor Range Performance Error 13-14
(Front Wheel Pulser Ring Malfunction)
Brake Switch Malfunction
P0504 145 - - 4-37
(Clutch Cruise Cancel Switch Correlation Failure)
r P0522 83 - 1
EOP Sensor Low
Ir
(EOP Sensor Low Voltage)
13-14
EOP Sensor High
P0523 83 - 1
(EOP Sensor High Voltage)
System Voltage
P0562 126 - 1 4-38
(Sub VB Relay Malfunction)
"
Cruise Control Switch Circuit Low
P0567 119 - - (RES/+ Cruise Control Switch Short Circuit)
4-40
[
Cruise Control Related Malfunction
P0574 121 - - 4-41
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(Cruise Vehicle Speed Correlation Failure)
P0580 118 - - (Cruise Main Switch, SET/- Cruise Control Lever Short
.: Circuit)
4-41
P0581 118 - - (Cruise Main Switch, SET/- Cruise Control Lever Open
Circuit)
Control Module Processor
P0606 84 84 1 4-42
(CPU in the ECM Malfunction)
ICM EEPROM Error
P062F 33 - 1
(ECM EEPROM Malfunction)
4-43
- ICM 02 Sensor CPU Performance Problem

P064D 131 1
(Left NF Sensor IC Circuit Abnormal)
4-43
- ICM 02 Sensor Processor Performance Problem
P064E 144 1
(Right NF Sensor IC Circuit Abnormal)
4-11
PGM-FI SYSTEM
MID Detected
Shift
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
MT model:
126 - 1 ECM/PCM Power Relay Control Circuit Low
(Ignition Hold Relay Stuck OFF)
P0686
DCT model:
- 37 1 ECM/PCM Power Relay Control Circuit Low
4-38
MT model:
126 - 1 ECM/PCM Power Relay Control Circuit High
(Ignition Hold Relay Stuck ON)
P0687
OCT model:
- 37 1 ECM/PCM Power Relay Control Circuit High
(Ignition Hold Relay Stuck ON)
P0704 113 - 1
Clutch Switch Input Circuit Malfunction
4-43
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(Clutch Cruise Cancel Switch Circuit Low Voltage)
DCT model:
P0715 - 53 1 Input Speed Sensor 1 Circuit 13-16
(Inner Mainshaft Speed Low)
Output Speed Sensor Range Performance Error
P0721 - 67 1 13-17
(VS Sensor Circuit No Signal)
MT model:
11 - 1 OS Sensor Circuit No Signal
P0722 4-45
DCT model:
- 11 1 OS Sensor Circuit No Signal
DCT model:
- 55 1 Pressure Control Solenoid Malfunction
(No.1 Linear Solenoid Valve Current Failure)
P0745 13-17
OCT model:
- 55 1 Pressure Control Solenoid Malfunction
(No.1 Linear Solenoid Valve Driver in the TCM Failure)
DCTmodel:
- 56 1 Pressure Control Solenoid 2 Malfunction
P0775 13-18
OCT model:
- 56 1 Pressure Control Solenoid 2 Malfunction
DCT model:
P0851 - 52 - Park/Neutral Switch Input Circuit Low
(Neutral Switch Stuck OFF)
13-19
OCT model:
P0852 - 52 - Park/Neutral Switch Input Circuit High
(Neutral Switch Stuck ON)
TBW Switch Malfunction (ON Side)
P1658 85 - 1
(TBW Relay Failure (ON Side))
4-47
TBW Switch Malfunction (OFF Side)
P1659 85 - 1
(TBW Relay Failure (OFF Side))
TBW Switch Malfunction
P1684 77 - 1 4-48
(TBW Return Spring Malfunction)
DCT model:
P1700 - 71 1 In Main/Countershaft SP Ratio Failure
(Inner Mainshaft/countershaft Speed Ratio Failure)
13-20
DCT model:
P1701 - 72 1 Outer Main/Countershaft SP Ratio Failure
(Outer Mainshaft/countershaft Speed Ratio Failure)
MT model:
41 - 1 GP Sensor Circuit Low 4-50
(GP Sensor Low Voltage)
P1702
DCT model:
- 51 1 TR Sensor Circuit Low 13-21
(TR Sensor Low Voltage)
4-12
PGM-FI SYSTEM·
MID Detected
Shift
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
MT model:
41 - 1 GP Sensor Circuit High 4-50
(GP Sensor High Voltage)
P1703
OCT model:
- 51 1 TR Sensor Circuit High 13-21
(TR Sensor High Voltage)
OCT model:
P1704 - 47 1
No.1 Clutch EOP Sensor Low Voltage
OCT model:
P1705 - 47 1
No.1 Clutch EOP Sensor High Voltage
13-22
OCT model:
P1706 - 48 1
No.2 Clutch EOP Sensor Low Voltage
OCT model:
P1707 - 48 1
No.2 Clutch EOP Sensor High Voltage
MT model:
108 - 1 Shift Spindle Angle Sensor Low Voltage 4-51
P1708 (Shift Spindle Switch Circuit Low Voltage)
OCT model:
- 21 1 13-23
Shift Spindle Angle Sensor Low Voltage
MT model:
108 - 1 Shift Spindle Angle Sensor High Voltage 4-51
P1709 (Shift Spindle Switch Circuit High Voltage)
OCT model:
- 21 1 13-23
Shift Spindle Angle Sensor High Voltage
OCT model:
P170A - 24 1
Shift Control Motor Drive Circuit
13-25
OCT model:
P170B - 31 1
Shift Control Motor Low Voltage
Shift Sensor Ground Fault
P170D 107 - 1
(Shift Stroke Sensor Circuit Low Voltage)
4-52
Shift Sensor Open Circuit
P170E 107 - 1
(Shift Stroke Sensor Circuit High Voltage)
OCT model:
P170F - 33 1 Learning Value Area Malfunction 13-26
(TCM EEPRPM Malfunction)
OCT model:
P1712 84 84 1 TCM CPU Malfunction 4-53
(CPU in the ECM or TCM Malfunction)
OCT model:
Spindle Operation During Shifter Stop
P1713 - 22 1 13-26
(Shift Spindle Operation Malfunction (After Operating
Gearshift Mechanism))
OCT model:
P1714 - 27 1 13-27
Shift Drum Position Malfunction
OCT model:
P1716 - 9 - Clutch Line EOP Sensor High Voltage
(Clutch Line EOP Sensor Low Voltage)
13-27
OCT model:
P1717 - 9 - Clutch Line EOP Sensor Low Voltage
(Clutch Line EOP Sensor High Voltage)
OCT model:
P1718 - 49 - Shift Control Motor Drive Circuit 13-29
(Clutch Line Low Oil Pressure)
OCT model:
P1719 - 68 1 Clutch (1) Being Dysversion 13-29
(No.1 Clutch Operation Malfunction (Clutch Slips))
OCT model:
P171A - 69 1 Clutch (2) Being Dysversion 13-30
4-13
PGM-FI SYSTEM
MID Detected
Shift
MIL (Driving page
blinks
blinks Cycle)
OCT model:
Clutch Bite Crowded (Clutch 1 No Opening)
P171B - 58 -
(No.1 Clutch Does Not Disengage (When Shifting
Gear))
13-30
OCT model:
P171C - 59 -
(No.2 Clutch Does Not Disengage (When Shifting
Gear))
OCT model:
P171D - 61 - Clutch Bite Crowded (1) Pressure No Opening
(No.1 Clutch Oil Pressure Canceling Malfunction)
OCT model:
Clutch (1) Hydraulic Pressure Malfunction
P171E - 61 1
(No.1 Clutch Oil Pressure Malfunction (at Clutch Initial
Diagnosis))
OCT model:
P171F - 61 1 Clutch (1) No Pressure
(No.1 Clutch No Oil Pressure)
OCT model:
P1720 - 61 1 Clutch (1) Hydraulic Pressure Low
(No.1 Clutch Oil Pressure Degradation)
OCT model:
P1721 - 62 - Clutch (1) Hydraulic Pressure Rise
(No.1 Clutch Oil Pressure High)
13-31
OCT model :
P1722 - 63 - Clutch Bite Crowded (2) Pressure No Opening
OCT model :
P1723 - 63 1
(No.2 Clutch Oil Pressure Malfunction (at Clutch Initial
Diagnosis))
OCT model:
P1724 - 63 1 Clutch (2) No Pressure
OCT model:
P1725 - 63 1 Clutch (2) Hydraulic Pressure Low
OCT model:
P1726 - 64 - Clutch (2) Hydraulic Pressure Rise
OCT model :
P1728 - 57 1 Shifter Malfunction
(Gearshift Mechanism Malfunction)
13-31
OCT model :
P1729 - 57 1 Shifter Setting Malfunction
(Gear Position Malfunction (Jumps Out of Gear))
OCT model:
P172A - 1 - Shift Angle Sensor Ground Fault
(Shift Pedal Angle Sensor (Option) Malfunction)
13-31
DCT model:
P172B - 1 - Shift Angle Sensor High Voltage
OCT model:
P172C - 46 - N-D Switch Signal Malfunction 13-33
(N-D Switch Malfunction)
OCT model:
P172D - 45 - Shifter Driven in Spindle Inactive 13-34
(Shift Switch Malfunction)
OCT model :
P172E - 32 1 FSR Malfunction 13-35
(Fail Safe Relay Circuit Malfunction)
4-14
PGM-FI SYSTEM
MID Detected
Shift
MIL (Driving page
blinks
blinks Cycle)
OCT model:
Spindle No Operation During Shifter Driv~ .
P172F - 23 1 13-36
(Shift Spindle Operation Malfunction (While Operating
Throttle Actuator Circuit Performance Problem
P2101 79 - 1
(TBW System Control Correlation Failure)
4-53
Throttle Actuator Current Performance Problem
P2118 78 - 1
(TBW Motor Malfunction)
APS 1 Sensor Circuit Low
P2122 74 - 1
(APS 1 (TCP) Low Voltage)
4-54
APS 1 Sensor Circuit High
P2123 74 - 1
(APS 1 (TCP) High Voltage)
APS 2 Sensor Circuit Low
P2127 75 - 1
(APS 2 (TCP) Low Voltage)
4-56
APS 2 Sensor Circuit High
P2128 75 - 1
(APS 2 (TCP) High Voltage)
TP Sensor 1/2 Voltage Correlation
73 - 1
(TP Sensors 1 and 2 Voltage Correlation Malfunction)
P2135 4-57
TP Sensor 1/2 Voltage Correlation
73 - 1
(TP Sensors 1 and 2 Short Circuit)
APS 1/2 Sensor Voltage Correlation
P2138 76 - 1 4-58
(APS 1 2 (TCP) Voltage Correlation Malfunction)
MT model:
66 - 1 VSP Sensor 2 Malfunction
(Rear Wheel Speed Sensor Malfunction)
P2158 4-59
OCT model:
- 66 1 VSP Sensor 2 Malfunction
OCT model :
P2765 - 54 1 Input Speed Sensor 2 Circuit 13-37
(Outer Mainshaft Speed Low)
CAN Communication Malfunction
U0001 103 - 1 4-60
(CAN Communication Malfunction)
CAN Communication Malfunction (PCM-ABS)
U0121 103 - 1 4-63
(ABS CAN Communication Malfunction)
CAN Communication Malfunction (IMU)
U0125 103 - 1
(IMU CAN Communication Malfunction)
4-63
CAN Communication Malfunction (TCM-GCM)
U0155 103 - 1 4-64
(Meter CAN Communication Malfunction)
CAN Communication Malfunction (PTCAN)
U019E 112 - 1
(Power train CAN Communication Malfunction)
4-65
4-15
PGM-FI SYSTEM
PGM-FI SYSTEM DTC
TROUBLESHOOTING
PRIOR DIAGNOSIS
Before processing the OTC troubleshooting, check as
follows:
• Check for loose or poor contact on the OTC related
connectors (each sensor, solenoid, unit etc.), then
recheck the OTC.
• Erase the OTC (page 4-8) and recheck it.
• Refer to probable cause of each detected OTC and
check the listed items first. If possible, correct the
abnormally.
NOTE:
• Always turn the ignition switch OFF when checking
the continuity of the circuit and before disconnecting
the connectors.
• Some OTCs have a recheck function, so that the
priority OTC is detected when the ignition switch is
switched from OFF to ON. Wait for 10 seconds and
check the OTC again.
COMMON TROUBLESHOOTING
INFORMATION
NOTE:
• Always use the test probe when inspecting at the
ECM, TCM, ABS modulator, BCU, and SCU
connectors.
TOOL:
• If the TCM is replaced, perform the Clutch Initialize

Learning Procedure (page 13-67).
• When performing the test ride in the procedure of
the troubleshooting, set the motorcycle to the
preferred value as below chart. Conduct a test ride
with your confirmation.
Motorcycle speed*: About 60 km/h (37 mph)
Running time: 1 minute or more
Engine revolution: 4,000- 7,500 r/min
Throttle opening angle: 14 degrees or more
*: If the test ride cannot be performed, replace parts that

may be abnormal.
i'
..
4-16
PGM-FI SYSTEM
DTC C0520
Probable cause:
• Faulty IMU or its related circuit (CAN lines included)
• Faulty ECM
Symptom/Fail-safe function :
• Engine operates normally
• HSTC does not operate
• Cruise control does not operate
1. IMU Inspection
Replace the IMU with a new one.
Erase the DTC.
Check the DTC with MCS.
Is same DTC indicated?
YES - Replace the ECM with a new one, and
recheck.
NO - Faulty original IMU
DTC P0031/DTC P0032/DTC P0051/

DTC P0052
Probable cause :
• Faulty A/F sensor heater or its related circuit
• Faulty ECM
• Fuel consumption deterioration
• Detected value feedback stops
1. A/F Sensor Heater Line Open Circuit Inspection
Disconnect the ECM 39P connector (page 4-71 ).
[1] [2]
Disconnect the ECM 33P (Gray) connector (page 4-
71 ).
Disconnect the A/F sensor connector (page 4-67).
Check for continuity between the wire harness side
left A/F sensor connector [1] and ECM 39P
connector [2] . w
CONNECTION: White -A14 A14
right A/F sensor connector [3] and ECM 33P (Gray)
connector [4].
CONNECTION : White - C22
Is there continuity?
YES - GO TO STEP 2. [3] [4]
NO - Open circuit in the White wire
w
C22
f
4-17
PGM-FI SYSTEM
2. A/F Sensor Heater Ground Line Open Circuit
Inspection
A/F sensor connector [1] and ground. [1] )
CONNECTION: Green - Ground
YES - GO TO STEP 3.
NO - Open circuit in the Green wire
3. A/F Sensor Heater Output Line Short Circuit

Inspection
[1]
A/F sensor connector [1] and ground.
CONNECTION: White - Ground
YES - Short circuit in the White wire
NO - GO TO STEP 4.
4. A/F Sensor Inspection

Replace the A/F sensor with a new one.
Connect the disconnected connector(s).
Erase the OTC.
Start the engine and wait for a minute.
Check the OTC with MCS.
recheck.
NO - Faulty original A/F sensor
4-18
PGM-FI SYSTEM
DTC POOD1 /DTC POOD3
Probable cause:
• Faulty ECM
1. A/F Sensor Inspection
Erase the OTC.
recheck.
DTC P0105
Probable cause:
• Faulty MAP sensor or its related circuit
• Loose or poor connection of the MAP sensor hose
• Clogged MAP sensor hose
• Faulty ECM
• Rough idling
• Driveability deterioration
1. MAP Sensor Inspection
Replace the MAP sensor with a new one.
Erase the OTC.
Start the engine and wait for three seconds.
recheck.
NO - Faulty original MAP sensor
lI
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r'
f
4-19
PGM-FI SYSTEM
DTC P0107/DTC P0108
Probable cause:
• Faulty MAP sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Rough idling
1. MAP Sensor Input Voltage Inspection
Disconnect the MAP sensor connector (page 4-68).
Turn the ignition switch ON. [1 ]
Measure the voltage at the wire harness side MAP
sensor connector [1].
CONNECTION: Yellow(+) - Gray(-)
Is the voltage within 4. 75 - 5.25 V?
YES - GO TO STEP 2.
NO - • Open or short circuit in the Yellow wire
• Open circuit in the Gray wire
• If the wire is OK, replace the ECM with
a new one, and recheck.
2. MAP Sensor Signal Line Open Circuit Inspection

MAP sensor connector [1] and ECM 39P connector
[2] [1]
l
[2].
CONNECTION: Light green - A 15
I
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l
YES - GO TO STEP 3.
A15 Lg J
NO - Open circuit in the Light green wire
l
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3. MAP Sensor Signal Line Short Circuit Inspection

[1]
Il
MAP sensor connector [1] and ground.
j
CONNECTION: Light green - Ground
YES
NO
- Short circuit in the Light green wire
- GO TO STEP 4.
lj
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4-20
PGM-FI SYSTEM
4. MAP Sensor Inspection
Replace the MAP sensor with a new one.
Erase the OTC.
Turn the ignition switch ON and wait for 10 seconds.
recheck.
NO - Faulty original MAP sensor
OTC P0112/DTC P0113

Probable cause:
• Faulty IAT sensor or its related circuit
• Faulty ECM
1. IAT Sensor Output Line Open Circuit Inspection
[2]
Disconnect the IAT sensor connector (page 7-15).
IAT sensor connector [1] and ECM 39P connector
[2].
CONNECTION: Yellow - A17
YES - GO TO STEP 2. y
A17
NO - Open circuit in the Yellow wire
2. IAT Sensor Output Line Short Circuit Inspection

IAT sensor connector [1] and ground.
CONNECTION: Yellow - Ground
YES - Short circuit in the Yellow wire
y
NO - GO TO STEP 3.
4-21
PGM-FI SYSTEM
3. IAT Sensor Ground Line Open Circuit Inspection
Disconnect the ECM 33P (Black) connector (page
4-71). [2]
IAT sensor connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Gray- 823
YES - GO TO STEP 4. Gr
NO - Open circuit in the Gray wire
4. IAT Sensor Inspection

Replace the IAT sensor with a new one.
Erase the OTC.
recheck.
NO - Faulty original IAT sensor
DTC P0117/DTC P0118

Probable cause:
• Faulty ECT sensor or its related circuit
• Faulty ECM
• Hard to start at a low temperature
1. ECT Sensor Output Line Open Circuit Inspection
[1] [2]
4-71).
Disconnect the ECT sensor connector (page 4-69).
ECT sensor connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Light green - 820
Lg B20
YES - GO TO STEP 2.
4-22
PGM-FI SYSTEM
2. ECT Sensor Output Line Short Circuit Inspection
ECT sensor connector [1) and ground .
YES - Short circuit in the Light green wire
NO - GO TO STEP 3. Lg
I!
f 3. ECT Sensor Ground Line Open Circuit
Inspection
I Check for continuity between the wire harness side
t ECT sensor connector [1) and ECM 33P (Black) [2]
connector [2].
CONNECTION: Gray- B23
f Is there continuity?
J
YES - GO TO STEP 4.
l
I
823 Gr
I
II 4. ECT Sensor Inspection
Replace the ECT sensor with a new one.
Erase the OTC.
Turn the ignition switch ON and wait for 10 seconds .
Check the OTC with MCS .
recheck.
NO - Faulty original ECT sensor
,
r
.
r
4-23
PGM-FI SYSTEM
DTC P0122/DTC P0123
Probable cause:
• Faulty TP sensor or its related circuit
• Faulty ECM
• Engine operates at idle speed
1. TP Sensor 1 Input Voltage Inspection
Disconnect the TBW unit connector (page 7-16).
[1)
Measure the voltage at the wire harness side TBW
unit connector [1).
CONNECTION: Yellow(+) - Light green(-)
Is about 5 Vindicated?
YES - GO TO STEP 2.
• Open circuit in the Light green wire
2. TP Sensor 1 Output Line Open Circuit

Inspection
(2)
4-71 ).
TBW unit connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Blue/black - 827
YES - GO TO STEP 3.
NO - Open circuit in the Blue/black wire
[1 )
3. TP Sensor 1 Output Line Short Circuit

Inspection
[1)
TBW unit connector [1] and ground.
CONNECTION: Blue/black- Ground
YES - Short circuit in the Blue/black wire
NO - GO TO STEP 4.
4-24
PGM-FI SYSTEM
4. TP Sensor 1 Inspection
Replace the throttle body (TP sensor).
Erase the OTC.
recheck.
NO - Faulty original TP sensor

DTC P0152
Probable cause:
• Faulty A/F sensor or its related circuit
• Faulty ECM
1. A/F Sensor Output Line Open Circuit Inspection
Disconnect the A/F sensor connector (page 4-67).
[1)
Disconnect the ECM connectors:
- A/F sensor 1: ECM 39P connector (page 4-71)
- A/F sensor 2: ECM 33P (Gray) connector (page
4-71)
A/F sensor 1: Check for continuity between the wire
harness side A/F sensor connector [1] and ECM
39P connector [2]. Bl
[2]
33P (Gray) connector [4].
CONNECTION:
A/F sensor 1: Black - A25
A/F sensor 2: Black - C32 [3]
YES - GO TO STEP 2.
NO - Open circuit in the Black wire
Bl
[4)
[
t
r 4-25
PGM-FI SYSTEM
2. A/F Sensor Output Line Short Circuit Inspection
A/F sensor connector [1] and ground. [1]
CONNECTION: Black- Ground

YES - Short circuit in the Black wire
NO - GO TO STEP 3.
) J
3. A/F Sensor Ground Line Open Circuit Inspection

harness side A/F sensor connector [1] and ECM [1] [2]
39P connector [2].
33P (Gray) connector [4] .
CONNECTION:
A/F sensor 1: Gray - A36
A/F sensor 2: Gray - C21
YES - GO TO STEP 4 .
Gr A36
[3] [4]
Gr C21
4. A/F sensor Inspection I

Erase the DTC.
1
Stop the engine.
I
j
recheck.
l
J
j
4-26
PGM-FI SYSTEM
DTC P0134/DTC P0154
Probable cause:
There is an exhaust leak
• Faulty ECM
• Exhaust gas too lean or too rich
1. A/F sensor Inspection
Erase the OTC.
Warm up the engine until the coolant temperature is
above 50°C (122°F) and keep the engine revolution
at 1,600 - 8,100 r/min with no 100 r/min variation a
second.
recheck.
DTC P0201 /DTC P0202

Probable cause:
• Faulty fuel injector
• Faulty ECM
• Engine does not start (Fuel injectors, fuel pump and
ignition shut down)
1. Fuel Injector Input Voltage Inspection
Disconnect the fuel injector connector (page 7-18).
[1]
Measure the voltage between the wire harness side
fuel injector connector [1] and ground.
CONNECTION: Brown(+) - Ground(-)
Is there battery voltage?
Br
YES - GO TO STEP 2.
NO - Open circuit in the Brown wire 8
r
t 4-27
PGM-FI SYSTEM
2. Fuel Injector Signal Line Open Circuit Inspection
Disconnect the ECM 33P {Black) connector (page
4-71 ).
[1] [2] J
fuel injector connector [1] and ECM 33P {Black)
connector [2] .
CONNECTION:
No.1: Blue - 87
No.2: Pink - 88
YES - GO TO STEP 3. B7
NO - • No.1 : Open circuit in the Blue wire

• No.2: Open circuit in the Pink wire
3. Fuel Injector Signal Line Short Circuit Inspection

[1]
fuel injector connector [1] and ground .
CONNECTION:
No.1: Blue - Ground
No.2: Pink - Ground
YES - • No.1: Short circuit in the Blue wire
• No.2: Short circuit in the Pink wire
NO - GO TO STEP 4.
4. Fuel Injector Inspection

Replace the fuel injector with a new one .
Erase the OTC.
recheck.
NO - Faulty original fuel injector
4-28
PGM-FI SYSTEM
DTC P0222/DTC P0223
Probable cause:
• Faulty ECM
1. TP Sensor 2 Input Voltage Inspection
[1]
Measure the voltage at the wire harness side TBW
I unit connector [1].
CONNECTION: Yellow(+) - Light green (-)
f Is about 5 Vindicated?
r
[ YES - GO TO STEP 2.
t • Open circuit in the Light green wire
2. TP Sensor 2 Output Line Open Circuit

Inspection
[2)
4-71 ).
TBW unit connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Blue/white - 828
YES - GO TO STEP 3.
NO - Open circuit in the Blue/white wire
[1)
3. TP Sensor 2 Output Line Short Circuit

Inspection
[1]
TBW unit connector [1] and ground.
CONNECTION: Blue/white - Ground
YES - Short circuit in the Blue/white wire
NO - GO TO STEP 4.
4-29
PGM-FI SYSTEM
4. TP Sensor 2 Inspection
Erase the OTC.
recheck.
NO - Faulty original TP Sensor
DTC P0351 /DTC P0352/DTC P0353/

DTC P0354
Probable cause:
• Faulty Ignition coil or its related circuit
• Faulty ECM
• Fuel injector and ignition coil shut down
1. Ignition Coil Primary Coil Input Voltage
Inspection
Remove the ignition coil tray without disconnecting
[1]
the ignition coil sub harness 6P connector (page 5-
10).
ignition coil wire connector [1] and ground.
CONNECTION:
No.1-1/No.2-1: Brown{+) - Ground{-)
No.1-2/No.2-2: Brown/black{+)- Ground{-) No.1 -1 /No.2-1 : Br
Is there battery voltage? No.1-2/No.2-2: Br/Bl
YES - GO TO STEP 2.
NO - • No.1-1/No.2-1:
Open circuit in the Brown wire
• No.1-2/No.2-2:
Open circuit in the Brown/black wire
2. Ignition Coil Primary Coil Signal Line Open
Circuit Inspection
Disconnect the ECM 33P {Black) connector (page
[1] [2]
4-71 ).
Check the continuity between the wire harness side
ignition coil wire connector [1] and ECM 33P {Black)
connector [2].
CONNECTION:
No.1 -1: Blue/black - B33
No.2-1: Blue/red - B22
No.1-2: Blue/white - B11
No.2-2: Blue/yellow- B10
YES - GO TO STEP 3.
NO - • No/1-1:
Open circuit in the Blue/black wire
• No.2-1:
Open circuit in the Blue/red wire
• No.1-2:
Open circuit in the Blue/white wire
• No.2-2: ·
Open circuit in the Blue/yellow wire
4-30
PGM-FI SYSTEM
3. Ignition Coil Primary Coil Signal Line Short
Circuit Inspection
ignition coil wire connector [1] and ground. [1 J
CONNECTION:
No.1-1: Blue/black - Ground
No.2-1 : Blue/red - Ground
No.1-2: Blue/white - Ground
No.2-2: Blue/yellow - Ground
Is there continuity? No.1-1 : Bu/Bl
YES - • No/1-1 : No.2-1 : Bu/R
Short circuit in the Blue/black wire No.1-2: Bu/W
• No.2-1 : No.2-2: Bu/Y
Short circuit in the Blue/red wire
• No.1-2:
Short circuit in the Blue/white wire
• No.2-2:
Short circuit in the Blue/yellow wire
NO - GO TO STEP 4.
4. Ignition Coil Primary Peak Voltage Inspection
Connect the ECM 33P {Black) connector.
Inspect the ignition coil primary peak voltage (page
5-7).
Is the peak voltage normal?
recheck.
NO - GO TO STEP 5.
5. Ignition Coil Inspection
Replace the Ignition coil with a new one.
Erase the OTC.
recheck.
NO - Faulty original ignition coil
4-31
PGM-FI SYSTEM
DTC P0412
Probable cause:
• Faulty PAIR control solenoid valve or its related
circuit
• Faulty ECM
1. PAIR Control Solenoid Valve Input Voltage
Inspection
Disconnect the PAIR control solenoid valve
connector (page 7-20). [1]
Turn the ignition switch ON .
Measure the voltage between the wire harness side Br
PAIR control solenoid valve connector (1) and
ground.
CONNECTION: Brown (+) - Ground (-)
YES - GO TO STEP 2.
NO - Open circuit in the Brown wire
2. PAIR Control Solenoid Valve Signal Line Open

Circuit Inspection
4-71 ). [2]
PAIR control solenoid valve connector (1) and ECM
33P (Black) connector (2).
CONNECTION: Yellow/blue - 82
YES - GO TO STEP 3.
NO - Open circuit in the Yellow/blue wire
Y/Bu
[1] ______.-
3. PAIR Control Solenoid Valve Signal Line Short

1 Circuit Inspection
[1]
PAIR control solenoid valve connector (1) and
ground.
CONNECTION: Yellow/blue - Ground Y/Bu
YES - Short circuit in the Yellow/blue wire
NO - GO TO STEP 4.
4-32
PGM-FI SYSTEM
4. PAIR Control Solenoid Valve Inspection
Replace the PAIR control solenoid valve with a new
one.
Erase the OTC.
recheck.
NO - Faulty original PAIR control solenoid valve
OTC P0443
Probable cause:
• Faulty EVAP purge control solenoid valve or its
related circuit
• Faulty ECM
1. EVAP Purge Control Solenoid Valve Input
Voltage Inspection
Disconnect the EVAP purge control solenoid valve
[1]
connector (page 7-22).
EVAP purge control solenoid valve connector [1]
and ground.
Br
CONNECTION: Brown(+)- Ground(-)
EB e
YES - GO TO STEP 2.
NO - Open circuit in the Brown wire
2. EVAP Purge Control Solenoid Valve Signal Line

Open Circuit Inspection
4-71 ). [2]
and ECM 33P (Black) connector [2].
CONNECTION: Yellow - B1
YES - GO TO STEP 3.
y
[1]
I
4-33
l,
PGM-FI SYSTEM
3. EVAP Purge Control Solenoid Valve Signal Line
Short Circuit Inspection
[1]
and ground.
NO - GO TO STEP 4. )
4. EVAP Purge Control Solenoid Valve Inspection

Replace the EVAP purge control solenoid valve with
a new one.
Erase the OTC.
Is same OTC indicated?
recheck.
NO - Faulty original EVAP purge solenoid valve
DTC P0479
Probable cause:
• Faulty EGCA motor
• Faulty ECV or its related parts
• Faulty ECM
• Oriveability deterioration
1. EGCA Motor Inspection
Replace the EGCA motor with a new one.
Erase the OTC.
recheck.
NO - Faulty original EGCA motor
4-34
PGM-FI SYSTEM
DTC P048D/DTC P048E
Probable cause:
• Faulty EGCA position sensor or its related circuit
• Faulty ECM
1. ECV POT Input Voltage Inspection
Disconnect the EGCA connector (page 4-70).
Turn the ignition switch ON. [1 J
EGCA connector [1] .
CONNECTION: Yellow(+) - Gray(-) Gr

YES - GO TO STEP 2.
2. ECV POT Output Line Open Circuit Inspection

[1] [2]
Disconnect the ECM 33P (Gray) connector.
EGCA connector [1] and ECM 33P (Gray) connector
[2].
CONNECTION: Black/red - C29
BI/R
C29
YES - GO TO STEP 3.
NO - Open circuit in Black/red wire
3. ECV POT Output Line Short Circuit Inspection

[1]
EGCA connector [1] and ground.
CONNECTION: Black/red - Ground
YES - Short circuit in Black/red wire
NO - GO TO STEP 4.
4-35
PGM-FI SYSTEM
4. ECV POT Inspection
Replace the EGCA with a new one.
Erase the OTC.
recheck.
NO - Faulty original EGCA
DTC P0500
Probable cause:
• Faulty front wheel speed sensor or its related circuit
• ABS modulator has OTC (CAN lines included)
• Faulty ECM
NOTE:
• When other OTC is displayed, together with P0500,
troubleshoot it first.
1. Front Wheel Speed Sensor Signal Output Line
Open Circuit Inspection
Disconnect the following:
[1]
- ABS modulator connector (page 20-8)
- ECM 33P (Black) connector (page 4-71)
ABS modulator connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Blue/yellow- 814
YES - GO TO STEP 2.
NO - Open circuit in the Blue/yellow wire
2. Front Wheel Speed Sensor Signal Output Line

[1]
ECM 33P (Black) connector [1] and ground.
CONNECTION: 814 - Ground
YES - Short circuit in the Blue/yellow wire
NO - GO TO STEP 3.
814
4-36
PGM-FI SYSTEM
3. ECM Inspection
Replace the ECM with a new one.
Erase the OTC.
Perform the test ride (page 4-16).
YES - Replace the ABS modulator with a new
one, and recheck.
NO - Faulty original ECM
DTC P0504
Probable cause:
• Faulty front/rear brake switch or its related circuit
• Faulty ECM
1. Cruise Cancel Switch Input Line Input Voltage
Inspection
Disconnect the right handlebar switch 4P connector
[1]
(page 22-34).
Measure the voltage at the wire harness side right
handlebar switch 4P connector [1] and ground.
CONNECTION: Brown (+) - Ground (-)
YES - GO TO STEP 2.
NO - Open or short circuit in Brown wire or its
related circuit
2. Cruise Cancel Switch Output Line Open Circuit

Inspection
Disconnect the rear brake switch 4P connector
[1]
(page 22-41 ).
right handlebar switch 4P connector [1] and rear
brake switch 4P connector [2].
CONNECTION: White - White
w [2]
YES - Open circuit in the White wire
NO - GO TO STEP 3.
4-37
PGM-FI SYSTEM
3. Cruise Cancel Switch Output Line Open Circuit
Inspection
Disconnect the ECM 33P (Gray) connector (page 4- 111
71 ). (2)
rear brake switch 4P connector [1] and ECM 33P
CONNECTION: White - C26
w
C26
YES - Open circuit in the White wire
NO - GO TO STEP 4.
4. Cruise Cancel Switch Inspection

Replace the brake switches with new one.
Erase the OTC.
Turn the ignition switch ON and apply the brakes.
recheck.
NO - Faulty original brake switches
DTC P0562/DTC P0686/DTC P0687

Probable cause:
•
•
Faulty sub VB relay or its related circuit
Blown sub fuse SUB VB 10 A
J
• Blown MAIN2 30 A fuse
• Faulty TCM
• Faulty ECM
1. Sub VB Relay Power Supply Voltage Inspection
Remove the sub VB relay (page 4-77).
Turn the ignition switch ON . [1 J
Measure the voltage at the wire harness (fuse/relay
box) side sub VB relay connector [1).
CONNECTION: Red/white (+) - Green (-)
YES - GO TO STEP 2. G
NO - • Open circuit in the Red/white wire
• Open circuit in the Green wire
4-38
PGM-FI SYSTEM
2. Sub VB Relay Coil Line Open Circuit Inspection
[1] [2]
Remove the sub VB relay (page 4-77).
sub VB relay connector [1] and ECM 39P connector
[2].
CONNECTION: Violet/yellow - A27
A2.7
YES - GO TO STEP 3.
NO - Open circuit in the VioleUyellow wire
3. Sub VB Relay Line Open Circuit Inspection

sub VB relay connector [1] and ECM 39P connector [1 J [2]
[2].
CONNECTION: Violet -AB
YES - GO TO STEP 4.
NO - Open circuit in the Violet wire
AS
4. Sub VB Relay Inspection

Replace the sub VB relay with a new one.
Erase the DTC.
YES - • Faulty TCM
• Faulty ECM
NO - Faulty original sub VB relay
4-39
PGM-FI SYSTEM
DTC P0567
Probable cause:
• Faulty right handlebar switch (RES/+) or its related
circuit
• Faulty ECM
1. RES/+ Cruise Control Lever Signal Line Open
Circuit Inspection
[1 ] [2]
71 ).
Disconnect the right handlebar switch 12P
right handlebar switch 12P connector [1] and ECM
33P (Gray) connector [2]. w
C31
1
YES - GO TO STEP 2.
2. RES/+ Cruise Control Lever Signal Line Short

Circuit Inspection
[1]
right handlebar switch 12P connector [1] and
ground.
Is there continuity? J
YES
NO
- Short circuit in the White wire
- GO TO STEP 3. j
3. RES/+ Cruise Control Lever Inspection

Replace the right handlebar switch with a new one.
Erase the OTC.
recheck.
NO - Faulty original right handlebar switch
(RES/+ cruise control lever)
4-40
PGM-FI SYSTEM
DTC P0574
Probable cause:
• Faulty VS sensor or its related circuit
• Faulty meter
• Faulty ECM
NOTE:
• When other DTC is displayed, together with P0574,
1. Meter Inspection
Replace the meter with a new one.
Erase the DTC.
Perform the test ride with cruise mode.
recheck.
NO - Faulty original meter
DTC P0580/DTC P0581

Probable cause:
• Faulty right handlebar switch (Cruise main switch,
SET/- cruise control lever) or its related circuit
• Faulty ECM
1. Cruise Main Switch, SET/- Cruise Control Lever
Signal Line Open Circuit Inspection
[1) [2)
4-71).
right handlebar switch 12P connector [1] and ECM
33P {Black) connector [2].
CONNECTION: White - B29
w
829
YES - GO TO STEP 2.
4-41
PGM-FI SYSTEM
Signal Line Short Circuit Inspection
[1]
ground.
CONNECTION: White -Ground
NO - GO TO STEP 3.

Inspection
Erase the OTC.
/s same DTC indicated?
recheck.
NO - Faulty original right handlebar switch
(Cruise main switch, SET/- cruise control
lever)
OTC P0606
Probable cause:
• Faulty ECM
• Hard to start
Diagnostic procedure:
1. Replace the ECM with a new one.
2. Erase the OTC.
3. Turn the ignition switch ON and wait for 10 seconds.
4. Check the OTC with MCS.
5. If the same OTC is not indicated, faulty original
ECM.
4-42
PGM-FI SYSTEM
OTC P062F
Probable cause:
• Faulty ECM
• Hard to start
• Does not hold the self-diagnosis data
- The MIL does not come on (the OTC can be
readout and erased only by MCS).
Diagnostic procedure:
1. Replace the ECM with a new one .
2. Erase the OTC.
3. Turn the ignition switch ON and wait for 10 seconds.
4. Check the OTC with MCS.
5. If the same OTC is not indicated, faulty original
ECM.
OTC P0640/0TC P064E

Probable cause:
• Faulty NF sensor or its related circuit
• Faulty ECM
f • Driveability deterioration
I 1. A/F Sensor Inspection
Replace the NF sensor with a new one.
Erase the OTC.
Turn the ignition switch ON and wait for 10 seconds
or start the engine and wait a minute.
i
rf Is same DTC indicated?
I
f recheck.
I
NO - Faulty original NF sensor
r
! OTC P0704
f Probable cause:
• Faulty clutch switch or its related circuit
• Faulty ECM
r Symptom/Fail-safe function:
1. Clutch Cruise Cancel Switch Input Line Input
Voltage Inspection
Disconnect the left handlebar switch 8P connector
(page 22-27). [1]
Measure the voltage at the wire harness side left
handlebar switch 8P connector [1] and ground.
CONNECTION: Brown (+) - Green (-)
YES - GO TO STEP 2.
NO - • Open or short circuit in Brown wire or
its related circuit
• Open circuit in Green wire
4-43
PGM-FI SYSTEM
2. Clutch Cruise Cancel Switch Output Line Open
Circuit Inspection
4-71 ). [1] [2]
left handlebar switch 8P connector [1] and ECM 33P
{Black) connector [2] .
CONNECTION: Black - 821
Bl
B21
YES - Open circuit in the Black wire
NO - GO TO STEP 3.
3. Clutch Cruise Cancel Switch Output Line Short

Circuit Inspection
[1]
left handlebar switch connector [1] and ground.
CONNECTION: Black - Ground
NO - GO TO STEP 4 .
4. Clutch Switch Output Line Open Circuit

Inspection
[1 ]
71 ).
8P (Gray) connector [1] and ECM 33P (Gray)
connector [2] .
CONNECTION : Black/red - C18
BI/R
C1 8
YES - Open circuit in the Black/red wire
NO - GO TO STEP 5.
l
1
i
j
4-44
PGM-FI SYSTEM
5. Clutch Switch Output Line Short Circuit
Inspection
[1 J
8P (Gray) connector [1] and ground.
CONNECTION: Black/red - Ground
YES - Short circuit in the Black/red wire
NO - GO TO STEP 6.
6. Clutch Switch Inspection

Replace the clutch switch with a new one.
Erase the OTC.
,- Is same DTC indicated?
recheck.
NO - • Faulty original clutch switch
• Faulty original clutch cruise cancel
switch
DTC P0722
Probable cause :
• Faulty VS sensor or its circuit
• Faulty ECM
1. VS Sensor Ground Line Open Circuit Inspection
Disconnect the VS sensor connector (page 4-73).
Check for continuity between the wire harness side [1 J
VS sensor connector [1] and ground .
YES - GO TO STEP 2.
4-45
PGM-FI SYSTEM
2. VS Sensor Input Line Open Circuit Inspection
Temporarily install the removed electrical parts in
the reverse order of removal. [1]
VS sensor connector [1] and ground .
CONNECTION: Black/red (+) - Green (-)
YES - GO TO STEP 3.
NO - Open circuit in the Black/red wire or its
related circuit
3. VS Sensor Signal Line Short Circuit Inspection

VS sensor connector [1] and ground . [1]
CONNECTION: Pink- Ground

YES - Short circuit in the Pink wire j
p
NO - GO TO STEP 4. 1
l
j
l
4. VS Sensor Signal Line Open Circuit Inspection

[1] [2]
J
l
71 ).
VS sensor connector [1] and ECM 33P (Gray)
connector [2].
CONNECTION: Pink - C16
Is there continuity? p
C16
YES - GO TO STEP 5.
I
NO - Open circuit in the Pink wire !
5. VS Sensor Inspection
Replace the VS sensor with a new one.
Erase the DTC.
l
j
l
recheck. 1 j
NO - Faulty original VS sensor i
1
j
J
j
l
4-46 j
PGM-FI SYSTEM
DTC P1658/DTC P1659
Probable cause:
[
• Faulty TBW relay or its related circuit
f • Blown sub fuse TBW 10 A
l • Faulty ECM
1. TBW Relay Input Voltage Inspection
Remove the TBW relay (page 4-76).
[1]
Measure the voltage at the wire harness (fuse/relay
box) side TBW relay connector [1].
' CONNECTION: Red/blue (+) - Green (-)

YES - GO TO STEP 2.
NO - • Open circuit in the Red/blue wire
2. TBW Relay Line Open Circuit Inspection

Disconnect the ECM 39P and ECM 33P (Gray)
connectors (page 4-71 ).
f TBW relay connector [1] and ECM 39P connector

[2]/ECM 33P (Gray) connector [3].
CONNECTION: Br/G
f
p Brown/green - A 1
Yellow/white - C10
' Is there continuity?

r YES - GO TO STEP 3.
NO - • Open circuit in the Brown/green wire
• Open circuit in the Yellow/white wire
[3] [1]
3. TBW Relay Line Short Circuit Inspection

[1]
TBW relay connector [1] and ground.
CONNECTION:
Brown/green - Ground
Yellow/white - Ground
YES - • Short circuit in the Brown/green wire
• Short circuit in the Yellow/white wire
NO - GO TO STEP 4.
r 4-47
PGM-FI SYSTEM
4. TBW Relay Inspection
Replace the TBW relay with a new one.
Erase the OTC.
Check the OTC with MCS. j
I
YES - Replace the ECM with a new one, and ij
recheck.
NO - Faulty original TBW relay
1
OTC P1684
,i
Probable cause:
• Faulty TBW return spring
• Faulty ECM
j
• Motorcycle speed is limited: approximately 120 km/h
(75 mph)
1. Throttle Valve and Return Spring Inspection
• Be careful not to damage the throttle valves.
J
• The return spring cannot be replaced. If the [1 J
return spring is faulty, replace the throttle body.
Remove the throttle body (page 7-16).
Open the throttle valve [1] with your finger. l
Does the throttle valve open and return I
smoothly?
YES - GO TO STEP 2.
j
NO - Faulty throttle body {throttle valve and/or j
return spring)
J
I
J
1'
I
'
j
4-48 l
~
PGM-FI SYSTEM
2. Throttle Body Inspection
Check the throttle bores [1] and valves visually for
carbon deposits.
Is there contamination?
YES - Clean the throttle bores and valves
carefully. (Do not apply commercially
available carburetor cleaners to the inside
of the throttle bore, which is coated with
molybdenum.)
NO - GO TO STEP 3.
[1]
3. TBW System Inspection

Replace the throttle body with a new one.
Erase the OTC.
recheck.
NO - Faulty original throttle body
4-49
PGM-FI SYSTEM
DTC P1702/DTC P1703
Probable cause:
j
• Faulty GP sensor or its related circuit '
• Faulty ECM
1. GP Sensor Input Voltage Inspection
Disconnect the GP sensor connector (page 4-73).
Turn the ignition switch ON. [1 ]
Measure the voltage at the wire harness side GP
sensor connector [1] .
J
YES - GO TO STEP 2.
'j
2. GP Sensor Signal Line Open Circuit Inspection l
l
[1] [2] 1
4-71 ).
GP sensor connector [1] and ECM 33P (Black)
connector [2] .
1l
~
YES - GO TO STEP 3. w 830 J
3. GP Sensor Output Line Short Circuit Inspection

[1]
GP sensor connector [1] and ground.
j
NO - GO TO STEP 4.
.I
l
1
4-50 I
I
PGM-FI SYSTEM
4. GP Sensor Inspection
Replace the GP sensor with a new one.
Erase the DTC.
recheck.
NO - Faulty original GP sensor
OTC P1708/DTC P1709

Probable cause:
• Faulty shift spindle switch or its related circuit
• Faulty ECM
1. Shift Spindle Switch Input Line Short Circuit
Inspection
71 ).
Remove the shift spindle switch terminal (page 4-
74 ).
shift spindle switch terminal and ground.
CONNECTION: Yellow/white - Ground
YES - Short circuit in the Yellow/white wire
NO - GO TO STEP 2.
2. Shift Spindle Switch Line Open Circuit
Inspection
shift spindle switch terminal [1] and ECM 33P (Gray) [1) [2)
connector [2].
CONNECTION: Yellow/white - C30
YES - GO TO STEP 3.
NO - Open circuit in the Yellow/white wire Y/W
3. Shift Spindle Switch Inspection

Replace the shift spindle switch with a new one.
Erase the DTC.
DTC P1708: Operate the UP shift three times or
more.
DTC P1709: Operate the DOWN shift three times or
more.
recheck.
NO - Faulty original shift spindle switch
4-51
PGM-FI SYSTEM
Il
DTC P170D/DTC P170E
Probable cause:
• Faulty shift stroke sensor or its related circuit
• Faulty ECM
• Gearshift function does not work
1. Shift Stroke Sensor Input Voltage Inspection
Disconnect the shift stroke sensor (option)
[1]
connector.
Measure the voltage at the wire harness side shift y
stroke sensor connector [1 ).
Gr
j
YES - GO TO STEP 2.
l
j
J
2. Shift Stroke Sensor Output Line Open Circuit
Inspection
71 ).
[2] J
shift stroke sensor connector [1) and ECM 33P
(Gray) connector [2).
l
CONNECTION: Black- C28
J
[1]
C28 '
YES
NO
- GO TO STEP 3.
- Open circuit in the Black wire I
3. Shift Stroke Sensor Output Line Short Circuit
Inspection j
[1] j
shift stroke sensor connector [1) and ground.
CONNECTION: Black - Ground 1
Bl
NO - GO TO STEP 4.
I
l
J
l
J
4-52 J
PGM-FI SYSTEM
4. Shift Stroke Sensor Inspection
Replace the shift stroke sensor with a new one.
' Erase the OTC.
recheck.
NO - Faulty original shift stroke sensor
DTC P1712
Probable cause:
• Faulty TCM or its related circuit
• Faulty ECM
1. TCM Inspection
Replace the TCM with a new one.
Erase the OTC.
recheck.
NO - Faulty original TCM
DTC P2101/DTC P2118

Probable cause:
• Faulty TBW motor or its related circuit
• Faulty ECM
1. TBW Motor Line Open Circuit Inspection
Disconnect the TBW motor connector (page 7-16).
4-71 ).
TBW motor connector [1] and ECM 33P (Black)
connector [2].
CONNECTION:
Red-B3
Blue- B4
YES - GO TO STEP 2.
NO - • Open circuit in the Red wire
• Open circuit in the Blue wire [2]
4-53
PGM-FI SYSTEM
2. TBW Motor Line Short Circuit Inspection 1
TBW motor connector [1] and ground.
CONNECTION:
Red-Ground
Blue - Ground
YES - • Short circuit in the Red wire
• Short circuit in the Blue wire
NO - GO TO STEP 3.
;
3. TBW Motor Inspection
Replace the throttle body (TBW motor).
Erase the DTC.
recheck. '
NO - Faulty original TBW motor j
J
OTC P2122/DTC P2123 J
Probable cause: l
• Faulty APS 1 or its related circuit
• Faulty ECM j
1. APS 1 Input Voltage Inspection
Disconnect the grip APS connector (page 22-34 ).
Measure the voltage at the wire harness side grip
APS connector [1].
CONNECTION: Brown (+) - Pink(-)
l
YES - GO TO STEP 2. l
NO - • Open circuit in the Brown wire
• Open circuit in the Pink wire
• If the wires are OK, replace the ECM
with a new one, and recheck.
I
~
[1) I
l
J
I
JI
1
J
4-54
PGM-FI SYSTEM
2. APS 1 Output Line Open Circuit Inspection
[2]
grip APS connector [1] and ECM 39P connector [2].
CONNECTION: Blue - A26
YES - Open circuit in the Blue wire A26
NO - GO TO STEP 3.
Bu
[1]
3. APS 1 Output Line Short Circuit Inspection

grip APS connector [1] and ground. [1]
CONNECTION: Blue - Ground

YES - Short circuit in the Blue wire
NO - GO TO STEP 4.
4. APS 1 Inspection
Replace the grip APS (right handlebar switch).
Erase the OTC.
f Check the OTC with MCS.
recheck.
NO - Faulty original APS
r
f
4-55
PGM-FI SYSTEM
DTC P2127/DTC P2128
Probable cause:
• Faulty APS 2 or its related circuit
• Faulty ECM
1. APS 2 Input Voltage Inspection
[1)
Measure the voltage at the wire harness side grip
APS connector (1).
CONNECTION: White (+) - Gray (-)
YES - GO TO STEP 2.
NO - • Open circuit in the White wire
• If the wires are OK, replace the ECM
with a new one, and recheck.
2. APS 2 Output Line Open Circuit Inspection

[1)
grip APS connector (1) and ECM 39P connector (2).
CONNECTION: Yellow - A38
YES - GO TO STEP 3.
3. APS 2 Output Line Short Circuit Inspection

[1)
grip APS connector (1) and ground.
NO - GO TO STEP 4.
4-56
PGM-FI SYSTEM
I
r
4. APS 2 Inspection
Erase the OTC.
' Turn the ignition switch ON and wait for 10 seconds.
ts same DTC indicated? ·
recheck.
NO - Faulty original grip APS
DTC P2135
l
I
Probable cause:
• Faulty ECM
! Symptom/Fail-safe function :
NOTE:
• Clean the throttle bores and valves carefully. (Do not
apply commercially available carburetor cleaners to
the inside of the throttle bore, which is coated with
I
molybdenum.)
1. TP Sensor Line Short Circuit Inspection
[1]
4-71 ).
r Check for continuity at the wire harness side TBW
unit connector [1].
CONNECTION: Blue/black - Blue/white
Is there no continuity?
YES - GO TO STEP 2.
NO - Short circuit of the Blue/black-to-Blue/
white wire
r 2. TP Sensor Inspection
'
Erase the OTC.
~echeck.
r NO - Faulty original TP sensor
!
t
l'
'
4-57
PGM-FI SYSTEM
DTC P2138
Probable cause:
• Faulty APS 1 and/or APS 2 or its related circuit
• Faulty ECM
1. APS Line Short Circuit Inspection
[1]
Check for continuity at the wire harness side APS
connector [1] .
CONNECTION: Blue-Yellow
YES - GO TO STEP 2.
y
NO - Short circuit of the Blue wire-to-Yellow wire
2. APS Inspection
Erase the OTC.
/s same DTC indicated? '
recheck.
NO - Faulty original APS
4-58
I
f
DTC P2158
Probable cause:
• Faulty rear wheel speed sensor or its related circuit
PGM-FI SYSTEM
• ABS modulator has OTC (CAN lines included}

• Faulty ECM
NOTE:
• When other OTC is displayed together with P2158,
1. Rear Wheel Speed Sensor Signal Output Line
rt Open Circuit Inspection
'
- ECM 33P (Black) connector (page 4-71)
ABS modulator connector [1] and ECM 33P (Black)
815
connector [2].
CONNECTION: 3- 815
YES - GO TO STEP 2.
NO - Open circuit in the Blue/black wire
[1]
2. Rear Wheel Speed Sensor Signal Output Line

[1]
ECM 33P (Black) connector [1] and ground.
CONNECTION: 815- Ground
YES - Short circuit in the Blue/black wire
NO - GO TO STEP 3.
3. ECM Inspection
Replace the ECM with a new one.
Erase the OTC.
YES - Replace the ABS modulator with a new
one, and recheck.
NO - Faulty original ECM
4-59
PGM-FI SYSTEM
DTC P2AOO/DTC P2A03
Probable cause:
• There is an exhaust leak
• Faulty ECM
• Hard to start at a low temperature
• Exhaust gas too lean or too rich
• Intake air or engine vacuum leaks
1. A/F sensor Inspection
Erase the OTC.
Start the engine and wait a minute.
recheck.
DTC U0001
NOTE:
• When other OTC is displayed, together with U0001,
Probable cause:
• Faulty CAN line(s)
• Faulty CAN connected unit(s)
• CAN communication failure
1. CAN Line (ECM-to-BCU) Open Circuit Inspection
- ECM 39P connector (page 4-71)
- BCU 39P connector (page 22-52)
ECM 39P connector [1] and BCU 39P connector [2].
CONNECTION:
A31 - Black/red
A30- Black
YES - GO TO STEP 2.
NO - • Open circuit in the Black/red wire
• Open circuit in the Black wire
J
4~0 J
PGM-FI SYSTEM
2. CAN Line (ECM-to-SCU) Open Circuit Inspection
Disconnect the SCU 48P connector (page 22-80).
ECM 39P connector [1] and SCU 48P connector [2].
CONNECTION:
A31 - Black/red
A30-Black
YES - GO TO STEP 3.
BI/R
3. CAN Line (ECM-to-lMU) Open Circuit Inspection

Disconnect the IMU connector {page 22-52).
[1]
•f ECM 39P connector [1] and IMU connector [2].
CONNECTION:
A31 - Black/red
A30-Black
YES - GO TO STEP 4.
NO - .
. Open circuit in the Black/red wire
Open circuit in the Black wire
[2]
4. CAN Line (ECM-to-TCM) Open Circuit Inspection
Disconnect the TCM 33P {Gray) connector {page
[1]
13-65).
ECM 39P connector [1] and TCM 33P {Gray)
connector [2].
CONNECTION:
I A31-B13
I
A30-B2
YES - GO TO STEP 5.
NO - .. Open circuit in the Black/red wire
Open circuit in the Black wire
I
[2]
5. CAN Line (ECM-to-Meter) Open Circuit
Inspection
[ Disconnect the meter 20P connector (page 22-14).
[1]
f Check the continuity between the wire harness side
r ECM 39P connector [1] and meter connector [2].
r CONNECTION:
A31 - Black/red
r A30- Black
' Is there continuity?

YES - GO TO STEP 6.
4-61
PGM-FI SYSTEM
6. CAN Line (ECM-to-ABS Modulator) Open Circuit
Inspection
Disconnect the ABS modulator connector (page 20-
[1)
8).
ECM 39P connector [1] and ABS modulator
connector [2].
CONNECTION:
A31-2
A30-11
YES - GO TO STEP 7.
7. CAN Line Short Circuit Inspection

j
[1)
ECM 39P connector [1] and ground.
CONNECTION:
A31-Ground
A30-Ground
I
YES - • Short circuit in the Black/red wire
• Short circuit in the Black wire
NO - GO TO STEP 8.
8. Communicated Part Inspection

Erase the DTC.
Replace the BCU, SCU (if equipped), IMU, TCM (If
equipped), meter, and ABS modulator one by one in
order with a new one.
recheck.
NO - Faulty original part
4-62
PGM-FI SYSTEM
DTC U0121
Probable cause:
1. CAN Line Open Circuit Inspection
[1 I
ECM 39P connector [1] and ABS modulator
connector [2].
CONNECTION:
A31-2
A30-11
YES - GO TO STEP 2.
2. ABS Modulator Inspection
Replace the ABS modulator with a new one.
Erase the DTC.
recheck.
NO - Faulty original ABS modulator
DTC U0125
Probable cause:
1. IMU Input Voltage Inspection
Disconnect the IMU connector (page 22-52).
Measure the voltage at the wire harness side IMU
connector [1).
CONNECTION: Black/red (+) - Green/blue (-)
YES - GO TO STEP 2.
NO - • Open or short circuit in the Black/red
wire
• Open circuit in the Green/blue wire
4-63
PGM-FI SYSTEM
- IMU connector (page 22-52)
ECM 39P connector [1] and IMU connector [2] .
CONNECTION:
A31 - Black/red
A30- Black
YES - GO TO STEP 3.
3. IMU Inspection
Replace the IMU with a new one.
Erase the DTC .
recheck.
DTC U0155
Probable cause:
[1 J
- Meter 20P connector (page 22-14)
ECM 39P connector [1] and meter connector [2] .
CONNECTION:
A31 - Black/red
A30- Black
YES - GO TO STEP 2.
2. Meter Inspection
Replace the meter with a new one.
Erase the DTC.
recheck.
NO - Faulty original meter
4-64
PGM-FI SYSTEM
DTC U019E
Probable cause:
1. Power Train CAN Line Open Circuit Inspection
[1]
- ECM 33P (Gray) connector (page 4-71)
- TCM 33P (Black) connector (page 13-65)
ECM 33P (Gray) connector [1] and TCM 33P
(Black) connector [2].
CONNECTION:
C25-A33
C24-A21
YES - GO TO STEP 2.
NO - • Open circuit in the Black/red wire [2]
2. Power Train CAN Line Short Circuit Inspection
[1]
ECM 33P (Gray) connector [1] and ground.
CONNECTION:
C25-Ground
C24-Ground
YES - • Short circuit in the Black/red wire
NO - GO TO STEP 3.
3. TCM Inspection
Erase the OTC.
recheck.
4-65
PGM-FI SYSTEM
MIL CIRCUIT TROUBLESHOOTING
When The Ignition Switch ON, The MIL
Does Not Come On
Check that the MIL comes on a few seconds and goes
off when the ignition switch is turned ON.
If the MIL and digital display do not function at all, refer
to meter power/ground line inspection (page 22-17).
When The Ignition Switch ON, The MIL

Does Not Go Off Within A Few
Seconds (Engine Starts)
NOTE:
• If the engine stop switch is in " ~ ". the MIL will stay
on even when the system is normal.
If the MIL stays on, check the meter indication when the
CAN line is abnormal (page 4-60).
If the indication is not according to above condition ,
check as follows.
[1]
TOOL:
Test probe, 2 pack 07ZAJ-RDJA 110
CONNECTION: A19- Ground

If there is continuity, check for short circuit in the Yellow
wire between the DLC and ECM.
If there is no continuity, replace the ECM with a known
good one and recheck (page 4-71 ).
4-66
PGM-FI SYSTEM
IMU
I
[3]
Remove the shock absorber (page 18-11 ).
- Nuts [1) [4]
- Washers [2)
- IMU mounting bolt/washers [3)
[2]
- IMU [4)
Remove the grommets [5] from the ABS modulator box
[6].
I NOTICE I
• Do not drop the /MU.
• Never use the dropped /MU.
• Do not use an impact wrench while removing or
installing the /MU.
• Do not have an impact on the /MU while removing or
installing it.
TORQUE:
IMU mounting bolt/washer:
6.0 N·m (0.6 kgf·m, 4.4 lbMt)
A/F SENSOR
I REMOVAL/INSTALLATION
I NOTICE I
• Handle the AIF sensor with care.
• Do not get grease, oil, or other materials in the AIF
sensor air hole.
• Be careful not to damage the sensor wire.
• Do not use an impact wrench while removing or
installing the AIF sensor.
LEFT SIDE
Remove the left middle cowl (page 2-7).
Open the clamp [1) and release the left A/F sensor wire
[2].
Disconnect the left A/F sensor 4P connector [3) .
r
I
4-67
PGM-FI SYSTEM
Remove the left A/F sensor [1] using the special tool.
TOOL:
Sensor socket wrench [2] FRXM17 (Snap-on)
or equivalent
TORQUE:24.5 N·m (2.5 kgf·m, 18 lbMt)
NOTE:
• Route the hose and wire properly (page 1-26).
RIGHT SIDE
Front
Open the clamp [1] and release the right A/F sensor
wire [2]. LRight
Disconnect the right A/F sensor 4P connector [3] .
NOTE:
• When disconnecting the linear solenoid 4P (Black)
connector [4] at the same time as the right A/F
sensor 4P connector, mark the main wire harness
side connectors to prevent the miss connection.

Remove the right A/F sensor [1] using the special tool.
TOOL:
Sensor socket wrench [2] FRXM17 (Snap on)
or equivalent
TORQUE:24.5 N·m (2.5 kgf·m, 18 lbMt)
NOTE:
MAP SENSOR
Remove the fuel tank (page 7-7).
Disconnect the MAP sensor 3P (Black) connector [1).
Remove the screw [2] and MAP sensor [3] from the
throttle body setting plate.
Disconnect the MAP sensor hose [4) .
4-68
PGM-FI SYSTEM
IAT SENSOR
Remove the screws [1].
Remove the IAT sensor [2] and 0-ring [3].
NOTE:
• Check the 0-ring and replace if necessary as a IAT
sensor assembly.
ECT SENSOR
Remove the thermostat (page 8-6).
Disconnect the ECT sensor 2P (Black) connector [1].
Remove the ECT sensor [2] and 0-ring [3].
TORQUE:12 N·m (1.2 kgf·m, 9 lbf-ft)
NOTE:
• Do not apply oil to the 0-ring.
• Check the 0-ring and replace if necessary as a ECT
sensor assembly.
'f INSPECTION
f Remove the ECT sensor (page 4-69).
Suspend the ECT sensor [1] in a pan of coolant on an
electric heating element and measure the resistance
through the sensor as the coolant heats up.
• Soak the ECT sensor in coolant up to its threads
with at least 40 mm (1.6 in) from the bottom of the
pan to the bottom of the sensor.
Keep the temperature constant for 3 minutes before
testing. A sudden change of temperature will result
in incorrect readings. Do not let the thermometer or
ECT sensor touch the pan.
Measure the resistance between the ECT sensor
terminals. [1]
(
.
r Temperature
Resistance
40°C (104°F)
1.0-1 .3 kO
100°C (212°F)
0.14-0.18 kO
Replace the ECT sensor if it is out of specification.
4-69
PGM-FI SYSTEM
EGCA
Disconnect the EGCA cables from the valve cable
guide of the muffler (page 2-47).
Disconnect the EGCA 6P connector [1].
bolt [2] and release the rear master cylinder reservoir
[3].
NOTE:
• Keep the rear master cylinder reservoir upright to
prevent air from entering the hydraulic system.
Remove the socket bolt A [4] and trim clip [5].
Loosen the socket bolt B [6] and remove the EGCA
assembly [7].
[2] [3]
[6]
[5]~
Remove the screw [1] and cable cover [2].

[3]/[4] [5] [6]
Remove the tapping screw [3] and washer [4].
Remove the EGCA [5] from the EGCA cover [6].
[1]
4-70
PGM-FI SYSTEM
Turn the EGCA pulley [1] and disconnect the EGCA
cables [2] from the EGCA pulley.
TORQUE:
Rear master cylinder reservoir mounting bolt:
10 N·m (1.0 kgf·m, 7 lbMt)
NOTE:
• Route the cables properly (page 1-26).
• If the EGCA is not replaced , install the EGCA and
then adjust the EGCA cable (page 3-17).
• If the EGCA is replaced with a new one, connect the
EGCA cables and remove the fixed screw from the
EGCA pulley. After installing the EGCA, perform the ~ - - - - - - -- - - - ' - -- - - - - _ _ J
operating inspection of the EGCA cable (page 3-17).
ECM
REMOVAL/ INSTALLATION
ECM
Release the fuel level sensor 2P (Black) connector [1]
and fuel pump unit 3P (Black) connector [2] from the
ECM tray lid [3].
Release the fuel tank breather hose [4] from the guide
[5].
Open the ECM tray lid by releasing its slot [6] from the
tab [7] .

ECM 39P (Black) connector [1]
- ECM 33P (Black) connector [2]
- ECM 33P (Gray) connector [3]
Remove the ECM [4] .
NOTE:
• Route the hose and wires properly (page 1-26).
ECMTRAY
Remove the ECM (page 4-71 ).
Remove the tool box (page 2-26).
4-71
PGM-FI SYSTEM
Remove the trim clips [1].
Release the tab [2] and remove the ECM tray [3].
POWER/GROUND LINE INSPECTION

POWER INPUT LINE
[1]
TOOL:
CONNECTION: A11 (+)-Ground(-)

There should be battery voltage with the ignition switch
turned ON.
If there is no voltage, check the following :
Open circuit in the Brown or Brown/black wires
between the Fl relay and ECM
Fl relay and related circuit
GROUND LINE
Disconnect the ECM 39P and 33P (Black) connectors [1]
(page 4-71 ).
G
Check for continuity between the following connector G (A10) (A9)
terminals and ground:
- ECM 39P connector [1]
- ECM 33P (Black) connector [2]
TOOL:
CONNECTION: Green (A9) - Ground

Green (A10)- Ground
Green (A22) - Ground
Green/blue (812) - Ground [2]
There should be continuity at all times.
If there is no continuity, check for open circuit in the
Green or Green/blue wires.
4-72
PGM-FI SYSTEM
VS SENSOR
Remove the battery box (page 21-6).
Disconnect the VS sensor 3P (Black) connector [1] .
Remove the bolt [2], VS sensor [3], and 0-ring [4].
NOTE:
• Replace the 0-ring with a new one.
• Apply engine oil to a new 0-ring.
GP SENSOR (MT model)

Disconnect the GP sensor 3P (Black) connector [1].

- GP sensor mounting bolt [1]
- Sensor cover [2]
- GP sensor [3]
- 0-ring [4]
TORQUE:
GP sensor mounting bolt:
12 N·m (1.2 kgf·m, 9 lbHt)
NOTE:
• Always replace the 0-ring with a new one.
Align the flat surfaces of the GP sensor and shift
drum end.
• Route the wire properly (page 1-26).
4-73
PGM-FI SYSTEM
SHIFT SPINDLE SWITCH (MT model)
Release the rubber cap [1].
Remove the nut [2] and disconnect the shift spindle
switch terminal [3].
Remove the shift spindle switch [4] and sealing washer
[5].
TORQUE:
Shift spindle switch:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Shift spindle switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
NOTE:
• Apply engine oil to the shift spindle switch threads
• Replace the sealing washer with a new one.
GRIP APS
GRIP APS INSPECTION
NOTE:
• Before starting the inspection, check for loose or
poor contact on the grip APS 8P connector and ECM
39P (Black) connector, then recheck the OTC.
1. APS 1 and 2 Input Voltage Inspection
[1]
Disconnect the grip APS 8P connector [1] (page 22-
34).
Measure the voltage at the harness side.
CONNECTION: Brown (+) [VCC 1) - Ground
White (+) [VCC 2) - Ground
Is the voltage about 5 V?
YES - GO TO STEP 2.
NO - Open or short circuit in the White or Brown
wire. If the wires are OK, replace the ECM
with a known good one and recheck (page
4-71 ).
2. APS 1 and 2 System Inspection
Erase the OTC (page 4-8).
Check the APS 1 and 2 with the MCS.
Note the APS 1 and 2 output voltage.
Calculate the 5 V / input voltage x output voltage.
Standard (at throttle opened):
APS 1: 4.878 - 4.902 V
APS 2: 4.878 - 4.902 V
Standard (at throttle closed):
APS 1: 0.137-0.161 V
APS 2: 0.083- 0.107 V
Is the voltage within standard?
YES - Intermittent failure
NO - GO TO STEP 3.
4-74
PGM-FI SYSTEM
3. APS System Inspection
Connect a 5 V battery to the grip APS 8P connector
terminals at the APS side as shown.
CONNECTION:
APS 1: Yellow/red(+)- Yellow/black(-)
APS 2: White/red (+) - White/black (-)
Measure the voltage at the APS side.

CONNECTION:
APS 1: Blue/white (+) - Yellow/black (-)
APS 2: Gray (+) - White/black (-) Y/R Y/81
Calculate the 5 V / input voltage x output voltage.

STANDARD (at throttle opened):
APS 1: 4.588 - 4.612 V ® 8 ® 8
APS 2: 2.288- 2.312 V 5V 5V
STANDARD (at throttle closed): BATIERY BATIERY
APS 1: 0.878 - 0.902 V
APS 2: 0.238 - 0.262 V
Is the voltage within standard?

YES - Replace the ECM with a known good one
and recheck (page 4-71 ).
NO - Replace the right handlebar switch with a
known good one and recheck (page 22-
34 ).
REMOVAUINSTALLATION
Refer to the right handlebar switch servicing (page 22-
34 ).
Fl RELAY
Remove the ECM tray (page 4-71 ).
Release the Fl relay [1] from the stay.
Disconnect the relay connector [2] and remove the Fl
relay.
4-75
PGM-FI SYSTEM
RELAY INSPECTION
Remove the Fl relay (page 4-75).
[1]
Connect an ohmmeter to the Fl relay [1] terminals as
shown.
Connect a 12 V battery to the Fl relay terminals as
shown.
There should be continuity only when 12 V battery is
connected.
If there is no continuity when the 12 V battery is
connected, replace the Fl relay.
Install the Fl relay (page 4-75).
TBWRELAY
Remove the power box cover and TBW relay [1].
·,
RELAY INSPECTION
Remove the TBW relay (page 4-76).
[1]
Connect an ohmmeter to the TBW relay [1] terminals as
shown.
Connect a 12 V battery to the TBW relay terminals as
shown.
There should be continuity only when 12 V battery is
connected.
If there is no continuity when the 12 V battery is
connected, replace the TBW relay.
Install the TBW relay (page 4-76).
4-76
PGM-FI SYSTEM
SUB VB RELAY
r
.'I Remove the main seat (page 2-5).
Remove the power box cover and sub VB relay [1].
- For relay inspection (page 4-76)
f CKP SENSOR
! REMOVAL/INSTALLATION
Disconnect the CKP sensor 3P (Gray) connector [1].
fr Remove the CKP sensor bolt [2], CKP sensor [3], and
0-ring [4].
,
i
f
TORQUE:
CKP sensor bolt:
12 N·m (1 .2 kgf·m, 9 lbMt)
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NOTE:
,
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4-77
MEMO
.
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5. IGNITION SYSTEM
SERVICE INFORMATION··· .. ··················· 5-2 IGNITION SYSTEM INSPECTION · · · · · · · · · · · · · 5-7
I
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TROUBLESHOOTING · · · · .... · · ...... · · .......... 5-3 IGNITION COIL .... ... ............................ 5-10
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SYSTEM LOCATION · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · 5-4
SYSTEM DIAGRAM · · · · · · · · · · · · · · · ·· · .. · .. · · · · · · · · 5-5

IGNITION TIMING · .. · · · · · · · .. · · · .. · · · · · · · · · · · · · · · 5-13
I
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5-1
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
NOTICE
• The ECM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may
damage the module. Always turn off the ignition switch before servicing.
• Use spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
• When servicing the ignition system , always follow the steps in the troubleshooting table (page 5-3).
• Some electrical components may be damaged if terminals or connectors are connected or disconnected wh ile the ignition switch
is turned to ON position and current is present.
• A faulty ignition system is often related to poorly connected or corroded connections. Check those connections before
proceeding .
• Make sure that the battery is adequately charged . Using the starter motor with a weak battery results in a slower engine
cranking speed as well as no spark at the spark plug.
• Refer to following components informations:
- ECM (page 4-71)
- TCM (OCT model) (page 13-65)
- IMU (page 4-67)
- Fl relay (page 4-75)
- Neutral switch (OCT model) (page 13-65)
- Neutral switch (MT model) (page 22-45)
- Engine stop switch (right handlebar switch) (page 22-34)
- CKP sensor (page 4-77)
- Sidestand switch (page 22-45)
• The following color codes are used throughout this section .
Lb = Light blue Lg = Light green 0 = Orange P = Pink R = Red V = Violet
TOOLS
lgnitionMate peak voltage tester Peak voltage adaptor Test probe , 2 pack
MTP07-0286 (U.S.A. only) 07HGJ-0020100 07ZAJ-ROJA 110
(Not available in U.S.A.)
with commercially available digital

multimeter (impedance 10 MO/OCV
minimum)
l
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5-2
IGNITION SYSTEM
I TROUBLESHOOTING
• Inspect the following before diagnosing the system.
- Faulty spark plug
- Loose spark plug cap and spark plug connection
r - Loose ignition coil connectors
- Water got into the spark plug cap (Leaking the ignition coil secondary voltage)
• "Initial voltage" of the ignition primary coil is battery voltage with the ignition switch turned ON (The engine is not cranked by the
starter motor).
No spark at spark plug
Unusual condition Probable cause (Check in numerical order)
Ignition No initial voltage with the 1. Faulty ignition switch
coil ignition switch ON (Other 2. Faulty Fl relay or its related circuits
primary electrical components are 3. An open circuit between the Fl relay and ignition coil wires
voltage normal). 4. Loose or poor connection of the primary terminal, or an open circuit in the
primary coil
5. Faulty ECM (in case when the initial voltage is normal with the ECM
connector disconnected}
Initial voltage is normal, but it 1. Incorrect peak voltage adaptor connections (System is normal if
drops by 2 - 4 V while cranking measured voltage is over the specifications with reverse connections)
the engine. 2. Battery is undercharged (Voltage drops largely when the engine is
started).
3. An open circuit or loose connection in ECM power/ground lines
4. An open circuit or loose connection between the ignition coil and ECM
wires
5. Faulty CKP sensor or related circuit
6. Faulty ECM (in case when above No. 1 through 5 are normal)
Initial voltage is normal, but 1. Incorrect peak voltage adaptor connections
there is no peak voltage while 2. Faulty peak voltage adaptor
cranking the engine. 3. Faulty CKP sensor
Initial voltage is normal, but 1. The multimeter impedance is too low; below 10 MO/DCV.
peak voltage is lower than the 2. Cranking speed is too slow (Battery is undercharged).
standard value. 3. The sampling timing of the tester and measured pulse were not
synchronized (System is normal if measured voltage is over the standard
voltage at least once)
Initial and peak voltages are 1. Faulty spark plug or leaking ignition coil secondary current ampere
I normal, but no spark jumps at

plug.
2. Faulty ignition coil
l
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5-3
IGNITION SYSTEM
SYSTEM LOCATION
IMU
No.1-1 IGNITION
COIL
J
POWER BOX
- ST-MAG
BATTERY TCM (DCT model )
CKP SENSOR SIDESTAND SWITCH _J

- MAIN FUSE 30 A
NEUTRAL SWITCH
5-4
IGNITION SYSTEM
SYSTEM DIAGRAM
MT model:
Bl/Gr Bl
J_ e BATTERY
EB ECM
Gr W y y Bl G Bl R w y
Lg
w
it BI/R
NEUTRAL
SWITCH IMU
ENGINE ~/W
STOP
SWITCH CKP
SENSOR
MAIN
FUSE
30A
IGNITION
SWITCH
ST-MAG
10 A Fl RELAY
0
Fl 15A
R ~O---R/Bl-<:l./'0-- Bl --.-wvv,------r-G
W ~ R / B u ------+-{)
.__~ 1- G
SIDESTAND
SWITCH
G---0~G/W
_L
Br/Bl
t
t:
Br
Br/BI
Br------.-----t-~
Br Br Br/Bl Br/Bl
Bl: Black Bu/Bl Bu/R Bu/W Bu/Y
Y: Yellow
Bu: Blue
~
..... ";l N
G: Green IGNITION ..... .....
R: Red
W: White
COILS
z
ci "'z
ci
z
ci "'z
ci
Br: Brown
Lg: Light green
Gr: Gray
iL iL iL iL
5-5
IGNITION SYSTEM
DCT model:
Bl/Gr Bl
J_ eBATIERY(±) TCM ECM
--
Bl
Gr w y y Bl G Bl R w y
w 1
BI/R
it BI/R
1
l
¥
NEUTRAL
SWITCH IMU
J
ENGINE iI
STOP
I
-- SWITCH CKP
SENSOR
MAIN
IGNITION
0 I
i
FUSE ST-MAG
30A
SWITCH
10 A
R _ /o--- R/BI -<:l./'C}- Bl
Fl RELAY
l
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G SIDESTAND
W - - - - - 0 . / 0 - - - R/Bu SWITCH
Fl 15A
G -o '------o-- G/W
G
_L
--
Br/Bl
Br
t
C r/Bl
Br
Br Br Br/Bl Br/Bl
Bl : Black Bu/Bl Bu/R Bu/W Bu/Y
Y: Yellow
Bu : Blue
..- ~ C\I
G: Green IGNITION ..-' ..- N
R: Red COILS ci ci ci
z z z
W: White
Br: Brown
Lg : Light green
Gr: Gray
iL- iL- iL- iL- Ij
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5-6
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
NOTE:
• If there is no spark at the plug, check all connections
for loose or poor contact before measuring the peak
voltage.
• Use a commercially available digital multimeter with
an impedance of 10 MO/DCV minimum.
• The display value differs depending upon the
internal impedance of the multimeter.
• If the peak voltage tester (U.S.A. only) is used,
follow the manufacturer's instructions.
Connect the peak voltage adaptor [1] to the digital
multimeter [2], or use the peak voltage tester. [2)
TOOLS:
lgnitionMate peak voltage tester MTP07-0286
(U.S.A. only) or
Peak voltage adaptor 07HGJ-0020100
(Not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 M!l/DCV minimum)
IGNITION COIL PRIMARY PEAK

VOLTAGE
NOTE:
• Check all system connections before performing this
inspection. Loose connectors can cause incorrect
readings.
• If the system is disconnected, incorrect peak voltage
might be measured.
Disconnect the spark plug caps (page 5-10).
Connect a known good spark plug [1] to the spark plug
cap and ground it to the cylinder head as done in a
spark test.
t_
5-7
IGNITION SYSTEM
With the ignition coil primary wire connected, connect
the peak voltage tester (U .S.A. only} or peak voltage
adaptor probes to the ignition coil primary terminal and
ground.
- No.1-1 ignition coil primary terminal [1]
No.1-2 ignition coil primary terminal [2]
- No.2-1 ignition coil primary terminal [3]
No.2-2 ignition coil primary terminal [4]
TOOLS:
lgnitionMate peak voltage tester MTP07-0286
(U.S.A. only) or
Peak voltage adaptor 07HGJ-0020100
(Not available in
U.S.A.)
with commercially available digital multimeter
(impedance 10 Mn/DCV minimum)
CONNECTION:
No.1-1: Blue/black (+) - Ground (-)
No.1-2: Blue/white(+)- Ground(-)
No.2-1: Blue/red (+) - Ground (-)
No.2-2: Blue/yellow(+) - Ground (-)
Turn the ignition switch ON . _J
Check the initial voltage at this time. I
The battery voltage should be measured. j
If the initial voltage cannot be measured, follow the
checks described in the troubleshooting table J
(page 5-3). l
j
Shift the transmission into neutral.
Crank the engine with the starter motor and measure l
the ignition coil primary peak voltage .
l
PEAK VOLTAGE: 100 V minimum .' I
If the peak voltage is abnormal, follow the checks

described in the troubleshooting table (page 5-3).
CKP SENSOR CIRCUIT INSPECTION l

Remove the skid plate (page 2-25). J
Disconnect the CKP sensor 3P (Gray) connector [1]. J
J
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5-8 J
IGNITION SYSTEM
POWER INPUT/GROUND LINE INSPECTION
Measure the voltage at the wire harness side CKP [1]
sensor 3P (Gray) connector [1] terminals.
CONNECTION: Yellow(+) - White(-)
STANDARD: 4.75- 5.25 V
If standard voltage does not appear, the Yellow and/or
White wires have an open circuit.
SIGNAL LINE INSPECTION

[1]
Disconnect the ECM 33P {Black) connector (page 4-
71 ).
CKP sensor 3P (Gray) connector [1] and ECM 33P
(Black) connector [2] terminals.
TOOL:
r
CONNECTION: Yellow- 816 y B16
I
If there is no continuity, check for open circuit in the
Yellow wire.

CKP sensor 3P (Gray) connector [1] terminal and [1]
ground .
CONNECTION: Yellow- Ground

If there is continuity, check for short circuit in the Yellow y
wire.
f
I
5-9
IGNITION SYSTEM
IGNITION COIL
IGNITION COIL TRAY REMOVAL/
INSTALLATION
Remove the PAIR control solenoid valve stay (page 7-
20).
Disconnect the No.1-2 spark plug cap [1] .
Disconnect the No.2-2 spark plug cap (1]. j

Release the spark plug wire clip [2] from the right
radiator shroud. J
J
Disconnect the ignition sub harness 6P connector [1] .

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1
''
5-10 J
IGNITION SYSTEM
Release the bosses [1] from the grommets [2] by pulling
the ignition coil tray assembly [3] rearward .
Disconnect the No.1-1 spark plug cap [4] and No.2-1
spark plug cap [5].
Remove the ignition coil tray assembly.
NOTE:
[1)
[3)
r
t [2)
k
r
'
[4) [5)
~
I
5-11
IGNITION SYSTEM
IGNITION COIL TRAY DISASSEMBLY/
ASSEMBLY
Remove the ignition coil tray assembly (page 5-10).
Release the wire clip [1] .
Remove the bolts [2] .
- No.1-1 ignition coil connectors [3]
Remove the following parts from the ignition tray [7] :
- No.1-1 ignition coil [8]
- Ignition sub harness [12]
NOTE:
• Route the wire harness properly (page 1-26).
1
[2]
'
~
(\ (10]
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[1] (12]
1
A
j
5-12
IGNITION SYSTEM
IGNITION TIMING
Warm up the engine.
Stop the engine and remove the timing hole cap.
Connect the timing light [1) to the No.1-2 spark plug
wire.
NOTE:
• Read the instructions for timing light operation.
Start the engine and let it idle.
IDLE SPEED: 1,250 ± 100 r/min
. The ignition timing is correct if the "F" mark [2) on the

flywheel aligns with the index mark [3) on the alternator
cover.
Apply engine oil to a new 0-ring [1) and install it to the

timing hole cap [2].
Apply grease to the timing hole cap threads.
Install and tighten the timing hole cap to the specified
torque.
TORQUE: 6.0 N·m (0.6 kgf·m, 4.4 lbHt)
,,_
5-13
MEMO
' .,
6. ELECTRIC STARTER
' SERVICE INFORMATION· .. ····················· 6-2 STARTER MOTOR····················· ············ 6-7
STARTER RELAY SWITCH········ ············· 6-9

' TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-3
SYSTEM LOCATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-4 STARTER RELAY································ 6-11
SYSTEM DIAGRAM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-5
6-1
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
I NOTICE
If current is kept flowing through the starter motor causing it to turn while the engine is not cranking over, the starter motor may be
damaged.
• The starter motor can be serviced with the engine installed in the frame.
• Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. )
• When servicing the starter system, always follow the steps in the troubleshooting table (page 6-3).
• Before starting any troubleshooting, check the DTC.
• Refer to the following components information:
- Neutral switch (OCT model) (page 13-65)
- Neutral switch (MT model) (page 22-45)
- Ignition switch (page 22-26)
- Starter switch (right handlebar switch) (page 22-34)
- Engine stop switch (right handlebar switch) (page 22-34)
- Clutch switch (MT model) (page 22-44)
- Sidestand switch (page 22-45) l
- The following color codes are used throughout this section.
Be= Beige Bl= Black

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Br= Brown Bu= Blue G = Green Gr= Gray
Lb = Light blue Lg = Light green 0 = Orange P = Pink R= Red V = Violet
W = White Y = Yellow Il
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6-2
ELECTRIC STARTER
TROUBLESHOOTING
It
Unusual condition Probable cause (Check in numerical order)
Starter motor DCT model: 1. Loose or poor contact on related connectors and terminals
does not turn 2. Blown fuse
3. Weak battery
4. Faulty CAN communication
5. Faulty starter relay switch
6. Faulty starter relay or its related circuits
7. Faulty neutral switch or its related circuits
8. Faulty TR sensor or its related circuits
9. Faulty starter motor or its related circuits
10.Faulty right handlebar switch or its related circuits
,- 11 .Faulty TCM
12.Faulty ECM (in case when above No. 1 through 11 are normal}
MT model: When the 1. Loose or poor contact on related connectors and terminals
transmission is in 2. Blown fuse
any gear with the 3. Weak battery
,.
II
sidestand retracted
and clutch lever
4. Faulty starter relay switch
5. Faulty starter relay or its related circuits
pulled in 6. Faulty clutch switch or its related circuits
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7. Faulty clutch cruise cancel switch or its related circuits
8. Faulty sidestand switch or its related circuits
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10.Faulty right handlebar switch or its related circuits
11 .Faulty ECM (in case when above No. 1 through 10 are normal)
When the 1. Loose or poor contact on related connectors and terminals
transmission is in 2. Blown fuse
neutral with the 3. Weak battery
I sidestand lowered 4. Faulty starter relay switch
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and clutch lever 5. Faulty starter relay or its related circuits
!- released 6. Faulty neutral switch or its related circuits
7. Faulty GP sensor or its related circuits
9. Faulty right handlebar switch or its related circuits
10.Faulty ECM (in case when above No. 1 through 9 are normal)
Starter motor turns slowly 1. Low battery voltage
2. Poorly connected battery terminal cable
3. Poorly connected starter motor cable
4. Faulty starter motor
5. Poorly connected battery ground cable
Starter motor turns, but engine does not turn 1. Starter motor is running backwards
- Case assembled improperly
- Terminals connected improperly
2. Faulty starter clutch
3. Damaged or faulty starter pinion gear and/or reduction gears
Starter relay switch "Clicks", but engine does not turn 1. Crankshaft does not turn due to engine problems
over
6-3
ELECTRIC STARTER
SYSTEM LOCATION
FRONT BRAKE SWITCH ENGINE STOP SWITCH
BATTERY
REAR BRAKE SWITCH
6-4
ELECTRIC STARTER
SYSTEM DIAGRAM
MT model:
from Fl RELAY
l CLUTCH CRUISE
CANCEL SWITCH
Br - - - - 0 - - 0 - Bl
Bl/Gr Bl G ----0~ BI/R ECM

_L 8 EB _[ CLUTCH
BATIERY SWITCH
.----Lg
Bl y Gr G Gr Gr W
BI/R w Y/W
n
NEUTRAL
SWITCH GP
IMU
SENSOR
lGNITION
? SWITCH
R R/BI
f ST-MAG
? 10A
Bl
t---B1
I ~G/R G
SIDESTAND
Bl
SWITCH
STARTER
RELAY G - - - 0~ G/W _____ _ J
G ,----G-~t---__j
STARTER _l_
RELAY
SWITCH STARTER
SWITCH
G~_)----_J
STARTER
MOTOR GTBI/W
Bl : Black ENGINE STOP
Y: Yellow SWITCH
G: Green
R: Red
W : White
Lg: Light green
Gr: Gray
6-5
ELECTRIC STARTER
DCT model:
Bl/Gr Bl
J_ 8 EB TCM ECM
BATIERY
'I
Y W Gr Bl
Bl G G Gr Gr W '
BI/R Y/W
~ 2Lg NEUTRAt/R
~ SWITCH
IMU
FRONT BRAKE
- SWITCH
.
IGNITION
SWITCH
HORN/STOP {BI/R ~0---- G/Y _w
10 A
o- R/BI ~ BI/R REAR BRAKE
I SWITCH
R/BI
I s~G1oi a,_,,./'~s,~G
--- Bl
R 1
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---Bl
G/R
STARTER
RELAY
G
l-
G
SIDESTAND
SWITCH
G ---0 ~ G/W - -----' 'i

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STARTER
RELAY
J_
SWITCH STARTER
SWITCH
Bl G -----00'.}----
Bl: Black
STARTER
MOTOR
G
U BI/W
Y: Yellow
G: Green ENGINE STOP
R: Red SWITCH
W: White
Lg: Light green
Gr: Gray
6-6
ELECTRIC STARTER
STARTER MOTOR
Release the boots [1].
Remove the starter motor cable terminal nut/washer [2]
and disconnect the starter motor cable [3].
Remove the bolts [4] and disconnect the battery (-)
negative cable [5].
Remove the starter motor [6] .
Remove the 0-ring [1].

TORQUE:
Starter motor cable terminal nut/washer:
10 N·m (1.0 kgf·m, 7 lbMt)
NOTE:
• Apply engine oil to the new 0-ring.
I NOTICE I
The coil may be damaged if the magnet pulls the armature against the motor case.
STARTER MOTOR SETIING BOLTS

4.9 N·m (0.5 kgf-m, 3.6 lbf-ft)
TERMINAL BOLT
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ARMATURE
NEGATIVE BRUSH
REAR COVER NUT/WASHER

~ - : , 0-RING
6-7
ELECTRIC STARTER
When installing the front cover [1] and rear cover [2]
onto the motor case [3], align the lines as shown. Align [2]
[1)
INSPECTION
FRONT COVER
Check the oil seal [1] in the front cover for deterioration,
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wear, or damage. [1 J
Turn the inner race of the bearing [2] in the front cover
with your finger.
The bearing should turn smoothly and quietly.
Also check that the outer race fits tightly in the front
cover.
Replace the starter motor as an assembly if necessary.
[2)
REAR COVER
Check for continuity or no continuity for each part of
rear cover [1] as below: [3] [1)
- Between the positive brush [2] and cable terminal

[3]: should be continuity.
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- Between the cable terminal and the rear cover: j
-,
should be no continuity. [2) i
- Between the positive brush and rear cover: should J
be no continuity.
- Between positive brush and negative brush [4]:
should be no continuity.
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ARMATURE j
Clean the metallic debris off the commutator bars [1 ].
[1)
Check the commutator bars for discoloration.
Check for continuity on the armature as below:
Between pair of commutator bars: there should be
continuity.
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Between each commutator bar and the armature
shaft [2]: should be no continuity. l
Replace the starter motor as an assembly if necessary.
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[2)
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6-8
ELECTRIC STARTER
,~ Remove the socket bolts [1].
r
Remove the battery box cover [2] .
..._
Release the starter relay switch [1] from the battery box.
t Remove the starter relay switch cover [2].
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Disconnect the
connector [1].
starter relay switch 4P (Black)
Remove the bolts [2].

r Disconnect the starter motor cable [3] and battery
positive(+) cable [4].
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INSPECTION
Remove the battery box cover (page 6-9).
f
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Shift the transmission into neutral.
Turn the ignition switch ON and engine stop switch "O".
t Push the starter switch.
r The coil is normal if the starter relay switch [1] clicks.

If you don't hear the starter relay switch "CLICK",
inspect the starter relay switch as follows:
..
r 6-9
ELECTRIC STARTER
STARTER RELAY SWITCH INPUT VOLTAGE LINE
INSPECTION
Disconnect the starter relay switch 4P (Black)
connector (page 6-9). [1]

starter relay switch 4P (Black) connector [1] terminals.
CONNECTION: Red - Black
R
If there is no continuity, check the following :
- Blown sub fuse ST-MAG 10 A
Red wire between the starter relay switch and
ignition switch
Red/black wire between the ignition switch and
power box
Black wire between the power box and starter relay
switch
Ignition switch
STARTER RELAY SWITCH GROUND LINE

INSPECTION
Remove the starter relay (page 6-11 ).
[1] [2]
Connect the wire harness side starter relay 4P
connector [1] terminals with a jumper wire [2].
CONNECTION: Green/red- Green
G/R

[1]
starter relay switch 4P {Black) connector [1] terminal
and ground .
CONNECTION: Green/red - Ground

If there is no continuity, check the following :
Green/red wire between the starter relay switch and
starter relay
- Green wire between the starter relay and ground
If wires are OK, check the starter relay.
6-10
ELECTRIC STARTER
OPERATION CHECK
Remove the starter relay switch (page 6-9).
Connect a 12 V battery to the starter relay switch as
shown.
There should be continuity between the cable terminals
when the battery is connected, and no continuity when
the battery is disconnected.
e
BATTERY
STARTER RELAY
Release the starter relay [1] from the stay.
Disconnect the relay connector [2] and remove the
starter relay.
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6-11
MEMO
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7. FUEL SYSTEM
SERVICE INFORMATION .. ······················ 7-2 FUEL RELAY ...................................... 7-14
COMPONENT LOCATION ....................... 7-3 AIR CLEANER HOUSING ..................... 7-14
FUEL LINE INSPECTION ........................ 7-4 THROTTLE BODY ............................... 7-16
FUEL TANK .......................................... 7-7 FUEL INJECTOR ................................. 7-17
FRONT CROSS PLATE .......................... 7-8 SECONDARY AIR SUPPLY SYSTEM ...... 7-19
FUEL PUMP UNIT .................................. 7-8 EVAP PURGE CONTROL SOLENOID VALVE/
CANISTER ......................................... 7-22
7-1
FUEL SYSTEM
SERVICE INFORMATION
GENERAL 4
• Before disconnecting the fuel feed hose, relieve fuel pressure from the system (page 7-4).
• Seal the intake ports with tape or a clean cloth to keep dirt and debris from entering the engine after the throttle body or fuel rail
has been removed.
• Do not damage the throttle body. It may cause incorrect throttle valve operation .
• Prevent dirt and debris from entering the throttle bore and air passages after the throttle body has been removed . Clean them
using compressed air if necessary.
• Do not loosen or tighten the white painted nuts and screws of the throttle body. Loosening or tightening them can cause throttle
valve and idle control failure .
• The parts of the throttle body not shown in this manual should not be disassembled.
• For fuel level sensor inspection (page 22-25).
TOOLS
Fuel pressure gauge Pressure gauge attachment set Hose attachment, 6 mm/9 mm l
07 406-0040004 070MJ-K260100 07ZAJ-S5A0130 l
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or 07406-0040008 (U .S.A. only) Not available in U.S.A. Not available in U.S.A.

or 07406-004000C (U.S.A. only)
Hose attachment, 8 mm/9 mm Attachment joint, 8 mm/9 mm Attachment joint, 6 mm/9 mm
07ZAJ-S7C0100 07ZAJ-S7C0200 07ZAJ-S5A0150
Not available in U.S.A. Not available in U.S.A. Not available in U.S.A.

Fuel pressure manifold hose Pressure gauge adapter male "C" Pressure gauge adapter female "C"
07AMJ-HW3A100 (U .S.A. only) 07AAJ-S6MA300 (U.S.A. only) 07AAJ-S6MA500 (U.S.A. only)
7-2
FUEL SYSTEM
COMPONENT LOCATION
7-3
FUEL SYSTEM
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING
NOTE:
• Before disconnecting the fuel hose, relieve pressure
from the system as follows.
1. Turn the ignition switch OFF.
2. Lift and support the fuel tank (page 3-4 ).
3. Disconnect the fuel pump unit 3P (Black) connector
[1].
4. Start the engine and let it idle until the engine stalls.
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QUICK CONNECT FITTING REMOVAL/
INSTALLATION j
NOTE: J
• Clean around the quick connect fitting before J
disconnecting the fuel feed hose, and be sure that
no dirt is allowed to enter into the fuel system.
I
• Do not bend or twist the fuel feed hose.
Relieve the fuel pressure (page 7-4 ).
Disconnect the battery negative(-) cable (page 21-6). j
Push the retainer tab [1 ] forward. [2]
Press down the retainer and disconnect the connector
[2] from the fuel pump joinUfuel rail.
NOTE:
• To prevent damage and keep foreign matter out,
cover the disconnected connector and pipe end with
the plastic bags [3] .
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Press the connector onto the fuel pump joinUfuel rail
until the retainer locks with a "CLICK".
NOTE:
I
• If it is hard to connect, put a small amount of engine
oil on the pipe end. j
Make sure the connection is secure; check visually and
by pulling the connector.
Increase the fuel pressure (page 7-5).
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7-4
FUEL SYSTEM
FUEL PRESSURE NORMALIZATION
1. Connect the fuel pump unit 3P (Black) connector [1].
Connect the battery negative(-) cable (page 21-6).
The fuel pump will run for about 2 seconds and fuel
pressure will rise.
NOTE:
• Do not start the engine.
4. Repeat previous step 2 or 3 times, and check that
there is no leakage in the fuel supply system.
5. Install the fuel tank (page 3-4).
FUEL PRESSURE TEST

Relieve the fuel pressure (page 7-4).
[1]
Disconnect the quick connect fitting (fuel pump side)
(page 7-4).
Attach the special tools between the fuel pump joint and
fuel feed hose.
TOOLS:
Fuel pressure gauge [1] 07406-0040004
Pressure gauge attachment set [2] 070MJ-K260100
Hose attachment, 6 mm/9 mm [3] 07ZAJ-S5A0130
Hose attachment, 8 mm/9 mm [4] 07ZAJ-57C0100
Attachment joint, 8 mm/9 mm [5] 07ZAJ-S7C0200
Attachment joint, 6 mm/9 mm [6] 07ZAJ-S5A0150
U.S.A. TOOLS:
Fuel pressure gauge 07406-0040008 or
07406-004000C
[5]
Fuel pressure manifold hose 07AMJ-HW3A 100
Pressure gauge adapter "C" 07AAJ-S6MA300
Pressure gauge adapter "C" 07AAJ-S6MA500 Fuel feed
hose side
Temporarily connect the battery negative (-) cable and Fuel pump
fuel pump unit 3P (Black) connector. side -
Start the engine and let it idle.
Read the fuel pressure. [4]
STANDARD:
324 - 367 kPa (3.3 - 3.7 kgf/cm2 , 47 - 53 psi)
If the fuel pressure is higher than specified, replace the
fuel pump unit.
If the fuel pressure is lower than specified, inspect the
following:
- Fuel line leaking
- Pinched or clogged fuel tank breather hose
- Fuel pump unit (page 7-8)
After inspection, relieve the fuel pressure (page 7-4).
Remove the special tools.
Connect the quick connect fitting (page 7-4 ).
7-5
FUEL SYSTEM
FUEL FLOW INSPECTION
Disconnect the quick connect fitting from the fuel rail
(page 7-4).
Place the end of the fuel feed hose [1] into an approved
fuel container.
NOTE:
• Clean up any spilled fuel.
Temporarily connect the battery negative(-) cable and
fuel pump unit 3P (Black) connector.
Measure the amount of fuel flow.
NOTE:
• The fuel pump operates for 2 seconds. Repeat this
procedure 5 times to meet the total measuring time .
• Return fuel to the fuel tank when the measurement
is completed.
Amount of fuel flow:

319 cm 3 (10.8 US oz, 11.2 Imp oz) minimum/
10 seconds at 12 V
If the fuel flow is less than specified, inspect the

following :
- Pinched or clogged fuel hose or fuel tank breather
hose
- Fuel pump unit (page 7-8)
Connect the quick connect fitting (page 7-4 ).
7-6
FUEL SYSTEM
FUEL TANK
Disconnect the quick connect fitting (fuel pump side)
(page 7-4).
- Fuel level sensor 2P {Black) connector [1]
- Fuel tank drain hose [2]
- Fuel tank breather hose [3]
Remove the fuel tank [4].
Remove the grommet [5] from the fuel tank.
Remove the fuel filler cap (6] by removing the fuel filler
f cap bolts, if necessary.
CRF1100D4 shown :
9.0mm
(0.35 in)
[5)
[2) [1 J
TORQUE:
Fuel filler cap bolt:
1.8 N·m (0.2 kgf·m, 1.3 lbHt)
NOTE:
• A pressure release can be heard when opening the
fuel cap , but this is not blockage of the passage. If
checking for clog in the passage of the fuel tank side
is necessary, apply air pressure to the breather hose
end with the fuel filler cap opened.
• If the fuel filler cap was removed, replace the
breather seal [1] with a new one.
• Route the hoses, wires and harness properly (page
1-26).
Connect the quick connect fitting (fuel pump side) (page
7-4).
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[ 7-7
FUEL SYSTEM
FRONT CROSS PLATE
- Rear seat under cover (page 2-34)
- Fuel tank (page 7-7)
Remove the front cross plate bolts [1] and front cross
plate [2].
TORQUE:
Front cross plate bolt:
12 N·m (1.2 kgf·m, 9 lbf-ft)
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FUEL PUMP UNIT
INSPECTION
Turn the ignition switch ON and confirm that the fuel
pump operates for a few seconds.
If the fuel pump does not operate, inspect as follows:
[1]
Disconnect the fuel pump unit 3P (Black) connector
(page 7-4).
Measure the voltage at the wire harness side 3P (Black)
connector [1].
CONNECTION: Yellow/red (+) - Green (-)
There should be battery voltage for a few seconds. 8

If there is battery voltage for a few seconds, replace the
fuel pump unit.
If there is no battery voltage, inspect the following:
- Blown MAIN2 fuse 30 A
Blown sub fuse FUEL PUMP 10 A
Fuel relay (page 7-14)
Fuel relay related circuit
Open circuit in the Yellow/red or Green wire ..
ECM power/ground line (page 4-72)
REMOVAL
Clean around the fuel pump unit.
Loosen the fuel pump unit mounting nuts [1] in a
crisscross pattern in 2 or 3 steps.
Remove the fuel pump unit mounting nuts and fuel
pump guard [2].
Remove the fuel pump unit [3] and packing [4].
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7-8
FUEL SYSTEM
DISASSEMBLY/INSPECTION
CRF1100A/D
Remove the screws [1], Black wire terminals [2], and
stoppers [3] .
Disconnect the White wire connector [4] and Blue wire
connector [5].
Remove the fuel filter assembly [1] and 0-ring [2] from
the fuel pump stay [3] .
Remove the chamber [1] by releasing the tabs [2].

[1)
Remove the fuel pump [1] and 0-ring [2].

[4]
Visually inspect the suction filter [3] for dirt, debris, or
any clogging .
Replace fuel pump unit as an assembly if the suction
filter is abnormal.
Remove the pressure regulator [4] and 0-ring [5] from
the fuel filter [6].
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7-9
FUEL SYSTEM
CRF11 OOA4/D4
Remove the screws [1], Black wire terminals [2], and
[3]
stoppers [3].
Disconnect the White wire connector [4] and Blue wire
connector (5].
Remove the fuel filter assembly (1] and 0-ring (2] from
the fuel pump stay [3].
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[3]~
Remove the chamber [1] by releasing the tabs (2].

[1]
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Remove the fuel pump [1] and 0-ring [2].
[5] [4]
Visually inspect the suction filter [3] for dirt, debris, or
any clogging .
Replace fuel pump unit as an assembly if the suction
filter is abnormal. J
Remove the pressure regulator [4] and 0-ring [5] from
the fuel filter [6].
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7-10
FUEL SYSTEM
ASSEMBLY
CRF1100A/D
Replace the fuel filter [1) with a new one.
Apply engine oil to a new 0-ring.
Install the 0-ring [2) to new pressure regulator [3).
Install the pressure regulator.
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[1]

Install the 0-ring [1) to the fuel pump [2).
Install the fuel pump.
NOTE:
• Align the Blue wire [3) with the fuel filter groove [4) .
• Lead the Black wire [5] through the hole [6) of the
fuel filter as shown.
Insert the suction filter [7] edge between the fuel pump
and pressure regulator.
Set the Blue wire [1) through the groove [2] of the fuel
filter [3) as shown.
Install the chamber [4). [2]
[3]

Install the 0-ring [1] to the fuel pump stay [2) .
Install the fuel filter assembly [3) by aligning the groove
with the fuel pump stay tab .
[2]/.
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7-11
I
FUEL SYSTEM
Install the stoppers [1] , Black wire terminals [2], and fuel
pump/reserve sensor terminal screws [3].
Tighten the fuel pump/reserve sensor terminal screws
to the specified torque.
Connect the White wire connector [4] and Blue wire
connector [5].
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CRF1100A4/D4
Replace the fuel filter [1] with a new one.
Install the 0-ring [2] to new pressure regulator [3].
Install the pressure regulator.
[1)~
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[2)
Install the 0-ring [1] to the fuel pump [2].
Install the fuel pump.
NOTE:
• Align the Blue wire [3] with the fuel filter groove [4].
• Lead the Black wire [5] through the hole [6] of the
fuel filter as shown .
Insert the suction filter [7] edge between the fuel pump
and pressure regulator.
Set the Blue wire [1] through the groove [2] of the fuel
filter [3] as shown. [4)~
Install the chamber [4] .
[2]
[1)
[3)
7-12
FUEL SYSTEM
Install the 0-ring [1] to the fuel pump stay [2].
Install the fuel filter assembly [3] by aligning the groove
with the fuel pump stay tab.
[2]~
Install the stoppers [1], Black wire terminals [2], and fuel
pump/reserve sensor terminal screws [3]. [1] [1]
Tighten the fuel pump/reserve sensor terminal screws

Connect the White wire connector [4] and Blue wire

connector [5].
INSTALLATION
Install a new packing [1] onto the fuel pump unit [2] .
[2]
NOTE:
• Always replace the packing with a new one.
• Be careful not to pinch any dirt or debris between the
fuel pump unit and packing.
• Align the packing tab with the fuel pipe.
Align
Install the fuel pump unit [1] into the fuel tank.
Install the fuel pump guard (2] and fuel pump unit
mounting nuts (3].
Tighten the fuel pump unit mounting nuts to the
specified torque in the sequence as shown.
Install the fuel tank (page 7-7).
7-13
FUEL SYSTEM
FUEL RELAY
Remove the power box cover and fuel relay [1].
AIR CLEANER HOUSING

REMOVAUINSTALLATION
- Horn (page 22-47)
- Fuel tank (page 7-7)
Open the clamp [1] and release the air cleaner housing
drain hose [2].
Remove the hose clips [3] and drain plugs [4].
Remove the wire band [5].
Open the clamp A [1].

OCT model: Open the clamp B [2].
Release the air cleaner housing drain hose [3].
Remove the hose clip [4] and drain plug [5].
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7-14
FUEL SYSTEM
Release the left and right air cleaner duct tabs [1] from
the inner covers.
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Release the ignition switch 2P connector [1] from the
stay.
Release the ignition switch wire [2] from the guide [3] .
Disconnect the air suction hose [4] .
Loosen the connecting hose band screws [5].

- Bolts [1]
- Collars A [2]
- BolUwasher (3]
Disconnect the air cleaner housing connecting hoses
[4] .
Pull the air cleaner housing [5] upward .
Disconnect the crankcase breather hose [6] from the
cylinder head cover.
Disconnect the IAT sensor 2P (Blue) connector [7] .
Remove the air cleaner housing.
Remove the collars B [8] .
Remove the following from the air cleaner housing:
- Grommets A [9]
- Collar C (10]
Grommet B (11]
[7]
7-15
FUEL SYSTEM
NOTE:
• Route the wires and hoses properly (page 1-26).
• Align the hose band holes with the connecting hose
bosses.
• Tighten the connecting hose band screws [1] until
the collars [2] are fully seated .
[2]
THROTTLE BODY
- Tool box (page 2-26)
- Air cleaner housing (page 7-14)
Loosen the insulator band screws [1].

TBW motor 2P connector [1]
- TBW unit 6P connector [2]
- MAP sensor 3P (Black) connector [3]
Fuel injector 2P (Gray) connectors [4]
Disconnect the EVAP purge control solenoid valve-to-
throttle body hose [5] from the EVAP purge control
solenoid valve [6].
Release the fuel feed hose [7] from the clamp [8] .
Remove the throttle body [9] .
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7-16
FUEL SYSTEM
NOTICE
• Do not loosen or tighten the white painted screws
[1 ], nut [2], and bolts [3] of the throttle body.
Loosening or tightening any of these can cause
throttle valve and idle control failure.
[1]

NOTE:
• Route the wires and hoses properly (page 1-26).
• Align the insulator band holes with the insulator
bosses.
• Tighten the insulator band screws [1] until the collars
[2] are fully seated .
[1]
[2]
FUEL INJECTOR
REMOVAL
Release the ignition switch 2P connector [1] from the
stay.
Release the fuel feed hose [2] from the clamp [3] .
Remove the MAP sensor screw/washer [4].
7-17
FUEL SYSTEM
Clean around the fuel injector base with compressed
air.
Disconnect the fuel injector 2P (Gray) connectors [1].
Remove the fuel injector assembly mounting bolts [2]
and fuel injector assembly [3].
Disconnect the quick connect fitting from the fuel rail
(page 7-4).
NOTE:
Be sure that no debris is allowed to enter the
combustion chamber.
Remove the fuel injectors [1] from the fuel injector joints
[2].
Remove the seal rings [3] and 0-rings [4] from the fuel
injectors.
Remove the fuel injector joints and 0-rings [5] from the
fuel rail [6].
INSTALLATION
Apply engine oil to new 0-rings.
Install the 0-rings [1] and fuel injector joints [2] to the
fuel rail [3].
Apply engine oil to new seal rings and new 0-rings.
Install the seal rings [4] and 0-rings [5] to the fuel
injectors [6].
Install the fuel injectors to the fuel injector joints.
NOTE:
• Align the fuel injector connectors with the fuel joint
tabs [7] as shown.
Connect the quick connect fitting to the fuel rail (page 7-

4).
Install the fuel injector assembly [1].
NOTE:
• When installing the fuel injector, be careful not to
damage the seal ring.
Install and tighten the fuel injector assembly mounting
bolts [2] to the specified torque.
Connect the fuel injector 2P connectors [3].
•
)
7-18
FUEL SYSTEM
Install the MAP sensor [1] to the MAP sensor stay.
Install and tighten the MAP sensor screw/washer [2] to
the specified torque.
Install the fuel feed hose [3] to the clamp [4].
Install the ignition switch 2P connector [5] to the stay.
Install the fuel tank (page 7-7).

SYSTEM INSPECTION
Start the engine and warm it up to normal operating
temperature.
Stop the engine.
Disconnect the air suction hose [1].
Check that the secondary air intake port [2] is clean and
free of carbon deposits.
Check the PAIR reed valve if the port is carbon fouled
(page 7-20).
Temporarily install the removed parts.

Lift the fuel tank (page 3-4 ).
Start the engine and open the throttle slightly to be
certain that air is sucked in through the disconnected air
suction hose [1) .
If the air is not drawn in, check the air suction hose and [1]
air supply hose [2) for clogs.
If the hoses are OK, check the PAIR control solenoid
valve [3) (page 7-21 ).
~ FRESH AIR
... EXHAUST GAS
7-19
FUEL SYSTEM
PAIR CONTROL SOLENOID VALVE
REMOVAUINSTALLATION
Disconnect the air suction hose [1] and air supply hose
[2].
Release the suspension rubber [3] from the PAIR
control solenoid valve stay.
Release the grommet [4] from the boss.
Disconnect the PAIR control solenoid valve 2P (Black)
connector [5].
Remove the PAIR control solenoid valve [6] .
•
Remove the suspension rubber and grommet from the
PAIR control solenoid valve.
Remove the screws [1] and PAIR control solenoid valve

stay [2].
INSPECTION
Remove the PAIR control solenoid valve (page 7-20).
Check the air flow through the solenoid valve.
Air should flow from suction hose fitting (A) to supply
hose fitting (B).
Connect a 12 V battery to the 2P connector [1] of the [1]
PAIR control solenoid valve.
Air should not flow when the battery is connected . (A) - + -
t:;::::==~-r\
Replace the solenoid valve if it does not operate
properly.
Install the PAIR control solenoid valve (page 7-20). (B).-
PAIR REED VALVE

REMOVAUINSTALLATION
Remove the cylinder head cover (page 10-5).
[1)
Remove the PAIR reed valve cover bolts [1].
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7-20
FUEL SYSTEM
Remove the PAIR reed valve cover [1].
NOTE:
• When installing the PAIR reed valve cover, align the
boss of the PAIR reed valve cover with the hole of
the PAIR reed valve.
Remove the PAIR reed valves [1] and port plates [2].
TORQUE:
PAIR reed valve cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
NOTE:
• Install the PAIR reed valves and port plates as
shown.
INSPECTION
Remove the PAIR reed valves (page 7-20).
Check the reed valve [1] for damage or fatigue.
Replace if necessary.
Replace the PAIR check valve if the rubber seat [2] is
cracked, deteriorated or damaged, or if there is
clearance between the reed and seat.
Install the PAIR reed valves (page 7-20).
[1] [2]
r
7-21
I
FUEL SYSTEM
EVAP PURGE CONTROL SOLENOID
VALVE/CANISTER
EVAP PURGE CONTROL SOLENOID
VALVE
REMOVAUINSTALLATION
- EVAP purge control solenoid valve 2P (Black)
connector [1]
- EVAP purge control solenoid valve-to-throttle body
hose [2]
- EVAP canister-to-purge control solenoid valve hose
[3]
Remove the screws [4] and EVAP purge control
solenoid valve [5].
INSPECTION
J
Remove the EVAP purge control solenoid valve (page
[3] [1)
7-22).
Check the air flow from hose fitting A (input port) to
hose fitting B (output port) of the EVAP purge control
solenoid valve [1].
Air should not flow.
Connect a 12 V battery [2] to the solenoid valve 2P
(Black) connector [3] as shown .
Air should flow out when the battery is connected .
Replace the solenoid valve if it does not operate
properly.
Install the EVAP purge control solenoid valve (page 7-
... (B)
...
(A)
[3]
22).
[2]
7-22
FUEL SYSTEM
EVAP CANISTER
REMOVAUINSTALLATION
Release the EVAP canister mounting rubber [1] from
the rear fender B stay.
Release the grommet [2] from the boss.
Pull the EVAP canister [3] up.

- EVAP canister drain hose [1]
- EVAP canister-to-purge control solenoid valve hose
[2]
- Fuel tank breather hose [3]
Remove the grommet [4] and EVAP canister mounting
rubber [5] from the EVAP canister [6].
NOTE:
• Route the hoses properly (page 1-26).
7-23
MEMO
8. COOLING SYSTEM
SERVICE INFORMATION ........................ 8-2 THERMOSTAT····· ································· 8-6
' TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-2 RADIATOR/COOLING FAN····················· 8-7

i
I SYSTEM FLOW PATTERN······················ 8-3 RADIATOR RESERVE TANK················· 8-11
I'"
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SYSTEM TESTING· .. ······························ 8-4 WATER PUMP···································· 8-11
COOLANT REPLACEMENT · · · · · · · · · · · · · · · · · · · · 8-5 FAN RELAY········································ 8-12
._
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8-1
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap.
NOTICE
Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages.
Using tap water may cause engine damage.
• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
• All cooling system services can be done with the engine installed in the frame.
• Avoid spilling coolant on painted surfaces.
• After servicing the system , check for leaks with a cooling system tester.
• Refer to the ECT sensor inspection (page 4-69).
TROUBLESHOOTING
Engine temperature too high
Faulty coolant temperature gauge or ECT sensor
Thermostat stuck closed
Faulty radiator cap
Insufficient coolant
Passage blocked in radiator, hoses or water jacket
Air in system
Faulty cooling fan motor
Faulty fan relay
Faulty water pump
Engine temperature too low
• Faulty coolant temperature gauge or ECT sensor
• Thermostat stuck open
• Faulty fan relay
Coolant leak
Faulty water pump mechanical seal
Deteriorated 0-rings
Faulty radiator cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or clamp
Damaged or deteriorated hose
Damaged radiator
8-2
COOLING SYSTEM
SYSTEM FLOW PATTERN
LEFT
RADIATOR
THERMOSTAT
RIGHT
RADIATOR
SIPHON HOSE
RADIATOR
RESERVE TANK
WATER PUMP
8-3
COOLING SYSTEM
SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
The engine must be cool before removing the

radiator cap, or severe scalding may result.
Wet the sealing surfaces of the cap [1], then install the
[1] [2]
cap onto the tester [2].
Pressure test the radiator cap.
Replace the radiator cap if it does not hold pressure, or
if relief pressure is too high or too low.
It must hold specified pressure for at least 6 seconds.
RADIATOR CAP RELIEF PRESSURE:
108 -137 kPa (1 .1 -1.4 kgf/cm2 , 16 - 20 psi)
Install the tester to the radiator.

Apply pressure to the radiator, engine, and hoses and
check for leaks.
I NOTICE I
Excessive pressure can damage the cooling system
components. Do not exceed 137 kPa (1.4 kgflcm 2,
20 psi).
'I
Repair or replace components if the system will not hold ~
specified pressure for at least 6 seconds.
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8-4
COOLING SYSTEM
COOLANT REPLACEMENT
REPLACEMENT/AIR BLEEDING
NOTE:
• When filling the system or reserve tank with coolant
or checking the coolant level, place the motorcycle in
an upright position on a flat, level surface.
- Clutch EOP sensor cover (OCT model) (page 2-27)
- Radiator cap (page 8-4)
, Remove the coolant drain bolt [1], sealing washer [2),

and drain the coolant.
Reinstall the coolant drain bolt with a new sealing
washer.
Tighten the coolant drain bolt to the specified torque.
Remove the radiator reserve tank (page 8-11 ).

Empty the coolant and rinse the inside of the reserve
tank with water.
Install the radiator reserve tank (page 8-11 ).
Fill the system with the recommended coolant through
the filler opening up to filler neck [1).
Remove the radiator reserve tank cap [2] and fill the
reserve tank to the upper level line.
Bleed air from the system as follows :
1. Shift the transmission into neutral.
Start the engine and let it idle for 2 - 3 minutes.
2. Snap the throttle 3 or 4 times to bleed air from the
system.
3. Stop the engine and add coolant up to the filler neck
if necessary.
4. Install the radiator cap .
5. Check the level of coolant in the reserve tank and fill
to the upper level line if it is low (page 3-14 ).
NOTE:
• When air bleeding is insufficient, level of coolant in
the reserve tank will decrease. If so, fill to the upper
level line with coolant.
Check that there are no coolant leaks.
- Radiator cap (page 8-4)
- Clutch EOP sensor cover (OCT model) (page 2-27)
8-5
COOLING SYSTEM
THERMOSTAT
Drain the coolant (page 8-5).
Remove the thermostat cover bolts [1] and open the
thermostat cover [2].
Remove the thermostat [1] from the cylinder head.

TORQUE:
Thermostat cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
NOTE:
• Install the thermostat with the air bleed hole [2]
facing up.
INSPECTION
Visually inspect the thermostat [1] for damage.
[2]
Check the thermostat rubber [2] for damage and
replace if necessary.
[1]
Heat a container of water with an electric heating

element for 5 minutes.
Suspend the thermostat [1] in heated water to check its
operation.
THERMOSTAT BEGIN TO OPEN:
80 - 84°C (176 -183°F)
VALVE LIFT:
8 mm (0.3 in) minimum at 95°C (203°F) [1]
NOTE:
• Do not let the thermostat or thermometer [2] touch
the container, or you will get a false reading .
Replace the thermostat if the valve opens at a
temperature other than those specified.
8-6
COOLING SYSTEM
RADIATOR/COOLING FAN
Remove the Inner covers (page 2-9).
Remove the horn (page 22-47).
Release the following from the right radiator shroud :
- Right handlebar switch 4P connector [1]
- Connector stay [2]
Clamp [3]
- Wire clip [4]
r
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I Release the following from the right radiator shroud:

'-
I - Right grip heater 2P connector [1]
- Right fan motor 2P connector [2]
- Siphon hose [3]
- Wire clip [4]
Disconnect the siphon hose [1].

Loosen the hose band screw [2].
Disconnect the radiator hose A (3].

Disconnect the radiator hose B [2].
Loosen the hose band screw (3].
Disconnect the lower radiator hose [4] .
8-7
COOLING SYSTEM
Remove the right radiator.
Release the following from the left radiator shroud:

- Clamp [1)
- Wire clip [2)
- Left A/F sensor 4P connector [3]
_.
Loosen the hose band screw [1).

Disconnect the upper radiator hose [2].
Disconnect left fan motor 2P (Black) connector [1).
8-8
COOLING SYSTEM
Loosen the hose band screw [1] .
Disconnect the lower radiator hose [2].
Remove the bolts [1] .

Remove the left radiator.

NOTE:
• Tighten the water hose band screws to the specified
range as shown.
• Route the hoses and wires properly (page 1-26).
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-5).
I
0 - 0.5 mm (0 - 0.02 in)
8-9
COOLING SYSTEM
Right side shown : FAN MOTOR SHROUD Lw

COOLING FAN MOUNTING NUTS
FAN MOTOR SHROUD BOLTS FAN MOTOR 1.0 N·m (0.1 kgf-m , 0.7 lbf-ft)
8.5 N·m (0.9 kgf-m , 6.3 lbf·ft)
FAN MOTOR
/
MOUNTING SCREWS
2.7 N·m (0 .3 kgf·m, 2.0 lbf-ft)
/
/, COOLING FAN
(
'
RADIATOR GRILL
/ '
/,/-;/
/, GROMMETS
/ COL~ \
J
RADIATOR
RADIATOR
SHROUD
NOTE:
• Align the cooling fan and fan motor shaft flat
surfaces.
• Apply locking agent to the cooling fan mounting nut
threads.
~ J
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8-10
COOLING SYSTEM
Remove the radiator reserve tank mounting bolt [1] .
Remove the radiator reserve tank [2] by releasing the
boss [3] from the frame .
Disconnect the siphon hose [4] and drain the coolant.
NOTE:
• Route the radiator reserve tank drain hose [5]
properly (page 1-26).
WATER PUMP
MECHANICAL SEAL INSPECTION
Check the water pump bleed pipe [1] for signs of
coolant leakage.
NOTE:
• A small amount of coolant weeping from the bleed
pipe is normal.
• Make sure that there is no continuous coolant
leakage from the bleed pipe while operating the
engine.
Replace the water pump as an assembly if necessary.
Install the skid plate (page 2-25).
REMOVAL
Remove the right crankcase cover:
- OCT model: (page 13-40)
Remove the coolant drain bolt [1] and sealing washer
[2] .
Remove the water pump cover bolts (3] and water
pump body [4].
8-11
COOLING SYSTEM
INSTALLATION
Install a new 0-ring [1] into the groove in the water
pump body [2].
Install the dowel pins [3] and water pump body.
Apply locking agent to the water pump cover bolts . -- - - -- -

threads (page 1-23).
Install and tighten the water pump cover bolts [1] to the
specified torque.
Install the coolant drain bolt [2] and a new sealing
washer [3].
Tighten the coolant drain bolt to the specified torque.
Install the right crankcase cover:
FAN RELAY
Remove the power box cover and fan relay [1].
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8-12
9. LUBRICATION SYSTEM
r
SERVICE INFORMATION· .. ········· ············ 9-2 OIL PUMP · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-6
TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · · · 9-3 OIL PUMP DRIVEN GEAR······················· 9-9
LUBRICATION SYSTEM DIAGRAM·········· 9-4 OIL STRAINER· .. ································· 9-10
r OIL PRESSURE INSPECTION · · · · · · · · · · · · · · · · · 9-6

t
9-1
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
• This section covers service of the oil pump and oil strainer.
• The oil pump and oil strainer can be serviced with the engine installed in the frame .
• The service procedures in this section must be performed with the engine oil drained .
• When removing and installing the oil pump , use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed , check that there are no oil leaks and that oil pressure is correct.
TOOLS
Oil pressure gauge attachment Oil filter wrench Oil pressure gauge set
070MJ-0010101 07HAA-PJ70101 07506-3000001
or 07AMJ-001A100 and 07APJ- or 07AAA-PLCA100 (U .S.A. only) or equivalent commercially available

004A160 fitting (U .S.A. only)
Oil pressure gauge attachment Bearing remover shaft set, 12 mm Remover weight
07 406-0030000 07936-1660101 07741-0010201
or equivalent commercially available or 07936-166010A (U .S.A. only) or 07936-371020A (U .S.A. only)

Remover handle Pilot, 16 mm Driver
07936-3710100 077 46-0041300 077 49-0010000
9-2
LUBRICATION SYSTEM
Pilot, 17 mm
077 46-0040400
TROUBLESHOOTING
Oil level too low
Oil consumption
External oil leak
Worn piston rings
Improperly installed piston rings
Worn cylinders
Worn valve stem seals
Worn valve guide
Low oil pressure
Oil level low
Clogged oil strainer
Faulty oil pump
Internal oil leak
Incorrect oil being used
Oil pressure relief valve stuck open
Clogged oil filter
No oil pressure
• Oil level too low
• Oil pressure relief valve stuck open
• Damaged oil pump
• Internal oil leak
High oil pressure
• Oil pressure relief valve stuck closed
• Clogged oil gallery or metering orifice
• Incorrect oil being used
Oil contamination
• Oil or filter not changed often enough
• Worn piston rings
Oil emulsification
• Blown cylinder head gasket
• Leaky coolant passage
• Entry of water
9-3
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
MT model:
CAMSHAFT
PISTON
CRANKSHAFT
ALTERNATOR
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EOP SWITCH
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ENGINE OIL
FILTER
CARTRIDGE
l.
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CLUTCH
COUNTERS HAFT
l
REAR BALANCER
SHAFT
SCAVENGE PUMP
OIL FILTER SCREEN
ENGINE OIL PRESSURE

RELIEF VALVE ENGINE OIL
OIL FEED PUMP
STRAINER
J
9-4 .,
I
LUBRICATION SYSTEM
DCT model:
CAMSHAFT
Fl
- No.1
LINEAR
SOLENOID
PISTON VALVE
No.2
r LINEAR
SOLENOID
VALVE
EOPSENSOR
ENGINE OIL
FILTER
CARTRIDGE No.1 CLUTCH
CLUTCH LINE
EOPSENSOR
SCAVENGE PUMP OCT OIL FILTER
r
OIL FILTER SCREEN
OIL PAN
9-5
LUBRICATION SYSTEM
OIL PRESSURE INSPECTION
Remove the engine oil filter cartridge (page 3-12).
Apply engine oil to the 0-ring and install the oil pressure
attachment [1] onto the oil filter boss.
TOOL:
Oil pressure gauge attachment 070MJ-0010101 or
07AMJ-001A100
and
07APJ-004A 160
(U.S.A. only)
Apply engine oil to the 0-ring and engine oil filter

cartridge threads.
Install the engine oil filter cartridge [2] onto the oil
pressure attachment.
TOOL:
07AAA-PL CA100
(U.S.A. only)
Connect the oil pressure gauge [3] and attachment [4]

to the oil pressure gauge attachment.
TOOLS:
Oil pressure gauge set 07506-3000001 or
equivalent
commercially
available
Oil pressure gauge attachment 07406-0030000 or
equivalent
commercially
available
Fill the engine with the recommended engine oil
(page 3-12).
Warm the engine to normal operating temperature
(approximately 80°C/176°F) and increase the engine
speed to 5,000 r/min and read the oil pressure. l
I
STANDARD: ~
614 kPa (6.3 kgf/cm2 , 89 psi)
at 5,000 r/min (80°C/176°F)
Stop the engine and remove the tools.

Install the engine oil filter cartridge (page 3-12).
OIL PUMP
Remove the oil strainer (page 9-10).
Remove the oil pump mounting bolts [1 J and oil pump
[2]. j
TORQUE:
Oil pump mounting bolt:
16 N·m (1.6 kgf·m, 12 lbf·ft)
NOTE:
• Align the oil pump driven shaft end with the oil pump
drive shaft groove.
9-6
LUBRICATION SYSTEM
NOTE:
• Dip all parts in clean engine oil.
MT model
FLANGE BOLT (6 x 75 mm)

12 N·m (1 .2 kgf·m, 9 lbf·ft)
FLANGE BOLTS (6 x 55 mm)

12 N ·m (1 .2 kgf·m, 9 lbf·ft)
OIL PUMP BODY A

12 N·m (1 .2 kgf·m , 9 lbf·ft)
OIL PUMP BODY C
SCAVENGE PUMP
INNER ROTOR
SCAVENGE PUMP
OUTER ROTOR
12 N ·m (1.2 kgf-m , 9 lbf·ft)
9-7
LUBRICATION SYSTEM
DCT model
FLANGE BOLT (6 x 95 mm) DCT OIL PRESSURE

12 N·m (1.2 kgf·m, 9 lbf-ft) RELIEF VALVE
FLANGE BOLTS (6 x 85 mm)

12 N·m (1.2 kgf·m, 9 lbf-ft) SEALING BOLT (24 mm)
30 N ·m (3.1 kgf·m , 22 lbf-ft)
FLANGE BOLT (6 x 65 mm) DCT OIL PUMP

12 N·m (1 .2 kgf·m, 9 lbf-ft) OUTER ROTOR
DCTOIL PUMP
INNER ROTOR
OIL PUMP SHAFT
.,~ 0-RING
DRIVE PIN
~ SEALING BOLT (22 mm)
' 30 N·m (3.1 kgf-m, 22 lbf-ft)
OIL PUMP BODY B SCAVENGE PUMP
INNER ROTOR FLANGE BOLT (6 x 20 mm)
12 N·m (1.2 kgf·m, 9 lbf-ft)
SCAVENGE PUMP
OUTER ROTOR
12 N ·m (1.2 kgf·m, 9 lbf-ft)
OIL PUMP BODY C
INSPECTION
OIL PUMP
Inspection the following parts for damage, abnormal
wear, deformation, or burning:
- Oil pump shaft
- Drive pin
- Inner rotor
- Outer rotor
- Oil pump body
Measure the oil pump clearances according to
LUBRICATION SYSTEM SPECIFICATIONS
(page 1-7).
If any of the measurement is out of the service limit,
replace the oil pump as an assembly.
9-8
LUBRICATION SYSTEM
PRESSURE RELIEF VALVE
Remove the pressure relief valve {page 9-7).
[1 J [1 J
Check the operation of the valve by pushing on the
piston [1].
- Engine oil pressure relief valve [2]
- OCT oil pressure relief valve {OCT model) [3]
[3] [2]
OIL PUMP DRIVEN GEAR

REMOVAL
Remove the rear balancer {page 14-9).
- Oil pump driven gear set plate bolt [1]
- Set plate [2]
- Oil pump driven gear (3]
- Washer [4]
INSTALLATION
Apply molybdenum oil solution to the oil pump driven
gear bearing roller surfaces.
Apply molybdenum oil solution to the oil pump driven
gear shaft outer surface.
Install the washer [1] to the oil pump driven gear [2].
Install the oil pump driven gear to the crankcase.
NOTE:
• Align the oil pump driven gear shaft groove with the
oil pump shaft end.
Apply locking agent to the oil pump driven gear set

plate bolt threads.
Install the set plate [1] and oil pump driven gear set
plate bolt (2].
Tighten the oil pump driven gear set plate bolt to the
specified torque.
Install the rear balancer {page 14-10).
9-9
LUBRICATION SYSTEM
BEARING REPLACEMENT
Remove the oil pump driven gear (page 9-9).
Remove the needle bearing (12 x 18 x 14 mm) [1] using
the special tools.
TOOLS:
Bearing remover shaft set, 07936-1660101 or
12mm 07936-16601 OA
(U.S.A. only)
Remover weight 07741-0010201 or
07936-371020A
(U.S.A. only)
Remover handle 07936-3710100 ..
the same special tools.
Apply engine oil to new needle bearing rolling areas
and contact surfaces. ~-"71111 121-""1~
Drive in the needle bearing (12 x 16 x 10 mm) using the \ ~- f.L_)
special tools until it is in position as shown.
TOOLS:
Pilot, 16 mm 07746-0041300
Driver 07749-0010000
NOTE:
• Drive in a new needle bearing with its marked side 0-0.5 mm
facing out. (0- 0.02 in)
Drive in the needle bearing (12 x 18 x 14 mm) using the 19.5- 20.0 mm
special tools until it is in position as shown. (0.77 - 0.79 in)
TOOLS:
Pilot, 17 mm 07746-0040400
Driver 07749-0010000
NOTE:
• Drive in a new needle bearing with its seal side J
facing out.
l
Install the oil pump driven gear (page 9-9). 1
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OIL STRAINER J
J
REMOVAL
J
Loosen the bolts [1] in a crisscross pattern in 2 or 3
steps.
Remove the bolts and oil pan [2].
I
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4
..
9-10
LUBRICATION SYSTEM
Remove the oil strainer [1] and seal ring [2] .
Clean the oil strainer and check for damage, replace it if
necessary.
Remove the gasket [1] and 0-rings [2] from the oil pan.
OCT model: Remove the oil joints [3] from the oil pan .
Remove the 0-rings [4] and back up rings [5] from the
oil joints.
[2]
Remove the oil filter screen [1] from the oil pan.
Clean the oil filter screen and check for damage,
replace it if necessary.
INSTALLATION
Install the oil filter screen [1] into the oil pan in the
direction as shown .
9-11
LUBRICATION SYSTEM I
Apply engine oil to a new 0-rings.
OCT model:
Install the new gasket [1] and 0-rings [2] to the oil pan.
Apply engine oil to a new 0-rings.
OCT model shown:
. . . [3]/[4]/(5]
[5~]
[4] j
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Install the new back up rings [3] and 0 -rings (4] to the
oil joints [5].
71 [3] j
Install the oil joints to the oil pan.
NOTE:
• Install the back up rings and 0-rings to the oil joints
as shown.
[1]
fl
Apply engine oil to a new seal ring.
Install the seal ring [1] to the oil pump.
Install the oil strainer [2].
NOTE:
• Align the oil strainer boss with the oil pump groove.
Install the oil pan [1].

Install and tighten the bolts [2] in a crisscross pattern in
2 or 3 steps.
'i
check that there are no oil leaks (page 3-12). I
•
j
9-12
10. CYLINDER HEADNAlVE/CAMSHAFT
SERVICE INFORMATION·· .. ·················· 10-2 ROCKER ARM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-9
TROUBLESHOOTING·························· 10-3 CAM CHAIN TENSIONER LIFTER········· 10-12
COMPONENT LOCATION····················· 10-4 CAMSHAFT·······································10-13 -
CYLINDER COMPRESSION············· ····· 10-5 CYLINDER HEAD/CAM CHAIN

TENSIONER······································ 10-19
CYLINDER HEAD COVER················ ····· 10-5
INSULATOR······································ 10-27
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SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves, rocker arms, and camshaft. These services can be done with the
engine installed in the frame.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Rocker arm, valve and camshaft lubricating oil is fed through oil passage in the cylinder head. Clean the oil passage before
assembling the cylinder head.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
TOOLS
Tensioner holder 8 Valve spring compressor Valve guide driver, 5.5 mm
070MG-OO 10100 07757-0010000 07742-0010100
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or 07AMG-001A100 (U .S.A. only)
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or 07AMG-MFJA100 (U.S.A. only)
Valve guide reamer, 5.5 mm Cutter holder, 5.5 mm Seat cutter, 40 mm (45° IN)
07984-2000001 07781 -0010101 07780-0010500 )
II
I
or 07984-200000D (U.S.A. only) or equivalent commercially available in or equivalent commercially available in

U.S.A. U.S.A.
I
Seat cutter, 35 mm (45° EX) Flat cutter, 38.5 mm (32° IN) Flat cutter, 33 mm (32° EX) J
07780-0010400 07780-0012400 07780-0012900
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or equivalent commercially available in or equivalent commercially available in or equivalent commercially available in
U.S.A. U.S.A. U.S.A.
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#
10-2
i' Interior cutter, 37.5 mm (60° IN) Interior cutter, 34 mm (60° EX)
07780-0014100 07780-0014700
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or equivalent commercially available in or equivalent commercially available in

U.S.A. U.S.A.
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing
noises to the top-end with a sounding rod or stethoscope.
• If the performance is poor at low speeds, check for a white smoke in the crankcase breather hose. If the hose is smoky, check
for seized piston ring (page 15-12).
Compression too low, hard starting or poor performance at low speed
Valves:
- Incorrect valve clearance
- Burned or bent valve
- Incorrect valve timing
- Broken valve spring
- Uneven valve seating
- Valve stuck open
Cylinder head :
- Leaking or damaged cylinder head gasket
- Loose spark plug
- Warped or cracked cylinder head
Cylinder/piston problem (page 15-2)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston head or combustion chamber
Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
• Cylinder/piston problem (page 15-2)
Excessive noise
Incorrect valve clearance
Sticking valve or broken valve spring
Excessively worn valve seat
Worn or damaged camshaft
Worn rocker arm and/or shaft
Worn rocker arm follower or valve stem end
Loose or worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Cylinder/piston problem (page 15-2)
Rough idle
• Low cylinder compression
10-3
COMPONENT LOCATION
10 N·m (1.0 kgf·m, 7 lbHt)
r 00
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12 N·m (1 .2 kgf·m, 9 lbHt)
20 N·m (2.0 kgf·m, 15 lbHt)
83 N·m (8.5 kgf-m , 61 lbHt)
. . - . . . - - - - 12 N·m (1.2 kgf·m, 9 lbf·ft)
,,,
23 N·m (2.3 kgf·m, 17 lbf·ft)
10-4
CYLINDER COMPRESSION
Warm up the engine to normal operating temperature.
Stop the engine, and remove the spark plugs (page 3-
6).
Disconnect the fuel pump unit 3P (Black) connector
(page 7-4).
Install the compression gauge [1] into the spark plugs
[1]
hole.
Turn the ignition switch ON and engine stop switch " O ".
MT model: Shift the transmission into the neutral position.
Open the throttle all the way and crank the engine with
the starter motor until the gauge reading stops rising .
The maximum reading is usually reached within 4 - 7
seconds. L _ __ _ _ __ _ _ _ _ _ _ _ _ _ _ ____,
COMPRESSION PRESSURE:
1.4 MPa (14.3 kgf/cm 2 , 203 psi) at 500 r/min
Low compression can be caused by:

- Blown cylinder head gasket
- Improper valve adjustment
- Valve leakage
- Worn piston ring or cylinder
High compression can be caused by:
- Carbon deposits in combustion chamber or on
piston head
CYLINDER HEAD COVER

REMOVAL
Remove the horn (page 22-47).
Release the following from the left radiator shroud:

- Clamp [1]
Wire clip [2]
- Left NF sensor 4P connector [3]
10-5
MT model: Release the clutch cable [1] to the clutch cable stay (2].
Remove the bolt [3] and clutch cable guide.
Disconnect the secondary air supply hose [1].

Remove the cylinder head cover bolts [2] and mounting
rubbers [3] .
Remove the cylinder head cover [1 ] to the right side as

shown.
10-6
Remove the plug pipe seals [1] and cylinder head cover
packing [2] from the cylinder head cover.
INSTALLATION
Install new plug pipe seals [1] to the cylinder head
[2]
cover.
NOTE:
• Install the plug pipe seals with their "OUT SIDE"
marks [2] facing up.
Install a new cylinder head cover packing [3] to the
cylinder head cover.
[3)
~
Clean the cylinder head [1] mating surface thoroughly.
Apply liquid sealant (TB5211 C manufactured by ~ (2(
ThreeBond , KE45T manufactured by Shin-Etsu Silicone
or an equivalent) to the cylinder head cover packing [2]
as shown.
NOTE:
• Do not apply more liquid sealant than necessary.
Insert the cylinder head cover [1] from the right side as
shown.
10-7
Install the cylinder head cover [1] on the cylinder head.
NOTE:
• Be sure to be installed the dowel pins [2] of the
cylinder head cover to the cylinder head holes
securely.
Check that the mounting rubbers [3] are in good
condition, and replace them if necessary.
Install the mounting rubbers.
NOTE:
• Install the mounting rubbers with their "UP" marks
[4] facing up.
Install and tighten the cylinder head cover bolts [5] to
(4)
Connect the secondary air supply hose [6].
(3)
MT model: Install the clutch cable stay [1] and bolt [2].
NOTE:
• Align the clutch cable stay tab with the frame hole.
Tighten the bolt securely.
Hook the clutch cable [3] to the clutch cable stay.
Install and tighten the bolts [1] securely.
10-8
Install the following to the left radiator shroud:
- Clamp [1]
- Wire clip [2]
Left A/F sensor 4P connector [3]
Install and tighten the bolts [1] securely.

Install the horn (page 22-47).
ROCKER ARM
REMOVAL
- Cylinder head cover (page 10-5)
- Crankshaft hole cap (page 3-7)
- Timing hole cap (page 3-7)
alternator cover.
the punch mark [4] on the sprocket is visible .
10-9
Remove the rocker arm shaft stopper bolt [1], sealing
washer [2], and rocker arm shaft bolts [3].
Temporarily install the suitable 6 mm bolt [1] to the

rocker arm shaft [2].
Remove the rocker arm shaft by pulling suitable 6 mm
bolt.
Remove the suitable 6 mm bolt from the rocker arm
shaft.
Remove the rocker arms A [3] and B [4].
INSPECTION
Inspect the following parts for damage, abnormal wear, I
deformation, burning. I
- Rocker arm A J
- Rocker arm B I
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- Rocker arm shaft
I
Measure each part according to CYLINDER HEAD/
VALVE/CAMSHAFT SPECIFICATIONS (page 1-8).
1
Replace any part if it is out of the service limit.
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10-10
INSTALLATION
alternator cover.
the punch mark [4] on the sprocket is visible.
The rocker arms have the following identification marks:

- "SM" mark [1]: rocker arm A
- "SAB" mark [2]: rocker arm 8
[1) [2]
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10-11
CYLINDER HEADNAlVE/CAMSHAFT
Apply molybdenum oil solution to the rocker arm sliding
area and thrust surface.
Apply molybdenum oil solution to the rocker arm shaft
outer surface.
Temporarily install the suitable 6 mm bolt (1] to the
rocker arm shaft [2].
Install the rocker arms A [3] and B [4] .
Install the rocker arm shaft.
NOTE:
• Install the rocker arm shaft by aligning its grooves
with the rocker arm shaft bolt holes of the cylinder
head.
Apply engine oil to the rocker arm shaft bolt threads and
seating surface.
Install and tighten the rocker arm shaft bolts (5] to the
specified torque.
Remove the suitable 6 mm bolt from the rocker arm

shaft.
Install the rocker arm shaft stopper bolt [6] and a new
sealing washer [7].
Tighten the rocker arm shaft stopper bolt to the
specified torque.
Install the following:

- Cylinder head cover (page 10-7)
- Crankshaft hole cap (page 3-10)
- Timing hole cap (page 3-10)
CAM CHAIN TENSIONER LIFTER

REMOVAL
Remove the cam chain tensioner lifter plug [1] and
sealing washer [2].
Release the cam chain tension by turning the cam
chain tensioner lifter shaft fully in (clockwise) and
secure it using the special tool.
TOOL:
Tensioner holder B [3] 070MG-0010100
U.S.A. TOOL:
Tensioner holder 07AMG-001A100 or
07AMG-MFJA100
Remove the bolts [4], cam chain tensioner lifter [5] and
gasket [6].
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10-12
INSTALLATION
Install the cam chain tensioner lifter [1] and a new
gasket [2].
Install and tighten the mounting bolts [3].
Remove the special tool [4].
Install the cam chain tensioner lifter plug [5] and a new
sealing washer [6].
Tighten the plug securely.
INSPECTION
Check the cam chain tensioner lifter operation:
- The cam chain tensioner lifter shaft [1] should not go
into the lifter body when it is pushed.
- When it is turned clockwise with the tensioner holder
or a screwdriver [2], the shaft should be pulled into
the lifter body. The shaft should spring out of the
lifter body as soon as the screwdriver is released.
CAMSHAFT
REMOVAL
Remove the rocker arms (page 10-9).
alternator cover.
Make sure that the punch mark [3] on the cam sprocket
aligns with the upper surface of the cylinder head as
shown.
If you plan to disassemble the camshaft and cam
sprocket, loosen the cam sprocket bolts [4] at this point.
NOTE:
• Do not remove the cam sprocket bolts yet.
10-13
Remove the cam chain tensioner lifter plug [1] and
sealing washer [2] .
Release the cam chain tension by turning the cam
chain tensioner lifter shaft fully in (clockwise) and
secure it using the special tool.
TOOL:
Tensioner holder B [3] 070MG-0010100
U.S.A. TOOL:
Tensioner holder 07AMG-001A100 or
07AMG-MFJA 100
Loosen the camshaft holder bolts [1] .

[1]
NOTE:
• Loosen the camshaft holder bolts in a crisscross
pattern in 2 or 3 steps.
Remove the camshaft holder bolts and camshaft
holders [2].
NOTE:
• Be careful not to let the camshaft holder bolts fall
into the crankcase.
• Do not forcibly remove the dowel pins from the
camshaft holders.
Remove the camshaft [1] by releasing the cam chain

[2] .
NOTE:
• Attach a piece of wire to the cam chain to prevent it
from falling into the crankcase .
Remove the cam sprocket bolts [3] and cam sprocket
[4] from the camshaft if necessary.
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I
Remove the valve lifters [1] and shims [2] . J

NOTE:
• Do not allow the shims to fall into the crankcase.
)
• Mark all valve lifters and shims to ensure correct
reassembly in their original locations.
• The shims can be easily removed with tweezers or a J
magnet.
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10-14
INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning, or clogs in oil passages.
- Cam sprocket
- Camshaft
- Camshaft holder
- Valve lifter
CAMSHAFT OIL CLEARANCE

NOTE:
• Do not rotate the camshaft during inspection.
Wipe any oil from the journals of the cylinder head,
camshaft and camshaft holder.
Set the camshaft onto the cylinder head without
installing the shims, valve lifters, and cam chain.
Lay a strip of plastigauge [1] lengthwise on each
camshaft journal and be sure to avoid the oil passages.
Install the camshaft holders [1] in the correct locations

(page 10-18). [2]~
NOTE:
• Be careful not to drop the plastigauge.
Apply engine oil to the threads and seating surfaces of
the camshaft holder bolts.
Install and tighten the camshaft holder bolts [2] to the
specified torque.
NOTE:
• Tighten the camshaft holder bolts in a crisscross
Loosen the camshaft holder bolts.
NOTE:
• Loosen the camshaft holder bolts in a crisscross
Remove the camshaft holder bolts and camshaft
holders.
10-15
Measure the compressed plastigauge at its widest point
on the camshaft to determine the oil clearance.
SERVICE LIMIT: 0.10 mm (0.004 in)

If the oil clearance exceeds the service limit, replace the
camshaft and recheck the oil clearance. ·
Replace the cylinder head and camshaft holders as a
set if the oil clearance still exceeds the service limit.
INSTALLATION I
Turn the crankshaft counterclockwise and align the "T2" j
mark [1] on the flywheel with the index mark (2] of the
alternator cover.
NOTE: J
• Be careful not to jam the cam chain and timing
sprocket of the crankshaft when rotating the
crankshaft.
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Install the shims [1] and valve lifters [2].

NOTE:
I
.••
• Do not allow the shims to fall into the crankcase.
• Install all valve lifters and shims in their original
locations. 'j
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10-16
If the cam sprockets bolts are removed, apply locking
agent to the cam sprocket bolts threads.
Loosely install the cam sprocket [1] and cam sprocket
bolts [2] to the camshaft [3].
Apply molybdenum oil solution to the camshaft journal,
cam lobes, and thrust surfaces.
Apply engine oil to the cam chain whole surface.
Install the cam chain (4] over the cam sprocket.
Set the camshaft onto the cylinder head.
NOTE:
• Make sure that the punch mark [5] on the cam
sprocket aligns with the upper surface of the cylinder
head as shown.
• Make sure that the camshaft end groove [6] is in
position as shown.
Apply molybdenum oil solution to the camshaft holder B

inside.
Install the camshaft holder B [1].
NOTE:
• Align the groove of the camshaft holder B with the
guide of the camshaft.
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10-17
I
Apply molybdenum oil solution to the left camshaft
holder A and right camshaft holder A insides. [5),
Install the left camshaft holder A [1] and right camshaft
holder A [2].
NOTE:
• The left camshaft holder A and right camshaft holder
A have the following identification marks:
- "A" mark [3]: left camshaft holder A
- "B" mark [4]: right camshaft holder A
Apply engine oil to the camshaft holder bolts threads
and seating surfaces.
Install and tighten the camshaft holder bolts [5] to the
specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt) (2)
NOTE:
• Tighten the camshaft holder bolts in a crisscross
(4) (3)
Remove the special tool [1].

Install the cam chain tensioner lifter plug [2] and a new
sealing washer [3] .
Tighten the plug securely.
If the cam sprocket bolts are removed, tighten the cam

sprocket bolts [1] to the specified torque.

Install the rocker arms (page 10-11 ).
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10-18
CYLINDER HEAD/CAM CHAIN

TENSIONER
REMOVAL
- Battery box cover (page 6-9)
Exhaust pipe (page 2-50)
Throttle body (page 7-16)
Thermostat (page 8-6)
Right crankcase cover (MT model) (page 12-5)
Primary drive gear (OCT model) (page 13-53)
Camshaft (page 10-13)
- Front head engine hanger bolts (left side) [1]
- Front head engine hanger bolt (right side} [2]
- Front head engine hanger plate [3]
Remove the 6 mm bolts [1].

Loosen the cylinder head bolt/washers [2].
NOTE:
Loosen the cylinder head bolt/washers in a
Remove the cam chain tensioner bolt (1], cam chain

tensioner [2], and washer (3].
Lift up the cylinder head [1] and gasket [2] to get the
clearance for cam chain guide [3] removal.
NOTE:
• Do not tap the cylinder head too hard and do not
damage the mating surface with a screwdriver.
Remove the cam chain guide.
Remove the cylinder head to the right side.
10-19
Remove the gasket [1] and dowel pins [2].
DISASSEMBLY
- Insulator (page 10-27)
- Cam chain tensioner lifter (page 10-12)
- Spark plugs (page 3-6) TOP VIEW
5mm
- ECT sensor (page 4-69)
Install the tappet hole protector into the valve lifter bore. /0>-;::::::::::::::::::::::::::~.:::··..
A tool can easily be made from a plastic 35 mm film
container or equivalent as shown.
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31 mm ff \\
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Remove the valve cotters [1] using the special tool as j
shown.
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TOOL: J
Valve spring compressor [2] 07757-0010000
NOTE:
• To prevent loss of tension, do not compress the
valve springs more than necessary.
Remove the tappet hole protector. ....
.... [1)

Spring retainers [1]
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- Intake valve springs [2]
Exhaust valve springs [3] J
Intake valves [4] J
Exhaust valves [5]
Intake stem seals [6]
Exhaust stem seals [7]
Spring seats [8]
NOTE:
• Mark all the parts so they can be placed back in their
original location.
[1 ) [3] (5) (7) (8) [6) (4) (2) [1) I'.
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10-20 1
Remove carbon deposits from the combustion chamber
[1].
INSPECTION
deformation, burning or clogs in oil passages.
- Cylinder head
Valve springs
Valves
Valve guides
Cam chain tensioner
Cam chain guide
Replace any part if it is out of service limit.
NOTE:
• Ream the valve guide using the valve guide reamer
to remove any carbon build up before measuring the
guide (page 10-22).
• Refer to valve seat inspection (page 10-22).
VALVE GUIDE REPLACEMENT

Disassemble the cylinder head (page 10-20).
[1]
Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
Heat the cylinder head to 100 - 150°C (212 - 302°F)
with a hot plate or oven.
NOTE:
• To avoid burns, wear heavy gloves when handling
the heated cylinder head.
• Do not use a torch to heat the cylinder head; it may
cause warping.
Support the cylinder head and drive out the valve
guides from combustion chamber side of the cylinder
head.
TOOL:
Valve guide driver, 5.5 mm [1] 07742-0010100
10-21
CYLINDER HEADNAlVE/CAMSHAFT
Drive in the valve guides [1 J to the specified depth from
the top of cylinder head .
SPECIFIED DEPTH:
IN: 12.9 - 13.2 mm (0.51 - 0.52 in)
EX: 15.1 -15.4 mm (0.59 - 0.61 in)
TOOL:
Valve guide driver, 5.5 mm [2] 07742-0010100
Let the cylinder head cool to room temperature .
qi [1]
[2]
Insert the reamer [1 J from the combustion chamber

side. [1 J
TOOL:
Valve guide reamer, 5.5 mm 07984-2000001 or
07984-200000D
(U.S.A. only)
NOTE :
• Always rotate the reamer clockwise . .,
• Use cutting oil on the reamer during this operation.
• Take care not to tilt or lean the reamer in the guide l
while reaming .
Clean the cylinder head thoroughly to remove any
metal particles.
Inspect the valve seat (page 10-22).
j
VALVE SEAT INSPECTION
j
Disassemble the cylinder head (page 10-20).
[1]
Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to the valve
seats.
Tap the valves and seats using a rubber hose or other
hand-lapping tool [1].
Measure the valve seat width according to CYLINDER
HEADNALVE/CAMSHAFT SPECIFICATIONS (page
v[
1-8). 00 c:::> 0 0
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Reface the valve seat (page 10-23) in the following
cases:
- Valve seat contact area is too wide or too narrow
- Valve seat contact surface is not center
- Damaged valve seat contact face
NOTE:
• The valves cannot be ground . If the valve face is
burned, badly worn , or if it contacts the seat
unevenly, replace the valve .
If the contact surface of the valve seat is abnormal, the
valve is tilted, inspect the valve stem-to-valve guide
clearance (page 1-8). J
If the valve stem-to-valve guide clearance are normal,
replace the valve guide (page 10-21 ).
I
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10-22
VALVE SEAT REFACING
Inspect the valve seat (page 10-22).
Reface the valve seat using the following tools.
TOOLS:
Cutter holder, 5.5 mm 07781-0010101
Seat cutter, 40 mm (45° IN) 07780-0010500
Seat cutter, 35 mm (45° EX) 07780-0010400
Flat cutter, 38.5 mm (32° IN) 07780-0012400
Flat cutter, 33 mm (32° EX) 07780-0012900
Interior cutter, 37.5 mm (60° IN) 07780-0014100
I Interior cutter, 34 mm (60° EX) 07780-0014700
I or equivalent commercially available in U.S.A.
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STANDARD:
IN: 1.1 -1.3 mm (0.04- 0.05 in)
EX: 1.3 - 1.5 mm (0.05 - 0.06 in)
SERVICE LIMITS:
IN: 1.5 mm (0.06 in)
EX: 1.9 mm (0.07 in)
NOTE:
• Follow the refacer manufacturer's operating
instructions.
• Be careful not to grind the seat more than
necessary.
1. Use a 45° seat cutter, remove any roughness or
irregularities from the seat.
2. Use a 32° flat cutter, remove the top 1/4 of the
existing valve seat material.
3. Use a 60° interior cutter, remove the bottom 1/4 of
the existing valve seat material.
4. Using a 45° seat cutter, cut the seat to the proper
[1]
width.
Make sure that all pitting and irregularities are
removed.
5. After cutting the seat, apply lapping compound to the
valve face, and lap the valve using light pressure.
NOTE:
• Excessive lapping pressure may deform or damage
the seat.
• Change the angle of lapping tool [1] frequently to
prevent uneven seat wear.
• Do not allow any lapping compound to enter the
guides.
After lapping, wash any residual compound off the
cylinder head and valve and recheck the seat contact.
Assemble the cylinder head (page 10-24).
10-23
ASSEMBLY
~"' EXHAUST VALVE SPRINGS
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~ EXHAUST STEM SEALS
INTAKE VALVE SPRINGS
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INTAKE STEM SEALS l
INTAKE EXHAUST
STEM SEAL STEM SEAL
LJ 71
INTAKE VALVES
EXHAUST VALVES
Blow through the oil passage in the cylinder head with ~
compressed air. II
Install the spring seats [1]. [5]
Apply engine oil to the inside of new stem seals.
Install new intake stem seals [2] and exhaust stem
seals [3] . [~i !
Apply molybdenum oil solution to the valve stem sliding

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·r .\
area and stem end .
Insert the intake valves [4] and exhaust valves [5] into
the valve guide while turning them slowly to avoid
damage to the stem seal.
Install the intake valve springs [6] and exhaust valve
springs [7] with the tightly wound coils facing the
combustion chamber.
[8] et,[3] [1 J [8]
NOTE:
• The valve springs have paint marks: Pink paint Green paint
- Intake valve spring: Green paint
- Exhaust valve spring: Pink paint
Install the valve spring retainers [8] . [7] [6]
l
COMBUSTION CHAMBER SIDE
10-24
Install the tappet hole protector into the valve lifter bore
(page 10-20).
Install the valve cotters [1] using the special tool as
shown.
TOOL:
Valve spring compressor [2] 07757-0010000
NOTE:
• To prevent loss of tension, do not compress the .... ....
valve springs more than necessary. .... [1]
Tap the tool gently to seat the valve cotters firmly using
a hammer.
NOTE:
• Support the cylinder head above the work bench
surface to prevent valve damage.
Cam chain tensioner lifter (page 10-13)
- Spark plugs (page 3-6)
- Insulator (page 10-27)
INSTALLATION
Install the dowel pins [1] and a new gasket [2].
NOTE:
• Route the cam chain [3] through the gasket.
Install the cylinder head [1] from the right side.

NOTE:
• Route the cam chain [2] through the cylinder head.
Lift up the cylinder head and gasket [3] to get the
clearance for cam chain guide installation.
10-25
Install the cam chain guide [1].
NOTE:
• Align the cam chain guide end with the groove in the
cam chain guide plate.
• Align the cam chain guide tabs [2] with the grooves
in the crankcase [3].
Install the gasket [4] and cylinder head [5] onto the
crankcase.
Apply locking agent to the cam chain tensioner pivot ...,......_ _ _ __

bolt threads.
Install the washer [1], cam chain tensioner [2], and cam
chain tensioner pivot bolt [3].
Tighten the bolt to the specified torque.
Apply molybdenum oil solution to the cylinder head bolt

threads and seating surface of cylinder head bolU
washers. ~ \
Apply engine oil to the washer of cylinder head bolU

washers.
Install and tighten the cylinder head bolUwashers [1] to
NOTE:
• Tighten the cylinder head bolUwashers in a
Install and tighten the 6 mm bolts [2] securely.
- Front head engine hanger bolt (right side) [2]
- Front head engine hanger bolts (left side) [3]
Tighten the front head engine hanger bolt (right side) to
Tighten the front head engine hanger bolts (left side) to


- Camshaft (page 10-16)
Primary drive gear (DCT model) (page 13-54)
Right crankcase cover (MT model) (page 12-7)
Thermostat (page 8-6)
Throttle body (page 7-16)
Exhaust pipe (page 2-51)
Battery box cover (page 6-9)
10-26
INSULATOR
Remove the throttle body (page 7-16).
Remove the insulator mounting bolts [1] and insulator
[2).
Remove the 0-rings [3) from the insulator.
TORQUE:
Insulator mounting bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
r
NOTE:
t
• Replace 0-rings with new ones.
• Apply engine oil to new 0-rings.
r 10-27
MEMO
11. ALTERNATOR/STARTER CLUTCH
r
SERVICE INFORMATION· .. ··············· .. ·· 11-2 STATOR············································ 11-5
TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · 11-2 FLYWHEEL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 11-6
COMPONENT LOCATION···················· · 11-3 STARTER CLUTCH····························· 11-8
ALTERNATOR COVER .. ······················· 11-4

I
r
'
11-1
AL TERNATOR/STARTER CLUTCH
SERVICE INFORMATION
GENERAL
• This section covers service of the alternator and starter clutch. All service can be done with the engine installed in the frame.
• For alternator inspection (page 21-10)
• For CKP sensor inspection (page 5-8)
• For starter motor service (page 6-7)
TOOLS
Flywheel holder Rotor puller
07725-0040001 07733-0020001
or 07933-3000001 (U.S.A. only)
TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter reduction gear/shaft
• Damaged or faulty starter motor pinion gear
• Damaged starter driven gear
11-2
COMPONENT LOCATION
',
137 N·m
(14.0 kgf-m, 101 lbf·ft)
It~
12 N·m
(1 .2 kgf·m, 9 lbf·ft)
11-3
ALTERNATOR COVER
Disconnect the alternator 3P (Gray) connector (page
21-9).
MT model: Remove the gearshift spindle cover (page 12-20).
OCT model: Remove the shift control motor cover (page 13-54).
Remove the wire band [1] .
MT model: Remove the clamp [1].

Release the alternator wire from the frame.
Disconnect the CKP sensor 3P (Gray) connector [1].

Release the wire clips [2].
OCT model: Remove the wire band [3].

- Dipstick [1]
- Alternator cover bolt (long) [2]
- Alternator cover bolts {short) [3]
- Skid plate stay [4]
- Stay [5]
NOTE:
• Loosen the bolts in a crisscross pattern in 2 or 3
steps.
Remove the alternator cover [6].
NOTE:
The alternator cover (stator) is magnetically
attracted to the flywheel, be careful during removal
and installation.
11-4
Remove the dowel pins [1] and oil orifice [2].
Clean off any sealant from the alternator cover mating
surfaces.
TORQUE:
Alternator cover bolt:
12 N·m (1.2 kgf·m, 9 lbMt)
NOTE:
• Apply liquid sealant (TB1207B manufactured by
Three bond or equivalent) to the alternator cover
mating surface as shown .
• Install the oil orifice with the narrow hole side facing
out.
STATOR
Remove the alternator cover (page 11-4).
Release the wire grommet [1] from the alternator cover
groove.
Remove the alternator wire clamper bolt [2] and
alternator wire clamper [3].
Remove the stator bolt [4] and stator [5]. [5)
TORQUE:
Stator bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
NOTE: 1=.[4)
• Apply locking agent to the stator bolt threads.
• Apply liquid sealant (TB1207B manufactured by
Three bond or equivalent) to the wire grommet as
shown.
,
11-5
FLYWHEEL
REMOVAL
Remove the alternator cover (page 11-4).
NOTE:
• Be careful not to damage the crank pulser plate [1)
when the flywheel servicing.
Remove the starter reduction gear shaft [2) and starter
reduction gear B [3).
Remove the starter reduction gear shaft [4) and starter
reduction gear A [5).
Hold the flywheel [1 J using the special tool and loosen

the flywheel mounting bolt [2).
TOOL:
Flywheel holder [3] 07725-0040001
Remove the flywheel mounting bolt and washer [4).
Remove the flywheel [1) using the special tool.
TOOL:
Rotor puller [2] 07733-0020001 or
07933-3000001
(U.S.A. only)
Remove the needle bearing [1] .

Remove the woodruff key [2].
NOTE:
• Be careful not to damage the key groove and
crankshaft.
11-6 •
I
J
Remove the starter driven gear (page 11-8).
Hold the flywheel [1] using the special tool.
TOOL:
Flywheel holder (2) 07725-0040001
Remove the crank pulser plate bolts [3] and crank
pulser plate [4].
Assembly is in the reverse order of disassembly.
NOTE:
• Be careful not to damage the crank pulser plate.
• Align the crank pulser plate tab with the flywheel
groove.
• Apply locking agent to the crank pulser plate bolt ' - - - - - - - - - - - - - - - - - - - " '
INSPECTION
Inspect the following parts for scratches, damage,
abnormal wear, or deformation.
- Starter reduction gear shaft
- Starter reduction gear
- Woodruff key
- Needle bearing
- Crank pulser plate
INSTALLATION
Install the woodruff key [1 J.
NOTE:
• Be careful not to damage the key groove and
crankshaft.
Apply engine oil to the needle bearing rotating area.
Install the needle bearing [2] .
Clean any oil from the crankshaft and flywheel tapered

areas thoroughly.
Install the flywheel [1] to the crankshaft.
NOTE:
• Be careful not to damage the crank pulser plate [2]
when the flywheel servicing .
• Align the woodruff key with flywheel keyway.
Apply engine oil to the flywheel mounting bolt threads
Install the washer [3] and flywheel mounting bolt [4] .
Hold the flywheel using the special tool and tighten the
flywheel mounting bolt to the specified torque .
TOOL:
11-7
Apply molybdenum oil solution to the starter reduction
gear shafts outer surfaces.
Install the starter reduction gear A [1] and shaft [2].
Install the starter reduction gear B (3] and shaft [4].
Install the alternator cover (page 11-4).
STARTER CLUTCH
REMOVAL
NOTE:
• Be careful not to damage the crank pulser plate
when the starter clutch servicing.
Remove the flywheel (page 11-6).
Make sure that the starter driven gear [1] turns
counterclockwise smoothly and does not turn
[1]
clockwise.
Remove the starter driven gear while turning the starter
driven gear counterclockwise.

[3]
TOOL:
Flywheel holder [2] 07725-0040001
Remove the starter clutch torx bolts [3] .
Remove the starter clutch assembly [1] .

Remove the starter one-way clutch [2] from the starter
clutch outer [3].
11-8
INSPECTION
- Starter driven gear
- Starter clutch outer
- Starter one-way clutch
Measure each part according to ALTERNATOR/
STARTER CLUTCH SPECIFICATIONS (page 1-8).
INSTALLATION
NOTE:
• Be careful not to damage the crank pulser plate
I
when the starter clutch servicing.
I
Apply engine oil to the starter one-way clutch sliding
r surface.
Install the starter one-way clutch [1] to the starter clutch
I
outer [2] .
Install the starter clutch assembly [3].
TOOL:
Apply locking agent to the starter clutch tone bolt

Install and tighten the starter clutch tone bolts [3] to the
specified torque.
r
[
Install the starter driven gear [1] into the starter clutch
'
I outer while turning the starter driven gear
counterclockwise.
r Recheck the one-way clutch operation (page 11 -8).

Install the flywheel (page 11 -7).
11-9
MEMO
12. CLUTCH/GEARSHIFT LINKAGE {MT model)
SERVICE INFORMATION· .. ··················· 12-2 PRIMARY DRIVE GEAR · · · · · · · · · · · · · · · · · · · · · · 12-18
TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · 12-3 GEARSHIFT LINKAGE························ 12-20
COMPONENT LOCATION····················· 12-4 GEARSHIFT ARM/GEARSHIFT

PEDAL········· ····································· 12-23
RIGHT CRANKCASE COVER·· .. ············ 12-5
CLUTCH LEVER· ································ 12-25
CLUTCH········· ···································· 12-9
r
12-1
CLUTCH/GEARSHIFT LINKAGE (MT model)
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame.
• Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle
creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.
TOOLS
Clutch center holder Driver Attachment, 28 x 30 mm
07724-0050002 07749-0010000 07946-1870100
', :
::.z...'::.:-.:::...-.;;.-::;:;::::::/'
or Commercially available in U.S.A.

Pilot, 17 mm Attachment, 42 mm Attachment, 42 x 4 7 mm
07746-0040400 07QAD-POA0100 077 46-0010300
··~--
.::,.!:.-
~ ~- -/
.. -<-'
Pilot, 35 mm Gear holder, 2.5

07746-0040800 07724-0010100
or 07724-001A100 (U.S.A. only)
12-2
TROUBLESHOOTING
Clutch lever is too hard to pull in
• Damaged, kinked or dirty clutch cable
• Improperly routed clutch cable
• Damaged clutch lifter mechanism
• Faulty clutch lifter bearing
• Clutch lifter pin installed improperly
Clutch slips when accelerating
• Clutch lifter sticking
• Worn clutch friction discs
• Weak clutch springs
• No clutch lever freeplay
• Engine oil mixed with molybdenum or graphite additive
Clutch will not disengage or motorcycle creeps with clutch disengaged
• Excessive clutch lever freeplay (page 3-25)
• Clutch plate warped
• Engine oil level too high, improper engine oil viscosity or additive used
• Loose clutch center lock nut
• Damaged clutch lifter mechanism
• Clutch lifter pin installed improperly
• Worn clutch outer slot and clutch center grooves
• Improper clutch operation
Hard to shift
• Incorrect clutch cable adjustment
• Improper clutch operation
• Improper engine oil viscosity
• Damaged or bent shift forks (page 14-14)
• Bent shift fork shaft (page 14-14)
• Bent shift fork claw (page 14-14)
• Loose shift drum center bolt
• Damaged shift drum center
• Damaged shift drum guide grooves (page 14-14)
• Damaged or bent gearshift spindle
• Damaged clutch cam
Transmission jumps out of gear
• Worn shift drum stopper arm
• Weak or broken shift drum stopper arm return spring
• Loose shift drum center bolt
• Damaged shift drum center
• Bent shift fork shaft (page 14-14)
• Damaged or bent shift forks (page 14-14)
• Worn gear engagement dogs or slots
- Mainshaft (page 14-15)
- Countershaft (page 14-14)
r
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Damaged or bent gearshift spindle
1'
r 12-3
COMPONENT LOCATION
23 N·m (2 .3 kgf-m , 17 lbf-ft)
12 N·m (1 .2 kgf·m , 9 lbf-ft)
\~A
~
12 N·m (1 .2 kgf-m, 9 lbf·ft)
128 N·m (13 .1 kgf-m, 94 lbf·ft)
~
~~
~
/ ;
v'
12 N·m (1 .2 kgf·m, 9 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
12-4
RIGHT CRANKCASE COVER

REMOVAL
Remove the right rear engine cover (page 2-27).
Loosen the lock nut [1) and lower adjusting nut [2).
Disconnect the clutch cable [3) from the clutch lifter
lever [4).
Cut off and remove the hose clamp [1].

Disconnect the bypass hose [2].
Disconnect the radiator hose B [4).
Remove the right crankcase cover bolts [1).

Turn the clutch lifter lever [2) counterclockwise to
disengage the lifter lever slit from the clutch lifter pin.
Remove the right crankcase cover [3) .
NOTE:
• Be careful not to drop the return spring [4).
.,
Ii
12-5
Remove the dowel pins (1] and gasket [2] .
Remove the 0-ring [1] .

'J
CLUTCH LIFTER LEVER

REMOVAUINSTALLATION
l
l
Remove the right crankcase cover (page 12-5). •
Remove the clutch lifter lever [1] and return spring [2].
Installation is in the reverse order or removal. J
j
NOTE:
• Align the return spring end with the clutch lifter lever
groove. t
• Hook the return spring end to the right crankcase
cover groove. ,•
J
J
•'
OIL SEAUBEARING REPLACEMENT
Remove the clutch lifter lever (page 12-6).
Remove the oil seal [1].
Check the needle bearings [2] and replace if necessary.
6.5- 7.5 mm
(0.26 - 0.30 in)
0.3-0.8 mm
I
l
(0.01 - 0.03 in)

NOTE:
• Coat new bearings with engine oil and install them to
the specified depth as shown .
J
• Replace the oil seal with a new one and install it to t
the specified depth as shown .
• Apply grease to a new oil seal lips.
69.4 - 70.4 mm
(2.73 - 2.77 in )
'
12-6
INSPECTION
abnormal wear and deformation. Replace if necessary.
- Clutch lifter lever
- Return spring
INSTALLATION
Clean the right crankcase cover mating surfaces
thoroughly.
Apply liquid sealant (TB1207B manufactured by Three
Bond or equivalent) to the right crankcase cover mating
surface as shown.
10 - 15 mm
(0.4 - 0.6 in)
10-15 mm
(0.4 - 0.6 in)
Coat a new 0-ring [1] with engine oil and install it onto
the groove of the water pump cover.
Align the water pump shaft slit with the water pump
cover index lines by rotating the water pump shaft.
Align the following by rotating the crankshaft:

- Primary drive gear index line [1]
- Crankcase 'V " mark [2]
Make sure that the front balancer shaft end [3] is in
position as shown.
12-7
Install the dowel pins [1] and a new gasket [2].
Turn the clutch lifter lever [1] clockwise so that the lever
slit [2] is in position as shown.
Install the right crankcase cover [1] by holding the

clutch lifter lever [2].
Install the right crankcase cover bolts [3] .
Tighten the right crankcase cover bolts in a crisscross
pattern in 2 or 3 steps to the specified torque.
TORQUE:12 N·m (1.2 kgf·m, 9 lbf-ft)
Connect the radiator hose B [1]. .

Tighten the hose band screw [2] to the specified range
(page 8-9).
j
12-8
Install a new hose clamp [1] onto the bypass hose [2].
Connect the bypass hose to the hose joint [3] .
Pinch the ear portion of the hose clamp with a special
tool until the pinched area clearance is to the dimension
as shown .
. TOOL:
Pincher [4] Oetiker 1098 or equivalent
,
[2]
[1]
[4] $1
r Connect the clutch cable [1] to the clutch lifter lever [2].
Install the right rear engine cover (page 2-27).
, Adjust the clutch cable freeplay (page 3-25).
I
CLUTCH
REMOVAL
,. Remove the right crankcase cover (page 12-5) .
Loosen the clutch set plate bolts [1] in a crisscross
,• pattern in 2 or 3 steps.
Remove the clutch set plate bolts, set plate [2], and
clutch springs [3] .
,
I
12-9
I
I
j
CLUTCH/GEARSHIFT LINKAGE (MT model) l
[8] [9) j
- Clutch pressure plate [1]
Clutch lifter pin [2] J
Clutch friction discs C [3]
Clutch plate C [4]
Clutch friction discs B [5] (6 pcs)
Clutch plates [6] (5 pcs)
Clutch plate B [7]
j
Judder spring [8]
Judder spring seats [9]
Remove the clutch spring seats [1 OJ from the clutch
pressure plate.
NOTE:
• When removing the clutch friction discs and clutch
plates, note the number of them.
Unstake the clutch center lock nut [1].

NOTE:
• Be careful not to damage the mainshaft threads.
j
l
-,1
••
Install special tool.
TOOL:
Clutch center holder [1] 07724-0050002 or
commercially
available in U.S.A.
Loosen the clutch center lock nut [2] while holding the
clutch center with the special tool. •
Remove the lock nut.
J
,t
Remove the spring washer [1], thrust washer [2], and J
clutch center [3].
'
••
'
•
12-10
Remove the washer [1] and clutch outer [2].
Remove the washer [1] and clutch outer guide [2] .
I INSPECTION
Check the following for scratches, damage, abnormal
r wear and deformation :
- Clutch pressure plate cam areas [1]
- Clutch pressure plate grooves [2]
- Clutch pressure plate disc sliding surface [3]
- Clutch pressure plate bearing [4]
Replace the clutch pressure plate [5] if necessary.
For bearing replacement (page 12-12)
Check the following for scratches, damage, abnormal

wear and deformation :
- Clutch center cam areas [1] [1)
- Clutch center grooves [2]
- Clutch center disc sliding surface [3]
Replace the clutch center [4] if necessary.
[2)
12-11
Check the following of the for scratches , damage,
abnormal wear and deformation: [21 [4)
- Clutch outer grooves [1]

- Clutch outer needle bearing [2]
- Primary driven gear [3]
Replace the clutch outer [4] if necessary.
For needle bearing replacement (page 12-13)
[3]

- Clutch springs
- Clutch spring seats
- Clutch lifter pin
- Clutch friction discs/plates
- Judder spring
- Judder spring seat
- Clutch outer guide
Measure each part according to CLUTCH/GEARSHIFT
LINKAGE SPECIFICATIONS {MT model) (page 1-8).
NOTE :
• Replace the clutch springs as a set.
• Replace the clutch friction discs and plates as a set.
CLUTCH PRESSURE PLATE BEARING

REPLACEMENT
Drive clutch pressure plate bearing out.
(2)
Coat a new clutch pressure plate bearing with engine
oil.
Drive the clutch pressure plate bearing [1] until it is fully
seated using special tools .
TOOLS:
Driver [2] 077 49-0010000 (3)
Attachment, 28 x 30 mm [3] 07946-1870100
Pilot, 17 mm [4] 077 46-0040400
NOTE:
• Install the clutch pressure plate bearing with its
marked side facing up. [4) - -
12-12
CLUTCH OUTER NEEDLE BEARING
REPLACEMENT
Remove the clutch outer needle bearing [1] using the , - - - -• • • •
special tools. I
liiiiil•--- 1
TOOLS:
Driver [2] 07749-0010000
Attachment, 42 mm [3] 07QAD-POA0100
(3)
Coat a new clutch outer needle bearing with engine oil.

Install the clutch outer needle bearing [1] into the clutch
outer to the specified range using the special tools.
TOOLS:
Driver [2] 077 49-0010000
Attachment, 42 x 47 mm [3] 077 46-0010300
Pilot, 35 mm [4] 077 46-0040800
NOTE:
• Install the clutch outer needle bearing with its
marked side facing up.
(1) :fl-"71
12-13
INSTALLATION
CLUTCH CENTER CLUTCH OUTER ~
JUDDER SPRING SEAT~
JUDDER
SPRING
71
CLUTCH CENTER
LOCK NUT
71
Jlr,..._------------~cLUTCH
~
FRICTION
DISCC
J
CLUTCH
PLATE B
CLUTCH PLATES
(5 pcs)
CLUTCH FRICTION
DISCS B (6 pcs)
71 CLUTCH FRICTION DISC c71
CLUTCH CLUTCH
FRICTION FRICTION
DISCS B DISCS C CLUTCH SPRING SEATS
CLUTCH PRESSURE PLATE
•
J
Apply molybdenum oil solution to the clutch outer guide
entire surface.
Install the clutch outer guide [1] and washer [2].
12-14
Apply engine oil to the clutch outer needle bearing.
Apply molybdenum oil solution to the primary driven
gear teeth and clutch outer sliding area.
Install the clutch outer [1] and washer [2].
Install the clutch center [1], thrust washer [2], and spring
washer [3].
NOTE:
• Install the spring washer with its "OUT" mark [4]
facing out.
Apply engine oil to a new clutch center lock nut threads

Install the clutch center lock nut [1] onto the mainshaft.
Install special tool.
TOOL:
Clutch center holder [2] 07724-0050002 or
commercially
available in U.S.A.
Tighten the clutch center lock nut to the specified torque

by holding the clutch center with the special tool.
TORQUE: 128 N ·m (13.1 kgf·m, 94 lbf-ft)
Stake the clutch center lock nut [1].

NOTE:
• Be careful not to damage the mainshaft threads .
.r-
12-15
Apply molybdenum oil solution to the entire surface of
judder spring seat and judder spring.
Install the judder spring seat (1] and judder spring [2] 71 71
[2] [1]
71 71
onto the clutch center [3] as shown. [1 J [3]
Apply engine oil to the entire surface of clutch friction
discs.
Install the clutch friction disc C [4] and clutch plate B (5]
onto the clutch center.
Install the clutch friction discs B [6] (6 pcs) and clutch
plates [7] (5 pcs) alternately, starting with the clutch
friction discs B.
NOTE:
The clutch friction disc C lining width is smaller than
the clutch friction disc B.
• Clutch plate surface treatment is difference from
clutch plate B.
[4]
-"71
Install the spring seats [1] onto the clutch pressure plate
(2) grooves.
NOTE:
• Make sure that the spring seats are fully seated in
the pressure plate grooves.
Install the clutch lifter pin [1 J.
12-16 l
I
Apply engine oil to the entire surface of clutch friction
discC.
Install the clutch friction disc C [1) onto the clutch
pressure plate [2).
Install the clutch plate C [3) onto the clutch friction disc
C.
NOTE:
• Align the clutch plate C grooves with the clutch
pressure plate lugs.
[3)
[1)
Install the clutch pressure plate assembly [1) by rotating

[1)
counterclockwise.
NOTE:
• Install the clutch disc C tabs [2) into the shallow slots
[3) of the clutch outer.
[3]
Install the clutch springs [1), clutch set plate [2] and
clutch set plate bolts [3).
Tighten the clutch set plate bolts in a crisscross pattern
in 2 or 3 steps to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbHt)
Install the right crankcase cover (page 12-7).
12-17
PRIMARY DRIVE GEAR
REMOVAL
Remove the cylinder head (page 10-19).
Remove the cam chain guide plate bolts [1], cam chain
guide plate [2], and cam chain [3].
Install the special tool between the primary drive and

driven gears.
TOOL:
Gear holder, 2.5 [1] 07724-0010100 or
07724-001A100
(U.S.A. only)
Remove the primary drive gear bolt [2] and washer [3].
Remove the special tool.
Remove the timing sprocket [1] and primary drive gear

[2] .
i
•
INSPECTION
- Primary drive gear
- Timing sprocket
12-18
INSTALLATION
Apply engine oil to the primary drive gear teeth.
Install the primary drive gear [1 ].
NOTE:
• Align the primary drive gear wide tooth with the
crankshaft wide tooth.
• Make sure that the primary drive gear index line is
positioned between the rear balancer driven gear
index lines.
Apply engine oil to the timing sprocket teeth.

Install the timing sprocket [1].
NOTE:
• Install the timing sprocket with its punch mark [2]
facing out.
• Align the timing sprocket wide tooth with the
Apply engine oil to the primary drive gear bolt threads

Install the washer [1] and primary drive gear bolt [2].
driven gears.
TOOL:
Gear holder, 2.5 [3] 07724-0010100 or
07724-001A100
(U.S.A. only)
Tighten the primary drive gear bolt to the specified
torque.
Remove the special tool.
Coat the cam chain with the engine oil.
Install the cam chain [1] .
Apply locking agent to the cam chain guide plate bolts
Install the cam chain guide plate [2] and cam chain
guide plate bolts [3].
Tighten the cam chain guide plate bolts securely.
Install the cylinder head (page 10-25).
12-19
GEARSHIFT LINKAGE
REMOVAL
- Clutch (page 12-9)
- Gearshift arm (page 12-23)
Remove the gearshift spindle cover bolts [1] .
Remove gearshift spindle cover [3].
Clean off any dirt from the gearshift spindle serration
[4]. J
j
Remove the gearshift spindle set plate bolt [1] and set
plate [2].
Remove the gearshift spindle assembly [1] and thrust

washer [2].
J
I
Remove the shift drum center bolt [1].
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12-20
I
Remove the shift drum center [1] while holding the shift . --,.!ffl'l".m
drum stopper arm [2] using a screwdriver as shown.

- Dowel pin [1]
- Shift drum stopper arm pivot bolt [2]
- Shift drum stopper arm [3]
- Shift drum return spring [4]
Washer [5]
INSPECTION
Inspect the following parts for damage, abnormal wear
and deformation. Replace if necessary.
- Shift drum center
- Shift drum stopper arm
- Shift drum return spring
- Gearshift spindle
12-21
INSTALLATION
Install a new oil seal [1] until it is fully seated .
Apply grease to the oil seal lips.
Apply locking agent to the shift drum stopper arm pivot

bolt threads (page 1-23).
- Shift drum return spring [1]
- Washer [2]
- Shift drum stopper arm pivot bolt [4]
Tighten the shift drum stopper arm pivot bolt to the
specified torque .
TORQUE: 12 N·m (1 .2 kgf·m, 9 lbf·ft)
Check the shift drum stopper arm for proper operation.

Install the dowel pin [5].
Hold the shift drum stopper arm [1] using a screwdriver.
Install the shift drum center [2].
NOTE:
• Align the shift drum center groove with the dowel
pin.
Apply locking agent to the shift drum center bolt threads

(page 1-23).
Install and tighten the shift drum center bolt [1] to the
specified torque.
12-22
Install the thrust washer [1] onto the gearshift spindle
[2].
Install the gearshift spindle into the crankcase.
NOTE:
• Align the gearshift spindle return spring ends with
the spring pin.
Apply locking agent to the gearshift spindle set plate - - - -

bolt threads (page 1-23).
Install the set plate [1] and gearshift spindle set plate
bolt [2].
NOTE:
• Install the set plate with its punch mark [3] facing
out.
Tighten the gearshift spindle set plate bolt to the
specified torque.
Install the gearshift spindle cover [1] and gearshift

spindle cover bolts [2].
Tighten the gearshift spindle cover bolts to the specified
torque.
Install the wire clip [3] to the gearshift spindle cover.
NOTE:
• Route the wire harness properly (page 1-26).
- Gearshift arm (page 12-23)
GEARSHIFT ARM/GEARSHIFT PEDAL

Remove the pinch bolt [1] and gearshift arm [2] from the
gearshift spindle [3].
12-23
Remove the gearshift pedal pivot bolt [1].
Remove the gearshift pedal [2] and washer [3].
Remove the dust seals [4].
Check the dust seals and tie-rod ball joint dust cover for
deterioration or damage, replace them if necessary.
TORQUE:
Gearshift pedal pivot bolt:
27 N·m (2.8 kgf·m, 20 lbf·ft)
NOTE:
• Apply grease to the dust seal lips.
• Install the dust seals with the seal lip side facing out.
• Apply grease to the gearshift pedal pivot sliding area
(grease groove) of the pivot bolt.
• Align the slit of the gearshift arm with the punch
mark on the spindle.
[2] [1]
When adjusting the gearshift pedal height, perform the

[1]
procedure as follows:
Loosen the lock nuts [1].
NOTE:
• The gearshift arm side lock nut has left hand 10.2 mm
threads. (0.40 in)
[2]
Adjust the tie-rod [2] length so that the distance
between the ball joint ends is standard length as shown.
After adjustment, tighten the lock nuts securely.
186.2-187.2 mm
(7.33 - 7.37 in)
[1]
10.2 mm
(0.40 in)
12-24
CLUTCH LEVER
Remove the left rearview mirror [1] .
Remove the screw [2] .

- Clutch switch connectors (upper side) [1]
- Cruise cancel switch connectors (lower side) [2]
Loosen the lock nut [1] and disconnect the clutch cable
by turning the adjuster bolt (2] .
Remove the bolts [3], holder [4], and clutch lever
assembly [5].
NOTE:
• Install the clutch lever assembly by aligning its end
with the paint mark on the handlebar.
Install the holder with its punch mark [6] facing up.
• Tighten the upper bolt first, then the lower bolt.
After installation, adjust the clutch lever freeplay (page
3-25).
12-25
CLUTCH CRUISE
CANCEL SWITCH
CLUTCH SWITCH
LOCK NUT
ADJUSTER BOLT
CLUTCH LEVER
BRACKET
Lw
CLUTCH SWITCH
MOUNTING SCREW
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
CLUTCH LEVER
CLUTCH LEVER PIVOT NUT 11a
5.9 N·m (0 .6 kgf·m, 4.4 lbf·ft) CLUTCH CRUISE CANCEL
SWITCH MOUNTING SCREW
1.5 N·m (0.2 kgf-m , 1.1 lbf·ft)
12-26
J
13. DUAL CLUTCH TRANSMISSION (DCT model)
SERVICE INFORMATION· .. ··················· 13-2 SHIFT CONTROL MOTOR/REDUCTION

GEARS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13-54
DCT SYMPTOM TROUBLESHOOTING · · · 13-4
GEARSHIFT LINKAGE························ 13-57
COMPONENT LOCATION····················· 13-5
MAINS HAFT SENSOR· .. ······················ 13-61
SYSTEM LOCATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13-6
TR SENSOR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13-62
SYSTEM DIAGRAM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13-7
SHIFT SPINDLE ANGLE SENSOR ··· · · ··· 13-63 . .
DCT TROUBLESHOOTING
INFORMATION···································· 13-8 CLUTCH EOP SENSOR······················· 13-63
DCT DTC INDEX .. ··············· ················ 13-10 EOT SENSOR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13-64
DCT DTC TROUBLESHOOTING ···········13-12 EOP SENSOR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13-64
CLUTCH OIL FEED PIPE · · · · · · · · · · · · · · · · · · · · · 13-38 NEUTRAL SWITCH····························· 13-65
RIGHT CRANKCASE COVER··········· ···· 13-40 TCM ················································· 13-65
LINEAR SOLENOID VALVE················· 13-47 DCT RELAY·················· ····················· 13-67
DUAL CLUTCH/PRIMARY DRIVEN CLUTCH INITIALIZE LEARNING

GEAR ···············································13-50 (TCM) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13-67
PRIMARY DRIVE GEAR · · · · · · · · · · · · · · · · · · · · · · 13-53
13-·1
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SERVICE INFORMATION
GENERAL
• This section covers service of the electrical and mechanical systems of the Dual Clutch Transmission (OCT).
• A faulty OCT system is often related to poorly connected or corroded connectors . Check those connections before proceeding .
• Read the "OCT Troubleshooting Information" carefully, and inspect and troubleshoot the OCT system according to the OTC.
Perform each step of the procedures one by one. Note the OTC and probable faulty part before starting diagnosis and
troubleshooting .
• The TCM may be damaged if dropped. Also, if a connector is disconnected when current is flowing, the excessive voltage may
damage the TCM . Always turn off the ignition switch before servicing .
• If the TCM and/or dual clutch are replaced , perform the clutch initialize learning procedure (page 13-67).
• The drive mode AT or MT are changed electrically with the NM switch. l•
• Be sure to use the recommended tires, and the specified drive and driven sprocket to operate the dual clutch transmission
system normally.
• For left handlebar switch service (page 22-27)
I
• For right handlebar switch service (page 22-34)
• For VS sensor service (page 4-73)
• For oil pump service (page 9-6)
J
For DCT System Troubleshooting J
• The OCT system is controlled by the TCM. Therefore, some detection items are shared in the PGM-FI and OCT systems, and
they may affect the operation of both systems.
• Before starting any troubleshooting, check the following items and refer to the appropriate troubleshooting.
- MIL lights or OTC for the PGM-FI system appeared (page 4-5). J
- Shift indicator blinks or OTC for the OCT system appeared (page 13-8)
- Symptom of the OCT system operation (page 13-4)
• The gearshift mechanism includes the following items. If the gearshift mechanism is faulty, refer to each component service.
- Shift control motor/reduction gears (page 13-54)
- Gearshift linkage (page 13-57)
l
J
- Shift drum/shift fork (page 14-14) J
Shift Control Motor Function Procedures

NOTE :
• If the system has a OTC, the function test does not work.
• The function test is not for the quality check of the shift control motor.
Conduct a test of the shift control motor when, the following items have been serviced or replaced .
- Shift control motor
-
-
Reduction gears
TR sensor j
- Shift spindle angle sensor
Connect the MCS (page 4-6), and perform the shift control motor function test.
Linear Solenoid Valve Function Procedures

NOTE:
l
• If the system has a OTC, the function test does not work .
• The function test is not for the quality check of the linear solenoid valve .
• Do not open the throttle while testing the linear solenoid valve function .
Conduct a test of the linear solenoid valves when the linear solenoid valves have been serviced or replaced .
Connect the MCS (page 4-6), and perform the linear solenoid valve function test.
13-2
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I
TOOLS
Test probe, 2 pack Remover weight Bearing remover shaft
07ZAJ-RDJA 110 07741-0010201 07 JAC-PH80200
or 07936-371020A (U.S.A. only) or commercially available 3/8 x 16 in.

slide hammer (U.S.A. only)
Adjustable bearing puller, 20 - 40 mm Driver Attachment, 52 x 55 mm
07JAC-PH80100 07749-0010000 07746-0010400
or 07736-A01000B used with

07YAC-001A200 (U.S.A. only)
Pilot, 40 mm Bearing remover set, 20 mm Remover handle
07746-0040900 07936-3710600 07936-3710100
Pilot, 20 mm Gear holder, 2.5

07746-0040500 07724-0010100
or 07724-001A100 (U.S.A. only)
13-3
j
.)

DCT SYMPTOM TROUBLESHOOTING
Check the shift indicator"-" blinking of the meter (page 13-8).
If the shift indicator "-" is blinking , refer to the OTC index (page 13-10) and begin the appropriate troubleshooting procedure.
If there are no "-" blinking, inspect the engine oil condition and follow the symptom troubleshooting described below.
CLUTCH SLIPS AND MOTORCYCLE DOES NOT ACCELERATE

Check the clutch clearance (page 13-51 ).
EXCESSIVE NOISE OR VIBRATION AROUND THE DCT SYSTEM

Inspect the following components:
- Clutch clearance
- Dual clutch needle bearings for wear or damage
- Primary drive for wear or damage
- Primary driven gear for wear or damage
- Each fastener is tightened to the correct torque value
Replace the damaged components if necessary and tighten the loose fasteners to the specified torque.
J
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13-4
COMPONENT LOCATION
31 N·m (3.2 kgf-m, 23 lbHt)
12 N·m (1 .2 kgf-m , 9 lbHt)
12 N·m (1 .2 kgf-m , 9 lbHt)
x1.~
12 N·m (1 .2 kgf-m, 9 lbMt)
12 N·m (1 .2 kgf-m , 9 lbHt)
\ .,
12 N·m (1 .2 kgf-m, 9 lbHt)

5.0 N·m (0.5 kgf-m , 3.7 lbHt)
13-5
SYSTEM LOCATION
FUSE BOX
- Fl 15 A
N-D SWITCH - MAIN2 30 A
-DCT-M 30 A
MID
Fl RELAY
METER
SHIFT UP
SWITCH(+) DLC
POWER BOX
SHIFT -SUB VB 10 A
CONTROL - ST-MAG 10 A
MOTOR - SUB VB RELAY
CKP SENSOR
VS SENSOR
SHIFT SPINDLE
EOP SENSOR
ANGLE SENSOR
No.2 CLUTCH
EOP SENSOR
INNER MAINSHAFT - MAIN FUSE 30 A
SENSOR
NEUTRAL SWITCH
EOT SENSOR
I
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~
13-6 J
DUAL CLUTCH TRANSMISSION (OCT model)
SYSTEM DIAGRAM
MAIN IGNITION Fl
n
FUSE SWITCH ST-MAG RELAY
Bl 30A R R/81 10A Bl G
-I
I
I+
w Fl 15A R/Bu
G
DCT
RELAY
- Y
~
Br/Bl Br
l
BATTERY DCT-M !_ RiW IO J W SUB V
-- ...
w__.:f'
30'-AO-_ __ . ~
G
RELAY
MAIN2 SUB VB -
,l.~
OV -
~ A7 IGP
._w
___"f'30'-A,_..,;R..,.:1'1'-~,_,,;R,i,i,i,
IW.. --.:!::.... A3 PVB
--.:!::.... A 14 PVB
V V A8 Bu
SUBVB LSOLHN A19
'Gr - - _ P- 825
.. NM2P PT_CANL A21
.·. PT_CANH A33
Bl
81/R
ECM
OUTER
MAINS HAFT
SENSOR 0~=1
l.J
V 81/W ~
G/81
I
-
Gr
- ""' P_ A18 NM1P I

FRM_CANL 82
FRM CANH 813
Bl
81/R
HI
-
0~
INNER
MAINSHAFT METER
SENSOR
,H
-- ~
Bl/Bu Bl ABS
832 HSFT I
SHIFT UP SWITCH (+) I MODULATOR
I
l:::
SHIFT DOWN SWITCH (·)
G/W
BCU
Bl/Bu V
831 RANGE i
I
NSWITCH
,r CRF110004
r·-------··--:
D SWITCH §:§:= . _ TCM ~ scu i I
T----------__.:
AIM SWITCH §:§:=-t--4--_--++--"G""--•
IW -I
CLUTCH
LINE EOP
D I I
I Y/R
Gr
R
Y/R
A22
81 8
A4
SG I
PLINEI
VCC I
IMU
SENSOR -
P/Bu
SFTMOP A1
No.1 CLUTCH
EOPSENSOR I I
I Y/R
Y/G
819 PC11 SFTMOP
SFTMOM
A12
A2
P/Bu
Y/Bu
Y/Bu
I
T
Bu
v I M SHIFT CONTROL
MOTOR
SFTMOM A13
No.2 CLUTCH
EOPSENSOR I I
I Y/R
Bl
88
'
PC2 1
ILSOL1P
ILSOL1M
AS
A9
y
w W/R ~r.!!!!!.:J l No.1 LINEAR
SOLENOID
Bu Gr
VALVE
w
......:,:--1--f-:!!'.....-t!~=:!~] 820 SPDLI ILSOL2P A6
Bu
;-'t'HIH , I No.2 LINEAR
\g -
SHIFT SPINDLE CD : 1 - - saii'1_ _ y Gr
rLSOL2M A10 SOLENOID
ANGLE SENSOR VALVE
G Gr
I w w
TR S~ SOR(cr'I...CD_-~......I Y/R t~~~~~f==J..::!:!...iE~~~
y
87 DRUMANGI I K-LINE 83
.----- ~ _:.:_-··,.
SHIFT PEDAL
: DUMMY
I
-1o- y
O =G~ r : : : : : : : : : : : : : : : : : - : : :_ _ I ~
v I
.
y
ANGLE SENSOR , Y
810 SFTPANG I I
L ___ ::-:- ~
EOT SENSOR D I 1---- Bu
821 TOILI ILG An G/Bu
..... ~ __ _J
DLC
I PG A23 ~ B l · Black
Ln A32 NEUTRAL! I PG Br : Brown
B u : Blue
NEUTRAL A
SWITCH 1r" ·-= G Green
G r . G ray
Lg : Light green
·. ... p : Pink
R : Red
w . White
y :Yellow
V : V io let
TCM 33P (Black) TCM 33P (Gray)

CONNECTOR A CONNECTORB
(T CM SIDE) (TCM SIDE)
13-7
DCT TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Intermittent Failure
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the shift indicator"-" does not come
on, check for poor contact or loose pins at all connectors related to the circuit that you are troubleshooting. If the shift indicator"-"
was on , but then went out, the original problem may be intermittent.
Opens and Shorts
"Opens" and "Shorts" are common electrical terms. An open is a break in a wire or at a connection . A short is an accidental
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all. With
TCMs this can sometimes mean something works, but not the way it's supposed to.
If the shift indicator"-" has come on
Refer to DTC READOUT (page 13-9).
If the shift indicator "-" did not stay on
If the shift indicator"-" did not stay on, but there is a driveability problem, do the SYMPTOM TROUBLESHOOTING (page 13-4).
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The DCT system is equipped with the self-diagnostic system. When any abnormality occurs in the DCT system , the TCM have the
shift indicator blinking "-" and stores a DTC in its erasable memory for the relevant system failure.
FAIL-SAFE FUNCTION
The DCT system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system.
When the TCM detects a problem in the DCT system, the TCM stops the gearshift function, and holds the gear position. Also, the
shift indicator blinks "-" to indicate the DTC.
CURRENT OTC/STORED DTC
The DTC is indicated in two ways according to the failure status.
• If the TCM detects a current problem, the shift indicator "-" will blink and begin to blink as its DTC when the sidestand is
lowered. The shift indicator"-" blink pattern will indicate the current DTC.
• If the TCM does not detect any current problem but has a problem stored in its memory, the shift indicator"-" will not light and
blink. If it is necessary to retrieve the past problem, readout the stored DTC by following the DTC readout procedure (page 13-
9).
Shift indicator "-" Blink Pattern
• If the MCS is not available, the DTC can be read from the TCM memory by the shift indicator"-" blink pattern (page 13-9).
• The number of shift indicator "-" blinks is the equivalent of the main code of the DTC (the sub code cannot be displayed by the
shift indicator"-").
• The shift indicator"-" has two types of blinks, a long blink and short blink. The long blinking lasts for 1.2 seconds, the short
blinking lasts for 0.4 seconds. One long blink is the equivalent of ten short blinks. For example, DTC 14 and DTC 8 are indicated
in the following blink pattern. l
4
• When there isn't a DTC, the shift indicator"-" lights for 2 seconds at intervals of 3 seconds.
0.4 sec. 0.4 sec. 0.4 sec.
ON
2 sec. 1.2sec. r -
MM rr 2 sec. 1.2sec.r -
MM
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OFF J
1. .I I, .1 W 1. .1W 1. .I 1. .I w\ 0.4 sec. l
2.5 sec. 2.5 sec. \ 0.4 sec. 2 _5 sec.
1~ DTC14 •I
\ 0.4 sec.
1~ DTC8
2.5 sec.
•I
2.5 sec.
1~ OTC 14 •I i
One long blink = 10 blinks, Eight short blinks
plus four short blinks
- - - - - - - - - - - - - - - - - - - - - - - - - - - - • . _ Pattern repeated
1 cycle
13-8
MCS INFORMATION
Refer to the PGM-FI system (page 4-6).
NOTE:
The front wheel speed sensor signal can be disabled with the MCS for testing . Never ride the motorcycle with the TCM in this mode.
DTC READOUT
NOTE:
• If there is any problem in the PGM-FI system, troubleshoot it first. Then recheck the OCT system after erasing the PGM-FI OTC.
Read the OTC and stored data with the MCS, and follow the troubleshooting index (page 13-10).
To read the OTC without the MCS, use the following procedure .
Reading DTC with the shift indicator "-"
1. Connect the SGS service connector to the OLC (page 4-6).
(1)
2. While pushing the shift up switch (+) [1], turn the ignition switch ON.
Read and note the shift indicator "-" blinks and refer to the
troubleshooting index (page 13-10).
NOTE:
• If the TCM has no DTC in its memory, the shift indicator "-" will start
blinking (page 13-9).
3. Release the shift up switch(+).
I
.
I ERASING DTC
Connect the MCS to the DLC (page 4-6).
Erase the DTC with the MCS while the engine is stopped .
How to erase the DTC without MCS
1. Erase the DTC (page 4-8).
2. The OTC is erased if the shift indicator"-" goes off and starts blinking as shown .
\ I
::-::: ON
r - - -,
2 sec.
r-----1
2 sec. 2 sec.
1._----1
''
OFF
3 sec. 3 sec. 3 sec.
----,-----1~~ [
1 cycle
~ Pattern repeated
NOTE:
Note that the OTC cannot be erased if the ignition switch is turned to "OFF" before the shift indicator "-" starts blinking.
4. Remove the special tool from the DLC .
13-9
DCT DTC INDEX
If MCS is not used, perform all on the corresponding main code (digits in front of hyphen) of the Honda code.
• About Diagnostic Trouble Codes other than in this OTC INDEX, refer to PGM-FI SYSTEM OTC INDEX (page 4-10).
• Follow the prior diagnosis notes before performing the troubleshooting, refer to the PRIOR DIAGNOSIS (page 13-12).
DTC Detected DIC Referto
DTC DTC name
(Honda code) (Driving Cycle) page
EQT Sensor Circuit Low
P0197 44-1 -
(EQT Sensor Low Voltage)
13-13
EQT Sensor Circuit High
P0198 44-2 -
(EQT Sensor High Voltage)
P0500 67-1 1 4-36
Vehicle Speed Sensor Range Performance Error
P0501 66-1 1 13-14
(Front Wheel Pulser Ring Malfunction)
EOP Sensor Low
P0522 - 1
(EOP Sensor Low Voltage)
13-14
EOP Sensor High
P0523 - 1
(EOP Sensor High Voltage)
System Voltage
P0562 37-1 1 4-38
(Sub VB Relay Malfunction)
Control Module Processor
P0606 - 1 4-42
(CPU in the ECM Malfunction)
ECM/PCM Power Relay Control Circuit Low
P0686 37-1 1
4-38
ECM/PCM Power Relay Control Circuit High
P0687 37-1 - (Ignition Hold Relay Stuck ON)
Input Speed Sensor 1 Circuit
P0715 53-1 1 13-16
(Inner Mainshaft Speed Low)
Output Speed Sensor Range Performance Error
P0721 67-1 1 13-17
OS Sensor Circuit No Signal
P0722 11-1 1 4-45
Pressure Control Solenoid Malfunction
55-1 1
P0745 13-17
Pressure Control Solenoid Malfunction
55-2 1
Pressure Control Solenoid 2 Malfunction
56-1 1
P0775 13-18
Pressure Control Solenoid 2 Malfunction
56-2 1
Park/Neutral Switch Input Circuit Low
P0851 52-1 -
(Neutral Switch Stuck OFF)
13-1 9
Park/Neutral Switch Input Circuit High
P0852 52-2 - (Neutral Switch Stuck ON)
In Main/Countershaft SP Ratio Failure
P1700 71-1 1
(Inner Mainshaft/countershaft Speed Ratio Failure)
13-20
Outer Main/Countershaft SP Ratio Failure
P1701 72-1 1
(Outer Mainshaft/countershaft Speed Ratio Failure)
TR Sensor Circuit Low
P1702 51-1 1
(TR Sensor Low Voltage)
13-21
TR Sensor Circuit High
P1703 51-2 1
(TR Sensor High Voltage)
P1704 47-1 1 No.1 Clutch EOP Sensor Low Voltage
P1705 47-2 1 No.1 Clutch EOP Sensor High Voltage
13-22
P1706 48-1 1 No.2 Clutch EOP Sensor Low Voltage
P1707 48-2 1 No.2 Clutch EOP Sensor High Voltage
P1708 21 -1 1 Shift Spindle Angle Sensor Low Voltage
13-23
P1709 21 -2 1 Shift Spindle Angle Sensor High Voltage
P170A 24-1 1 Shift Control Motor Drive Circuit
13-25
P1708 31 -1 1 Shift Control Motor Low Voltage
Learning Value Area Malfunction
P170F 33-2 1 13-26
(TCM EEPRPM Malfunction)
TCM CPU Malfunction
P1712 84-2 1 4-53
(CPU in the ECM or TCM Malfunction)
13-10
DTC Detected DIC Referto
DTC DTC name
(Honda code) (Driving Cycle) page
Spindle Operation During Shifter Stop
P1713 22-1 1 (Shift Spindle Operation Malfunction (After Operating 13-26
P1714 . 27-1 1 Shift Drum Position Malfunction 13-27
Clutch Line EOP Sensor High Voltage
P1716 9-2 -
(Clutch Line EOP Sensor Low Voltage)
13-27
Clutch Line EOP Sensor Low Voltage
P1717 9-1 -
(Clutch Line EOP Sensor High Voltage)
Shift Control Motor Drive Circuit
P1718 49-1 - 13-29
(Clutch Line Low Oil Pressure)
Clutch (1) Being Dysversion
P1719 68-1 1 13-29
•
•I
Clutch (2) Being Dysversion
P171A 69-1 1 13-30
P171B 58-1 -
(No.1 Clutch Does Not Disengage (When Shifting Gear))
13-30
P171C 59-1 -
(No.2 Clutch Does Not Disengage (When Shifting Gear))
Clutch Bite Crowded (1) Pressure No Opening
P171D 61-4 -
P171E 61-1 1 (No.1 Clutch Oil Pressure Malfunction (at Clutch Initial
Diagnosis))
Clutch (1) No Pressure
P171F 61-2 1
Clutch (1) Hydraulic Pressure Low
P1720 61-3 1
Clutch (1) Hydraulic Pressure Rise
P1721 62-1 -
13-31
Clutch Bite Crowded (2) Pressure No Opening
P1722 63-4 -
P1723 63-1 1 (No.2 Clutch Oil Pressure Malfunction (at Clutch Initial
Diagnosis))
Clutch (2) No Pressure
P1724 63-2 1
Clutch (2) Hydraulic Pressure Low
P1725 63-3 1
Clutch (2) Hydraulic Pressure Rise
P1726 64-1 - (No.2 Clutch Oil Pressure High)
Shifter Malfunction
P1728 57-1 1
(Gearshift Mechanism Malfunction)
13-31
Shifter Setting Malfunction
P1729 57-2 1
(Gear Position Malfunction (Jumps Out of Gear))
Shift Angle Sensor Ground Fault
P172A 1-1 -
13-31
Shift Angle Sensor High Voltage
P172B 1-1 -
N-D Switch Signal Malfunction
P172C 46-1 - 13-33
(N-D Switch Malfunction)
Shifter Driven in Spindle Inactive
P172D 45-1 - 13-34
(Shift Switch Malfunction)
FSR Malfunction
P172E 32-1 1 13-35
(Fail Safe Relay Circuit Malfunction)
Spindle No Operation During Shifter Drive
P172F 23-1 1 (Shift Spindle Operation Malfunction (While Operating 13-36
P2158 66-1 1 4-59
Input Speed Sensor 2 Circuit
P2765 54-1 1 13-37
(Outer Mainshaft Speed Low)
CAN Communication Malfunction (PTCAN)
U019E 112-1 1 4-65
(Power train CAN Communication Malfunction)
13-11
'f
DCT DTC TROUBLESHOOTING
PRIOR DIAGNOSIS J
Before processing the OTC troubleshooting, check as
follows:
• Check for loose or poor contact on the OTC related
connectors (each sensor, solenoid, unit etc.), then
recheck the OTC.
• Erase the OTC (page 13-9) and recheck it.
• Refer to probable cause of each detected OTC and
check the listed items first. If possible, correct the
abnormally.
NOTE:
• Always turn the ignition switch OFF when checking
the continuity of the circuit and before disconnecting
the connectors.
• Some OTCs have a recheck function, so that the
priority OTC is detected when the ignition switch is
switched from OFF to ON . Wait for 10 seconds and
check the OTC again.
COMMON TROUBLESHOOTING
INFORMATION
NOTE:
• Always use the test probe when inspecting at the
ECM, TCM, ABS modulator, BCU, and SCU
connectors.
TOOL:
• If the TCM is replaced, perform the Clutch Initialize
Learning Procedure (page 13-67).
• When performing the test ride in the procedure of
the troubleshooting, set the motorcycle to the
preferred value as below chart. Conduct a test ride
with your confirmation .
Motorcycle speed*: About 60 km/h (37 mph)
Running time: 1 minute or more
Engine revolution: 4,000- 7,500 r/min
Throttle opening angle: 14 degrees or more
*: If the test ride cannot be performed, replace parts that

may be abnormal.
i
J
13-12
DTC P0197/DTC P0198
Probable cause:
• Faulty EOT sensor or its related circuit
• Faulty TCM
• Gearshift function works normally
1. EQT Sensor Input Line Open Circuit Inspection
Disconnect the TCM 33P (Gray) connector (page
13-65).
Disconnect the EQT sensor connector (page 13-
64 ).
EQT sensor connector [1] and TCM 33P (Gray) B21
connector [2].
Bu
CONNECTION: Blue - 821
YES - GO TO STEP 2.
NO - Open circuit in the Blue wire
[1] [2]
2. EQT Sensor Ground Line Open Circuit

Inspection
Disconnect the TCM 33P (Black) connector (page
13-65).
EQT sensor connector [1] and TCM 33P (Black)
connector [2].
CONNECTION: Gray - A22
YES - GO TO STEP 3.
[1] [2]
3. EOT Sensor Input Line Short Circuit Inspection

[1]
EQT sensor connector [1] and ground.
YES - Short circuit in the Blue wire
NO - GO TO STEP 4.
13-13
1
4. EQT Sensor Inspection
Replace the EQT sensor with a new one.
Erase the OTC.
YES - Replace the TCM with a new one, and
recheck.
NO - Faulty original EOT sensor j
DTC P0501 J
Probable cause:
• Faulty front wheel pulser ring
• Contaminated pulser ring (iron or other magnetic
deposits)
• Faulty front wheel speed sensor or its related circuit
• ABS modulator has OTC
• Faulty ECM
Refer to OTC POSOO troubleshooting (page 4-36).
DTC P0522/DTC P0523

Probable cause:
• Faulty EOP sensor or its related circuit
• Faulty ECM
1. EOP Sensor Input Line Open Circuit Inspection
Disconnect the EOP sensor connector (page 13-
64 ).
Measure the voltage at the wire harness side EOP
CONNECTION: Yellow(+)- Gray(-)
YES - GO TO STEP 2.
[1]
13-14
2. EOP Sensor Output Line Open Circuit
Inspection
[1] [2]
71 ).
EOP sensor connector [1] and ECM 33P (Gray)
connector [2].
YES - GO TO STEP 3. w
C20
3. EOP Sensor Output Line Short Circuit

Inspection
EOP sensor connector [1] and ground. [1]

NO - GO TO STEP 4. w
4. EOP Sensor Inspection

Replace the EOP sensor with a new one.
Erase the OTC.
recheck.
NO - Faulty original EOP sensor
13-15
DTC P0715
Probable cause:
• Electromagnetic interference
• Faulty inner mainshaft sensor or its related circuit
• Faulty TCM
1. Inner Mainshaft Sensor Input Voltage Inspection
'I
Disconnect the inner mainshaft sensor connector J
(page 13-61 ). [1)
J
Measure the voltage at the wire harness side inner
mainshaft sensor connector [1].
.
J
CONNECTION: Violet(+) - Gray(-)

Is there about battery voltage?
YES - GO TO STEP 2.
NO - • Open or short circuit in the Violet wire
• If the wire is OK, replace the TCM with
a new one , and recheck.
2. Inner Mainshaft Sensor Output Line Open

Circuit Inspection
inner mainshaft sensor connector [1 J and TCM 33P
{Black) connector [2].
CONNECTION: Pink-A18
A18
YES - GO TO STEP 3. p
NO - Open circuit in the Pink wire
[1) (2)
3. Inner Mainshaft Sensor Output Line Short

Circuit Inspection
[1)
inner mainshaft sensor connector [1] and ground.
CONNECTION: Pink - Ground
YES - Short circuit in the Pink wire
NO - GO TO STEP 4.
13-16
4. Inner Mainshaft Sensor Inspection
Replace the inner mainshaft sensor with a new one.
Erase the OTC.
recheck.
NO - Faulty original inner mainshaft sensor
DTC P0721
Probable cause:
• Faulty rear wheel pulser ring or its related parts
• ABS modulator has OTC
• Faulty ECM
• Cruise control does not work
NOTE:
1. Rear Wheel Pulser Ring Inspection
Replace the rear wheel pulser ring with a new one.
Erase the OTC.
recheck.
NO - Faulty original rear wheel pulser ring
DTC P0745
Probable cause:
• Faulty No.1 linear solenoid valve or its related circuit
• Faulty TCM
1. No.1 Linear Solenoid Valve Line Open Circuit
Inspection
[1] [2]
13-65).
\
Disconnect the liner solenoid valve connector (page
13-47).
linear solenoid valve connector [1] and TCM 33P
(Black) connector [2] .
CONNECTION:
Yellow-AS
White-A9
YES - GO TO STEP 2.
NO - • Open circuit in the Yellow wire
• Open circuit in the White wire
13-17
2. No.1 Linear Solenoid Valve Line Short Circuit
Inspection
[1]
linear solenoid valve connector [1] and ground .
CONNECTION:
Yellow - Ground
White - Ground y
Is there continuity? w
YES - • Short circuit in the Yellow wire
• Short circuit in the White wire
NO - GO TO STEP 3.
J
3. No.1 Linear Solenoid Valve Inspection

Replace the linear solenoid valve with a new one.
Connect the disconnected connector(s) .
Erase the OTC.
Start the engine and wait for 10 seconds.
recheck.
NO - Faulty original No.1 linear solenoid valve
DTC P0775
Probable cause :
• Faulty No.2 linear solenoid valve or its related circuit
• Faulty TCM
1. No.2 Linear Solenoid Valve Line Open Circuit
Inspection
[1] [2]
13-65).
Disconnect the liner solenoid valve connector (page
13-47).
linear solenoid valve connector [1] and TCM 33P
(Black) connector [2] .
CONNECTION:
Blue-A6 Gr
Gray-A10
YES - GO TO STEP 2.
NO - • Open circuit in the Blue wire
13-18
2. No.2 Linear Solenoid Valve Line Short Circuit
Inspection
[1]
linear solenoid valve connector [1] and ground.
CONNECTION:
Blue - Ground
Gray- Ground Bu
Is there continuity? Gr
YES - • Short circuit in the Blue wire
• Short circuit in the Gray wire
NO - GO TO STEP 3.
3. No.2 Linear Solenoid Valve Inspection

Replace the linear solenoid valve with a new one.
Erase the OTC.
Start the engine and wait for 10 seconds.
recheck.
NO - Faulty original No.2 linear solenoid valve
DTC P0851/DTC P0852

Probable cause:
• Faulty neutral switch or its related circuit
• Faulty TCM
1. Neutral Switch Line Open Circuit Inspection
13-65). [1] [2]
Remove the neutral switch terminal (page 13-65).
TCM 33P (Black) connector [1] and neutral switch
terminal [2].
CONNECTION: A32 - Light green
Lg
YES - GO TO STEP 2.
A32
2. Neutral Switch Line Short Circuit Inspection

Check for continuity between the neutral switch
terminal and ground.
NO - GO TO STEP 3.
13-19
3. Neutral Switch Inspection
Replace the neutral switch with a new one.
Erase the OTC.
Turn the ignition switch ON with gearshift "N"
position.
Shift the gearshift 1st position and wait for 10
seconds.
Recheck the OTC with MCS.
recheck.
NO - Faulty original neutral switch
DTC P1700/DTC P1701

Probable cause:
• Faulty VS sensor or its related circuit
• Faulty inner mainshaft sensor or its related circuit
• Faulty outer mainshaft sensor or its related circuit
• Faulty TCM
NOTE:
• When other OTC is displayed, together with P1700/
P1701 first.
1. TCM Inspection
Erase the OTC.
Run the motorcycle for a minute in each gear as
follows:
- P1700: Drive the motorcycle in 1st, 3rd and 5th
gear.
- P1701 : Drive the motorcycle in 2nd, 4th and 6th
gear.
YES - Replace the main wire harness with a new
one, and recheck.
13-20
DTC P1702/DTC P1703
Probable cause:
• Faulty TR sensor or its related circuit
• Faulty TCM
1. TR Sensor Input Voltage Inspection
Disconnect the TR sensor connector (page 13-62).
[1]
Measure the voltage at the wire harness side TR

YES - GO TO STEP 2.
a new one , and recheck.
2. TR Sensor Signal Line Open Circuit Inspection

[1] [2)
13-65).
TR sensor connector [1] and TCM 33P (Gray)
connector [2].
w B7
YES - GO TO STEP 3.
3. TR Sensor Output Line Short Circuit Inspection

[1)
TR sensor connector [1] and ground.
NO - GO TO STEP 4.
13-21
4. TR Sensor Inspection
Replace the TR sensor with a new one.
Erase the OTC.
recheck.
NO - Faulty original TR sensor

DTC P1707
Probable cause:
• Faulty No.1 clutch EOP sensor or its related circuit
• Faulty TCM
Gearshift function does not work
1. Clutch EOP Sensor Input Voltage Inspection
Disconnect the following connectors:
- No.1 clutch EOP sensor connector (page 13-63)
- No.2 clutch EOP sensor connector (page 13-63)
Measure the voltage at the wire harness side clutch
EOP sensor connector [1] .
CONNECTION: Yellow/red (+) - Gray(-)
YES - GO TO STEP 2.
NO - • Open or short circuit in the Yellow/red
wire
• If the wire is OK, replace the TCM with [1)
2. Clutch EOP Sensor Output Line Open Circuit
Inspection
[1) (2)
13-65).
clutch EOP sensor connector [1] and TCM 33P
CONNECTION:
No.1 clutch EOP sensor: I
Yellow/green - B19 J
No.2 clutch EOP sensor:
Black- B8 l
YES - GO TO STEP 3.
NO - • Open circuit in the Yellow/green wire
13-22
3. Clutch EOP Sensor Output Line Short Circuit
Inspection
[1]
clutch EOP sensor connector [1] and ground.
CONNECTION:
Yellow/green - Ground
No.1: Y/G
Black - Ground No.2: Bl
YES - • Short circuit in the Yellow/green wire
NO - GO TO STEP 4.
4. Clutch EOP Sensor Inspection

Replace the clutch EOP sensor with a new one.
Erase the OTC.
recheck.
NO - Faulty original clutch EOP sensor
DTC P1708/DTC P1709

Probable cause:
• Faulty shift spindle angle sensor or its related circuit
• Faulty TCM
1. Shift Spindle Angle Sensor Input Voltage
Inspection
Disconnect the shift spindle angle sensor connector
(page 13-63). [1]
Measure the voltage at the wire harness side shift
spindle angle sensor connector [1].

YES - GO TO STEP 2.
13-23
2. Shift Spindle Angle Sensor Signal Line Open
Circuit Inspection
[1] [2]
13-65).
shift spindle angle sensor connector [1] and TCM
33P (Gray) connector [2].
CONNECTION: White - 820
Is there continuity? w
YES - GO TO STEP 3. B20
3. Shift Spindle Angle Sensor Output Line Short

Circuit Inspection
[1]
shift spindle angle sensor connector [1] and ground.
NO - GO TO STEP 4.
4. Shift Spindle Angle Sensor Inspection

Replace the shift spindle angle sensor with a new
one.
Erase the OTC.
~
recheck.
i
NO - Faulty original shift spindle angle sensor
13-24
DTC P170A/DTC P1708
Probable cause:
• Faulty shift control motor or its related circuit
• Faulty TCM
Gearshift function does not work
1. Shift Control Motor Line Open Circuit Inspection
[2]
- TCM 33P (Black) connector (page 13-65)
- Shift control motor connector (page 13-54)
shift control motor connector [1) and TCM 33P
(Black) connector [2).
CONNECTION:
B1ue-A1
B1ue-A12
Yellow-A2
Yellow-A13
YES - GO TO STEP 2.
NO - • Open circuit in the Blue or Pink/blue ~[_1_1- - - - - - - - - -- - -- - -~
wire
• Open circuit in the Yellow or Yellow/
blue wire
2. Shift Control Motor Line Short Circuit Inspection
shift control motor connector [1) and ground.
CONNECTION:
Blue - Ground
Yellow - Ground
Bu y
YES - • Short circuit in the Blue or Pink/blue
wire
• Short circuit in the Yellow or Yellow/
blue wire
NO - GO TO STEP 3.
[1)
3. Shift Control Motor Inspection

Replace the shift control motor with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 1O seconds.
recheck.
NO - Faulty original shift control motor
13-25
DUAL CLUTCH TRANSMISSION {DCT model)
DTC P170F
Probable cause:
• Faulty TCM
• Gearshift system stops
1. TCM Inspection
Erase the OTC.
YES - Replace the main wire harness with a new
one , and recheck.
DTC P1713
Probable cause:
• Faulty shift spindle angle sensor
• Faulty gearshift mechanism (reduction gears)
• Faulty shift control motor
• Faulty shift spindle angle sensor installation status
• Faulty TCM
1. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a new
one.
Erase the OTC.
Drive the motorcycle using gears from 1st to 6th for
a minute in each gear, and then drive the
motorcycle using gears from 6th to 1st for a minute
in each gear.
Check the OTC with MCS .
recheck.
NO - Faulty original shift spindle angle sensor
,J
'
13-26
DTC P1714
Probable cause:
• Faulty TR sensor
• Faulty gearshift mechanism (reduction gears)
• Faulty shift control motor
• Faulty TR sensor installation status
• Faulty TCM
1. TR Sensor Inspection
Replace the TR sensor with a new one.
Erase the OTC.
in each gear.
recheck.
NO - Faulty original TR sensor
DTC P1716/DTC P1717

Probable cause:
• Faulty clutch line EOP sensor or its related circuit
• Faulty TCM
1. Clutch Line EOP Sensor Input Voltage
Inspection
Disconnect the clutch line EOP sensor connector
(page 13-63).
Measure the voltage at the wire harness side clutch
line EOP sensor connector [1 ].
CONNECTION: Yellow/red (+) - Gray(-)
YES - GO TO STEP 2.
NO - • Open or short circuit in the Yellow/red
wire
[1 J
.
13-27
2. Clutch Line EOP Sensor Output Line Open
Circuit Inspection
[1] [2]
13-65).
clutch line EOP sensor connector [1] and TCM 33P
CONNECTION: Red - 818
YES - GO TO STEP 3. R
818
NO - Open circuit in the Red wire
3. Clutch Line EOP Sensor Output Line Short

Circuit Inspection
[1]
clutch line EOP sensor [1] and ground.
CONNECTION: Red - Ground
YES - Short circuit in the Red wire
NO - GO TO STEP 4.
4. Clutch Line EOP Sensor Inspection

Replace the clutch line EOP sensor with a new one.
Erase the OTC.
recheck.
NO - Faulty original clutch line EOP sensor
I
J
1
J
13-28
DTC P1718
Probable cause :
• Engine oil level is low
• Faulty oil pump
• Faulty clutch oil filter or its oil circuit
• Faulty clutch line EOP sensor
• Faulty TCM
1. Clutch Line EOP Sensor Inspection
Replace the clutch line EOP sensor with a new one.
Erase the DTC.
in each gear.
recheck.
NO - Faulty original clutch line EOP sensor
DTC P1719
Probable cause :
• Faulty No.1 clutch
• Faulty VS sensor
• Faulty TCM
1. No.1 Clutch Inspection
Replace the No.1 clutch assembly with a new one.
Erase the DTC.
Drive the motorcycle in 1st, 3rd and 5th gear for a
minute in each gear.
recheck.
NO - Faulty original No.1 clutch assembly
13-29
DTC P171A
Probable cause:
• Faulty No.2 clutch
• Faulty VS sensor
• Faulty TCM
1. No.2 Clutch Inspection
Replace the No.2 clutch assembly with a new one.
Erase the OTC.
Drive the motorcycle in 2nd, 4th and 6th gear for a
recheck.
NO - Faulty original No.2 clutch assembly
DTC P171B/DTC P171C

Probable cause:
• OTC P171 B: Faulty No.1 clutch sticking
• OTC P171 C: Faulty No.2 clutch sticking
• Faulty clutch oil circuit
• Faulty TCM
1. Clutch Inspection
Replace the clutch assembly with a new one.
- OTC 1718: No.1 clutch assembly
- OTC 171 C: No.2 clutch assembly
Erase the OTC.
Drive the motorcycle using following gears for a
- OTC 171B: 1st, 3rd, 5th
- OTC 171C: 2nd, 4th, 6th
recheck.
NO - Faulty original clutch assembly
13-30
DTC P171D/DTC P171E/DTC P171F/
DTC P1726
Probable cause:
• Engine oil level is low
• Faulty oil pump
• Faulty clutch oil circuit
• Faulty clutch line EOP sensor
• Faulty TCM
1. Clutch EOP Sensor Inspection
Replace the clutch EOP sensor with a new one.
Erase the OTC.
Drive the motorcycle using all gears for a minute in
each gear.
recheck.
NO - Faulty original clutch EOP sensor
DTC P1728/DTC P1729

Probable cause:
• Faulty gearshift mechanism
• Faulty TR sensor
• Faulty TCM
Refer to OTC P1714 (page 13-27).
DTC P172A/DTC P1728

Probable cause:
• Faulty OCT shift pedal (option) mechanism
• Faulty shift pedal angle sensor or its related circuit
• Faulty TCM
• OCT shift pedal (option) function does not work
1. Shift Pedal Angle Sensor Input Voltage
Inspection
Disconnect the shift pedal angle sensor connector
(page 13-63). [1]
Measure the voltage at the wire harness side shift
pedal angle sensor connector [1].
Is the voltage within 4.75- 5.25 V?
YES - GO TO STEP 2.
13-31
2. Shift Pedal Angle Sensor Output Line Open
Circuit Inspection
13-65).
shift pedal angle sensor connector [1] and TCM 33P
CONNECTION: Yellow- B10
Is there continuity? y
YES - GO TO STEP 3.
[1] [2] l
I
3. Shift Pedal Angle Sensor Output Line Short
Circuit Inspection
j
[1] J
shift pedal angle sensor connector [1] and ground .
YES - Short circuit in the Yellow wire.
NO - GO TO STEP 4.
4. Shift Pedal Angle Sensor Inspection

Replace the shift pedal angle sensor with a new
one.
Erase the OTC.
recheck.
NO - Faulty original shift pedal angle sensor
l
j
j
13-32 j
DTC P172C
Probable cause:
• Faulty N-D switch or its related circuit
• Faulty TCM
• N-D switch does not work
1. N-D Switch Signal Line Open Circuit Inspection
[1) [2)
13-65).
connector (page 22-34 ).
Check for continu ity between the wire harness side
right handlebar switch 12P connector [1) and TCM
33P (Gray) connector [2) .
CONNECTION: Violet - B31
V
Is there continuity? 831
YES - GO TO STEP 2.
NO - Open circuit in the Violet wire
2. N-D Switch Signal Line Short Circuit Inspection

[1)
ground.
CONNECTION: Violet - Ground
YES - Short circuit in the Violet wire
NO - GO TO STEP 3.
3. N-D Switch Ground Line Open Circuit Inspection

[1) [2)
13-65).
right handlebar switch 12P connector [1] and 33P
(Black) connector [2) .
CONNECTION: Gray - A22
YES - GO TO STEP 4. Gr
A22
r
'
13-33
DUAL CLUTCH TRANSMISSION (DCT model}
4. N-D Switch Inspection
Erase the OTC.
recheck.
NO - Faulty original N-D switch
DTC P172D
Probable cause:
• Faulty shift switch or its related circuit
• Faulty TCM
• Shift switch does not work
1. Shift Switch Signal Line Open Circuit Inspection
[1 ] [2]
13-65).
Disconnect the left handlebar switch 12P connector
(page 22-27).
left handlebar switch 12P connector [1] and TCM
33P (Gray) connector [2] .
CONNECTION: Black- 832 Bl
Is there continuity? B32
YES - GO TO STEP 2.
NO - Open circuit in the Black wire
2. Shift Switch Signal Line Short Circuit Inspection

[1]
left handlebar switch 12P connector [1] and ground.
NO - GO TO STEP 3.
:
I
J
J
J
J
l
13-34 I
'
3. Shift Switch Ground Line Open Circuit
Inspection
[1] [2]
13-65).
left handlebar switch 12P connector [1] and TCM
33P (Black) connector [2].
CONNECTION: Gray -A22
Gr
YES - GO TO STEP 4. A22
4. Shift Switch Inspection

Replace the left handlebar switch with a new one.
Erase the OTC.
recheck.
NO - Faulty original shift switch
DTC P172E
Probable cause:
• Faulty OCT relay or its related circuit
• Blown DCT-M 30 A fuse
• Faulty TCM
• OCT relay does not work
1. DCT Relay Input Voltage Inspection
Remove the OCT relay (page 13-67).
Measure the voltage at the relay connector [1].
CONNECTION: Red/white(+)- Green(-)
YES - GO TO STEP 2.
[1]
r
r
13-35
2. OCT Relay Output Line Open Circuit Inspection
[1] [2]
13-65).
relay connector [1) and TCM 33P {Black) connector
[2).
CONNECTION:
White-A3
White-A14
YES - GO TO STEP 3.
3. OCT Relay Coil Input Line Open Circuit

Inspection
[1] [2]
71 ).
relay connector [1) and ECM 33P (Gray) connector
[2).
CONNECTION: Yellow - Yellow (C9)
YES - GO TO STEP 4. y
Y(C9)
4. OCT Relay Inspection

Replace the OCT relay with a new one.
Erase the OTC.
recheck.
NO - Faulty original OCT relay )
DTC P172F
Probable cause:
• Faulty shift spindle angle sensor
• Faulty TCM
I
• Gearshift function does not work i
J
Refer to OTC P1713 (page 13-26).
13-36
DTC P2765
Probable cause :
• Electromagnetic interference
• Faulty outer mainshaft sensor or its related circuit
• Faulty TCM
1. Outer Mainshaft Sensor Input Voltage
Inspection
Disconnect the outer mainshaft sensor connector
[1]
(page 13-62).
Temporarily install the removed electrical parts in
the reverse order of remova l.
Measure the voltage at the wire harness side outer
mainshaft sensor connector [1] .
CONNECTION: Violet(+) - Gray (-)
Is there about battery voltage?
YES - GO TO STEP 2.
NO - • Open or short circuit in the Violet wire
2. Outer Mainshaft Sensor Output Line Open
Circuit Inspection
[1) [2)
13-65).
outer mainshaft sensor connector [1] and TCM 33P
(Gray) connector [2] .
CONNECTION: Pink- 825
p
825
YES - GO TO STEP 3.
NO - Open circuit in the Pink wire
3. Outer Mainshaft Sensor Output Line Short

Circuit Inspection
[1)
outer mainshaft sensor connector [1] and ground.
CONNECTION: Pink - Ground
YES - Short circuit in the Pink wire
NO - GO TO STEP 4 .
.
13-37
4. Outer Mainshaft Sensor Inspection
Replace the outer mainshaft sensor with a new one.
Erase the OTC.
Drive the motorcycle in 2nd, 4th and 6th gear for a
recheck.
NO - Faulty original outer mainshaft sensor
CLUTCH OIL FEED PIPE

REMOVAL
- Feed pipe cover bolts [1]
- Sealing washers [2]
- Feed pipe cover [3]
- 0-ring [4]
Remove the inner clutch oil feed pipe [1].

NOTE:
• Be careful not to bend or damage the inner clutch oil
feed pipe.

- Feed pipe guide plate bolts [1]
- Feed pipe guide plate [2]
- 0-rings [3]
13-38
- Outer clutch oil feed pipe [1]
- 0-ring [2]
NOTE:
• Be careful not to bend or damage the outer clutch oil
feed pipe.
INSPECTION
Inspect the following parts for scratches, bending or
clogging .
- Inner clutch oil feed pipe
- Outer clutch oil feed pipe
Measure each part according to DUAL CLUTCH
TRANSMISSION SPECIFICATIONS (page 1-8) (OCT
model).
INSTALLATION
Install the 0-ring [1] to the outer clutch oil feed pipe [2].
Install the outer clutch oil feed pipe into the right
crankcase cover.
NOTE:
• Align the feed pipe tabs with the right crankcase
cover lugs.
Apply engine oil to new 0-rings.

Install the 0-rings [1] to the feed pipe guide plate [2]
grooves.
Install the feed pipe guide plate.
NOTE:
• Align the feed pipe guide plate pin with the right
crankcase cover hole.
13-39
Install and tighten the feed pipe guide plate bolts [1] to
.i'
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Install the inner clutch oil feed pipe [1] to the feed pipe
guide plate.
NOTE :
• Align the feed pipe tabs with the guide plate lugs.
Install the 0-ring [2] to the feed pipe cover [3] groove.
Install the feed pipe cover.

- New sealing washers [1]
- Feed pipe cover bolts [2]
I
Tighten the feed pipe cover bolts to the specified J
torque. iI
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) I
I
RIGHT CRANKCASE COVER
REMOVAL
Remove the clutch EOP sensor cover (page 2-27).
Remove right rear engine cover (page 2-27).
Remove the clutch oil feed pipe (page 13-38).
Remove the shift spindle angle sensor bolt [1], shift J
spindle angle sensor [2], and 0-ring [3] .
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13-40
- Clutch line EOP sensor 3P (Gray) connector [1]
- No.1 clutch EOP sensor 3P (Gray) connector [2]
- No.2 clutch EOP sensor 3P (Black) connector [3]
Remove the clutch EOP sensor wire stay bolt [4] and
stay [5].
Open the clamps [1].

Release the linear solenoid valve wire [2] and main wire
harness [3] from the clamps.
Disconnect the linear solenoid valve 4P (Black)
connector [4].
NOTE:
• When disconnecting the right A/F sensor 4P
connector and linear solenoid valve 4P (Black)
connector at the same time, mark the main wire
harness side connectors to prevent the
misconnection.

Disconnect the radiator hose B [2].
Remove the water pipe bolts [1].

Disconnect the water pipe [2] from the right crankcase
cover.
Remove the 0-ring [3] from the water pipe.
13-41
Remove the right crankcase cover bolts (1].
Remove the right crankcase cover [2].
Remove the gasket [1], dowel pins [2], and oil joint [3].
Remove the 0-rings [4] and back up rings [5] from the
oil joint.
Check the bearings [1] and replace if necessary (page -~~~~~~,::

;
13-43).
1
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13-42 '.
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BEARING REPLACEMENT
Remove the bearing (40 x 52 x 7 mm) [1] using special
tools.
TOOLS:
Remover weight 07741-0010201
Bearing remover shaft 07JAC-PH80200
Adjustable bearing puller,
20 - 40 mm 07JAC-PH80100
U.S.A. TOOLS:
Adjustable bearing puller, 07736-A01000B with
25-40 mm 07YAC-001 A200
Remover weight 07936-371020A
Bearing remover shaft Commercially
available 3/8 x 16 in.
slide hammer
Apply engine oil to a new bearing (40 x 52 x 7 mm).
Drive in the bearings until it is fully seated using special
tools.
TOOLS:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 40 mm 07746-0040900
NOTE:
• Drive in the bearing (40 x 52 x 7 mm) with the
marking side facing up.
Remove the bearing (6304) [1] using special tools.
TOOLS:
07936-371020A
(U.S.A. only)
Bearing remover set, 20 mm 07936-3710600
Remover handle 07936-3710100
Apply engine oil to a new bearing (6304 ).
Drive in the bearing (6304) until it is fully seated using
special tools.
TOOLS:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 20 mm 07746-0040500
NOTE:
• Drive in the bearing (6304) with the marking side
facing up.
13-43
INSTALLATION
Clean the right crankcase cover mating surfaces
thoroughly.
Apply liquid sealant (TB1207B manufactured by Three
Bond or equivalent) to the right crankcase cover mating
surface as shown. 10- 15 mm
(0.4 - 0.6 in)
10 -15 mm
(0.4 - 0.6 in)
Apply engine oil to new 0-rings [1] and new back up

rings [2] and install them onto the oil joint [3] as shown.
Install the oil joint into the crankcase hole.
Coat a new 0-ring [1] with engine oil and install it onto
the groove of the water pump cover.
Align the water pump shaft slit with the water pump
cover index lines by rotating the water pump shaft.
Align the following by rotating the crankshaft:

- Primary drive gear index line [1]
- Crankcase "V " mark [2]
Make sure that the front balancer shaft end [3] is in
position as shown.
13-44
Install the dowel pins [1] and new gasket [2].
Install the right crankcase cover [1].

Install the right crankcase cover bolts [2].
Tighten the right crankcase cover bolts in a crisscross
pattern in 2 or 3 steps to the specified torque.
TORQUE: 12 N·m (1 .2 kgf·m, 9 lbMt)
Coat a new 0-ring with engine oil.

Install the 0-ring [1] onto the water pipe [2].
Connect the water pipe [1] to the right crankcase cover.

Install and tighten the water pipe bolts [2] to the
specified torque.
13-45
Connect the radiator hose B [1].
Tighten the hose band screw [2] to the specified range
(page 8-9).
Connect the linear solenoid valve 4P (Black) connector

[1].
Clamp the linear solenoid valve wire [2] and main wire
harness [3] with the clamps [4).
NOTE:
Install the stay [1] and clutch EOP sensor wire stay bolt
[2].
Tighten the clutch EOP sensor wire stay bolt to the
specified torque.
Connect the following:

Install the 0-ring [1] onto the shift spindle angle sensor
[2].
Install the shift spindle angle sensor.
NOTE:
• Align the flat surfaces of the shift spindle angle
sensor and gearshift spindle end.
1
13-46
Install and tighten the shift spindle angle sensor bolt [1]
NOTE:
Install the clutch oil feed pipe (page 13-39).
Install right rear engine cover (page 2-27).
Install the clutch EOP sensor cover (page 2-27).
LINEAR SOLENOID VALVE

REMOVAL
NOTE:
• Keep dust and dirt away from all the parts.
• Be careful not to damage the mating surfaces of the
valve body components.
Open the clamps [1] and release the linear solenoid
valve wire [2] from the clamps.
Disconnect the linear solenoid valve 4P (Black)
connector [3].
NOTE:
• When disconnecting the right NF sensor 4P
connector and linear solenoid valve 4P (Black)
connector at the same time, mark the main wire
harness side connectors to prevent the
misconnection.
Remove the linear solenoid valve body mounting bolts
[1] and linear solenoid valve body [2].
13-47
- Separator plate (1)
- Dowel pins (2)
- 0-rings [3]
- Spool valve filter/packing [4]
Remove the packing from the spool valve filter.
Check the spool valve filter and replace if necessary.
LINEAR SOLENOID
VALVE BODY
STOPPER PLATE
~
LINEAR SOLENOID VAL VE
STOPPER PLATE BOLT
12 N·m (1.2 kgf·m, 9 lbMt)
LINEAR SOLENOID VALVES
NOTE :
• Clean all the parts with compressed air. Make sure .
that there is no dust or lint on any parts.
• Apply locking agent to the solenoid valve stopper
plate bolt threads (page 1-23). J
• Apply liquid sealant (TB1207B manufactured by I
Three Bond or equivalent) to the grommet mating J
surface of the valve body as shown. '
13-48
INSTALLATION
Install the following to the linear solenoid valve body.
- 0-ring [1]
,.,[1]
- Dowel pins [2]
- Separator plate [3]
Coat a new packing [1] with engine oil.

Install the packing to the spool valve filter [2] .
Install the spool valve filter/packing onto the right
crankcase cover as shown.
Install the 0-ring [3].
Install the linear solenoid valve body [4].
[11$171
OUTSIDE
INSIDE
[2]
Install and tighten the linear solenoid valve body

mounting bolts [1] to the specified torque.
13-49
Connect the linear solenoid valve 4P (Black) connector
[1].
Clamp the linear solenoid valve wire [2) and main wire
harness [3) with the clamps [4].
NOTE:
Install the clutch EOP sensor cover (page 2-27).
Install the right middle cowl (page 2-8).
DUAL CLUTCH/PRIMARY DRIVEN

GEAR
REMOVAL
Remove the primary drive gear (page 13-53).
Remove the dual clutch assembly [1) from the
mainshaft.
Remove the seal rings [1] from the mainshaft grooves.
DISASSEMBLY
Remove the following from the clutches .
Clutch 1 guide [1)
- Clutch 2 guide [2)
- Washers [3]
13-50
Remove the following from the primary driven gear:
[1] [3]
- No.1 Clutch assembly [1)
- No.2 Clutch assembly [2)
- 0-rings [3)
NOTE:
• Do not disassemble the clutch assembly.
• The No.1 clutch assembly and No.2 clutch assembly
are the same parts.
[2]
'
[3]
CLUTCH INITIAL CLEARANCE

Set a dial indicator on the end plate [1) with the plate
lowered. 1.3 mm (0.05 in)
~
Lift the end plate against the snap ring and read the
clearance, and record it.
Perform this inspection at the three points 120° apart.
If the measured valve exceeds the service limit, replace
the clutch assembly.
ASSEMBLY
Coat new 0-rings with engine oil.
[3]
Install the 0-rings [1) into the grooves of the primary
driven gear [2].
Apply molybdenum oil solution to the primary driven
gear teeth, friction springs, and boss sliding area.
Install the No.1 clutch assembly [3) and No.2 clutch
assembly [4) to the primary driven gear.
.
~,,,
~~ .
,, [4]
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The clutch guides are different shapes as shown.
CLUTCH 1 GUIDE CLUTCH 2 GUIDE
Small Large
13-51
Place the dual clutch assembly [1] with it index line [2]
of the primary driven gear facing up.
Apply engine oil to the needle bearings in the primary
driven gear.
[5)
Line up the tabs [3] of the clutch discs [4].
Install the washer [5] onto the clutch assembly.
Install clutch 1 guide [6] into the clutch on the index line
side by aligning the gear teeth with the clutch disc tabs.
[1)
[5) [6)
[4)
Turn over the dual clutch assembly while holding clutch

1 guide.
Apply engine oil to the needle bearings in the primary
driven gear.
[3)
Line up the tabs [1] of the clutch discs [2].
Install the washer [3] onto the clutch assembly.
Install clutch 2 guide [4] into the clutch by aligning the
gear teeth with the clutch disc tabs.
[3] [4)
[2)
13-52
INSTALLATION
Apply engine oil to new seal rings.
Install the new seal rings [1] into the mainshaft grooves.
Push in the seal rings to seat them into the grooves as \
shown.
X 0
r1H
Install the dual clutch assembly [1] onto the mainshaft.
NOTE:
• The dual clutch assembly should be installed with
the index line [2] facing the outside of the engine.
• Be careful not to damage the seal rings.
Install the primary drive gear (page 13-54).
PRIMARY DRIVE GEAR

REMOVAL
Remove the right crankcase cover (page 13-40).
driven gears.
TOOL:
Gear holder, 2.5 [1] 07724-0010100 or
07724-001A100
(U.S.A. only)
Loosen the primary drive gear nut [2] .

NOTE:
• The primary drive gear nut has left-hand thread .
Remove the primary drive gear nut, washer [3], and
primary drive gear [4] from the crankshaft.
Check the primary drive gear for scratches, damage,
13-53
INSTALLATION
Apply molybdenum oil solution to the primary drive gear
sliding surface.
Install the primary drive gear (1) to the crankshaft.
NOTE:
• Align primary drive gear wide tooth with the
Apply engine oil to the primary drive gear nut threads

Install the washer [1] and primary drive gear nut [2].
driven gears.
TOOL:
Gear holder, 2.5 [3] 07724-0010100 or
07724-001A100
(U.S.A. only)
Tighten the primary drive gear nut to the specified
torque.
TORQUE: 118 N ·m (12.0 kgf·m, 87 lbMt)
NOTE:
• The primary drive gear nut has left-hand thread.
,
Install the right crankcase cover (page 13-44). I
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SHIFT CONTROL MOTOR/REDUCTION
GEARS
REMOVAL
Remove the shift control motor cover bolts [1] and shift
control motor cover [2].
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13-54
I
Disconnect the shift control motor 2P (Black) connector
[1].
- Shift control motor mounting torJ< bolts [2]
Shift control motor [3]
0-ring [4]
Remove the reduction gear cover torJ< bolts [1] and

reduction gear cover [2].
Remove the dowel pins [1] and gasket [2].

Remove the reduction gears [3].
BEARING REPLACEMENT
Heat the reduction gear cover to 80°C (176°F) evenly
using a heat gun.
NOTE:
• Do not use a torch to heat the reduction gear cover;
,.,
[1]
it may cause warping.

Tap the reduction gear cover lightly and remove the
bearings.
- Radial ball bearing (699ZZ) [1]
Apply engine oil to new bearings.
Drive in new bearings squarely until they are fully
seated. ~----------------~
NOTE:
• Drive in new bearings with the marking side facing
up.
For crankcase side bearings replacement (page 14-23)
13-55
INSTALLATION
Apply 2 - 4 g (0.07 - 0.14 oz) of specified grease to the
reduction gear bearing journals [1] .
SPECIFIED GREASE:
UNIREX N3 manufactured by ExxonMobil or
equivalent
Apply 2 - 4 g (0.07 - 0.14 oz) of specified grease to the

reduction gear teeth .
SPECIFIED GREASE:
UNIREX N3 manufactured by ExxonMobil or
equivalent
Install the reduction gear B [1] .

NOTE:
• Align the reduction gear B ends with the ribs of the
crankcase.
Install the reduction gear C [2].
NOTE:
• Align each clinched tooth of the ..reduction gear C
and gearshift spindle.
Install reduction gear A [3].
Install the dowel pins [1] and gasket [2].
Install the reduction gear cover [1] and reduction gear

cover torJ< bolts [2].
Tighten the reduction gear cover torJ< bolts to the
specified torque.
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13-56 j
!
Install the 0-ring [1] into the groove in the shift control
motor [2] .
Install the shift control motor.
Install the shift control motor mounting tone bolts [1].

Tighten the shift control motor mounting tone bolts to the
specified torque.
Connect the shift control motor 2P (Black) connector -
[2].
Install the shift control motor cover [1] and shift control
motor cover bolts [2].
Tighten the shift control motor cover bolts to the
specified torque.
NOTE:
,.
GEARSHIFT LINKAGE
r REMOVAL
- Dual clutch (page 13-50)
- Gearshift spindle [1]
,
,
- Washer [2]
- Drum shifter collar [3]
13-57
Remove the drum shifter guide plate/drum shifter
assembly mounting bolts [1].
Remove the drum shifter guide plate/drum shifter
assembly [2].

- Guide plate distance collar [1] 1
- Dowel pin [2] (if necessary)
- Stopper arm side collar [3]
- Shift drum center bolt [4] I
''
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Remove the shift drum center [1] while holding the shift
drum stopper arm [2] using a screwdriver as shown. I

:
- Stopper arm collar [2]
Stopper arm return spring [3]
- Shift drum center dowel pin [4]
- Dowel pin [5] (if necessary)
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13-58
,
INSPECTION
- Gearshift spindle, spindle arm, return spring
- Drum shifter guide plate
- Drum shifter
- Ratchet pawls
- Plungers
- Plunger springs
INSTALLATION
Install the oil seal [1] until it is in position as shown.
, Apply grease to the oil seal lips.
11.9-12.4 mm
(0.47 - 0.49 in)
13-59
Install the following: [3] [4] [5]
't~~~
- Shift drum center dowel pin [1]
- Dowel pin [2] (if you removed)
Stopper arm collar [4]
- Stopper arm return spring [5]
Hold the shift drum stopper arm [1] with a screwdriver.

Install the shift drum center [2].
NOTE :
• Aligning the shift drum center groove with the dowel
pin.
Apply locking agent to the shift drum center bolt threads

(page 1-23). I
Install and tighten the shift drum center bolt [1] to the
specified torque.

- Dowel pin [2] (if you removed)
- Guide plate distance collar [3]
- Stopper arm side collar [4]
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Install the following in the drum shifter [1] :
- Plunger springs [2]
- Plungers [3]
- Ratchet pawls [4]
Set the drum shifter assembly in the drum shifter guide
plate [5].
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[5]
13-60
Install the drum shifter guide plate/drum shifter
assembly [1].
Apply locking agent to the threads of the drum shifter
guide plate/drum shifter assembly mounting bolts [2]
(page 1-23).
Install and tighten the drum shifter guide plate/drum
shifter assembly mounting bolts.
Install the drum shifter collar [1] onto the drum shifter.
Install the thrust washer [2] onto the gearshift spindle
[3].
Install the gearshift spindle into the crankcase .
NOTE:
• Align the gearshift spindle return spring ends with
the spring pin.
• Align the gearshift spindle arm hole with the drum
shifter collar.
- Reduction gears/shift control motor (page 13-56)
MAINSHAFT SENSOR
INNER MAINSHAFT SENSOR
Disconnect the inner mainshaft sensor 3P (Black)
connector [1].
Remove the bolts [1], inner mainshaft sensor [2] , and

0-ring [3] .
NOTE:
• Replace the 0 -ring with a new one.
13-61
OUTER MAINSHAFT SENSOR
Disconnect the outer mainshaft sensor 3P {Black) ~[2)
connector [1].
Remove the bolt [2], outer mainshaft sensor [3], and 0-
ring [4].
«!I
NOTE: ~ [3)
~ ~[4]
~ -"718' I
1
TR SENSOR
Remove the left rear cover (page 2-26). J
Remove the shift control motor cover (page 13-54 ). l
I
Disconnect the TR sensor 3P (Black) connector [1]. I

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- Bolt [1]
- Sensor cover [2]
- TR sensor [3]
- 0-ring [4]
TORQUE:
I
TR sensor mounting bolt:
i
12 N·m (1.2 kgf·m, 9 lbHt) J
NOTE: I
• Always replace the 0-ring with a new one.
• Align the flat surfaces of the TR sensor and shift
drum end.
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• Route the wires properly (page 1-26). t
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13-62
SHIFT SPINDLE ANGLE SENSOR

Remove right rear engine cover (page 2-27).
Remove the rear shock absorber (page 18-11 ).
Disconnect the shift spindle angle sensor 3P (Blue)
connector [1] . ,._..~~J
Remove the shift spindle angle sensor bolt [1 J, shift

spindle angle sensor [2], and 0-ring (3).
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TORQUE:
Shift spindle angle sensor bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
NOTE:
• Always replace the 0-ring [1] with a new one.
• Apply eng ine oil to a new 0-ring.
• Align the flat surfaces of the shift spindle angle
sensor and gearshift spindle end.
CLUTCH EOP SENSOR

- Clutch line EOP sensor 3P (Gray) connector [1)
- No.1 clutch EOP sensor 3P (Gray) connector (2)
- Clutch line EOP sensor (4)
- No.1 clutch EOP sensor [5)
- No.2 clutch EOP sensor [6]
NOTE:
• These three clutch EOP sensors are the same parts.
13-63
TORQUE:
No.1/No.2 clutch EOP sensor:
20 N·m (2.0 kgf·m, 15 lbMt)
Clutch line EOP sensor:
20 N·m (2.0 kgf·m, 15 lbMt)
NOTE:
• Replace the 0-ring [1] with a new one.
• Coat a new 0-ring with engine oil.
.II
EOT SENSOR
Disconnect the EOT sensor 2P (Black) connector [1] .
Remove the EOT sensor [2] and sealing washer [3] .
TORQUE:
EOT sensor:
15 N·m (1.5 kgf·m, 11 lbMt)
NOTE:
• Apply engine oil to the EOT sensor threads and
seating surface.
• Replace the sealing washer with a new one. ,,
I
Fill the engine oil with the recommended engine oil

(page 3-12).
EOP SENSOR l
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Disconnect the EOP sensor 3P (Black) connector [2]. .j

Remove the EOP sensor [3] .
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[2] [1 J [3] ;'
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13-64
TORQUE:
EOP sensor:
22 N·m (2.2 kgf·m, 16 lbHt)
NOTE:
• Replace the 0-ring [1] with a new one.
• Apply engine oil to the 0-ring.
Fill the engine oil with the recommended engine oil
(page 3-12).
NEUTRAL SWITCH
Remove the nut [2] and disconnect the neutral switch
terminal [3].
Remove the neutral switch [4] and sealing washer [5].
TORQUE:
Neutral switch:
12 N·m (1.2 kgf·m, 9 lbHt)
Neutral switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbHt)
NOTE:
• Apply engine oil to the neutral switch threads and
seating surface.
TCM
Remove the BCU (page 22-52).
Open the TCM holder [1] .
Disconnect the TCM 33P (Black) connector [2] and
TCM 33P (Gray) connector [3].
Remove the TCM [4].
NOTE:
• If the TCM is replaced, perform the clutch initialize
learning procedure (page 13-67).
13-65
POWER INPUT LINE
Disconnect the TCM 33P (Black) connector (page 13-
65). [1 ]

Measure the voltage between the 33P (Black)
connector [1] and ground.
TOOL:
CONNECTION: A7 {+) - Ground {-)
There should be battery voltage.

If there is no voltage, check the following:
Open circuit in the Brown wire between the TCM
and Fl relay
- Faulty Fl relay or its circuits
POWER GROUND LINE
65). i
Check for continuity between the wire harness side 33P J
I
{Black) connector [1] and ground. I
TOOL:
CONNECTION: A23 - Ground

A24-Ground

If there is no continuity, check for an open circuit in the
Green wires.
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LOGIC GROUND LINE
65).
Check for continuity between the wire harness side 33P
(Black) connector [1] and ground.
[1]
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TOOL:
'
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CONNECTION: A11 - Ground

If there is no continuity, check for an open circuit in the
Green/blue wire.
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•
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13-66
J
DCT RELAY
Release the OCT relay [1] from the stay.
Disconnect the relay connector [2] and remove the OCT
relay.
CLUTCH INITIALIZE LEARNING (TCM)

NOTE:
• If the TCM and/or clutch assembly are replaced,
perform this procedure.
• Before starting this procedure, check the following :
- PGM-FI system and OCT system have no OTC.
- Engine idle speed is normal.
- Transmission is in neutral and cooling fan stops.
• Do not operate the throttle during Clutch Initialize
Learning.
1. Warm up the engine to the normal operating
temperature (engine oil temperature: 50 - 110°C/ Clutch Initialize Learning is necessary:
122 - 230°F) then stop it.
.-----~ ~ ~
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NOTE:
• If the TCM is replaced with a new one, the shift
indicator [1] and S mode level indicator [2] will
[1]-
,.:.., w_l
: ,;,
:-.1.~)-: I~
: ~ I..!
: ,.;,,.: r'.411•~
[2]
.,-.-~:;,-. iII.. I
display in the figure as shown when the ignition
switch is turned ON.
In this status, the Clutch Initialization Learning is Extremely low oil temperature:
.•.
iI
necessary.
• When the shift indicator displays as shown, the ,------ ~ :-,:--:,,::,,~ ,------ l~i!!
:~
~ :-
engine must be warmed before proceeding:
.;':-\ i ..ir:~jt:)b/
i------· §~. i ~-~i~
i·------·
- Large "L": extremely low oil temperature indicator
- Small "L": low oil temperature indicator
I 1
. .: ._. .,.
(11
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1· ;('I·· ·''·1
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[1]
Low oil temperature:
[1]
13-67
2. Turn the ignition switch ON while pushing the 0-S
side of the N-D switch [1) .
The MIL [2) will come on.
Release the N-0 switch after the MIL goes off.
Each indicator displays as shown.
[1)
[2)
When only the dual clutch When the TCM is

assembly is replaced replaced :
(when in the neutral gear): I
J
3. Push the N-0 switch [1) in the sequence as follows:

- Push the 0-S side of the N-D switch
- Push the D-S side of the N-D switch
- Push the N side of the N-0 switch
- Push the D-S side of the N-0 switch
- Push the N side of the N-0 switch
The TCM is ready to Clutch Initialize Learning when
the shift indicator [2) and S mode level indicator [3)
light as shown.
NOTE:
• When the shift indicator displays as follows, the
engine is not warmed up enough.
- Large "L": extremely low oil temperature
- Small "L": low oil temperature Ready to Clutch Initialize Learning:
If so, warm up the engine until the "L" on the shift J'
indicator goes off. I
Stop the engine and perform steps 2 and 3 again .
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Extremely low oil temperature: j
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Low oil temperature:
13-68 j
4. Start the engine and let it idle.
Successful:
The shift indicator and S mode level indicator light
during Clutch Initialize Learning.
Then each indicator displays as follows:
• The Clutch Initialize Learning is successful:
- Shift indicator displays "N".
- S mode level indicator goes off.
Unsuccessful:
• The Clutch Initialize Learning is unsuccessful:
- The shift indicator and S mode level indicator stay
on.
·_:_:_: Wi I
::,....
... : 1F1
~, ~-~
,·I
II!:'',·~ I -----,
.__:_:Wi
: .;,: 1¥1
. . :~, 1
I
II!:'',·~
~-~
NOTE:
• If the Clutch Initialize Learning is unsuccessful,
perform the initialize learning procedure from step 2 ~ - - - - - - - - - - - - - - - - - - '
again.
5. Stop the engine.
13-69
MEMO
i I
•
.
t
j
I
J
14. CRANKCASE/TRANSMISSION/BALANCER
SERVICE INFORMATION·· .. ·················· 14-2 CRANKCASE SEPARATION················ 14-12
TROUBLESHOOTING · · ···· ···· · ··· ··· · ·· · ·· ·· · 14-4 TRANSMISSION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14-14
COMPONENT LOCATION ..................... 14-5 CRANKCASE ASSEMBLY ................... 14-27
BALANCER······ .... ····· ... ················ .... ·· 14-7
14-1
j
SERVICE INFORMATION
GENERAL
I
,
• Be careful not to damage the crankcase mating surfaces when servicing.

• Clean the oil passages before assembling the crankcase halves.
.
• Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thorough ly. 1
!
MT model I
The crankcase must be separated to service the following :

- Transmission
- Crankshaft (page 15-4) •r
- Piston/cylinder (page 15-12) I
I
• The following components must be removed before separating the crankcase: I
- Engine (page 16-4)

- Primary drive gear (page 12-18)
- Balancer (page 14-7)
- Flywheel (page 11-6)
- Oil pump (page 9-6)
- Starter motor (page 6-7)
- VS sensor (page 4-73)
- GP sensor (page 4-73) ;
- Shift spindle switch (page 4-74) I
- Neutral switch (page 22-45) "
DCT model
• The crankcase must be separated to service the following :
- Transmission
j
- Crankshaft (page 15-4) l
- Piston/cylinder (page 15-12) ;
• The following components must be removed before separating the crankcase: I
- Engine (page 16-4)
- Cylinder head (page 10-19)
- Mainshaft sensors (page 13-61)
- VS sensor (page 4-73)
- Neutral switch (page 13-65)
14-2
TOOLS
Gear holder, 2.5 Bearing remover shaft set, 25 mm Remover weight
07724-0010100 07936-ZV10100 07741-0010201
or 07724-001A100 (U .S.A. only) or 07936-ZV1A100 (U.S.A. only) or 07936-371020A (U.S.A. only)

Driver, 15 x 280L Attachment, 52 x 55 mm Pilot, 25 mm
07949-3710001 07746-0010400 077 46-0040600
® .
'
Pilot, 12 mm Seal driver, 14 x 22 mm

07746-0040200 07PPD-YE10100
14-3
TROUBLESHOOTING
Hard to shift
Improper clutch operation
Incorrect engine oil weight
Bent shift fork
Bent shift fork shaft
Bent shift fork claw
Damaged shift drum groove
Bent gearshift spindle
- MT model (page 12-20)
I
j
- OCT model (page 13-57)
l
Transmission jumps out of gear l
Worn gear dogs J
Worn gear shifter groove
Bent shift fork shaft l
J
Worn or bent shift forks
Broken shift drum stopper arm
Broken shift drum stopper arm return spring
j
- OCT model (page 13-57) i
Broken gearshift spindle return spring J
- MT model (page 12-20) )
Excessive engine noise
• Worn or damaged transmission gear
• Worn or damaged transmission bearings
• Worn or damaged balancer
l
J
j
••
"
14-4
COMPONENT LOCATION
MT model:
43 N·m (4.4 kgf·m, 32 lbf·ft)
39 N·m (4.0 kgf·m, 29 lbf·ft)
·- 24 N·m (2.4 kgf·m, 18 lbf·ft)

r
( f
li i
24 N-m (2.4 kgf·m, 18 lbf-ft)
i
0
12 N·m (1 .2 kgf·m, 9 lbf·ft)
'
12 N·m (1 .2 kgf-m , 9 lbf·ft)
103 N·m (10.5 kgf·m, 76 lbf·ft)

12 N·m (1 .2 kgf·m, 9 lbf·ft)
14-5
DCT model:
39 N·m (4.0 kgf·m, 29 lbf-ft)
<.
43 N·m (4.4 kgf·m, 32 lbHt) 24 N·m (2.4 kgf·m, 18 lbf-ft)
24 N·m (2.4 kgf·m, 18 lbf-ft)
24 N·m (2.4 kgf.m, 18 lbfft)
I
J
24 N·m (2.4 kgf·m, 18 lbf·ft)
I'
29 N·m (3.0 kgf·m, 21 lbf·ft)
J
)
J
J
j
1l
I
12 N·m (1.2 kgf-m, 9 lbf·ft)
.
,
J
12 N·m (1 .2 kgf-m, 9 lbf·ft)
103 N·m (10.5 kgf·m, 76 lbf·ft)
14-6
BALANCER
FRONT BALANCER
REMOVAL
Remove the flywheel (page 11-6).
Install the special tool between the front balancer drive
and driven gears.
TOOL:
Gear holder, 2.5 [1] 07724-0010100 or
07724-001A100
(U.S.A. only)
Remove the front balancer shaft bolt [2], washer [3],

and front balancer driven gear [4].
Remove the left front balancer weight [1].
Remove the front balancer bearing set plate bolts [1]

and set plate [2].
Remove the front balancer shaft [3].
Check for damage of the front balancer shaft, and
Remove the left front balancer bearing [1].

Check the left front balancer bearing should turn
smoothly and quietly, and replace it if necessary.
14-7
INSTALLATION
Apply engine oil to the left front balancer bearing rolling - - - -
area and contact surface.
Install the left front balancer bearing [1].
NOTE:
• Install the left front balancer bearing with the marked
side facing out.
.i
I
I
J
Install the front balancer shaft [1] .

Apply locking agent to the front balancer bearing set
plate bolts threads (page 1-23).
Install the set plate [2] and front balancer bearing set
plate bolts [3].
NOTE:
• Install the set plate with its "OUTSIDE" mark [4]
.
J
facing out. l
Tighten the front balancer bearing set plate bolts to the
specified torque.
'
Install the left front balancer weight [1] . I

NOTE: .
:
• Align the left front balancer weight wide tooth with J

the front balancer shaft clinched tooth . I
J
l
i
I
Apply engine oil to the front balancer driven gear teeth .

Install the front balancer driven gear [1 ].
NOTE:
Align the front balancer driven gear wide tooth with
the front balancer shaft clinched tooth .
• Make sure that the drive gear index line [2] is
positioned between the front balancer driven gear
index lines [3].
I
J
l
I
14-8
Install the special tool between the front balancer drive
gear and driven gear.
TOOL:
Gear holder, 2.5 [1] 07724-0010100 or
07724-001A100
(U.S.A. only)
Apply engine oi l to the front balancer shaft bolt threads

Install the washer [2] and front balancer shaft bolt [3].
Tighten the front balancer shaft bolt to the specified
torque.
Install the flywheel (page 11-7).
REAR BALANCER
REMOVAL
Remove the rear balancer shaft holder bolts [1] and
rear balancer shaft holder [2].

- Collar [1]
- Thrust spring [2]
- Washers [3]
- Thrust bearing [4]
,
[2] [3]
14-9
- Rear balancer driven gear (1]
- Needle bearing [2]
Check the needle bearing for wear or damage, smooth
operation, and replace it if necessary.
Remove the rear balancer gear shaft [1] and rear

balancer washer [2].
Check for damage of the rear balancer gear shaft, and
INSTALLATION
Apply molybdenum oil solution to the rear balancer
washer seating surface.
Install the rear balancer gear shaft [1] and rear balancer J
washer [2].
I
J
''
I
)
j
I
l
f
l
f
14-10 j
If you are replacing the rear balancer driven gear and/or
needle bearing, record the balancer driven gear I.D.
code [1] of the balancer weight.
If you are reusing the rear balancer driven gear,
measure the balancer driven gear journal I.D.
Determine the replacement needle bearing parts No.
with reference to the balancer driven gear I.D. code or
the measured balancer driven gear journal I. D.
Refer to the rear balancer needle bearing selection
table below for bearing selection.
NEEDLE BEARING 0.0.:
91015-MJP-G51 {Blue mark): Thickest
91016-MJP-G51 {White mark): t
91017-MJP-G51 {Green mark): Thinnest
REAR BALANCER NEEDLE BEARING SELECTION
TABLE:
REAR BALANCER DRIVEN GEAR I.D. CODE
a b C
27.000 - 27.005 mm 26.996 - 27.000 mm 26.992 - 26.996 mm
(1.0630 - 1.0632 in) (1 .0628 - 1.0630 in) (1 .0627 - 1.0628 in)
NEEDLE BEARING PARTS NO. 91015-MJP-G51 91016-MJP-G51 91017-MJP-G51
Coat the needle bearing and rear balancer driven gear - - - - - ~~

teeth with engine oil.
- Needle bearing [1]
- Rear balancer driven gear [2]
NOTE:
• Align the oil pump drive gear [3] tooth of rear
balancer driven gear with the oil pump driven gear
[4] tooth.
• Make sure that the drive gear index line [5] is
positioned between the rear balancer driven gear
index lines [6].
[4) [3)
[2)
Outside i
14-11
Coat the thrust bearing with engine oil.
Apply molybdenum oil solution to the thrust spring
sliding surface.
- Washers [1]
- Thrust bearing [2]
- Thrust spring [3]
- Collar [4] [4]
NOTE:
• Install the thrust spring as shown .
Install the rear balancer shaft holder (1].

NOTE:
• Align the dowel pins of the rear balancer shaft holder
with the crankcase holes.
Install and tighten the rear balancer shaft holder bolts

[1] to the specified torque.

CRANKCASE SEPARATION '
l
Remove the engine (page 16-4).
Remove the bolts [1], water hose flange [2], and 0-ring
[3] .
Remove the necessary parts for separating the
crankcase by referring to Service Information (page 14-
2).
-
14-12 j
J
OCT model: Remove the following :
- Cam chain guide plate bolts [1]
- Cam chain guide plate [2]
- Cam chain [3]
- Timing sprocket [4]
Place the engine upside down.

Loosen the following :
- Crankcase 6 mm bolts {short) [1]
- Crankcase 6 mm bolt {long) [2]
NOTE:
• Loosen the crankcase 6 mm bolts alternately from
outside to inside in 2 or 3 steps.
Loosen the following:
- Crankcase 8 mm bolts {short) [3]
- Crankcase 8 mm bolts (middle) [4]
- Crankcase 10 mm bolt [6]
NOTE:
• Loosen the crankcase 8 mm and 10 mm bolts in a
- Crankcase 6 mm bolts (short) [1]
- 6 mm sealing washers [3]
- Crankcase 8 mm bolts (short) [4]
t - Crankcase 8 mm bolts (middle) [5]
[6]/(7]
- Crankcase 8 mm bolt (long) [6] [5]
- 8 mm sealing washers [7]
I - Crankcase 10 mm bolt [8]

[5]/(7]
[8]
[5]
f
r [1]/(3]
Loosen the following :

- Crankcase main journal bolts (short) [1]
- Crankcase main journal bolt (middle) [2]
- Crankcase main journal bolts (long) [3]
NOTE:
• Loosen the crankcase main journal bolts in a
Remove the crankcase main journal bolts.
Separate the lower crankcase from the upper
crankcase . [3]
NOTE:
• Do not pry the crankcase halves with a screwdriver.
14-13
Remove the dowel pins [1], oil orifice A [2], and oil
orifice B [3].
Clean any sealant off from the crankcase mating
surface.
Clean the oil orifice in solvent thoroughly.
Check the oil orifice for clog, and replace them if
necessary. [2) [3)
TRANSMISSION
REMOVAL
COUNTERS HAFT
Separate the crankcase halves (page 14-12).
Remove the countershaft assembly [1 ].
Remove the dowel pin [2].
SHIFT FORK/SHIFT DRUM

Remove the countershaft (page 14-14).
Remove the shift drum bearing setting bolt/washer [1].
MT model: Remove the following:

- Shift fork shaft [1]
- Countershaft shift forks [2]
Mainshaft shift fork (3)
14-14
OCT model: Remove the following:
Countershaft shift fork shaft [1]
- Countershaft shift forks [2]
- Mainshaft shift fork shaft [3]
- Mainshaft shift forks [4]
Remove the shift drum bearing setting bolt/washer [1].
Remove the shift drum bearing [1] and shift drum [2].
MAINS HAFT
Remove the shift forks/shift drum (page 14-14).
Remove the mainshaft bearing set plate bolts [1] and
set plate [2].
14-15
Remove the right mainshaft bearing [1] by moving the
mainshaft assembly [2].
Remove the mainshaft assembly.
NOTE:
OCT model:
• When removing the mainshaft assembly, position
the crankshaft [3] as shown.
'
j
14-16
(MT model)
Clean all disassembled parts in solvent thoroughly.
NOTE:
• Do not expand the snap ring more than necessary
for removal. To remove a snap ring , expand the
snap ring and pull it off using the gear behind it.
• Keep track of the disassembled parts (gears,
bushings , washers, and snap rings) by sliding them
onto a tool or a piece of wire .
• Apply engine oil to the gear teeth, rotating surface
and bearing .
• Apply molybdenum oil solution to the spline bushing
outer surface, bushing inner and outer surface, shift
fork grooves.
MAINSHAFT
M6 GEAR (36T)
M2 GEAR (18T)
~ WASHER
SPLINE WASHER
SNAP RING
THRUST WASHER
MAINSHAFT/M1 GEAR (15T)
, : Gear teeth , rotating surfaces
~ : Bushing surfaces, needle bearing surfaces,

Ill and shifter gear grooves/spline area
14-17
COUNTERSHAFT
THRUST WASHER
C1 GEAR (43T)
C1 GEAR BUSHING
C4 GEAR (32T~ COLLAR

C3 GEAR (37T)
q\~ ;::_ LOCK WASHER
~~ SPLINE WASHER
SPLINE WASHER
C2 GEAR (34T)
OIL SEAL ..-----ii.
-"l :Gear teeth, rotating surfaces

~ : Bushing/collar surfaces, needle bearing surfaces,
I and shifter gear grooves/spline area
NOTE:
• Align the lock washer tabs with the spline washer
grooves.
• Always install the thrust washers and snap rings with CORRECT INCORRECT
the chamfered (rolled) edge facing away from the
thrust load .
• Install the snap rings [1] so that the end gap aligns
with the groove of the splines.
• Make sure that the snap rings are fully seated in the
shaft groove after installing them .
[1 J
14-18
(DCT model)
Clean all disassembled parts in solvent thoroughly.
NOTE:
• Do not expand the snap ring more than necessary
for removal. To remove a snap ring, expand the
snap ring and pull it off using the gear behind it.
• Keep track of the disassembled parts (gears,
bushings, washers, and snap rings) by sliding them
onto a tool or a piece of wire.
• Apply engine oil to the gear teeth, rotating surface
and bearing.
• Apply molybdenum oil solution to the spline bushing
outer surface, bushing inner and outer surface, shift
fork grooves.
MAINSHAFT
OUTER MAINSHAFT/M2 GEAR (21T)
THRUST WASHER
M5 GEAR (37T)
INNER MAINSHAFT/M1 GEAR (1 6T)
~ : Gear teeth , rotating surfaces
-Jn : Bushing surfaces, needle bearing surfaces,

II and shifter gear grooves/spline area
14-19
COUNTERS HAFT
C2 GEAR (37T)
THRUST WASHER
C2 GEAR BUSHING
C1 GEAR (41T)
SNAP RING
BEARING SET RING
SPLINE WASHER
--mint OIL SEAL
, : Gear teeth, rotating surfaces
~ : Bushing surfaces, needle bearing surfaces,

Ill and shifter gear grooves/spline area
NOTE:
• Align the lock washer tabs with the spline washer
grooves.
• Always install the thrust washers and snap rings with CORRECT INCORRECT
the chamfered (rolled) edge facing away from the
thrust load.
• Install the snap rings [1] so that the end gap aligns
with the groove of the splines.
• Make sure that the snap rings are fully seated in the
shaft groove after installing them.
[1]
14-20
INSPECTION
- Transmission gears
- Transmission bushings
- Transmission bearings
- Shift drum/bearing
- Shift forks
- Shift fork shafts
Measure each part according to CRANKCASE/
TRANSMISSION SPECIFICATIONS (page 1-9).
UPPER CRANKCASE BEARING

REPLACEMENT (MT model)
Before replacing the bearing, remove the following:
- Transmission (page 14-14)
- Crankshaft (page 15-4)
- Piston (page 15-12)
f. LEFT MAINSHAFT BEARING
Remove the left mainshaft bearing [1] using the special
tools.
TOOLS:
Bearing remover shaft set, 07936-ZV10100 or
25mm 07936-ZV1A100
(U.S.A. only)
07936-371020A
(U.S.A. only)
Apply engine oil to a new left mainshaft bearing.
Drive in the left mainshaft bearing until it is fully seated
using the special tools.
TOOLS:
Driver, 15 x 280L 07949-3710001
Attachment, 52 x 55 mm 07746-0010400
Pilot, 25 mm 07746-0040600
NOTE:
• Drive in a new bearing squarely with the marked
side facing in.
removal.
14-21
UPPER CRANKCASE BEARING
REPLACEMENT (DCT model)
Before replacing the bearings, remove the following :
- Piston (page 15-12)
LEFT MAINSHAFT BEARING
Remove the left mainshaft bearing [1] using the special
tools.
TOOLS:
Bearing remover shaft set, 07936-ZV10100 or
25mm 07936-ZV1A100
(U.S.A. only)
07936-371020A
(U.S.A. only)
Apply engine oil to a new left mainshaft bearing.

Drive in the left mainshaft bearing until it is fully seated
using the special tools .
TOOLS:
Driver, 15 x 280L 07949-3710001
Attachment, 52 x 55 mm 07746-0010400
Pilot, 25 mm 077 46-0040600
NOTE:
• Drive in a new bearing squarely with the marked
side facing in.
removal.
14-22
SHIFT DRUM NEEDLE BEARING
Drive out the shift drum needle bearing [1].
Apply engine oil to a new needle bearing.
Drive in the needle bearing until it is in position as
shown using the special tools.
TOOLS:
Driver, 15 x 280L 07949-3710001
Pilot, 12 mm 07746-0040200
NOTE:
• Drive in a new needle bearing squarely with the
marked side facing out.
removal.
.,~[1]
115.1-116.1 mm
(4.53 - 4.57 in)
SHIFT CONTROL MOTOR REDUCTION GEAR

BEARING
Heat the upper crankcase to 80°C (176°F) evenly using
a heat gun.
NOTE:
• Do not use a torch to heat the upper crankcase; it
may cause warping.
Tap the upper crankcase lightly and remove the
bearings.
Apply engine oil to new bearings.
Drive in the bearings squarely until they are fully
seated.
NOTE:
• Drive in the bearings with the marked side facing
toward the outside of the crankcase.
removal.
14-23
GEARSHIFT SPINDLE NEEDLE BEARING
Heat the upper crankcase to 80°C (176°F) evenly using
a heat gun.
NOTE:
• Do not use a torch to heat the upper crankcase; it
may cause warping .
Tap the upper crankcase lightly and remove the
gearshift spindle needle bearing [1] .
Apply engine oil to a new needle bearing.
Drive in the needle bearing until it is in position as
shown.
TOOL:
Seal driver, 14 x 22 mm 07PPD-YE10100
NOTE:
• Drive in the needle bearing with the marked side
facing toward the outside of the crankcase.
Install the removed parts in the reverse order of 17.7 -18.2 mm
removal. (0.70 - 0.72 in)
fl-"71 [1]
INSTALLATION
MAINSHAFT
Install the mainshaft assembly [1] into the upper
crankcase.
NOTE:
OCT model:
• When install the mainshaft assembly, position the
crankshaft [2] as shown.
Insert the mainshaft end to the left mainshaft bearing
[3].
Apply engine oil to the right mainshaft bearing.

Install the right mainshaft bearing [1] into the upper
crankcase.
NOTE:
• Install the bearing into the crankcase with the
marked side facing out.
14-24
Apply locking agent to the mainshaft bearing set plate
bolts threads (page 1-23).
11""'-- ----
Install the mainshaft bearing set plate [1].
Install and tighten the mainshaft bearing set plate bolts
SHIFT DRUM/SHIFT FORK

Apply engine oil to the shift drum bearing.
Install the shift drum [1] and shift drum bearing [2] into
the lower crankcase.
Apply locking agent to the shift drum bearing setting

bolt/washer threads (page 1-23).
Install and tighten the shift drum bearing setting bolt/
washer [1] to the specified torque.
14-25
The shift forks have the following identification marks:
MT model:
- MT model :
- "C" mark [1] : mainshaft shift fork
- No mark [2]: left/right countershaft shift fork
- OCT model:
- "L" mark [3]: left mainshaft shift fork
- "R" mark [4]: right mainshaft shift fork
- "C" mark [5]: countershaft shift fork
[2] [2]
(1)
OCT model:
MT model: Apply molybdenum oil solution to the shift fork shaft

outer surface.
Install the mainshaft shift fork [1] into the M3/M4 gear
with the identification marks facing toward the right side
of the engine.
Install the countershaft shift forks [2] with the
identification marks facing toward the right side of the
engine.
Insert the shift fork shaft [3].
NOTE:
• Make sure that each shift fork guide pin is positioned
in the correct guide grooves of the shift drum.
OCT model: Install the following with the identification marks facing
toward the right side of the engine:
- Left mainshaft shift fork [1] into the M3 gear
- Right mainshaft shift fork [2] into the M4 gear
Apply molybdenum oil solution to the shift fork shafts
outer surface.
Insert the mainshaft shift fork shaft [3] .
Install the countershaft shift forks [4] with the
identification marks facing toward the left side of the
engine.
Insert the countershaft shift fork shaft [5].
NOTE:
• Make sure that each shift fork guide pin is positioned
in the correct guide grooves of the shift drum.
14-26
Apply locking agent to the shift drum bearing setting
bolt/washer threads (page 1-23).
Install and tighten the shift drum bearing setting bolt/
washer [1] to the specified torque.
COUNTERSHAFT
Install the dowel pin [1] onto the upper crankcase hole.
Install the countershaft assembly [2] .
NOTE:
• Align the needle bearing cap hole [3] with the dowel
pin.
• Align the set ring with the upper crankcase groove.
• Align the oil seal flange with the upper crankcase
groove.
Assemble the crankcase halves (page 14-27).
CRANKCASE ASSEMBLY
Apply liquid sealant (TB12078 manufactured by Three
Bond or equivalent) to the crankcase mating surface as
shown.
NOTE:
• Do not apply liquid sealant to the crankcase main
journal bolts area and the oil passage area.
14-27
Install the dowel pins [1], oil orifice A [2], and oil orifice
B [3] onto the upper crankcase.
NOTE:
• Install the oil orifice A with its narrow hole side facing
the upper crankcase.
[3]
[2]
Apply molybdenum oil solution to the main journal

bearing sliding surfaces on the lower crankcase. 71 [3]
Install the lower crankcase onto the upper crankcase.

NOTE:
• Make sure the upper and lower crankcases are
seated securely.
Apply molybdenum oil solution to the following bolt
threads and seating surfaces.
Install and tighten the following bolts to the specified
torque: [1]
-
-
Crankcase main journal bolt (middle) [2)
Crankcase main journal bolts (short) [3)
71
NOTE:
• Tighten the crankcase main journal bolts in a
-
-
Crankcase
New 8 mm
Crankcase
10 mm bolt (1)
sealing washers (2)
8 mm bolt (long) [3]
-~
-~
---
- Crankcase 8 mm bolts (middle) (4)
Crankcase 8 mm bolts (short) (5) [2]/[3]
- New 6 mm sealing washers (6) [4]
Crankcase 6 mm bolt (long) [7)
- Crankcase 6 mm bolts (short) [8)
--- [1]
-~
[2]/[4]
[4]
[6]/[8]
..._. [5]
14-28
Tighten the following bolts to the specified torque:
- Crankcase 10 mm bolt [1)
- Crankcase 8 mm bolt (long) [2)
- Crankcase 8 mm bolts (middle) [3]
- Crankcase 8 mm bolts (short) [4) [5)
TORQUE: [2)
Crankcase 10 mm bolt: [3)
39 N·m (4.0 kgf·m, 29 lbMt)
[3) [1)
Crankcase 8 mm bolt (long/middle/short):
24 N·m (2.4 kgf·m, 18 lbMt) [3)
NOTE:
[6] [4)
• Tighten the crankcase 10 mm and 8 mm bolts in a
Tighten the crankcase 6 mm bolt (long) [5] and 6 mm
bolt (short) [6] securely .
NOTE:
• Tighten the crankcase 6 mm bolts alternately from
inside to outside in 2 or 3 steps.
OCT model: Install the timing sprocket [1) .
NOTE:
• Install the timing sprocket with its punch mark [2)
facing outside as shown .
• Align the timing sprocket wide teeth with the
crankshaft wide teeth .
Coat the cam chain with the engine oil.
Install the cam chain [3) .
Apply locking agent to the cam chain guide plate bolts
Install the cam chain guide plate [4) and cam chain
guide plate bolts [5] .
Tighten the cam chain guide plate bolts securely.
Install the removed parts to the crankcase by refer to
Service Information (page 14-2).
Install the 0-ring [1) into the groove in the water hose
flange [2].
Install and tighten the bolts [3) securely.
Install the engine (page 16-12).
14-29
MEMO
15. CRANKSHAFT/PISTON/CYLINDER
SERVICE INFORMATION· .. ··················· 15-2 MAIN JOURNAL BEARING · · · · · · · · · · · · · · · · · · · 15-6
TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · 15-2 CRANKPIN BEARING · · · · · · · · · · · · · · · · · · · · · · · · · · 15-9
COMPONENT LOCATION····················· 15-3 PISTON/CYLINDER···························· 15-12
CRANKSHAFT···································· 15-4
15-1
SERVICE INFORMATION
GENERAL
• The crankcase must be separated to service the crankshaft, pistons and connecting rods.
• Mark and store the connecting rods, crankpin bearing caps, crankpin bearing and main journal bearing to be sure of their correct
locations for reassembly.
• The crankpin bearing and main journal bearing are select fit and are identified by color codes. Select replacement bearings from
the selection tables. After selecting new bearings, recheck the oil clearance with plastigauge. Incorrect oil clearance can cause
severe engine damage.
• Clean the oil passages in the upper crankcase with compressed air before installing the pistons.
TROUBLESHOOTING
Cylinder compression is too low, hard to starting, or poor performance at low speed
• Leaking cylinder head gasket
• Loose spark plug
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
Cylinder compression too high, overheating, or knocking
• Excessive carbon built-up on piston head or combustion chamber
Excessive smoke
• Worn cylinder, piston, or piston ring
• Improper installation of piston rings
• Scored or scratched piston or cylinder inner surface
Abnormal noise
• Worn piston pin or piston pin hole
• Worn connecting rod small end
• Bent connecting rod
• Worn cylinder, piston , or piston rings
• Worn main journal bearings
• Worn crankpin bearings
Engine vibration
• Excessive crankshaft runout
15-2
COMPONENT LOCATION
22 N·m (2.2 kgf-m , 16 lbf-ft) + 1200
MT model shown:
1,
1I
15-3
CRANKSHAFT
SIDE CLEARANCE INSPECTION
Measure the connecting rod side clearance .

If the clearance exceeds the service limit, replace the
connecting rod.
Recheck and if still out of limit, replace the crankshaft.
REMOVAL
I NOTICE
Mark the crankpin bearing caps and bearings as you
remove them to indicate the correct cylinder for
reassembly.
Remove the crankpin bearing cap bolts [1] and crankpin
bearing caps [2].
Remove the crankshaft [3] .
INSPECTION
Support the crankshaft [1] on both end journals.
[1 J
Set a dial gauge on the crankshaft.
Rotate the crankshaft two revolutions (720°) and read
the runout.
SERVICE LIMIT:
0.03 mm (0.001 in)
Check the balancer drive gear teeth for abnormal wear
or damage.
15-4
INSTALLATION
Apply molybdenum oil solution to the main journal
bearing [1] sliding surfaces on the upper crankcase.
Apply molybdenum oil solution to the crankpin bearing
[2] sliding surfaces on the connecting rods.
Apply molybdenum oil solution to the thrust surfaces of

the crankshaft as shown.
Install the crankshaft [1] onto the upper crankcase and

set the connecting rods onto the crankpins.
NOTE:
• Be careful not to damage the crankpin, main journal
and main journal bearings.
Apply molybdenum oil solution to the crankpin bearing
sliding surfaces on the crankpin bearing caps [2].
Install the crankpin bearing caps.
NOTE:
• Align the I.D. code number on the crankpin bearing
caps and connecting rods.
Apply engine oil to new crankpin bearing cap bolt

Install and tighten the crankpin bearing cap bolts [1] to
the specified torque in 2 or 3 steps alternately.
Further tighten the bolts 120°.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) + 120°
Assemble the crankcase halves (page 14-27).
15-5
MAIN JOURNAL BEARING
I NOTICE I
Do not interchange the main journal bearings. They
must be installed in their original locations or the correct
bearing oil clearance may not be obtained, resulting in
Remove the crankshaft {page 15-4 ).
BEARING INSPECTION
Inspect the main journal bearings [1] on the upper and
lower crankcase halves for unusual wear or peeling.
Check the main journal bearing tabs for damage.
OIL CLEARANCE INSPECTION

NOTE:
• Do not rotate the crankshaft during inspection.
Clean off any oil from the main journal bearings and
main journals.
Install the crankshaft [1] onto the upper crankcase.
Lay a strip of plastigauge [2] lengthwise on each main
journal and be sure to avoid the oil hole.
Install the dowel pins [1].

[1] [1)
[1]
15-6 l
J
Install the lower crankcase onto the upper crankcase.
NOTE:
71 [3] '
• Make sure the upper and lower crankcases are

seated securely.
Apply molybdenum oil solution to the following bolt
Install and tighten the following bolts to the specified
torque:
- Crankcase main journal bolt (middle) [2] [1]
TORQUE: 43 N·m (4.4 kgf·m, 32 lbMt) 71
NOTE:
• Tighten the crankcase main journal bolts in a
Loosen the following:
- Crankcase main journal bolt (middle) [2]
NOTE:
• Loosen the crankcase main journal bolts in a
Remove the crankcase main journal bolts.
Separate the lower crankcase from the upper
crankcase .

on each main journal to determine the oil clearance.
If the oil clearance exceeds the service limit, select the

replacement bearing (page 15-7).
MAIN JOURNAL BEARING

SELECTION
Record the crankcase bearing support 1.0. code letters
[1] from left side of the upper crankcase as shown.
NOTE:
• Letters (A, B or C) on the left side of upper
crankcase are bearing support 1.0. codes from left to
right.
[1]
15-7
If you are replacing the crankshaft, record the
corresponding main journal 0.0. code numbers [1] from
the crank weight.
NOTE:
• Numbers (1, 2 or 3) on the crank weight are main
journal O.D. codes from left to right.
If you are reusing the crankshaft, measure the main
journal O.D. with a micrometer.
Determine the replacement bearing color code [1] with

[1)
the main journal 0 .0 . code number or the measured
main journal 0 .0 ., and the crankcase bearing support
1.0. code.
Refer to the main journal bearing selection table below
for bearing selection.
MAIN JOURNAL BEARING THICKNESS:
A: Blue: Thickest
B: Black:
C: Brown: t
D: Green:
E: Yellow: Thinnest
MAIN JOURNAL BEARING SELECTION TABLE:

BEARING SUPPORT I.D. CODE
A B C
47.000 - 47.006 mm 47.006-47.012 mm 47.012-47.018 mm
(1 .8504 - 1.8506 in) (1.8506 - 1.8509 in) (1 .8509 - 1.8511 in)
MAIN JOURNAL 44.004-44.010 mm
1 E (Yellow) D (Green) C (Brown)
0 .0 . CODE (1 .7324 - 1.7327 in)
NUMBER 43.998 - 44.004 mm
2 D (Green) C (Brown) B (Black)
(1 .7322-1 .7324 in)
43.992 - 43.998 mm
3 C (Brown) B (Black) A (Blue)
(1 .7320-1 .7322 in)
NOTICE
After selecting new bearings, recheck the clearance
with a plastigauge. Incorrect clearance can cause
BEARING INSTALLATION
Clean the main journal bearing outer surfaces and
crankcase bearing inserts.
Install the main journal bearings [1].
NOTE:
• Install the main journal bearing by aligning each tab
with each groove.
;
'
15-8 j
CRANKPIN BEARING
I NOTICE I
Do not interchange the crankpin bearings. They must
be installed in their original locations or the correct
bearing oil clearance may not be obtained, resulting in
Remove the crankshaft (page 15-4 ).
BEARING INSPECTION
Check the crankpin bearings [1] for unusual wear or
peeling.
Check the crankpin bearing tabs for damage.
OIL CLEARANCE INSPECTION

NOTE:
• Do not rotate the crankshaft during inspection .
Clean off any oil from the crankpin bearings and
crankpins.
Carefully install the crankshaft [1] onto the upper
crankcase.
Set the connecting rods onto the crankpins.
Lay a strip of plastigauge [2] lengthwise on each
crankpin and be sure to avoid the oil holes.
Install the crankpin bearing caps [1].

NOTE:
• Align the I.D. code number on the crankpin bearing
caps and connecting rods.
15-9
Apply engine oil to the crankpin bearing cap bolt (reuse)
Install and tighten the crankpin bearing cap bolts [1] to
the specified torque in 2 or 3 steps alternately.
Further tighten the bolts 90°.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbMt) + 90°
Remove the crankpin bearing cap bolts and crankpin

bearing caps [2].

on each crankpin to determine the oil clearance.
If the oil clearance exceeds the service limit, select the

correct replacement bearings (page 15-10).
BEARING SELECTION
Record the connecting rod I.D. code number [1] or
[1]
measure the connecting rod I.D.
NOTE:
• Numbers (1 , 2, or 3) on the connecting rods are the
connecting rod I.D. codes.
• When measure the connecting rod I.D., install the
crankpin bearing cap without installing the crankpin
bearing.
'
I
J
If you are replacing the crankshaft, record the

I
corresponding crankpin O.D. code letter [1] . I•
NOTE:
• Letters (A, B, or C) on the crank weight are the '
crankpin O.D. codes from left to right.
If you are reusing the crankshaft, measure the crankpin
O.D. with a micrometer.
~
I
i
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I
15-10
1
Determine the replacement bearing color code [1] with
[1]
the connecting rod 1.0. code number or the measured
connecting rod 1.0., and the crankpin 0.0. code letter or
measured crankpin 0.0.
Refer to the crankpin bearing selection table below for
bearing selection.
CRANKPIN BEARING THICKNESS:
A: Blue: Thickest
B: Black:
C: Brown: l
D: Green:
, E: Yellow: Thinnest
CRANKPIN BEARING SELECTION TABLE:

CONNECTING ROD I.D. CODE
1 2 3
47.000 - 47.006 mm 47.006- 47.012 mm 47.012-47.018 mm
(1.8504 - 1.8506 in) (1 .8506 - 1.8509 in) (1.8509 - 1.8511 in)
CRANKPIN 43.992 - 43.998 mm
A E (Yellow) D (Green) C (Brown)
0.0. CODE (1 .7320 - 1.7322 in)
43.986 - 43.992 mm
B D (Green) C (Brown) B (Black)
(1 .7317-1 .7320 in)
43.980 - 43.986 mm
C C (Brown) B (Black) A (Blue)
(1 .7315-1 .7317 in)
NOTICE
After selecting new bearings, recheck the clearance
with a plastigauge. Incorrect clearance can cause
BEARING INSTALLATION
Clean the crankpin bearing outer surfaces, crankpin
bearing cap and connecting rod .
Install the crankpin bearings [1] onto the crankpin
bearing cap and connecting rod.
NOTE:
• Install the crankpin bearings by aligning each tab
with each groove.
Align
15-11
PISTON/CYLINDER
PISTON/CONNECTING ROD
REMOVAL
I NOTICE I
• Before piston removal, place a clean shop towel
around the connecting rod to prevent damaging the I
cylinder inner surface.
• Do not try to remove the piston/connecting rod
j
assembly from bottom of the cylinder; the assembly
will get stuck in the gap between the cylinder sleeve
and the upper crankcase.
• Do not interchange the crankpin bearing. They must
be installed in their original locations or the correct
bearing oil clearance may not be obtained, resulting l
in severe engine damage. I
-
-
Transmission (page 14-14)
Crankshaft (page 15-4)
I
1
J
Remove the piston/connecting rod assembly [1] from
the top of the cylinder.
J
PISTON REMOVAL
Remove the piston pin clips [1].
[3]
Push the piston pin [2] out of the piston [3] and
connecting rod [4].
Remove the piston.
PISTON RING REMOVAL

Spread each piston ring ends and remove them by
lifting up at a point opposite the gap.
NOTE:
• Be careful not to damage the piston ring by
spreading the ends too far.
Clean carbon deposits from the piston ring grooves with
a ring that will be discarded.
NOTE:
• Never use a wire brush; it will scratch the groove.
15-12 ]
INSPECTION
- Cylinder
- Piston
- Piston rings
- Piston pin
- Connecting rod small end
Measure each part and calculate the clearance
according to CRANKSHAFT/PISTON/CYLINDER
SPECIFICATIONS (page 1-10).
PISTON RING INSTALLATION

Clean the piston ring grooves thoroughly.
, [1]
Install the piston rings.
NOTE:
• Apply engine oil to the piston ring entire surfaces
and piston ring grooves.
• Avoid piston and piston ring damage during
installation.
• Install the top ring [1] and second ring [2] with their ~ ~ . [1]
marks [3] facing up.
Install the top ring and second ring in the correct
~ ~ [2]
position as shown.
• To install the oil ring [4], install the spacer [5] first,
then install the side rails [6] .
After installation, the rings should rotate freely in the
ring groove.
}-r:! 1•1
Stagger the piston ring end gaps 120° apart from each
other.
Stagger the side rail end gaps as shown.
PISTON INSTALLATION
Apply engine oil to the piston pin hole inner surface.
[2] [1]
Apply molybdenum oil solution to the connecting rod
small end inner surface.
Assemble the piston [1] and connecting rod [2] with the
connecting rod "MKS" mark [3] facing to the piston
"MKS" mark [4] side.
[4]
15-13
I l
I
Apply molybdenum oil solution to the piston pin outer

. I
surface.
'
Install the piston pin [1].
-~
[1) I
Secure the piston pin using new piston pin clips [2].
NOTE:
(2) '
J
I
• Make sure that the piston pin clips are seated .__..
securely. 1
• Do not align the piston pin clip end gap with the J
piston cut-out [3] as shown. )
',
I
[2) [3)
PISTON/CONNECTING ROD
INSTALLATION
Apply engine oil to the piston and cylinder inner surface.
Install the piston/connecting rod assemblies [1] into the
cylinders using a commercially available piston ring
compressor tool [2]. I
I NOTICE I l
J
• While installing the piston, be careful not to damage
the top surface of the cylinder, especially around the
cylinder bore. I
• Be careful not to damage the cylinder inner surface
with the connecting rod.
NOTE:
• When reusing the connecting rods, they must be
l
I
installed in their original locations.
I
• Install the piston/connecting rod assembly with the
"IN" mark [3] facing the intake side. J
• Make sure the piston ring compressor tool sits flush
on the top surface of the cylinder.
Use the handle of a plastic hammer or equivalent tool to
tap the piston into the cylinder.
'
-
-
Crankshaft (page 15-5)
Transmission (page 14-24)
j
j
J
PISTON OIL JET REMOVAL/
INSTALLATION
Remove the piston oil jets [1] and 0-rings [2].
NOTE:
• Replace the 0 -rings with new ones.
• Apply engine oil to new 0-rings.
• Install the piston oil jets into the holes of upper
crankcase as shown.
l
J
15-14 I
16. ENGINE REMOVAUINSTALLATION
SERVICE INFORMATION· .. ··················· 16-2 ENGINE REMOVAL····························· 16-4
COMPONENT LOCATION····················· 16-3 ENGINE INSTALLATION····················· 16-12
16-1
SERVICE INFORMATION
GENERAL
• A hoist or equivalent is required to support the motorcycle when removing and installing the engine.
• When removing/installing the engine , tape the frame around the engine beforehand for frame protection . j
• When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence. If
you mistake the torque or sequence, loosen all mounting fasteners, then tighten them again to the specified torque in the correct
l
sequence.
• MT model:
l
The following components can be serviced with the engine installed in the frame .
I j
- Throttle body (page 7-16) l

- Water pump (page 8-11)
- Oil pump (page 9-6) J
- Rocker arm (page 10-9)
- Cylinder head/valves (page 10-19)
I
- Stator (page 11-5)
I
l
• OCT model: l
The following components can be serviced with the engine installed in the frame .
' j
I
- Throttle body (page 7-16) I'
- Water pump (page 8-11)
- Rocker arm (page 10-9) j
- Cylinder head/valves (page 10-19) l
- Stator (page 11-5) l
j
- Dual clutch (page 13-50) j
• The following components require engine removal for service . l
- Piston/cylinder (page 15-12)
j
l
.
1
j
;
16-2
COMPONENT LOCATION
MT model shown :
12 N·m
(1 .2 kgf-m , 9 lbf·ft)
44N·m
(4.5 kgf·m, 32 lbf·ft)
r
32 N·m
(3.3 kgf·m, 24 lbf-ft)
t\
54N ·m
(5.5 kgf-m , 40 lbf-ft)
44 N·m
(4.5 kgf-m, 32 lbf·ft)
32 N·m
44 N·m
(4 .5 kgf·m, 32 lbf·ft)
16-3
ENGINE REMOVAL
Support the motorcycle using a safety stand or hoist.
MT model:
- Heel guards (page 2-26)
- Right rear engine cover (page 2-27)
- Muffler/exhaust pipe (page 2-45)
- Engine oil filter (page 3-12)
- Ignition coil tray (page 5-10)
- Radiator (page 8-7)
- Radiator reserve tank (page 8-11)
- Battery box (page 21-6)
- Rear brake pedal (page 19-16)
- Main step bracket (page 2-27)
- Gearshift spindle cover (page 12-20)
- Shift pedal (page 12-23)
OCT model:
- EQT sensor (page 13-64) I
i~
- Shift control motor cover (page 13-54)
- Clutch EOP sensor cover (page 2-27)
- CKP sensor (page 4-77) l
J'
Release the fuel tank drain hose [1] and EVAP canister
drain hose [2] from the skid plate bracket [3].
Remove the bolts [4] and skid plate bracket. l
l
•
[4] [3] [1] [2]
Disconnect the alternator 3P (Gray) connector (page l

21 -9). j
Remove the wire band [1]. l
j
Release the alternator wire [3] from the frame.
J
'l
l
l
16-4 I
'
MT model: Remove the wire clamps [1].
MT model: Release the alternator wire clip [1].

Remove the alternator cover bolt [2] and stay [3].
Disconnect the EOP switch terminal [4].
Remove the EOP switch [5] .
OCT model: Release the alternator wire clip [1].

Remove the alternator cover bolt [2] and stay [3].
Disconnect the EOP sensor 3P (Black) connector [5].
Remove the EOP sensor [6].
Remove the alternator cover bolts [1] and skid plate

stay [2].
'
i
16-5
l
Remove the fuel tank drain hose [1] and EVAP canister
drain hose [2] from the connector cover.
Remove the connector cover [3] by releasing the
connector cover bosses [4].
MT model: Disconnect the following:

MT model:
- Sidestand switch 2P (Black) connector [1]
- GP sensor 3P (Black) connector [2]
Shift stroke sensor (option) 4P connector [3]
- Neutral switch terminal [4]
- Shift spindle switch terminal [5]
OCT model: Disconnect the following:

OCT model:
- Sidestand switch 2P (Black) connector [1]
TR sensor 3P (Black) connector [2]
Inner mainshaft sensor 3P (Black) connector [3]
Shift spindle angle sensor 3P (Blue) connector [4]
Gear change switch (option) 3P (Black) connector
[5]
Neutral switch terminal [6]
Release the wire clips [7].
Remove the bolts [1] and harness clip stay [2].
16-6
MT model: Disconnect the starter motor cable terminal [1] and VS
sensor 3P (Black) connector [2] .
OCT model: Disconnect the following:

- Starter motor cable terminal [1]
- VS sensor 3P (Black) connector [2]
- Outer mainshaft sensor 3P (Black) connector [3]
Disconnect the ECT sensor 2P (Black) connector [1].
OCT model: Disconnect the shift control motor 2P (Black) connector ..,.,.._,,,,,----.;;;:----.iac-.;;~~
[1 ].
16-7
ENGINE REMOVAL/INSTALLATION I
.•
J
MT model: Remove the bolt [1] and clutch cable holder [2] .
Disconnect the clutch cable [3] from the clutch lifter
.
J
lever [4] . J
I
I
i
I
'
MT model: Remove the bolt [1] and clutch cable guide [2] .
I
j
1
I
I
J
Remove the bolt [1] and battery box stay [2] .

j
l
J
[2] [1 ]
OCT model: Disconnect linear solenoid 4P (Black) connector [1]. I
j
t
!
I
;
I
!
I
j
'f
'
I
j
I
;
,
I
I
.
'
16-8 I
OCT model: Remove the wire clamp [1].
Remove the clutch EOP sensor wire stay bolt [5] and
stay [6].
Conventional Remove the bolt [1].

suspension model:
Release the brake hose guide [2].
Remove the bolt [1] and radiator reserve tank stay [2].
OCT model: Release the EOT sensor wire clip [3] from the radiator
reserve tank stay.

Remove the drive sprocket bolt [1] and washer [2].
Remove the drive sprocket (3] from the countershaft
and drive chain.
16-9
OCT model: Release the parking brake cable clip [1].
Support the engine using a jack or other adjustable

support.
Remove the swingarm pivot nut [1] and pivot bolt [2] .
Pull the swingarm rearward.

- Rear upper nut [1]
- Rear upper bolt [2]
- Collars [3]
Rear engine upper hanger bolts [4]
- Rear engine upper hanger plate [5]

Front head engine hanger bolts (left side) [1]
- Front head engine hanger bolt (right side) [2]
16-10
r Remove the following :
- Front engine hanger nut (10 mm) [1]
I Front engine hanger bolt (10 mm) [2]
Collars [3]
Front engine hanger nuts (8 mm) [4]
Front engine hanger bolts (8 mm) [5]
Right front engine hanger plate [6]
Left front engine hanger plate [7]
r
' Remove the following :
- Front lower nut [1]
- Front lower bolt (2]
- Right front lower engine hanger bolt (long) [3]
- Right front lower engine hanger bolt (short) [4]
- Right front lower engine hanger plate [5]

- Rear lowernut(1]
- Rear lower bolt (2]
- Collars [3]
Carefully maneuver the engine and remove it out of the
frame to the right.
NOTE:
• During engine removal, hold the engine securely
and be careful not to damage the frame and engine.
• Note the direction of the bolts.
• Mark and store all the bolts, nuts, and collars to
ensure that they are reinstalled in their original
locations.
16-11
ENGINE INSTALLATION
I
~
Place a jack or other adjustable support under the

engine.
NOTE:
• During engine installation, hold the engine securely
and be careful not to damage the frame and engine.
• Carefully align the mounting points with the jack to
prevent damage to the engine, frame, water hoses,
brake pipes, wires, and cables.
Apply engine oil to the swingarm pivot nut threads and
seating surface.
Loosely install the following into the correct position.
- Swingarm pivot bolt [1) and nut [2]
Rear lower bolt [3], collars [4), and nut [5)
- Right front lower engine hanger bolt (long) [6)/(short)
[7) and right front lower engine hanger plate [8)
- Front lower bolt [9) and nut [10)
- Front engine hanger bolt (10 mm) [11)/(8 mm) [12) ,
collars [13), hanger plates [14), and nut (10 mm)
[15)/(8 mm) [16)
Front head engine hanger bolts (right side) [17)/(left
.
side) [18) and hanger plate [19) J
- Rear engine upper hanger plate [20) and bolts [21)
- Rear upper bolt [22), collars [23) and nut [24)
NOTE:
• The jack height must be continually adjusted to
relieve stress for ease of bolt installation .
Route the hoses, wires, and cables properly (page 1-
26).
MT model shown:
(23] (22]
(20]
(24)
,a [2] _______.
[5] (14]
[9] [6] [8] [7]
16-12
Tighten the right front lower engine hanger bolt (short)
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf-ft)
Tighten the right front lower engine hanger bolt (long)
Tighten the rear engine upper hanger bolts [1] to the

specified torque.
Tighten the swingarm pivot nut [1] to the specified

torque.
Tighten the rear lower nut [1] to the specified torque.
16-13
Tighten the front lower nut [1] to the specified torque.
Tighten the front engine hanger nuts (8 mm) [1] to the

specified torque.

Tighten the front engine hanger nut (10 mm) [2] to the
specified torque.
Tighten the front head engine hanger bolt (right side) [1]

Tighten the front head engine hanger bolts (left side) [2]
Tighten the rear upper nut [1] to the specified torque.
16-14
OCT model: Install the parking brake cable clip [1].
Install the drive sprocket [1] in the drive chain .

NOTE:
• Install the drive sprocket with the mark [2] side
facing out.
Install the drive sprocket onto the countershaft.
Install the washer [3] and drive sprocket bolt [4] .
Tighten the drive sprocket bolt to the specified torque.
Install the radiator reserve tank stay [1] and bolt [2] .
OCT model: Install the EOT sensor wire clip [3] to the radiator
reserve tank stay.
Conventional Install the brake hose guide [1] and bolt [2].
suspension model: Tighten the bolt securely.
16-15
OCT model: Connect the following :
Clutch line EOP sensor 3P (Gray) connector [1]
Install the stay [4] and clutch EOP sensor wire stay bolt
[5].
Tighten the clutch EOP sensor wire stay bolt to the
specified torque.
Install the wire clamp [6].
OCT model: Connect linear solenoid 4P (Black) connector [1].

I
l.
I
I
J
I
l
Install the battery box stay [1] and bolt [2] .

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MT model: Install the clutch cable guide [1] and bolt [2].
NOTE:
• Align the clutch cable guide tab with the frame hole.
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16-16 I
MT model: Connect the clutch cable [1] to the clutch lifter arm [2].
Install the clutch cable holder [3] and bolt [4].
NOTE:
• Align the clutch cable holder slit with the frame tab.
OCT model: Connect the shift control motor 2P (Black) connector .-~..,,,=-----.;:--..Ei!~"'iii.i~
[1].
Connect the ECT sensor 2P (Black) connector [1].
MT model: Connect the starter motor cable terminal [1] and VS

sensor 3P (Black) connector [2] .
16-17
OCT model: Connect the following :
- Starter motor cable terminal [1)
- VS sensor 3P (Black) connector [2)
- Outer mainshaft sensor 3P (Black) connector [3)
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Install the harness clip stay [1) and bolts [2). I
Tighten the bolts securely.
'
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MT model: Connect the following :
MT model : :
I
- Neutral switch terminal [1)
- Shift spindle switch terminal [2)
- Sidestand switch 2P (Black) connector [3)
- GP sensor 3P (Black) connector [4)
Shift stroke sensor (option) 4P connector [5)
Install the wire clip [6).
OCT model: Connect the following:

DCT model:
- Neutral switch terminal [1 J
- Sidestand switch 2P (Black) connector [2)
- TR sensor 3P (Black) connector [3)
- Inner mainshaft sensor 3P (Black) connector [4) r
t
- Shift spindle angle sensor 3P (Blue) connector [5] J
Gear change switch (option) 3P (Black) connector
[6)
Install the wire clips [7] .
16-18
Install the connector cover [1].
NOTE:
• Install the connector cover bosses [2] to the harness
clip stay holes.
Install the fuel tank drain hose [3] and EVAP canister
drain hose [4] to the connector cover.
Install the skid plate stay [1] and alternator cover bolts
[2].
Tighten the alternator cover bolt to the specified torque.
MT model: Install the EOP switch [1] (page 22-25).

Connect the EOP switch terminal [2].
Install the stay [3] and alternator cover bolt [4].
Install the alternator wire clip [5].
OCT model: Install the EOP sensor [1] (page 13-64).

Connect the EOP sensor 3P (Black) connector [2].
Install the wire band [3].
Install the stay [4] and alternator cover bolt [5].
Install the alternator wire clip [6].
16-19
MT model: Install the wire clamps [1].
Install the alternator wire [1] onto the frame.

Install the wire clip [2] and wire band [3].
Connect the alternator 3P (Gray) connector (page 21-
9).
Install the skid plate bracket [1] and bolts [2].

Install the fuel tank drain hose [3] and EVAP canister
drain hose [4] to the skid plate bracket.
[2] [1] [3] (4]
16-20
Support the motorcycle using a safety stand or hoist.
• MT model:
- Gearshift spindle cover (page 12-23)
- Shift pedal (page 12-23)
• OCT model:
- EOT sensor (page 13-64)
- Clutch EOP sensor cover (page 2-27)
Adjust the drive chain slack (page 3-18).
16-21
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17. FRONT WHEEUSUSPENSION/STEERING
~
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SERVICE INFORMATION ...................... 17-2 FRONT WHEEL .. ································ 17-15
TROUBLESHOOTING·························· 17-4 FORK··············································· 17-22
COMPONENT LOCATION····················· 17-5 STEERING STEM······························· 17-47
HANDLEBAR······································ 17-6
..
17-1
FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION
GENERAL
• When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist.
• This motorcycle is equipped with an aluminum tapered handlebar. Scratching or bending of the handlebar may cause breakage.
Replace the handlebar with a new one if damaged.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• Do not operate the brake lever after removing the caliper and front wheel.
• After the front wheel installation, check the brake operation by applying the brake lever.
• When using the lock nut wrench, use a deflecting beam type torque wrench 500 mm (20.0 in) long. The lock nut wrench
increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the fork
bolt. The specification is the actual torque applied to the fork bolt, not the reading on the torque wrench when used with the lock
nut wrench. The procedure later in the text gives both actual and indicated torque readings.
• For brake system information (page 19-2)
• For electronic suspension troubleshooting (page 22-84)
TOOLS
Bearing remover head, 20 mm Bearing remover shaft Driver
07746-0050600 07746-0050100 077 49-0010000
Attachment, 42 x 47 mm Pilot, 20 mm Fork bolt wrench

077 46-0010300 07746-0040500 070MA-MKS0100 ;
Lock nut wrench, 50 mm Pin type wrench Spring collar holder

07WMA-KZ30100 070MA-MKS0200 070MF-MBZC110
or 07AMC-MFJA100 (U.S.A. only)
17-2
Stopper plate Rod guide wrench Fork seal driver, 45.2 mm
070MF-MBZC130 070MB-MKS0100 07KMD-KZ30100
or 07AMB-KZ3A100 (U .S.A. only) or 07KMD-KZ3010A (U.S.A. only)

Damper rod holder Steering stem socket Adjustable bearing puller, 20 - 40 mm
070MF-MBZC120 07916-KA50100 07JAC-PH80100
or 070MF-MBZA120 (U.S.A. only) or 07736-A01000B used with

07YAC-001A200 (U.S.A. only)
Bearing remover shaft Remover weight Bearing remover
07 JAC-PH80200 07741-0010201 07946-3710500
'
or commercially available 3/8 x 16 in. or 07936-371020A (U.S.A. only)
slide hammer (U.S.A. only)
Inner driver, 30 x 36 x 300 L Attachment, 52 x 55 mm
07946-MBOOOOO 07746-0010400
17-3
TROUBLESHOOTING
Hard steering I
)
• Steering head bearing adjustment nut too tight
• Worn or damaged steering head bearings
• Bent steering stem
• Insufficient tire pressure
• Faulty tire
Steers to one side or does not track straight
Damaged or loose steering head bearings
Loose steering stem adjusting nut
Bent forks
Unevenly adjusted right and left forks
Bent axle
Worn or damaged wheel bearings
Bent frame
Front wheel wobbling
• Bent rim
• Bent spoke
• Worn or damaged front wheel bearings
• Faulty tire
• Unbalanced front tire and wheel
Front wheel hard to turn
• Faulty front wheel bearing
• Bent front axle
• Front brake drag
Soft suspension
• Insufficient fluid in fork
• Incorrect fork fluid weight
• Weak fork springs
Stiff suspension
• Bent fork pipes
• Too much fluid in fork
• Incorrect fork fluid weight
• Clogged fork fluid passage
Front suspension noise
• Insufficient fluid in fork
• Loose fork fasteners
J'
17-4
COMPONENT LOCATION
32 N·m
(3.3 kgf·m , 24 lbf·ft)
r
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45 N·m
22 N·m
(2.2 kgf-m, 16 lbf·ft) 65 N·m
(6.6 kgf-m, 48 lbf·ft)
17-5
HANDLEBAR
REMOVAL
Remove the knuckle guards (page 2-22).
[1]
Remove the rearview mirrors [1].
MT model: Remove the wire clamps [1).

- Clutch switch connectors (upper side) [2)
- Cruise cancel switch connectors (lower side) [3)
OCT model: Remove the wire clamps [1).

Disconnect the parking brake switch connectors [2).
MT model: Remove the

assembly [3].
17-6
OCT model: Remove the bolts [1], holder [2], and parking brake
lever assembly [3].
Remove the left handlebar switch screws [1].

Separate the left handlebar switch housing [2].
Remove the screw [1].

Remove the left handlebar switch front housing [2] by
opening the setting plate [3].
CRF1100AID: Remove the left handlebar grip [4] if necessary.
CRF1100A4/D4: Remove the left grip heater if necessary (page 22-48).
Remove the wire clamp [1].

' Disconnect the following:
- Front brake switch connectors (upper side) [2]
17-7
Remove the bolts [1] , holder [2], and front master
cylinder [3].
NOTE:
• Keep the front master cylinder upright to prevent air
from entering the hydraulic system.
Remove the right handlebar switch screws [1] .

Separate the right handlebar switch housing [2].
CRF1100A4/D4: Release the wire clip [3].
Remove the screw [1] and right handlebar switch

housing [2] .
Remove the throttle grip pipe [3].
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- Handlebar upper holder bolts [1]
- Handlebar upper holders [2] J
- Handlebar [3]
17-8
Remove the screw [1]. [4]
Open the setting plate [2].
Remove the grip APS [3] from the handlebar [4] .
Check the handlebar for scratches or bend . If the
handlebar is damaged, replace with a new one.
,' INSTALLATION
NOTE:
• The scratches or bend of the handlebar may cause
breakage. Replace the damaged handlebar with a
new one.
• Route the hoses, cables, and wires properly (page
1-26).
• CRF1100A4/D4:
If the grip heater is removed, refer to grip heater
r installation (page 22-48).
CRF1100AID: If the left handlebar grip are removed , clean the inside
CRF11 OOA/D:
surface of the handlebar grip [1 ].
Apply Honda Bond A or Pro Honda Handgrip Cement
(U.S.A. only) to the inside surface of the grip and
outside surface of the handlebar [2].
Wait 3 - 5 minutes and install the grip.
Rotate the grip for even application of the adhesive.
NOTE:
• Allow the adhesive to dry for 1 hour before using.
Install the grip APS [1] to the handlebar [2].

[2]
Set the setting plate [3] .
NOTE:
• Align the setting plate tab with the handlebar hole.
Install and tighten the screw [4] securely.
17-9
Place the handlebar [1] on the lower holders [2].
NOTE:
• Align the paint mark on the handlebar with the edge
of the lower holder.
Install the handlebar upper holders [3].
NOTE:
• Install the handlebar upper holder with the punch
marks [4] facing front.
Install the handlebar upper holder bolts [5].
Tighten the front bolts first, then the rear bolts to the
specified torque.
Apply grease to the throttle grip pipe [1] and APS [2]
contact area as shown. [1)
- , 3mm
(0.1 in)
5mm
(0.2 in)
Install the throttle grip pipe [1] as shown.

[1) J
NOTE: I
• Align the throttle grip pipe tabs [2] with t he grip APS
grooves [3] . j
17-10
Install the right handlebar switch rear housing [1] .
NOTE:
• Align the rear housing tabs with the holes.
Install the right handlebar switch front housing [1].

NOTE:
• Al ign the front housing boss with the hole.
Install and tighten the right handlebar switch screws [2]
to the specified torque .
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbMt)
CRF1100A4/D4: Install the wire clip [3] .
Install the front master cylinder [1] by aligning its end

Install the front master cylinder holder [2] with its "UP"
mark [3] facing up.
Install the front master cylinder holder bolts, and tighten
the upper bolt [4] first, then the lower bolt [5] to the
specified torque.
TORQUE: 9.8 N·m (1.0 kgf·m , 7.2 lbHt)
Connect the following :

Install the wire clamp [3] .
17-11
Install the left handlebar switch front housing [1] .
Set the setting plate [2].
NOTE :
.,
Install the left handlebar switch rear housing [1].
Install and tighten the left handlebar switch screws [2] to
MT model: Install the clutch lever assembly [1] by aligning its end
Install the holder [2] with its punch mark [3] facing up.
Install the bolts, and tighten the upper bolt [4] first, then
the lower bolt [5] .
OCT model: Install the parking brake lever assembly [1] by aligning
its end with the paint mark on the handlebar.
the lower bolt [5] .
~ -
17-12
MT model: Connect the following:
Install the wire clamps [3].
OCT model: Connect the parking brake switch connectors [1].

Install the rearview mirrors [1].

[1]
Install the knuckle guards (page 2-22).
17-13
HANDLEBAR WEIGHT
- Handlebar weight bolt [1]
Rubber [2] l
Handlebar weight A [3]
Snap ring [4]
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Handlebar weight B [5] (5)
Handlebar weight rubbers [6] J
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0-ring [7]
'
TORQUE:
I
Handlebar weight bolt:
55 N·m (5.6 kgf·m, 41 lbf-ft) (4)
NOTE:
• Always replace the handlebar weight bolt, 0-ring , ~
snap ring, and handlebar weight rubbers with new ~[1) (2) (3)
ones.
• Apply engine oil to a new 0-ring .
• Install the handlebar weight rubbers as shown.
HANDLEBAR LOWER HOLDER

Loosen the handlebar lower holder nuts [1].
(3)
- Handlebar upper holder bolts [2]
- Handlebar upper holders [3]
- Handlebar [4]
(2)
(2)
[1)
17-14
- Handlebar lower holder nuts [1]
- Washers [2]
- Handlebar lower holders [3]
- Damper rubbers [4]
TORQUE:
Handlebar upper holder bolt:
32 N·m (3.3 kgf·m, 24 lbMt)
Handlebar lower holder nut:
39 N·m (4.0 kgf·m, 29 lbMt)
NOTE:
• Align the paint mark on the handlebar [1] with the
edge of lower holder.
• Install the handlebar upper holders [2] with their
punch marks [3] facing front.
• When tightening the handlebar upper holder bolts,
tighten the front bolts [4] first then the rear bolts [5].
FRONT WHEEL
REMOVAL
Remove the front brake caliper mounting bolts [1] and
front brake calipers [2].
NOTE:
• Do not suspend the front brake caliper from the
brake hose. Do not twist the brake hose.
• Do not operate the brake lever after removing the
front brake calipers.
Remove the front axle nut [1].

Loosen the left front axle holder pinch bolts [2].
Loosen the right front axle holder pinch bolts [3].
Support the motorcycle using a safety stand or hoist,
raise the front wheel off the ground.
Remove the front axle [4] and front wheel.
17-15
Remove the side collars (1].
INSPECTION
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the outer race fits tightly in the wheel
hub. J
deformation, or bend. ·
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Front axle
Front wheel -'
Measure each part according to FRONT WHEEL/
SUSPENSION/STEERING SPECIFICATIONS (page 1-
10).
WHEEL BALANCE
NOTE: I
• Carefully check balance before installing the wheel. l
• The wheel balance must be checked when the tire is I
remounted . J
Note the rotating direction mark [1] on the tire, and upon
tire installation, always fit the tire so that the mark faces
in the normal rotating direction.
ll
NOTE:
• For optimum balance, the tire balance mark [2] (light
mass point: a paint dot on the side wall) must be
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located next to the valve stem [3]. Remount the tire if
necessary.
Mount the wheel, tire, and brake disc assembly on an

inspection stand [1].
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) part of the wheel with chalk.
Do this 2 or 3 times to verify the heaviest area.
If the wheel is balanced, it will not stop consistently in
the same position.
To balance the wheel, install a new balance weight on
the lightest side of the rim, on the side opposite the
chalk marks. Add just enough weight so the wheel will
no longer stop in the same position when it is spun.
Do not add more than 60 g (2.1 oz) to the wheel.
17-16
CRF1100A/D
• FRONT BRAKE DISC BOLTS

S 20 N·m (2.0 kgf·m, 15 lbf·ft)
• BEARING
S (6004UU)
.... ...,
~
.-tiiiiiii
•
I
PULSER RING
• BEARING
S (6004UU)
PULSER RING BOLTS

7.0 N·m (0.7 kgf·m, 5.2 lbf-ft)

S 20 N·m (2.0 kgf·m, 15 lbf·ft)
NOTE:
• Install the dust seals until they are flush with the
wheel hub surface.
• Install the brake discs by aligning their arrow marks
with the wheel hub arrow mark.
If the rim [1], hub [2], and spokes are disassembled,
assemble them as follows:
28.5 - 30.5 mm
Place the rim on a work bench . (1 .12-1.20in)
Place the hub in the center of the rim, and begin the
lacing with new spokes.
Adjust the hub position so the distance from the hub left
end surface to the side of the rim is specified range as
shown.
Tighten the spokes to the specified torque in a
crisscross pattern in two of three steps.
17-17
CRF1100A4/D4
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- ~ FRONT BRAKE DISC BOLTS
20 N·m (2 .0 kgf·m, 15 lbf·ft)
lllijjjlt
RIGHT FRONT BRAKE DISC 1

• BEARING j
S (6004UU )
. , ,,..fig
•
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...
PULSER RING
.
.
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PULSER RING BOLTS
7.0 N·m (0 .7 kgf·m, 5.2 lbf-ft)

S 20 N·m (2.0 kgf·m, 15 lbf·ft)
NOTE: J
wheel hub surface. J
• Install the brake discs by align ing their arrow marks '
with the wheel hub arrow mark. l
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1
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17-18
B
Measure the width of the rim to obtain the dimension B.
NOTE:
• When measurement, except 80 mm (3.1 in) from
welded area of the rim .
Perform the following calculation to obtain the
dimension A.
58 mm (2.3 in) - B/2 = A [1]
Place the rim on a work bench.
[2]
NOTE:
• Always replace the spokes with new ones.
Adjust the hub position so the distance from the hub
right end surface to the side of the rim is A ± 1.0 mm (A
± 0.04 in) as shown.
crisscross pattern in two or three steps.
NOTE:
• Tighten the spokes with a ball point wrench.
TIRE VALVE REMOVAUINSTALLATION

(CRF11 OOA4/D4)
Remove the tire.
[1]
Remove the nut [1], tire valve [2] and 0-ring [3].
Clean the valve installation area of the rim with a
degreasing agent.
If a puncture repair product was used, thoroughly clean
the inside of the wheel rim.
Install a new 0 -ring onto the tire valve.
NOTE:
• Do not apply grease to the 0-ring.
Gradually screw in the tire valve and position it with the
valve neck facing the right of the motorcycle and
parallel with the axle. [2]
Make sure that the valve seating surface is fully seated
on the wheel and tighten the valve nut while holding the Rotating Direction
tire valve.
TORQUE: 6.5 N·m (0.7 kgf·m, 4.8 lbf·ft) [1] [2]
After the tire valve installation, make sure that the tire
valve neck is facing to the right side and parallel to the
axle direction.
Install the tire.
17-19
WHEEL BEARING REPLACEMENT
Install the bearing remover head [1] into the bearing [2].
From the opposite side, install the bearing remover
shaft [3] and drive the bearing out of the wheel hub.
TOOLS:
Bearing remover head, 20 mm 07746-0050600
Bearing remover shaft 07746-0050100
Remove the distance collar and drive out the other

bearing .
NOTE:
• Replace the wheel bearings in pairs.
• Do not reuse old bearings.
Drive in a new left bearing [1] squarely with the marked

side facing up until it is fully seated .
Install the distance collar.
Drive in a new right bearing squarely with the marked
side facing up until it is seated on the collar.
TOOLS:
Driver [2] 077 49-0010000
Attachment, 42 x 47 mm [3] 077 46-0010300
Pilot, 20 mm [4] 077 46-0040500
INSTALLATION
Install the side collars [1] to the front wheel.
1
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Apply a thin coat of grease to the front axle sliding

surface.
Install the front wheel between the forks . ,
NOTE: J
• Be careful not to damage the pulser ring .
Install the front axle [1 J from the right side.
17-20
Install and tighten the front axle nut [1J to the specified
torque.

Tighten the left front axle holder pinch bolts [2] to the
specified torque.
Install the front brake calipers [1] and new front brake .----..----=""........~
caliper mounting bolts [2].
Tighten the front brake caliper mounting bolts to the
specified torque.
With the front brake applied, pump the forks up and
down several times to seat the axle and check brake
operation.
Tighten the right front axle holder pinch bolts [1] to the
specified torque.

Check the clearance gap between the front wheel
speed sensor bracket and pulser ring (page 20-26).
.
17-21
FORK
REMOVAL
- Front fender (page 2-23)
- Front wheel (page 17-15)
Remove the bolt [1] and front wheel speed sensor [2] .
Electronic Remove the wire clamps [1].

suspension model:
- Front suspension solenoid 2P connector [2]
- Front suspension stroke sensor connector [3]
Conventional Loosen the top bridge pinch bolts [1] .

suspension model:
If you plan to disassemble the fork, loosen the fork bolts
[2] at this point. But do not remove yet.
NOTE:
• Be careful not to damage the fork bolt.
Electronic Loosen the top bridge pinch bolts [1].

suspension model:
If you plan to disassemble the fork, loosen the fork bolts
[2] using the special tools at this point. But do not
remove yet.
TOOLS:
Fork bolt wrench [3] 070MA-MKS0100
Lock nut wrench, 50 mm [4] 07WMA-KZ30100
NOTE:
17-22
Loosen the fork bottom bridge pinch bolts [1] while
holding the forks [2].
Remove the forks.
DISASSEMBLY
MODEL)
Turn the following adjusters counterclockwise to the
softest position.
- Rebound damping adjuster [1 ]
- Pre-load adjuster [2]
- Compression damping adjuster [3]
NOTE:
• Be sure to record the number of turns from the
starting position.
[3]
Remove the fork bolt [1].

[1 J
NOTE:
Remove the 0-ring [2] from the fork bolt.
Push the outer pipe [1] slowly down, and gently seat the
dust seal [2] onto the axle holder [3].
17-23
Attach the special tool to the spring collar holes [1].
TOOL:
Spring collar holder [2] 070MF-MBZC110 or
07AMC-MFJA100
(U.S.A. only)
Compress the spring collar [3] with the spring collar

holder.
Insert the special tool between the fork damper lock nut
[4] and spring seat stopper [5].
TOOL:
Stopper plate [6] 070MF-MBZC130 or
07 AMB-KZ3A 100
(U.S.A. only)
Loosen the fork bolt [1) while holding the fork damper
lock nut [2].
NOTE :

- Fork bolt [1]
- Stopper plate [2)
- Spring collar holder [3)
- Spring seat stopper [4)
- Spring collar [5)
Pour out the fork fluid by pumping the outer pipe [1)
several times .
Pour out the fork fluid from the fork damper by pumping
the damper rod [2] several times.
Remove the fork spring [3).
17-24
r Hold the axle holder in a vise with soft jaws or a shop

towel.
I
•~ Remove the fork center bolt [1] and sealing washer [2] .
Remove the fork damper [1] and centering plate [2] .
[1]
Remove the dust seal [1].

Remove the oil seal stopper ring [2].
NOTE:
• Do not scratch the slide pipe surface.
Pull the slide pipe [1] out until you feel resistance from
the slider bush ing. Then move it in and out, tapping the
bushing lightly until the outer pipe [2] separates from
the slide pipe.
The guide bushing will be forced out by the slider
bushing.
.
i
17-25
[3] [2]
- Slider bushing [1]
Guide bushing [2]
- Back-up ring [3] [1] -'
- Oil seal [4]
- Stopper ring (5]
- Dust seal [6]
NOTE:
Do not remove the slider bushing unless it is
necessary to replace with a new one.
(5] (4)
DISASSEMBLY
(ELECTRONIC SUSPENSION MODEL)
LEFT {Solenoid side)
Remove the suspension solenoid [1] using the special
tools.
TOOLS:
Pin type wrench [2] 070MA-MKS0200
NOTE:
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•
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Remove the following from the outer collar [1] : j

- Plug bolt [2] l
- Collar [3] J
- Solenoid valve [4]
Remove the 0-ring [5] and grommet [6] from the plug
bolt.
t
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I
17-26
Remove the fork bolt [1] using the special tools .
[1) [1]
TOOLS:
NOTE:
Push the outer pipe [1] slowly down , and gently seat the
dust seal [2] onto the axle holder [3] .
Attach the special tool to the spring collar holes [1].
TOOL:
07AMC-MFJA 100
(U.S.A. only)

holder.
[4] and spring seat stopper [5] .
TOOL:
07 AMB-KZ3A 100
(U.S.A. only)
Loosen the fork bolt [1] using special tools while holding
the fork damper lock nut [2].
TOOLS:
NOTE:
17-27
- Fork bolt [1] [2)
- 0-ring [2]
- Stopper plate [3]
- Spring collar holder [4]
[3)

- Spring seat stopper [1]
- Spring collar [2]
,,,'
[2) ___________.,
Pour out the fork fluid by pumping the outer pipe [1]
several times. 'I
Pour out the fork fluid from the fork damper by pumping j
;
the damper rod [2] several times.
j
Remove the fork spring [3] .
Hold the axle holder in a vise with soft jaws or a shop

towel.
Remove the fork center bolt [1] and sealing washer [2] .
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I
I
17-28
Remove the oil seal stopper ring [2).
NOTE:
,
the slider bushing. Then move it in and out, tapping the
the slide pipe.
bushing.

- Guide bushing [2]
- Back-up ring [3]
- Oil seal [4]
- Stopper ring [5]
- Dust seal [6]
NOTE:
[5] [4]
RIGHT (Stroke sensor side)

Remove the fork bolt [1] using the special tools.
TOOLS:
NOTE:
17-29
Push the outer pipe [1] slowly down, and gently seat the
1
dust seal [2] onto the axle holder (3] .
"'
4
ll
I
4
[2] l
j
[3] I
I
;'
Attach the special tool to the inner fork bolt [1 ].
TOOL:
Rod guide wrench [2] 070MB-MKS0100
Remove the inner fork bolt while compressing the fork
bolt (3].
Remove the fork bolt.
Remove the inner rod [1] and fork spring [2] .
Pour out the fork fluid .
j
.
j
I
l
;
I1
17-30
!
Remove the oil seal stopper ring [2].
NOTE:
,
the slider bushing. Then move it in and out, tapping the
the slide pipe.
bushing.

[3] [2)
- Guide bushing [2]
- Back-up ring [3]
- Oil seal [4]
- Stopper ring [5]
- Dust seal [6]
NOTE:
[5] [4)
17-31
INSPECTION
deformation, looseness or bend.
• Conventional suspension model:
- Fork bolt
- Outer pipe
- Slide pipe
- Fork damper
- Centering plate
- Spring seat stopper
- Spring collar
- Fork spring
- Guide bushing
- Slider bushing
..
- Back-up ring
• Electronic suspension model (solenoid side):
- Suspension solenoid
- Fork bolt
- Outer pipe
- Slide pipe
- Fork damper
- Spring seat stopper
- Spring collar
- Fork spring
- Guide bushing
,l
- Slider bushing
- Back-up ring
• Electronic suspension model (stroke sensor side):
- Fork bolt (stroke sensor)
- Inner fork bolt
- Outer pipe
- Slide pipe
- Inner rod lI
- Fork spring
- Guide bushing l
- Slider bushing
- Back-up ring
-
Measure each part according to FRONT WHEEL/
SUSPENSION/STEERING SPECIFICATIONS
(page 1-10).
.
j
i
l
I
I
1
I
•
17-32 J
J
ASSEMBLY
MODEL)
NOTE:
• Before assembly, wash all parts with a high flash
point or non-flammable solvent and blow them dry.
FORK DAMPER LOCK NUT FORK DAMPER SPRING SEAT

j 20N ·~ -~kgf·m, 15L lbfft) ~ STOPPER
SLIDE PIPE
r SLIDER
BUSHING
/ /UIDE
§:i(/ ~USHING
0-RING
f!3'
BACK-UP 8'1
~RING
. ~ etl
~ ~OIL SEAL FORK BOLT
35 N·m
(3.6 kgf·m, 26 lbf-ft)
STOPPER
DUST SEAL
R
r_J
u~J J FORK SPRING
LJ
FORK CENTER BOLT
34 N·m (3 .5 kgf-m , 25 lbf-ft)
8'1 OUTER PIPE
CENTERING PLATE
SPRING COLLAR
Wrap the edge and groove of the slide pipe [1 J with tape
, [2]. [2]
'
Apply fork fluid to new dust seal lips.
Install the dust seal (3] onto the slide pipe.
/
17-33
Apply fork fluid to new oil seal lips.
[4] [5] [6]
Install the stopper ring [1] and oil seal [2] onto the slide
pipe [3].
NOTE:
• Install the oil seal with its marked side facing toward
the axle holder.
Remove the tape from the slide pipe.
Install the back-up ring [4], guide bushing [5] onto the
slide pipe.
Install the slider bushing [6] onto the slide pipe if it is [2] l
removed.
NOTE:
let [3] [7]
)
• Remove any burrs from the bushing mating surface,

being careful not to peel off the coating .
• Do not open the slider bushing slit more than
necessary.
Install the slide pipe into the outer pipe [7].
Drive the oil seal [1 ] with the guide bushing [2] and
back-up ring [3] into the outer pipe until the stopper ring
groove [4] is visible using the special tools.
TOOL:
Fork seal driver, 45.2 mm [5] 07KMD-KZ30100 or
07KMD-KZ301 OA
(U.S.A. only)
'I
Install the stopper ring [1] into the groove securely.
'
NOTE:
• Do not scratch the slide pipe surface. j
I
Install the dust seal [2]. l
I
I
I
l
l
Install the centering plate [1] to the fork damper [2] .
[1] J
Install the fork damper/centering plate into the slide
pipe/outer pipe assembly [3].
[2]
J
I
l
I
I
(3)
l
•
'I
17-34 j
Install the fork center bolt [1] with a new sealing washer
[2].
towel.
Tighten the fork center bolt to the specified torque .
Pour the specified amount of recommended fork fluid .
RECOMMENDED FORK FLUID:

Fork Fluid (viscosity: 1OW)
FORK FLUID CAPACITY:
708 ± 2.5 cm 3 (23.9 ± 0.1 US oz, 24.9 ± 0.1 Imp oz)
Tighten the fork damper lock nut [1) fully.
[1]
,
Bleed the air from the fork as follows:
1. Extend the fork, cover the top of the outer pipe [1)
with your hand and compress the fork slowly. [ 11
2. Remove your hand and extend the fork slowly.
Repeat above procedure 2 or 3 times.
3. Install the special tool to the fork damper rod [2].
TOOL:
Damper rod holder [3] 070MF-MBZC120 or
070MF-MBZA 120
(U.S.A. only)
Pump the fork damper rod slowly 8 - 10 times.
17-35
Slowly push the outer pipe [1 ], and gently seat the dust
seal [2] onto the axle holder [3] and leave it for 5
minutes.
After the fork fluid level stabilizes, measure the fork fluid
level from the top of the outer pipe.
FORK FLUID LEVEL:
93 mm (3.7 in)
NOTE: I
I
• Be sure the oil level is the same in both forks.
I
)
Install the fork spring [1] into the slide pipe with its
Up
tapered side facing up.
Install the spring collar [2] and spring seat stopper [3].
- - - [1)
Attach the special tool to the spring collar holes [1] .
TOOL:
j'
07AMC-MFJA100
(U.S.A. only)
While pulling the damper rod holder (3] up, compress
the spring collar [4] with the special tool.
TOOL:
07AMB-KZ3A 100 J
(U.S.A. only) J
Remove the damper rod holder.
Recheck the fork damper lock nut [1] is tightened fully.
Install the fork bolt [2] to the fork damper [3] until it is
fully seated.
[3]
'
I
j
[1)
I
)
J
l
J
17-36 J
Tighten the fork damper lock nut [1] to the specified
torque.
NOTE:
• Tighten the fork damper lock nut with the specified
torque by tightening the fork bolt (pre-load adjuster)
[2] while holding the fork damper lock nut.
Be careful not to damage the fork bolt.

holder [2].
Remove the stopper plate [3].
Remove the spring collar holder.
Apply fork fluid to a new 0-ring.

[2]
Install the 0-ring [1] to the fork bolt [2].
Install the fork bolt.
NOTE:
• Tighten the fork bolt after installing the fork into the
steering stem.
Return the following adjusters to their original positions

as noted during disassembly.
Rebound damping adjuster [1]
- Pre-load adjuster [2]
- Compression damping adjuster [3]
[3]
17-37
ASSEMBLY
(ELECTRONIC SUSPENSION MODEL)
LEFT (Solenoid side) I'
NOTE:
• Before assembly, wash all parts with a high flash i
point or non-flammable solvent and blow them dry. j
l
l
SUSPENSION SOLENOID i
I
15 N·m (1.5 kgf-m , 11 lbf·ft)
!
FORK DAMPER LOCK NUT J
20 N·m (2.0 kgf·m, 15 lbf-ft)
FORK DAMPER
PLUG BOLT
SLIDE PIPE
} n --:711 ~ y ~ 0-RING
eta
SLIDER Iii s CY"
~~
BUSHING
0-RIN~G 0-RING
/ /UIDE /, j ._., ..
~/~~SHING 'liiiill'.
I
~ _BACK-UP 1
~RING FORK BOLT
35N ·m
~ •"I (3.6 kgf·m, 26 lbf-ft)
~~SEAL SPRING SEAT

STOPPER
I
STOPPER
RING
J
.r _.,
~ SEALING DUST SEAL OUTER PIPE
SPRING COLLAR l
J'
etl I
'liiiill' WASHER FORK SPRING
~ FORK CENTER BOLT

' 20 N·m (2.0 kgf·m , 15 lbf·ft)
Wrap the edge and groove of the slide pipe [1] with tape J
[2].
l
Install the dust seal [3] onto the slide pipe.
j
l
J
l
j
1
I
'
i
I
17-38 '
pipe [3] .
r NOTE:
[7]
the axle holder.
Remove the tape from the slide pipe.
[1)//
Install the back-up ring [4], guide bushing [5] onto the
slide pipe. [2)/
,
Install the slider bushing [6] onto the slide pipe if it is
removed. ltll [3]
NOTE :
t • Remove any burrs from the bushing mating surface,
necessary.
Install the slide pipe into the outer pipe [7] .
Drive the oil seal [1] with the guide bushing [2] and
groove [4] is visible using the special tools.
TOOL:
07KMD-KZ301 OA
(U.S.A. only)
, Install the stopper ring [1] into the groove securely.

NOTE:
Install the dust seal [2].
Apply locking agent to the fork center bolt threads.

Install the fork center bolt [1] with a new sealing washer
[2] .
towel.
Tighten the fork center bolt to the specified torque.
17-39
Pour the specified amount of recommended fork fluid.
RECOMMENDED FORK FLUID: j

Fork Fluid (viscosity: 1OW) J
FORK FLUID CAPACITY:
664 ± 2.5 cm 3 (22.5 ± 0.1 US oz, 23.4 ± 0.1 Imp oz)
Tighten the fork damper lock nut [1) fully.
[1]
•
j
•
I
I
;,
Bleed the air from the fork as follows: I
1. Extend the fork, cover the top of the outer pipe [1) [1 ] f
with your hand and compress the fork slowly. }
2. Remove your hand and extend the fork slowly. J
Repeat above procedure 2 or 3 times.
3. Install the special tool to the fork damper rod [2).
TOOL:
Damper rod holder [3] 070MF-MBZC120 or
070MF-MBZA 120
(U.S.A. only)
Pump the fork damper rod slowly 8 - 10 times.
I
I
Slowly push the outer pipe [1). and gently seat the dust
l
[1]
seal [2) onto the axle holder [3] and leave it for 5
minutes.
FORK FLUID LEVEL:
[2]
f
f'
69 mm (2.7 in)
J
I
lI
[3]
17-40
Install the fork spring [1 J into the slide pipe with its
Up
tapered side facing up.
Install the spring collar [2] and spring seat stopper [3] .
,.
r
Attach the special tool to the spring collar holes [1] .
TOOL:
07AMC-MFJA100
(U.S.A. only)
While pulling the damper rod holder [3] up, compress
the spring collar [4] with the special tool.
TOOL:
07 AMB-KZ3A 100
(U.S.A. only)
Remove the damper rod holder.
Recheck the fork damper lock nut [1] is tightened fully.
[3)
Apply fork fluid to a new 0-ring [2] and install it to the
fork bolt [3].
Install the fork bolt to the fork damper [4] until it is fully
se~ed . ~]
[1]
TOOLS: [3]
TORQUE:
Actual : 20 N·m (2.0 kgf·m, 15 lbMt)
Indicated: 18 N·m (1.8 kgf·m, 13 lbMt)
NOTE:
• Tighten the fork damper lock nut with the specified
torque by tightening the fork bolt [4] while holding
the fork damper lock nut.
17-41
holder [2].
Remove the stopper plate [3].
NOTE:
• Be sure to insert the fork bolt [4] to the spring seat
stopper [5].
Remove the spring collar holder.

(2) (2)
Install the 0-ring [1] to the fork bolt [2] .
Install the fork bolt using the special tools.
TOOLS:
Fork bolt wrench [3]
I
j
Lock nut wrench, 50 mm [4]

070MA-MKS0100
07WMA-KZ30100
t.
l
NOTE: j
steering stem.
Clean the suspension solenoid whole surface.

NOTE:
• Do not wipe with a cloth after cleaning. Let it
naturally dry. (2)
J
Apply fork fluid to a new 0-ring. (2)
Install the 0 -ring [1] to the plug bolt [2] .
(3) (4)
Install the grommet [3] to the plug bolt.
Assemble the plug bolt, collar [4], and solenoid valve (4) (5)
[5].
NOTE:
• Align the solenoid valve tabs with the plug bolt and Align
collar grooves.
Install the solenoid valve assembly to the outer collar
[6].
Install the 0 -ring [1] and suspension solenoid [2].
$II (1)
C
'
].
17-42
l
Tighten the suspension solenoid [1] using the special
tools to the specified torque .
TOOLS: [2)
Pin type wrench [2] 070MA-MKS0200
TORQUE: 15 N·m (1.5 kgf·m, 11 lbHt) [1)
NOTE:
Pump the fork [1] several times to bleed the air.
RIGHT (Stroke sensor side)

NOTE:
• Before assembly, wash all parts with a high flash
point or non-flammable solvent and blow them dry.
OUTER PIPE
SLIDE PIPE
J
~0-RING
etl
SLIDER
/
BUSHING
/GUIDE
I
f5f/ ~USHING
~ BACK-UP
~ RING
~ >stl
; ~OILSE~
STOPPER
RING 90 N·m
(9.2 kgf-m , 66 lbf·ft)
DUST SEAL
LJ
et I INNER ROD
FORK SPRING
17-43
"f
Wrap the edge and groove of the slide pipe [1] with tape
[2]. [2]
,.l
Install the dust seal [3] onto the slide pipe.
/ ;
l
;'

'
J
[4] [5] [6]
pipe [3].
NOTE:
[7]
1l
the axle holder.
Remove the tape from the slide pipe. I
Install the back-up ring [4] , guide bushing [5] onto the
[2]
1'
slide pipe. j
Install the slider bushing [6] onto the slide pipe if it is
removed . lfl [3] j
NOTE:
• Remove any burrs from the bushing mating surface ,
.'
J

necessary.
Install the slide pipe into the outer pipe [7] .
Drive the oil seal [1] with the guide bushing [2] and
-'
groove [4] is visible using the special tool.
TOOL:
07KMD-KZ301 OA
{U.S.A. only)
•
j
l
Install the stopper ring [1] into the groove securely.
NOTE: t
• Do not scratch the slide pipe surface .
Install the dust seal [2].
17-44
Pour the specified amount of recommended fork fluid .
RECOMMENDED FORK FLUID:

Fork Fluid (viscosity: 10W)
' FORK FLUID CAPACITY:

637 ± 2.5 cm3 (21.5 ± 0.1 US oz, 22.4 ± 0.1 Imp oz)
Slowly push the outer pipe [1], and gently seat the dust
seal [2) onto the axle holder [3) and leave it for 5
minutes.
FORK FLUID LEVEL:
139 mm (5.5 in)
Install the inner rod [1 ).

Pump the inner rod slowly several times to bleed the
air.
Install the fork spring [2) with its tapered side facing up.
Install the fork bolt [1).

Tighten the inner fork bolt [2) using the special tool to
TOOL:
Rod guide wrench [3] 070MB-MKS0100
TORQUE:
Actual: 90 N·m (9.2 kgf·m, 66 lbf·ft)
Indicated: 82 N·m (8.4 kgf·m, 60 lbf·ft)
17-45
J
j
Install the 0-ring [1 ] to the fork bolt [2]. 7
4
Install and tighten the fork bolt using the special tools. I
TOOLS:
NOTE: 1
I
• Be careful not to damage the fork bolt. J
steering stem. l
'
INSTALLATION
Install the forks [1] through the bottom bridge and top
bridge.
NOTE :
• Align the end of the outer pipe with the top bridge
upper surface.
Tighten the bottom bridge pinch bolts [2] to the
specified torque.
Conventional If the fork bolt [1] is loosened, tighten it to the specified

suspension model: torque .

,, I
NOTE:
Tighten the top bridge pinch bolts [2] to the specified
torque.
Electronic If the fork bolt [1] is loosened, tighten it using the special
suspension model: tools to the specified torque.
TOOLS:
TORQUE:
Actual: 35 N·m (3.6 kgf·m, 26 lbf·ft)
Indicated: 32 N·m (3.3 kgf·m, 24 lbf·ft)
NOTE:
Tighten the top bridge pinch bolts [4] to the specified
torque.
17-46
Electronic Connect the following :
suspension model: - Front suspension solenoid 2P connector [1]
- Front suspension stroke sensor connector [2]
Install the wire clamps [3] .
Install the front wheel speed sensor [1] and a new bolt
[2] .
Front wheel (page 17-20)
- Front fender (page 2-23)
STEERING STEM
REMOVAL
Remove the handlebar lower holder (page 17-14 ).
Electronic Disconnect the following connectors (page 17-22):
suspension model:
- Front suspension solenoid 2P connector
- Front suspension stroke sensor connector
Disconnect the ignition switch 2P (Brown) connector [1] .

Remove the socket bolt [2] and stay [3] .
Release the ignition switch wire clip [4] from the stay.
17-47
Release the left handlebar switch wire clip [1].
Release the left grip heater 2P connector [2] from the
stay.
Conventional Remove the wire clamp [3].
suspension model:
Release the right handlebar switch wire clip [1] .

MT model: Release the clutch cable [2] from the cable guide.
OCT model: Release the parking brake cable [2] from the cable
guide.
Remove the steering stem nut [1] and washer [2] .

Remove the forks (page 17-22).
Remove the top bridge [3].
Remove the bolt [1] and brake hose clamp [2] .
17-48
Loosen and remove the steering stem adjusting nut [1]
using the special tool.
TOOL:
Steering stem socket [2] 07916-KA50100

- Upper dust seal [1]
- Upper inner race [2]
- Upper bearing [3]
- Steering stem [4]
Lower bearing [5]
BEARING REPLACEMENT
NOTE:
• Replace the bearing , outer race, and inner race as a
set.
Remove the upper outer race using a special tools.
TOOLS:
Adjustable bearing puller, 07 JAC-PH80100 or
20-40 mm [1]
Bearing remover shaft [2] 07 JAC-PH80200
Remover weight [3] 07741-0010201
U.S.A. TOOLS:
Adjustable bearing puller, 07736-A010008 with
25-40mm 07YAC-001 A200
Remover weight 07936-371020A
Bearing remover shaft Commercially
available 3/8 x 16 in.
slide hammer
Remove the lower outer race using the special tool and
suitable shaft.
TOOL:
Bearing remover [1] 07946-3710500
17-49
Temporarily install the steering stem nut [1] onto the
steering stem [2] to prevent the threads from being [2]
damaged when removing the lower inner race [3] from
the steering stem.
Remove the lower inner race with a chisel or equivalent
tools, being careful not to damage the steering stem.
Remove the lower dust seal [4].
Apply specified grease to a new lower dust seal lips

(page 1-25).
Install the lower dust seal [1] to the steering stem [2].
Install a new lower inner race [3] using a hydraulic
press and special tool.
TOOL:
Inner driver, 30 x 36 x 300 L [4] 07946-MBOOOOO
J
Drive in a new upper outer race [1] using the special
tools.
'
J
TOOLS:
Driver [2] 07749-0010000
Attachment, 42 x 47 mm [3] 07746-0010300
Drive in a new lower outer race [1] using the special

tools.
TOOLS:
Driver [2] 07749-0010000
Attachment, 52 x 55 mm [3] 07746-0010400
J
17-50
INSTALLATION
...~ . , : BEARINGS, BEARING RACES, DUST SEALS
LOWER OUTER RACE ~ \
LOWER B E A R I N G ~
l-- ~ ;TEmNGSTEM
ADJUSTING NUT
I ~ UPPER DUST
LOWER INNER RACE ~ , :::~R INNER
~ RACE
LOWER DUST SEAL / . L
UPPER BEARING
UPPER OUTER RACE
BRAKE HOSE CLAMP

STEERING STEM
Apply specified grease (page 1-25) to the upper and

lower bearings and bearing races.
- Lower bearing [1]
- Steering stem [2]
- Upper bearing [3]
- Upper inner race [4]
- Upper dust seal [5]
Apply 0.10 - 0.30 g (0.004 - 0.011 oz) of urea based

multi-purpose extreme pressure grease NLGI #2
(EXCELITE EP2 manufactured by KYODO YUSHI CO.,
LTD. or equivalent) to the steering stem adjusting nut
[1] threads.
Tighten the adjusting nut to the initial torque by holding
the steering stem.
TOOL:
17-51
Move the steering stem [1] right and left, lock-to-lock,
five times to seat the bearings.
Retighten the steering stem adjusting nut [1] to the

specified torque using a special tool.
TOOL:

Recheck that the steering stem moves smoothly without
play or binding .
Install the brake hose clamp [1] and bolt [2] and tighten
the bolt securely.
Install the top bridge [1] .

Install the washer [2] and steering stem nut [3] , but do
not tighten it yet.
Temporarily install the forks [4].
Tighten the steering stem nut to the specified torque.
Turn the steering stem left and right, lock-to-lock
several times to make sure the steering stem moves
smoothly without play or binding .
17-52
Install the right handlebar switch wire clip [1]
MT model: Install the clutch cable [2] into the cable guide.
OCT model: Install the parking brake cable [2] into the cable guide.
Install the left handlebar switch wire clip [1 ].

Install the left grip heater 2P connector [2].
Conventional Install the wire clamp [3].
suspension model:
Install the ignition switch wire clip [1] to the stay [2].
Install the stay and socket bolt [3].
NOTE:
• Align the stay tab with the frame hole.
Tighten the socket bolt securely.
Connect the ignition switch 2P (Brown) connector [1] .

Electronic Connect the following connectors (page 17-46):
suspension model:
- Front suspension solenoid 2P connector
- Front suspension stroke sensor connector
Forks (page 17-46)
Handlebar lower holder (page 17-14)
17-53
MEMO
18. REAR WHEEUSUSPENSION
SERVICE INFORMATION· ..................... 18-2 SHOCK ABSORBER··························· 18-11
TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · 18-4 CUSHION LINKAGE···························· 18-19
COMPONENT LOCATION············· ········ 18-5 SWINGARM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 18-24
REAR WHEEL····································· 18-6
18-1
REAR WHEEL/SUSPENSION
SERVICE INFORMATION
GENERAL
• When servicing the rear wheel and suspension , support the motorcycle using a safety stand or hoist.
• A contam inated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
• After the rear wheel installation, check the brake operation by applying the brake pedal.
• Use Honda Genuine replacement bolts and nuts for all suspension pivot and mounting point.
• For brake system information (page 19-2)
• For wheel balance inspection (page 17-16)
• For driven sprocket inspection (page 3-19)
• For electronic suspension troubleshooting (page 22-85)
TOOLS
Driver Attachment, 22 x 24 mm Pilot, 20 mm
07749-0010000 0 7746-001 0800 077 46-0040500
® -
,
or 07746-001A800 (U .S.A. only)

Bearing remover head , 20 mm Bearing remover shaft Attachment, 42 x 4 7 mm
077 46-0050600 07GGD-0010100 07746-0010300
Attachment, 28 x 30 mm Attachment, 52 x 55 mm Pin type wrench

07946-1870100 077 46-0010400 070MA-MKS0200
18-2
Remover weight Remover handle Bearing remover set, 17 mm
07741 -0010201 07936-3710100 07936-3710300
or 07936-371020A (U .S.A. only)

Bearing remover set, 20 mm Driver, 15 x 280L Pilot, 17 mm
07936-3710600 07949-3710001 07746-0040400
Attachment, 32 x 35 mm Pilot, 32 mm Pilot, 25 mm

07746-0010100 07MAD-PR90200 07746-0040600
®
.
-
/
Pilot, 22 mm
07746-0041000
18-3
TROUBLESHOOTING
Steers to one side or does not track straight
• Drive chain adjusters not adjusted equally
• Bent axle
• Bent frame
• Worn swingarm pivot components
Rear wheel wobbling
Bent rim
Unbalanced tire and wheel
Faulty tire
Worn wheel bearings
Worn driven flange bearings
Insufficient tire pressure
Damaged suspension or swingarm pivot bearings
Wheel nut not tightened properly
Bent frame or swingarm
Bent spoke
Wheel turns hard
• Faulty wheel bearings
• Faulty driven flange bearings
• Bent axle
• Brake drag (page 19-2)
• Drive chain too tight (page 3-18)
Soft suspension
• Improper shock absorber spring preload
• Incorrect suspension adjustment
• Weak shock absorber spring
• Oil leakage from damper unit
• Faulty tire
Stiff suspension
Incorrect suspension adjustment
Bent damper rod
Damaged bushing
Damaged shock absorber or swingarm pivot bearing
Improperly tightened swingarm pivot
Bent swingarm pivot or frame
Tire pressure too high
Faulty suspension linkage
Rear suspension noisy
• Loose suspension fasteners
• Worn shock absorber mount bushings
• Faulty shock absorber
18-4
COMPONENT LOCATION
CRF1100D4 shown:
80 N·m (8.2 kgf·m, 59 lbf·ft)
54 N·m (5.5 kgf·m, 40 lbf·ft)
1.2 N·m (0.1 kgf·m , 0.9 lbf-ft)
44 N·m (4.5 kgf·m, 32 lbf·ft)
~ 100 N·m (10.2 kgf·m, 74 lbf-ft)
~
~~
54 N·m (5.5 kgf-m , 40 lbf-ft)
18-5
REAR WHEEL
REMOVAL
Push the rear wheel forward .
Derail the drive chain [1) from the driven sprocket.
Remove the rear axle nut [2), washer [3) and right
adjusting plate [4).
Remove the rear axle [5], left adjusting plate [6) and
rear wheel.
NOTE:
• Do not suspend the rear brake caliper assembly
from the brake hose. Do not twist the brake hose.
• Do not operate the brake pedal after removing the
rear wheel.
NOTE:
OCT model: Do not operate the parking brake lever after
removing the rear wheel.
Remove the side collars [1).
INSPECTION
Turn the inner race of each wheel bearing with your
finger.
The wheel bearings should turn smoothly and quietly.
Also check that the outer race fits tightly in the wheel
hub.
deformation or bends.
- Rear axle
- Rearwheel
Measure each part according to REAR WHEEL/
SUSPENSION SPECIFICATIONS (page 1-11).
Refer to the wheel balance service (page 17-16).
18-6
CRF1100A/D
DRIVEN FLANGE DAMPER RUBBERS
DRIVEN
SPROCKET~~~~~--•
-~
......
PULSER RING BOLTS
J
~
,t
, / .:
DRIVEN SPROCKET NUTS
•
100 N·m (10 .2 kgf·m, 74 lbf·ft)

REAR WHEEL
DISTANCE COLLAR B
. ,,-
j/ ~ /
I
...
/
. ..
t
{
r
I
I
. \$1 PULSER RING
BRAKE DISC BOLTS

42 N·m (4.3 kgf-m , 31 lbf·ft)
'
.,
LEFT WHEEL
BEARING 6204 (UU) DISTANCE COLLAR
RIGHT WHEEL
DUST SEAL :11 -~
BEARING 6204 (UU)
NOTE:
• Install the driven sprocket on the driven flange with
the stamped mark facing out.
• Install the rear wheel dust seal until it is flush with
the wheel hub surface.
• Install the driven flange dust seal until it is flush with
the driven flange surface.
• Align the arrow mark on the rear brake disc with the
rotating direction of the rear wheel.
assemble them as follows: 5.2- 7.2 mm
(0 .20 - 0.28 in)
[1]
Adjust the hub position so the distance from the hub left
end surface to the side of the rim is specified range as
shown.
Tighten the spokes to the specified torque in a [2]
crisscross pattern in two of three steps.
18-7
CRF1100A4/D4
REAR WHEEL
DISTANCE COLLAR B
DRIVEN SPROCKET
-~
.__..
PULSER RING BOLTS
/
DRIVEN SPROCKET NUTS
100 N·m (10.2 kgf-m , 74 lbMt)
~
LEFT WHEEL
BEARING 6204 (UU)
0-RING
-~ _-fiiiiw
"liiiil'
S
~
-~-~
DUST SEAL
.__..
RIGHT WHEEL
BEARING 6204 (UU)
DISTANCE COLLAR
NOTE:
• For tire valve service (page 17-19)
• Install the driven sprocket on the driven flange with
the stamped mark facing out.
• Install the rear wheel dust seal until it is flush with
the wheel hub surface.
• Install the driven flange dust seal until it is flush with
the driven flange surface.
• Align the arrow mark on the rear brake disc with the
rotating direction of the rear wheel.
18-8
Measure the width of the rim to obtain the dimension B.
NOTE:
• When measurement, except 80 mm (3.1 in) from
welded area of the rim.
Perform the following calculation to obtain the
dimension A. [1]
75.5 mm (2.97 in) - 8/2 = A

NOTE:
• Always replace the spokes with new ones.
Adjust the hub position so the distance from the hub
right end surface to the side of the rim is A ± 1.0 mm (A
± 0.04 in) as shown.
crisscross pattern in two or three steps.
, TORQUE: 5.0 N·m (0.5 kgf·m, 3.7 lbf-ft)
NOTE:
• Tighten the spokes with a ball point wrench .
WHEEL BEARING REPLACEMENT

Drive the rear wheel distance collar B [1] out of the
driven flange bearing using the special tools.
TOOLS:
Driver [2] 07749-0010000 [2]
Attachment, 22 x 24 mm [3] 07746-0010800 or
07746-001 ASOO
(U.S.A. only) [5]
Pilot, 20 mm [4] 07746-0040500
Drive the driven flange bearing [5] out.
Install the bearing remover head [1] into the wheel

bearing.
From the opposite side, install the bearing remover
shaft [2] and drive the wheel bearing out of the wheel
hub.
TOOLS:
Bearing remover head, 20 mm 07746-0050600
Bearing remover shaft 07GGD-0010100
Remove the distance collar and drive the other wheel

bearing out.
18-9
Drive in a new right wheel bearing [1] squarely until it is
fully seated.
TOOLS:
Driver [2] 07749-0010000
Attachment, 42 x 47 mm [3] 07746-0010300
Pilot, 20 mm [4] 07746-0040500
NOTE:
• Replace the driven flange and wheel bearings as a
set.
Install the distance collar.
Drive in a new left wheel bearing squarely until it is ._....,.,,.,,.,i,,Cl!lr.t '
seated on the distance collar.
Drive in the rear wheel distance collar B [1] to a new
driven flange bearing [2].
TOOLS:
[3]
Driver [3] 07749-0010000
Attachment, 28 x 30 mm [4] 07946-1870100
Pilot, 20 mm [5] 07746-0040500
[4]
NOTE:
• Replace the driven flange and wheel bearings as a
set.
• Do not reuse old bearing.
Drive in the driven flange bearing/rear wheel distance

collar B [1] squarely with the rear wheel distance collar
B side facing down until it is fully seated.
[2]
TOOLS:
Driver [2] 07749-0010000
Attachment, 52 x 55 mm [3] 07746-0010400 [3]
Pilot, 20 mm [4] 07746-0040500
INSTALLATION
Install the rear brake caliper assembly [1] to the
swingarm.
NOTE:
Align the caliper bracket groove with swingarm
guide.
I
I
'
18-10
Install the side collars [1].
Apply a thin coat of grease to the rear axle outer

surface.
Install the rear wheel in the swingarm.
NOTE:
• Install the brake disc between the brake pads.
• Be careful not to damage the brake pads.
Install the drive chain [1] over the driven sprocket.
Install the left adjusting plate [2] and rear axle [3] from
the left side.
Install the right adjusting plate [4], washer [5] and rear
axle nut [6].
Adjust the drive chain slack (page 3-18).
Check the clearance gap between the rear wheel speed
sensor bracket and pulser ring (page 20-26).
SHOCK ABSORBER
CONVENTIONAL SUSPENSION
MODEL
REMOVAUINSTALLATION
Remove the rear cushion connecting rod nut [1] and
rear cushion connecting rod bolt [2].
Remove the shock absorber lower nut [3] and shock
absorber lower bolt [4].
18-11
Remove the shock absorber upper nut [1] and shock
absorber upper bolt [2].
Remove the shock absorber [1] downward.

NOTE:
• Lift the swingarm [2] and remove the shock absorber
while turning it.
TORQUE:
Shock absorber upper nut:
54 N·m (5.5 kgf·m, 40 lbf-ft)
Shock absorber lower nut:
44 N·m (4.5 kgf·m, 32 lbf·ft)
Rear cushion connecting rod nut:
54 N·m (5.5 kgf·m, 40 lbf·ft)
NOTE:
• Install the bolts from the left side.
INSPECTION
Visually inspect the shock absorber for wear or
[4)
damage.
Check the following : [3]
- Damper rod [1] for bends or damage
- Damper unit [2] for deformation or oil leaks
- Rubber bumper [3] for wear or damage
- Bushing [4] for wear or damage
Replace the shock absorber assembly if necessary.
18-12
ELECTRONIC SUSPENSION MODEL
REMOVAL
DCT model shown:
- Right heel guard (page 2-26)
- Front cross plate (page 7-8) [1]
and raise the rear wheel off the ground .
- Rear brake switch 4P (Black) connector [1]
- Rear wheel speed sensor 2P (Black) connector [2]
Release the rear brake switch wire [3] and rear wheel
speed sensor wire [4] from the guide [5].
Release the power box [6].
OCT model: Remove the DCT relay (7].
Disconnect the rear suspension pre-load motor 2P
connector [1].
Disconnect the rear suspension position sensor 3P
Disconnect the rear suspension solenoid 2P connector

[1 ].
Release the rear suspension solenoid wire clip [2] .
Remove the brake hose clamp screw [1] and brake

hose clamp [2] .
Remove the brake hose guide screws [3] and brake
hose guide [4] .
Remove the bolt [5] and brake hose clamp [6].
18-13
Remove the bolts [1] and washers [2].
Remove the rear suspension level adjuster (3] by
releasing its boss [4] from the grommet of the rear
suspension level adjuster bracket.
I
Release the rear suspension level adjuster hose [1] J
from the hose guide [2].
Remove the bolt [3] and brake hose guide (4]. '
J
- Rear master cylinder reservoir mounting bolts [5] J
- Rear master cylinder mounting bolts [6]
NOTE:
• Keep the rear master cylinder reservoir [7] and rear
master cylinder [8] upright to prevent air from
entering the hydraulic system.
Remove the rear brake switch spring [9] from the
middle arm (1 OJ.
•
I
I

J
rear cushion connecting rod bolt [2].
Remove the shock absorber lower nut [3] and shock j
absorber lower bolt [4]. I
lI
.
I
J
18-14
Remove the shock absorber upper nut [1] and shock
absorber upper bolt [2].
Remove the shock absorber.
,
REAR SUSPENSION LEVEL ADJUSTER BRACKET
REMOVAUINSTALLATION
Remove the rear shock absorber (page 18-13).
Remove the bolts [1] and rear suspension level adjuster
bracket [2].
Remove the following from the rear suspension level
adjuster bracket:
- Grommet [3]
- Collars [4]
- Special nuts [5]
INSPECTION
Visually inspect the shock absorber for wear or
damage.
Check the following:
- Damper rod [1] for bends or damage
- Damper unit [2] for deformation or oil leaks
- Rubber bumper [3] for wear or damage
- Bushing [4] for wear or damage
• - Rear suspension level adjuster [5] for leakage or
damage
- Rear suspension level adjuster hose [6] and fittings
[7] for loose connections, deterioration, cracks,
damage or signs of leakage
Replace the shock absorber assembly if necessary. [1]
18-15
SUSPENSION SOLENOID REPLACEMENT i
Remove the rear shock absorber (page 18-13).
Remove the suspension solenoid [1] from the rear
[1]
,
I
shock absorber [2] using special tool. •j

TOOL:
Pin type wrench 070MA-MKS0200
Remove the 0-ring [3] from the plug bolt [4] . l

;
1
Apply engine oil to a new 0-ring. J
Install the 0-ring to the plug bolt. [2] I
Install the suspension solenoid to the rear shock
absorber using special tool.
'
Tighten the suspension solenoid to the special torque.
Install the rear shock absorber (page 18-16).
INSTALLATION
J
Install the shock absorber.
I
NOTE: I
• Route the hose, wire, and cable properly (page 1- "

26).
Install the shock absorber upper bolt [1] from the left
side.
Install and tighten the shock absorber upper nut [2] to
I
I
Install the shock absorber lower bolt [3] from the left t
side. }
Install and tighten the shock absorber lower nut [4] to I
the specified torque .
Install the rear cushion connecting rod bolt [5] from the
left side.
Install and tighten the rear cushion connecting rod nut
;
~
l
II
)
J
J
l
I
J
18-16 I
Install the rear brake switch spring [1] to the middle arm
[2].
Install the rear master cylinder [3] and rear master
cylinder mounting bolts [4] .
Tighten the rear master cylinder mounting bolts to the
specified torque .
Install the rear master cylinder reservoir [5] and rear
, master cylinder reservoir mounting bolt [6] .
Tighten the rear master cylinder reservoir mounting bolt
Install the brake hose guide [7] and bolt [8].
Install the rear suspension level adjuster hose [9] to the
hose guide [10].
Install the rear suspension level adjuster [1] to the rear

suspension level adjuster bracket.
NOTE:
• Align the rear suspension level adjuster boss [2] with
the grommet of the rear suspension level adjuster
bracket.
Install the washers [3] and bolts [4].
Tighten the bolts securely.
Install the brake hose clamp [1] and bolt [2].

Install the brake hose guide [3] and new brake hose
guide screws [4].
Tighten the brake hose guide screws to the specified
torque .
Install the brake hose clamp [5] and new brake hose
clamp screw [6].
Tighten the brake hose clamp screw to the specified
torque .
NOTE:
26).
18-17
Install the rear suspension solenoid wire clip [1].
Connect the rear suspension solenoid 2P connector [2].
;
•
I
I
Connect the rear suspension pre-load motor 2P i---::::;::.~~ -~Y-- --:i

connector [1] .
Connect the rear suspension position sensor 3P (Gray)
I
connector [2].
1
i
I
J
I

-
-
Rear brake switch 4P (Black) connector [1]
Rear wheel speed sensor 2P (Black) connector [2]
l
I
l
Install the rear brake switch wire [3] and rear wheel
speed sensor wire [4] to the guide [5] .
JI
Install the power box [6].
OCT model: Install the DCT relay [7].
- Front cross plate (page 7-8)
- Right heel guard (page 2-26)
.
'
•
I
I
f
1
I
I
I
I
tj
I
l
•
t
18-18
'
DISPOSAL
ACAUTION
• Do not use a long-running drill bits which could
cause a buildup of excessive heat and pressure
inside the damper, leading to an explosion and
severe injury.
• The shock absorber contains nitrogen gas and
oil under high pressure. Do not drill any further
down the damper case than the measurement
given below, or you may drill into the oil
chamber. Then high pressure oil may cause
, serious injury.
• Always wear eye protection to avoid getting
metal shavings in your eyes when the gas
pressure is released . The plastic bag is only
intended to shield you from the escaping gas.
Mark the center of the damper case at the point from

the center of the upper eyelet is 35 mm (1.4 in) and drill
the damper case at the marked point.
Wrap the shock absorber inside a plastic bag and
. support it upright in a vise as shown .
Drill 3 mm hole at the marked point using a drill motor
'~ while the air is freed suitably so that the plastic bag
does not explode.
CUSHION LINKAGE
REMOVAL
Remove the left main step bracket (page 2-27).
If you plan to disassemble cushion linkage, loosen the
rear cushion connecting rod nut [1] .
- Front cushion connecting rod bolt (2]
- Front cushion connecting rod nut [3]
- Shock absorber lower bolt [4]
- Shock absorber lower nut (5]
- Cushion arm bolt [6]
Cushion arm nut [7]
- Cushion arm/connecting rod assembly (8]
DISASSEMBLY
rear cushion connecting rod bolt [2]. [4]
Disassemble the cushion arm [3] and cushion

connecting rod [4].
[1]
[3]
18-19
Remove the collars [1] and dust seals [2] from the
cushion arm [3] .
[1]
Remove the collar [1] from the cushion connecting rod

[2].
[2]
~ [1]
INSPECTION
Check the needle bearing for wear or damage or loose
fit, and replace it if necessary.
Inspect the following parts for cracks, damage,
abnormal wear, deformation or bend and replace if
necessary.
- Cushion arm
- Cushion connecting rod
- Collars
18-20
BEARING REPLACEMENT
CUSHION ARM
Remove the needle bearings (17 x 24 x 30 mm) [1]
[2] [4]
TOOLS:
Remover weight (2] 07741-0010201 or
07936-371020A
(U.S.A. only)
Remover handle [3] 07936-3710100
Bearing remover set, 17 mm [4] 07936-3710300
TOOLS:
07936-371020A
(U.S.A. only)
Remover handle 07936-3710100
Bearing remover set, 20 mm 07936-3710600
the special tools and hydraulic press.
TOOLS: [2]
Driver, 15 x 280L (2] 07949-3710001
07746-001 A800
(U.S.A. only)
[3]
18-21
Apply molybdenum disulfide grease to new needle
bearing rotating areas.
NOTE: (2)
• Do not reuse old bearings. I
Install the needle bearing (17 x 24 x 17 mm) [1] to the
specified range using the special tools and hydraulic / J
press as shown.
J
TOOLS:
Driver, 15 x 280L [2] 07949-3710001 ~ .
07746-001 A800
(U.S.A. only)
fl
- : : ::"S""! (5) J
Pilot, 17 mm [4] 07746-0040400
NOTE: Needle bearing Needle bearings

1
li
• Install the needle bearing with the marked side (1 7 x 24 x 17 mm): (20 x 26 x 20 mm):
facing outside.
Install the needle bearings (20 x 26 x 20 mm) [5] to the 5.8-6.2 mm 5.3-5.7 mm
(0.23 - 0.24 in) (0.21 - 0.22 in)
specified range using the special tools and hydraulic
press as shown. ,,
TOOLS: ~ ~
~~
i
Driver, 15 x 280L 07949-3710001 i
Attachment, 22 x 24 mm 07746-0010800 or 1
; I:
t
07746-001 A800
Pilot, 20 mm
NOTE:
(U.S.A. only)
07746-0040500
• Install the needle bearing with the marked side

I
[1 ) ~ . , l.
;
I
J
facing outside.
Install the needle bearings (17 x 24 x 30 mm) [6] until it I
is flush with the cushion arm surface using the special
tools and hydraulic press.
TOOLS:
'
Driver, 15 x 280L 07949-3710001
Attachment, 32 x 35 mm 07746-0010100
Pilot, 17 mm 07746-0040400
NOTE:
facing outside.
CUSHION CONNECTING ROD

TOOLS:
(3) (2)
lI
Bearing remover set, 17 mm [2] 07936-3710300
Remover weight [3] 07741-0010201 or
07936-371020A
(U.S.A. only)
Remover handle [4] 07936-3710100
~
i
J
18-22
'.
Apply molybdenum disulfide grease to new needle
bearing rotating areas.
NOTE:
Install the needle bearings (17 x 24 x 30 mm) [1] until it
is flush with the cushion arm surface using the special
tools and hydraulic press.
TOOLS:
Driver [2] 077 49-0010000
Attachment, 32 x 35 mm [3] 077 46-0010100
Pilot, 17 mm [4] 077 46-0040400
NOTE:
facing outside.
ASSEMBLY/INSTALLATION
Apply molybdenum disulfide grease to new dust seal
lips.
Install the dust seals [1] into the cushion arm [2] until
they are fully seated.
Install the collars [3] .
Install the collar [1] into the cushion connecting rod [2].
[2]
~ [1]
Assemble the cushion arm [1] and cushion connecting

rod [2] .
Install the rear cushion connecting rod bolt [3] and rear
cushion connecting rod nut [4].
NOTE:
• Assemble the cushion arm and cushion connecting
rod with "UP" mark [5] of the cushion connecting rod
facing up.
(4)
[1)
18-23
Install the cushion arm/connecting rod assembly [1] and
cushion arm bolt [2].
NOTE:
• Install the cushion arm bolt from the right side.
Install and tighten the cushion arm nut [3] to the
specified torque.
Install the shock absorber lower bolt [4] from the left
side.
Install and tighten the shock absorber lower nut [5] to
Apply engine oil to the front cushion connecting rod nut
Install the front cushion connecting rod bolt [6] from the
left side.
Install and tighten the front cushion connecting rod nut
If the cushion linkage is disassembled, tighten the rear
cushion connecting rod nut [8] to the specified torque.
Install the left main step bracket (page 2-27).
SWINGARM
REMOVAL
- Rear wheel (page 18-6)
Remove the socket bolts [1] and drive chain case [2].
Remove the brake hose clamp screw [1] and brake ~

hose clamp [2] . l
j
1
Remove the brake hose guide screws (3] and brake ~
hose guide [4].

18-24
Remove the cushion arm nut [1] and cushion arm bolt
[2].
Remove the swingarm pivot nut [1], swingarm pivot bolt

[2] and swingarm [3].
NOTE:
• Be careful not to damage the rear brake switch
spring.
18-25
;
DUST SEAL
NEEDLE BEARING
(24 x 31 x 28 mm) PIVOT COLLAR A / SNAP RING
\if/ et..-.
~BEARING6003
.,~ DUST SEAL
NEEDLE BEARING ~
/'
,-.
l' -~~
:;,T SEAL
LEFTPIVOT -
DISTANCE COLLAR .,
•f-llll
~
......
/ I
.,~
DUST SEAL
DRIVE CHAIN
ADJUSTING BOLT
~~
I
DRIVE CHAIN
ADJUSTING BOLT
~ WASHERSB
.,
LOCK NUT
DRIVE CHAIN GUARD BOLTS

10 N·m (1. 0 kgf·m, 7 lbf·ft)
DRIVE CHAIN SLIDER SCREWS
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
DRIVE CHAIN SLIDER SCREWS
4.2 N·m (0.4 kgf-m , 3.1 lbf·ft)
NOTE :
swingarm surface.
• Apply molybdenum disulfide grease to the dust seal
lips.
INSPECTION
or deformation and replace if necessary.
- Dust seals
- Pivot collars
- Swingarm
- Bearings
- Drive chain slider i'
J
J
l
~
18-26 J
PIVOT BEARING REPLACEMENT
Remove the snap ring [1] from the right pivot.
,'
1 [1]
•
Remove the ball bearing 6003 [1] out of the right pivot
using the special tools and hydraulic press.
TOOLS:
Driver, 15 x 280L [2] 07949-3710001
07746-001A800
(U.S.A. only)
Pilot, 17 mm [4] 07746-0040400
Remove the needle bearing (24 x 31 x 28 mm) [1] out of

the right pivot using the special tools and hydraulic
press.
TOOLS:
Driver [2] 07749-0010000
Attachment, 28 x 30 mm [3] 07946-1870100
Remove the needle bearing (1] out of the left pivot using
the special tools and hydraulic press.
TOOLS:
Driver, 15 x 280L (2] 07949-3710001
Pilot, 32 mm (3] 07MAD-PR90200
18-27
Apply molybdenum disulfide grease to a new needle
bearing rotating area.
Install the needle bearing [1] into the left pivot to the
5.0-5.5 mm
(0.20 - 0.22 in)
.
,;
I
specified range using the special tools and hydraulic

press as shown .
TOOLS:
,,
Driver [2] 07749-0010000 [4] ....
Attachment, 32 x 35 mm [3] 07746-0010100
Pilot, 25 mm [4] 077 46-0040600 [1]
NOTE:
facing up.
~ J
Apply molybdenum disulfide grease to a new needle

bearing (24 x 31 x 28 mm) rotating area.
Install the needle bearing (24 x 31 x 28 mm) [1] into the 4.5-5.0 mm ,
right pivot to the specified range using the special tools (0.18-0.20 in) f
and hydraulic press as shown. I
J
TOOLS: I
Driver, 15 x 280L [2]
Attachment, 28 x 30 mm [3]
07949-3710001
07946-1870100
J
;
Pilot, 22 mm [4] 077 46-0041000
NOTE :
• Install the needle bearing with the marked side .I
facing up.
Apply grease to a new ball bearing 6003 rotating area .

j
J
Install the ball bearing 6003 [1] into the right pivot until it
is fully seated using the special tools and hydraulic
press. I
TOOLS: ';
Driver [2] 077 49-0010000
Attachment, 32 x 35 mm [3] 07746-0010100 J
Pilot, 17 mm [4] 077 46-0040400
NOTE:
• Install the ball bearing with the marked side facing
out.
II
)
Install the snap ring [1] into the right pivot groove
securely.
[1] j
NOTE:
• Do not reuse the snap ring which could easily spin in
the groove.
• Make sure that the snap ring is firmly seated in the
j.
groove. J
1
l
•I
.
I
p
18-28
INSTALLATION
Set the drive chain onto the swingarm .
Install the swingarm [1] to the frame .
NOTE:
• Be careful not to damage the rear brake switch
spring.
Install the swingarm pivot bolt [2] from the left side.
Apply engine oil to the swingarm pivot nut threads and
seating surface.
Install and tighten the swingarm pivot nut [3] to the
specified torque.
Install the cushion arm bolt [1] from the right side.
Install and tighten the cushion arm nut [2] to the
specified torque.
Install the brake hose clamp [1] and bolt [2].

Install the brake hose guide [3] and new brake hose
guide screws [4].
Tighten the brake hose guide screws to the specified
torque .
Install the brake hose clamp (5] and new brake hose
clamp screw [6].
Tighten the brake hose clamp screw to the specified
torque .
NOTE:
26).
Install the drive chain case [1] and socket bolts [2] .
l Tighten the bolt securely.
"' Install the following:
;
- Rear wheel (page 18-10)
18-29
MEMO
19. HYDRAULIC BRAKE
,
SERVICE INFORMATION··· .. ················· 19-2 REAR BRAKE PEDAL························· 19-16
TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · 19-2 REAR MASTER CYLINDER .................. 19-17
COMPONENT LOCATION····················· 19-3 FRONT BRAKE CALIPER···················· 19-19
BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER·· .. ·············· .. ·· 19-21

AIR BLEEDING · · · · .. · .. · · · · .. · .. · .. · .. · .. · .... · · · 19-6
PARKING BRAKE LEVER
BRAKE PAD/DISC ............................... 19-8 (OCT model} · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19-23
FRONT MASTER CYLINDER ................ 19-13 PARKING BRAKE CALIPER

(OCT model} · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19-25
..
19-1
HYDRAULIC BRAKE
SERVICE INFORMATION
GENERAL
ACAUTION
Frequent inhalation of brake pad dust, regardless of material composition , could be hazardous to your health .
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
NOTICE
Spilling brake fluid will severely damage instrument lenses and painted surface. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
• Check the brake system by applying the brake lever or pedal after the air bleeding .
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled .
• Always use fresh Honda DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid
as they may not be compatible .
• Always check brake operation before riding the motorcycle.
• This section covers service of the conventional brake components of the brake system . For Anti-lock Brake System (ABS)
service (page 20-2).
TROUBLESHOOTING
Brake lever/pedal soft or spongy
• Air in hydraulic system
• Low brake fluid level
• Leaking hydraulic system
• Clogged fluid passage
• Contaminated brake pad/disc
• Worn caliper piston seals
• Worn master cylinder piston cups
• Worn brake pad/disc
• Contaminated caliper
• Caliper not sliding properly
• Warped/deformed brake disc
• Sticking/worn caliper piston
• Sticking/worn master piston
• Contaminated master cylinder
• Bent brake lever/pedal
Brake lever/pedal hard
Clogged/restricted hydraulic system
Sticking/worn caliper piston
Caliper not sliding properly
Clogged/restricted fluid passage
Worn caliper piston seal
Sticking/worn master piston
Bent brake lever/pedal
Brake drag
• Contaminated brake pad/disc
• Misaligned wheel
• Clogged/restricted brake hose joint
• Warped/deformed brake disc
• Caliper not sliding properly
• Clogged/restricted brake hydraulic system
• Sticking/worn caliper piston
• Clogged master cylinder port
19-2
HYDRAULIC BRAKE
COMPONENT LOCATION
FRONT
CRF1100A4/D4 shown :
34N·m
(3.5 kgf·m , 25 lbf-ft)
Right side shown :
34 N·m
(3.5 kgf·m , 25 lbf-ft)
45N ·m
(4.6 kgf-m , 33 lbf-ft)
19-3
HYDRAULIC BRAKE
REAR ..'
l
'
; 34 N·m
(3 .5 kgf·m , 25 lbf-ft)
!('),'
14 N·m
(1.4 kgf-m , 10 lbf-ft)
•
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f
J
J
J
22 N·m
(2 .2 kgf·m, 16 lbf-ft)
J
I
!
'I
19-4
j
HYDRAULIC BRAKE
DCT model:
9.0 N·m
(0.9 kgf·m , 6.6 lbf-ft)
19-5
HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
Front brake: Turn the handlebar until the reservoir is parallel to the
ground .
- Front master cylinder reservoir cap screws [1]
- Reservoir cap [2]
- Set plate [3]
- Diaphragm [4]
Rear brake: Support the motorcycle in an upright position.

bolt [1] .
Release the rear master cylinder reservoir [2] .
- Rear master cylinder reservoir cap screws [3]
-
Reservoir cap [4]
Set plate [5]
Diaphragm [6]
.
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J
Temporarily install the rear master cylinder reservoir

and rear master cylinder reservoir mounting bolt.
Connect a bleed hose to the bleed valve [1] .

Loosen the bleed valve and pump the brake lever/pedal
until no more fluid flows out of the bleed valve.
Tighten the bleed valve.
l
~
19-6
HYDRAULIC BRAKE
BRAKE FLUID FILLING/AIR BLEEDING
Fill the reservoir with Honda DOT 4 brake fluid to the
upper level line [1] from a sealed container.
Connect a commercially available brake bleeder to the
bleed valve [2].
Operate the brake bleeder and loosen the bleed valve.
If an automatic refill system is not used, add fluid when
the fluid level in the reservoir is low.
NOTE:
• Check the fluid level often while bleeding the brake
to prevent air from being pumped into the system.
• When using a brake bleeding tool, follow the
manufacturer's operating instructions.
Perform the bleeding procedure until the system is
completely flushed/bled.
NOTE:
• If air enters the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
Close the bleed valve and operate the brake lever/
pedal. If it still feels spongy, bleed the system again.
After bleeding the system completely, tighten the bleed
valve to the specified torque.
upper level line from a sealed container.
If the brake bleeder is not available, perform the

following procedure.
upper level line [1] from a sealed container.
Pump up the system pressure with the brake lever/
pedal until the lever/pedal resistance is felt.
Connect a bleed hose to the bleed valve [2].
1. Squeeze the brake lever/pedal all the way and
loosen the bleed valve 1/4 turn . Wait several
seconds and then close the bleed valve.
NOTE:
• Do not release the brake lever/pedal until the bleed
valve has been closed .
2. Release the brake lever/pedal slowly and wait
several seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding the system completely, tighten the bleed
valve to the specified torque.
upper level line from a sealed container.
19-7
HYDRAULIC BRAKE
Front brake: Install the following:
- Diaphragm [1 J
- Set plate [2)
- Reservoir cap [3)
- Front master cylinder reservoir cap screws [4]
Tighten the front master cylinder reservoir cap screws 'l
1
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J
[2] J
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[1] I
Rear brake: Remove the rear master cylinder reservoir mounting

bolt [1] and rear master cylinder reservoir [2] .
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1
I
- Diaphragm [3)
- Set plate [4] J
- Reservoir cap [5] I
- Rear master cylinder reservoir cap screws [6)
Tighten the rear master cylinder reservoir cap screws to
the specified torque .
•
Install the rear master cylinder reservoir and rear
master cylinder reservoir mounting bolt. ,!'
.
Tighten the rear master cylinder reservoir mounting bolt J
to the specified torque. ' - - - - - - -- ------------_J
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TORQUE: 10 N·m (1.0 kgf·m, 7 lbf-ft) J
)
BRAKE PAD/DISC
NOTE:
j'
I
• Always replace the brake pads in pairs to assure
even disc pressure.
• Check the brake fluid level in the master cylinder
reservoir as this operation causes the level to rise.
FRONT BRAKE PAD REPLACEMENT
Remove the front brake caliper mounting bolts [1) and _ _ _ _ _.._,__..:,Iii
front brake calipers [2].
NOTE :
• Do not operate the brake lever after removing the
front brake calipers.
19-8
HYDRAULIC BRAKE
f
Remove the brake pads (1).
Check the pad spring (2) and replace if necessary.
NOTE:
• Install the pad spring with its arrow marks (3) facing
up.
Install new brake pads.
NOTE:
• Align the pad lugs (4) with the caliper grooves [5].
• Make sure that the brake pads seat against the pad
spring.
r
!
Install the front brake calipers (1) and new front brake
caliper mounting bolts (2).
Tighten the front brake caliper mounting bolts to the
, specified torque.
r
Operate the brake lever to seat the caliper pistons
against the pads.
r
REAR BRAKE PAD REPLACEMENT
,
r Remove the brake pad pin [1] and rear brake caliper
mounting bolt [2].
Lift the rear brake caliper [3].
Remove the brake pads (4).
NOTE:
• Do not operate the brake pedal after removing the
brake pads.
19-9
HYDRAULIC BRAKE
Install new brake pads [1] .
NOTE:
• Make sure that the brake pad retainer [2] and pad
spring are installed to the rear brake caliper.
• Make sure that the brake pad ends seat against the
retainer.
Lower the rear brake caliper [3].
Loosely install a new rear brake caliper mounting bolt
[4] .
Check that the brake pad pin stopper ring [5] is in good
condition , and replace it if necessary.
Apply silicone grease to the brake pad pin stopper ring .
Install the brake pad pin [6] by pushing the brake pads.
NOTE:
• Align the brake pad pin holes of the brake pads and
caliper body.
Tighten the rear brake caliper mounting bolt [1) to the I
specified torque.

J
Tighten the brake pad pin [2) to the specified torque .
!
Operate the brake pedal to seat the caliper piston
against the pads.
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PARKING BRAKE PAD
REPLACEMENT (DCT model) '
REMOVAL
I
Remove the parking brake caliper cover bolts [1) and
parking brake caliper cover [2).
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19-10 •
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,,, Remove the drive chain guard bolts [1] and drive chain
guard [2] .
HYDRAULIC BRAKE
, - - - - - - ~ - - --ir;;;;;:::;::-,.
Loosen the parking brake pad pins [1].
Remove the parking brake caliper mounting bolts [1]

and parking brake caliper [2] .
Remove the parking brake pad pins [1] and parking

brake pads [2].
19-11
HYDRAULIC BRAKE
INSTALLATION
Install new parking brake pads [1].
NOTE:
• Make sure the pad spring is installed in position.
Install new parking brake pad pins [2] .
I,
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I
Install the parking brake caliper [1] and new parking

brake caliper mounting bolts [2] . IA ;\l \1.-:--·\ f
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Tighten the parking brake caliper mounting bolts to the
specified torque. 1
TORQUE: 30 N·m (3.1 kgf·m, 22 lbMt) r
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I•
Tighten the parking brake pad pins [1] to the specified
torque .
TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbMt)

'1
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Install the drive chain guard [1] and drive chain guard l
bolts [2] . s
1
Tighten the drive chain guard bolts to the specified
I
torque.
,,
J
J
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:
19-12
l
HYDRAULIC BRAKE
Install the parking brake caliper cover [1] and parking
brake caliper cover bolts [2].
Tighten the parking brake caliper cover bolts to the
specified torque.
Check the parking brake lock operation (page 3-23).
BRAKE DISC INSPECTION

Visually inspect the brake discs for damage or cracks.
Measure the brake disc according to HYDRAULIC
BRAKE SPECIFICATIONS (page 1-11) and replace if
necessary.
FRONT MASTER CYLINDER

Drain the brake fluid from the front brake hydraulic
system (page 19-6).
Remove the rearview mirror [1].

Remove the oil bolt [3], sealing washers [4] and brake
hose [5].
NOTE:
• When removing the oil bolt, cover the end of the
brake hose to prevent contamination.
• Avoid spilling fluid on painted, plastic, or rubber
parts.
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19-13
HYDRAULIC BRAKE
Remove the front master cylinder holder bolts [1],
holder [2], and front master cylinder [3].
l
•
TORQUE:
Front master cylinder holder bolt:
9.8 N·m (1.0 kgf·m, 7.2 lbMt)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft) f
NOTE:
I
• Align the end of the master cylinder with the
handlebar paint mark.
I
• Install the holder with the "UP" mark [4] facing up. J
• When tightening the front master cylinder holder
bolts, tighten the upper bolt first, then the lower bolt
to the specified torque .
• Always replace the sealing washers with new ones.
• Install the brake hose eyelet joint against the master
cylinder stopper.
Fill the reservoir to the upper level and bleed the front
brake system (page 19-7).
J
J
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J
J
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~
19-14
HYDRAULIC BRAKE
I SECONDARY C'UP \ I PRIMARY CUP
I MASTER P I S T O N ~ SPRING
FRONT MASTER
CYLINDER
~BOOT~ ~
SNAP RING
FRONT BRAKE LEVER FRONT BRAKE/

CRUISE CANCEL SWITCH
I
f ~ FRONT BRAKE SWITCH
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'
FRONT BRAKE LEVER PIVOT BOLT
1.0 N·m (0.1 kgf·m , 0.7 lbf·ft)
MOUNTING SCREW
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
[
I
l KNUCKLE GUARD HOLDER
I FRONT BRAKE LEVER PIVOT NUT

5.9 N·m (0.6 kgf-m , 4.4 lbf-ft)
t; NOTE:
I • Apply 0.10 g (0.004 oz) of silicone grease to the
I
following:
,
I
l - Front brake lever pivot bolts sliding surface
- Front brake lever-to-master piston contacting area
• Install the snap ring with the chamfered edge facing
' the thrust load side and be certain it is firmly seated
in the groove. Do not reuse the snap ring which
r could easily spin in the groove.

• Replace the piston and cups as a set.
• Do not allow the piston cup lips to turn inside out.
• Align the switch boss with the master cylinder hole
properly.
INSPECTION
Inspect the following parts for scoring, scratches,
deterioration, or damage.
- Front master cylinder
- Master piston
- Piston cups
- Spring
- Boot
Measure each part according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-11 ).
r'
l 19-15
HYDRAULIC BRAKE
REAR BRAKE PEDAL
..
I
REMOVAL/INSTALLATION ,.
Remove the right heel guard (page 2-26).
, , - ~ DUST SEALS
,,
COTIERPIN
+ Left
I
1
J
J
RETURN
SPRING
BRAKE PEDAL I
PINCH BOLT
J
MIDDLE ARM
fl ~ DUST SEAL
I
NOTE :
• Align the brake pedal slit with the middle arm punch
mark.
• Apply grease to the middle arm pivot sliding surface. 1
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19-16 j
HYDRAULIC BRAKE
f REAR MASTER CYLINDER

r,. REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic
system (page 19-6).
hose [3].
NOTE:
brake hose to prevent contamination.
• Avoid spilling fluid on painted , plastic, or rubber
parts.
r
Remove the cotter pin [1] and joint pin [2] .

Remove the rear master cylinder mounting bolts [3] and
rear master cylinder [4] .
TORQUE:
Rear master cylinder mounting bolt:
14 N·m (1.4 kgf·m, 10 lbHt)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbHt)
NOTE:
• Always replace the cotter pin and sealing washers
with new ones.
• Install the brake hose eyelet joint against the master
cylinder stopper.
Fill and bleed the rear brake hydraulic system (page 19-
7).
19-17
HYDRAULIC BRAKE
REAR MASTER CYLINDER

RESERVOIR
SPRING
.'
HOSE
I
PRIMARY CUP
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I
MASTER PISTON I
!
J
SECONDARY CUP j
~
REAR MASTER CYLINDER
I j
J
J
CONNECTOR SCREW
1.5 N·m (0 .2 kgf·m, 1.1 lbf·ft) '
J
REAR MASTER CYLINDER J

CONNECTOR i
PUSH ROD LOCK NUT
17.2 N·m (1.8 kgf-m , 13 lbf-ft)
REAR MASTER CYLINDER PUSH ROD JOINT
NOTE : I
l'
• Apply 0.10 g (0 .004 oz) of silicone grease to the
following :
- Rear master cylinder push rod sliding surface
- Rear master cylinder push rod boot fitting area
..
• Install the snap ring with the chamfered edge facing
the thrust load side and be certain it is firmly seated
in the groove. Do not reuse the snap ring which
could easily spin in the groove.
• Replace the piston , spring , and cup as a set.
• Do not allow the piston cup lips to turn inside out.
J
• Apply locking agent to the rear master cylinder J
connector screw threads (page 1-23).
If the push rod [1] , push rod lock nut [2] and push rod j
joint are disassembled , adjust the push rod length as
shown .
V.y1 J
NOTE:
• Make sure that the lower end of the push rod thread ~ [1)
is visible inside the joint.
After adjustment, tighten the push rod lock nut to the )
specified torque .
TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbf·ft)
73 .0 - 75.0 mm
(2.87 - 2.95 in )
i•
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19-18
J
HYDRAULIC BRAKE
INSPECTION
Check the following parts for scoring, scratches,
- Rear master cylinder
- Master piston
- Piston cups
- Spring
Boot
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-11 ).
FRONT BRAKE CALIPER

Drain the brake fluid from the front brake hydraulic _ __ _,....o.:-.rw.
system (page 19-6).
hose [3] .
NOTE:
brake hose to prevent contamination .
• Avoid spilling fluid on painted, plastic, or rubber
parts.
Remove the front brake caliper mounting bolts [4] and
front brake caliper [5] .
TORQUE:
L Front brake caliper mounting bolt:
45 N·m (4.6 kgf·m, 33 lbHt)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbHt)
NOTE:
• Always replace the front brake caliper mounting
bolts and sealing washers with new ones.
• Install the brake hose eyelet joint against the brake
caliper stopper.
7).
19-19
HYDRAULIC BRAKE
.,~
DUST SEAL A Ls FRONT BRAKE CALIPER
' ASSEMBLY TORX BOLTS
27 N·m (2.8 kgf·m, 20 lbf·ft)
I CALIPER
PISTONS A
(larger O.D.) PAD SPRING
BLEED VALVE
I CALIPER
PISTONS A
(larger O.D.)
PISTON SEAL B
etl
DUST SEAL B ..
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I CALIPER
PISTON B
(smaller O.D.)
J
PISTON SEAL B
I CALIPER
PISTON B
(smaller O.D.)
8'1
NOTE:
..
DUST SEAL B
~
I
J
'
• Be careful not to damage each piston.
J
• When removing the caliper pistons with compressed I
J
air, place a shop towel over the piston to prevent
damaging the piston and caliper body. Do not use
high pressure or bring the nozzle too close to the
fluid inlet.
• Mark the pistons to ensure correct reassembly.
• Be careful not to damage the piston sliding surface.
• Install each caliper piston in their proper locations.
- Piston A: larger O.D. J
- Piston B: smaller O.D.
19-20
r HYDRAULIC BRAKE
I INSPECTION
Check the following parts for scoring , scratches,
- Caliper cylinder of caliper bodies
- Caliper pistons
r Measure the parts according to HYDRAULIC BRAKE
~ SPECIFICATIONS (page 1-11 ).
REAR BRAKE CALIPER

Drain the brake fluid from the rear brake hydraulic
system (page 19-6).
hose [3].
NOTE:
• Avoid spilling fluid on painted , plastic, or rubber
parts.
Remove the brake pads (page 19-9).
Remove the rear brake caliper [4] by lifting and pulling
right.
TORQUE:
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)
NOTE:
• Always replace the sealing washers with new ones.
• Install the brake hose eyelet joint against the brake
caliper stopper.
7).
19-21
L
HYDRAULIC BRAKE
BRAKE PAD
RETAINER~
CALIPER BODY
,,..
REAR BRAKE CALIPER
PIN BOLT
27 N·m (2.8 kgf·m, 20 lbf·ft)
CALIPER
BRACKET
,,..
I CALIPER
PISTON
CALIPER SLEEVE
PAD SPRING
PISTON SEAL :111 SLEEVE BOOT
DUST SEAL ~ ,,..

NOTE:
• Be careful not to damage the piston .
• When removing the caliper piston with compressed
air, place a shop towel over the piston to prevent
damaging the piston and caliper body. Do not use
high pressure or bring the nozzle too close to the
fluid inlet.
• Be careful not to damage the piston sliding surface.
• Apply 0.4 g (0.01 oz) of silicone grease to the
following:
- Sleeve sliding area
- Rear brake caliper pin bolt sliding surface
• If the pad retainer is removed , apply ThreeBond
1521 or an equivalent to the retainer seating surface.
INSPECTION
Check the following parts for scoring , scratches,
deterioration, or damage. I
j
- Caliper cylinder of caliper body
- Caliper piston
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS and replace if necessary (page 1- l
j
11 ).
l
J
19-22
HYDRAULIC BRAKE
PARKING BRAKE LEVER (DCT model)

Remove the rearview mirror [1].
Disconnect the parking brake switch connectors [1] .
Remove the bolts [1], holder [2], and parking brake

lever assembly [3].
Loosen the lock nut [4] and disconnect the parking
brake cable by turning the adjuster bolt [5].
NOTE:
• Install the parking brake lever assembly by aligning
its end with the paint mark on the handlebar.
• Install the holder with its punch mark [6] facing up.
• Tighten the upper bolt first, then the lower bolt.
After installation, adjust the parking brake lock
operation (page 3-23).
19-23
HYDRAULIC BRAKE
PARKING BRAKE STOPPER STAY

HEX BOLT
2.3 N ·m (0.2 kgf·m , 1.7 lbf·ft)
ADJUSTER BOLT
----
STOPPER STA Y
PARKING BRAKE STOPPER STAY
FLANGE BOLT
11 .9 N·m (1 .2 kgf·m, 9 lbf·ft)
~
LOCK LEVER PIVOT BOLT
~ 6.9 N·m (0.7 kgf m, 5.1 lbfft)
-~
PARKING BRAKE LEVER
PIVOT BOLT
~ LOCK LEVER
1.0 N·m (0.1 kgf·m, 0.7 lbf-ft)
PLASTIC WASHER
~
RETURN SPRING
WELL NUT _____.t:)

PARKING BRAKE
LEVER
KNUCKLE GUARD
HOLDER
PARKING BRAKE LEVER

PIVOT NUT
5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)
~
PARKING BRAKE SWITCH
MOUNTING SCREW j
1.2 N ·m (0.1 kgf-m , 0.9 lbf·ft)
l
.
J
19-24
HYDRAULIC BRAKE
PARKING BRAKE CALIPER

(DCT model)
Remove the parking brake pads (page 19-10).
Release the cap boot (1] from the parking brake cable
[2].
Remove the parking brake cable from the cable stay [3] ,,
of the caliper body.
Disconnect the parking brake cable end from the brake
arm [4].
After installing, check the parking brake lock operation
(page 3-23).
DISASSEMBLY
Remove the parking brake caliper pin bolt [1].
[1)

[2] [1)
- Parking brake bracket [1]
- Pad spring [2]
- Bracket pin boot (3]
Caliper pin boots [4]
- Sleeve [5]
[3]
Remove the adjuster lock nut (1 ] while holding the

[1]
brake arm [2] .
Remove the brake arm. [3)
r Remove the brake shaft boot [3].
[2)
19-25
HYDRAULIC BRAKE
j
j
Remove the push rod [1] while holding the brake shaft
[2] .
Remove the brake shaft and push rod/piston assembly. f
j
I
I
Remove the dust seal [1] .

l
!
i
!
Clean the caliper cylinder of caliper body and brake i
shaft sliding surface.
i
1
!I
j
;
j
;
INSPECTION
Inspect the following parts for scoring , scratches, or
'
f
II
l
damage. I
l
- Caliper cylinder of caliper body ~
- Caliper piston
I
;
I
]
j
l
1
'I
'
1
19-26
HYDRAULIC BRAKE
ASSEMBLY
DUST SEAL
,risiaf
BRAKE SHAFT
CALIPER BODY
SLEEVE
ADJUSTER LOCK NUT

,risiaf
17.2 N·m (1 .8 kgf·m, 13 lbf·ft) CALIPER PIN BOOT
.C,. PARKING BRAKE CALIPER PIN BOLT

22 N·m (2.2 kgf·m, 16 lbf·ft)
Apply silicone grease to new dust seal lips.

Install the dust seal (1] into the seal groove in the
caliper body.
,,
,risiaf [1]
Apply 0.4 g minimum of silicone grease to the parking
brake shaft threads. [1] ,risiaf
Install the parking brake shaft [1] to the caliper body [2] .
Screw the parking brake shaft in completely.
[4)
NOTE:
• Make sure that the punch mark [3] of the brake shaft [3)
is positioned opposite the index line (4].
[2)
19-27
HYDRAULIC BRAKE
Apply 0.4 g minimum of silicone grease to the push rod
rolling surface and piston sliding surface.
Align the punch mark [1] with the index line [2] by
turning the brake shaft [3] clockwise.
Install the push rod [4] while holding the brake shaft.
Apply 0.4 g minimum of silicone grease to the brake

shaft boot lips. Align
~
Install the brake shaft boot [1] to the caliper groove. [2] [1]
Install the brake arm [2] by aligning the punch marks as
shown.
Install the adjuster lock nut [1].

Tighten the adjuster lock nut to the specified torque
while holding the brake arm [2].
TORQUE:17.2 N·m (1.8 kgf·m, 13 lbf·ft)
[2]
Apply 0.4 g minimum of silicone grease to the bracket

[4] [5]
pin boot and caliper pin boots insides.
- Bracket pin boot [1]
- Caliper pin boots [2]
-
-
Sleeve [3]
Pad spring [4]
~ >
- Parking brake bracket [5]
[1]
~
[2]~
19-28
HYDRAULIC BRAKE
Apply locking agent to the parking brake caliper pin bolt
threads.
Install and tighten the parking brake caliper pin bolt [1]
19-29
MEMO
)
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20. ANTI-LOCK BRAKE SYSTEM {ABS)
SERVICE INFORMATION· .. ··················· 20-2 ABS INDICATOR CIRCUIT

TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · 20-11
SYSTEM LOCATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · 20-3
ABS OTC TROUBLESHOOTING · · · · · · · · · · · 20-13
SYSTEM DIAGRAM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 20-4
WHEEL SPEED SENSOR · · · · · · · · · · · · · · · · · · · · 20-24
ABS TROUBLESHOOTING
INFORMATION···································· 20-6 ABS MODULATOR ·····························20-27
ABS OTC INDEX .. · · · · · · · · · · · · · · · · · · · · · · · · · · · .. · · 20-9
Ell
20-1
SERVICE INFORMATION
GENERAL
NOTICE
• The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing, the excessive
voltage may damage the control unit. Always turn off the ignition switch before servicing.
• Spilling brake fluid will severely damage plastic parts and painted surfaces. It is also harmful to some rubber parts.
• The ABS control unit is integrated in the ABS modulator. Do not disassemble the ABS modulator. Replace the ABS modulator
as an assembly when it is faulty.
• The ABS control unit performs pre-start self-diagnosis to check whether the ABS functions normally until the motorcycle speed
reaches 10 km/h (6 mph). After pre-start self-diagnosis, the ABS control unit monitors the ABS functions and motorcycle running
condition constantly until the ignition switch is turned OFF (ordinary self-diagnosis).
• When the ABS control unit detects a problem, it stops the ABS function, switches back to the conventional brake operation, and
turns on or blinks the ABS indicator. Take care during the test-ride.
• When the ABS control unit detects a problem in the rear ABS off indicator circuit, it stops the rear ABS off mode function,
switches back to the normal ABS operation, and turns on or blinks the ABS indicator and turns off the rear ABS off indicator.
• When there are following problem in the ABS system, it stops the ABS level changing.
- ABS system malfunction
- Meter malfunction
- Faulty CAN communication or open circuit in the CAN lines
- Wheel speed sensor malfunction
- IMU malfunction
• Read "ABS TROUBLESHOOTING INFORMATION" carefully, inspect and troubleshoot the ABS according to the diagnostic
troubleshooting flow chart. Observe each step of the procedures one by one. Write down the OTC and probable faulty part
before starting diagnosis and troubleshooting .
• Use a fully charged battery. Do not diagnose with a charger connected to the battery.
• After troubleshooting, erase the OTC and test-ride the motorcycle to check that the ABS indicator operates normally during pre-
start self-diagnosis (page 20-6).
• Problems not caused by the faulty ABS (e.g. brake disc squeak, unevenly worn brake pad) cannot be detected by the ABS
diagnosis system.
• Before wheel speed sensor servicing, check the following :
- Iron or other magnetic deposits between the pulser ring and wheel speed sensor
- Pulser ring slots for obstructions
- Installation condition of the pulser ring or wheel speed sensor for looseness J
I
- Pulser ring and sensor tip for deformation or damage
J
• Be careful not to damage the pulser ring when removing and installing the wheel.
• For pulser ring service:
- Front: (page 17-17) J
- Rear: (page 18-7) ]
• The following color codes are used throughout this section .
W = White Y= Yellow
TOOL
Test probe, 2 pack
07ZAJ-RDJA 110
•
1
·,!•
•
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20-2 I
'•
SYSTEM LOCATION
POWER BOX
-ABS MAIN 10 A
- HORN/STOP 1O A
BATIERY
ABS FSR+ 20 A
DLC
REAR WHEEL FUSE BOX

SPEED SENSOR - MAIN2 FUSE 30 A

- MAIN FUSE 30 A
- ABS-M 30A
ABS MODULATOR
20-3
SYSTEM DIAGRAM
MT model:
-
Bl/Gr Bl l
- I I+ J
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--
--
-
BATTERY
BI/R G/Y
IGNITION
MAIN FUSE SWITCH HORN/STOP FRONT BRAKE
30 A 10A SWITCH
--" -
w R - R/81 BI/R G/Y ~ G
" ~
Bl _ Bl G BRAKE/TAI L
LIGHT
ABS MAIN
10A RIG
REAR BRAKE
SWITCH
G/Y
--
--
-
-----v " " ~ 7 IG I IBLS 4
METER
PUMP MOTOR
W/Bu
~
IND 13 ® - ABS
INDICATOR
ABS-M
30 A
'
R/Y
.............,;
- 9 MR+BI
MODE IND 16
WIG
-
® - REAR ABS
OFF
INDICATOR
- Bl
G
1 MOTORGN DI - BI/R MID
_L
--
- CRF1100A4
MAIN2 FUSE ABS FSR +

r· -- -
'
w 30 A R
"
R 20 A RIG
, ~ 18 FSR +BI
I scu ;
e sous"''""'-"
I
'' -- --
IMU
BCU
- - - - - - - - - - - - - - - Bu't! 17 FVWS(-)1
-
I BI/R
8 FVWB(+)I CAN-H 2
I Bl
CAN-L 11
I w
I I
- - - - - Bu- 15 RVW S (-)I FPO 12
Bu/Y
Bu/Bl
ECM
6 RVWB(+) I RPO 3
I
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I
I -
1'
I I
FRONT WHEEL REAR WHEEL
I 1
SPEED SENSOR SPEED SENSOR
. w
~
DIAG 5 J
I I I - I scs 14
y
00"
..1..
0 0
G
GND 10
DLC
1,
1: ...L
-- --
-
FRONT PULSER RING REAR PULSER RING -
ABS MODULATOR
Bl Black
Bu Blue
G Green
Gr Gray
R Red
W White
ABS MODULATOR 18P (Black) CONN ECTOR (MODULATOR SIDE) Y Yellow
20-4 l
1
OCT model:
r
-::1 - I
BI i
1-t-
--
--
-
BATTERY
IGNITION
BI/R
- G/Y
MAIN FUSE SWITCH HORN/STOP FRONT BRAKE

30A 10A SWITCH
w -...._- R _ R/BI
.... BI/R G/Y ~
~
G
Bl _ Bl _ G BRAKE/TAIL
LIGHT
_ ABS MAIN
.!_OA
.... RIG
~
7
REAR BRAKE
SWITCH
IGI BLS 4
GIY
METER
--
--
-
W/Bu ® - ABS
i ~R IND 13 INDICATOR
--
ABS-M L.. WIG ® - REARABS
IMODE IND 16 OFF
~~A~
G
9
1
MR +B l
MOTORGND I
- ,-
INDICATOR Bl
BI/R MID
_l_
--
- ·-------
CRF1100D4
I
MAIN2 FUSE ABS FSR +
30A '' scu
w -...._-
R R ~~A~ 18 FSR +B I
!- -- --
IMU
e
-
SOLENOID VALVE
-
BCU
·-
TCM
'!:!
- - - - - - - - - - - - - - - Bu 17 FVWS(-)1
I BI/R
8 FVWB(+) I CAN-H 2
I Bl
CAN-L 11
I
w
I I
---- Bu
15 RVWS(-) 1 FPO 12
Bu/Y
Bu/Bl
ECM
I I
6 RVWB(+) I RPO 3
I I -
I I
FRONT WHEEL REAR WHEEL
I
SPEED SENSOR SPEED SENSOR 1
DIAG 5
w
I - I I I scs 14
y
..1.. """~
0 0
G
GND 10
DLC
..L
-- --
-
FRONT PULSER RING REAR PULSER RING -
t ABS MODULATOR
•'
Bl Black
Bu Blue
G Green
Gr Gray
R Red
w White
ABS MODULATOR 18P (Black) CONNECTOR (MODULATOR SIDE) y Yellow
20-5
ABS TROUBLESHOOTING INFORMATION

SYSTEM DESCRIPTION
SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM
The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When
there is any abnormality, the problem and the associated part can be detected by reading the Diagnostic Trouble Code (OTC).
When the motorcycle is running , pulse signals generated at the front and rear wheel speed sensors are sent to the ABS control unit.
When the motorcycle speed reaches approximately 6 km/h (4 mph), the ABS control unit operates the pump motor to check it.
When the motorcycle speed reaches 10 km/h (6 mph), the ABS control unit turns off the ABS indicator if the system is normal and
the pre-start self-diagnosis is completed.
If any problem is detected, the ABS indicator blinks or comes on and stays on to notify the rider of the problem.
The ordinary self-diagnosis is also made while the motorcycle is running after the pre-start diagnosis is completed. When the ABS
indicator blinks or stays on, the cause of the problem can be identified by retrieving the OTC (page 20-7).
If the ABS indicators do not come on when the ignition switch is turned ON , or the indicator stays on after the pre-start self-
diagnosis is completed although the ABS is normal, the indicator circuit may be faulty. Follow the troubleshooting (page 20-11 ).
Pre-start serf-diagnosis when the system is normal:
IGNITION ON
SWITCH OFF
Running
ENGINE
Stop
MOTORCYCLE
SPEED
0 ------------------------------ 4.. (4 mph) o, abo,e
ON
PUMP
MOTOR OFF
1 I
ON
ABS
INDICATOR OFF L
t
Pre-start serf-diagnosis is
2 sec.
REAR ON completed at 10 km/h (6 mph)
ABS OFF
INDICATOR OFF
t
CPU completion of
the initial settings
PRE-START SELF-DIAGNOSIS PROCEDURE (Daily check)

1. Turn the ignition switch ON and engine stop switch "O".
2. Make sure the ABS indicator and rear ABS off indicator comes on .
3. After CPU initial settings completes, the rear ABS off indicator will go off after approximately 2 seconds if system is normal. I
J
4. Start the engine.
5. Ride the motorcycle and increase the motorcycle speed to approximately 10 km/h (6 mph). j
6. The ABS is normal if the ABS indicator goes off.
MCS INFORMATION
20-6
OTC READOUT
NOTE:
• The OTC is not erased by turning the ignition switch to OFF while the OTC is being indicated. Note that turning the ignition
switch ON again does not indicate the OTC. To show the OTC again, repeat the OTC readout procedures from the beginning.
• Be sure to record the indicated OTC.
• After diagnostic troubleshooting, erase the OTC and perform the pre-start self-diagnosis procedure to be sure that there is no
problem in the ABS (page 20-6).
• Do not apply the brake during OTC readout.
Read the OTC, stored data and follow the OTC index (page 20-9).
If the MCS is not available, perform the following .
Reading DTC with the ABS indicator

1. Connect the SCS service connector to the DLC (page 4-6).
The ABS indicator should come on for 2 seconds (start signal), then goes off for 3.6 seconds and starts OTC indication.
The OTC is indicated by the number of the times of the ABS indicator blinking.
If the OTC is not stored, the ABS indicator stays on .
3. Turn the ignition switch OFF and disconnect the SCS service connector.
Install the removed parts in the reverse order of removal.
DTC INDICATION PATTERN

NOTE:
• The ABS indicator indicates the OTC by blinking a specified number of times.
The indicator has two types of blinking, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for
, 0.3 seconds. For example, when one long blink is followed by two short blinks, the OTC is 1-2 (one long blink= 1 blink, plus two
short blinks = 2 blinks).
r • When the ABS control unit stores some DTCs, the ABS indicator shows the DTCs in the order from the lowest number to highest
number. For example, when the ABS indicator indicates code 1-2, then indicates code 2-3, two failures have occurred.
IGNITION ON
1.3 sec.
SWITCH OFF
1.3 sec. 1.3sec. :
. : :.
Pattern repeated
I 2 sec. _....,.,...: - - :..,__ 0.3 sec. ____., ~
~
ABS ON
:.. ..: . 3.6 sec.
INDICATOR OFF
OTC start signal ~ ,._ ;...,.;1----- - - - -
0.4 sec. 3.6 sec.
'-----y-----..1
Lowest number DTC Highest number DTC
(Example: Code 1-2) (Example: Code 2-3)
When the DTC is not stored:
. 2 sec. . 3.6 sec.

; ABS ON
:.. ..:.. ..:
INDICATOR OFF
20-7
ERASING STORED DTC
NOTE:
• The stored OTC can not be erased by simply disconnecting the battery negative (- ) cable .
Erase the OTC with the MCS while the engine is stopped.
How to erase the DTC without MCS
1. Connect the SCS service connector to the DLC (page 4-6).
2. Turn the ignition switch ON while squeezing either brake lever. The ABS indicator should come on for 2 seconds and go off.
3. Release the brake lever immediately after the ABS indicator goes off. The ABS indicator should come on.
4. Squeeze the brake lever immediately after the ABS indicator comes on. The ABS indicator should go off.
5. Release the brake lever immediately after the ABS indicator goes off.
When the OTC is erased, the ABS indicator blinks 2 times and stays on .
If the ABS indicator does not blink 2 times, the self-diagnostic memory has not been erased , so try again.
6. Turn the ignition switch OFF and disconnect the SCS service connector. J
Install the removed parts in the reverse order of removal.
!
CIRCUIT INSPECTION
INSPECTION AT ABS MODULATOR CONNECTOR
Disconnect: Connect:
[1] [2]
Disconnecting procedure:
Turn the lock lever [1] to this side while pressing the lock tab [2] to release it.
Be sure the lock lever is turned all the way and disconnect the ABS )
modulator 18P {Black) connector [3] .
Connecting procedure:
J
Be sure to seat the lock lever against the wire side of the connector fully.
Connect the ABS modulator 18P (Black) connector by pressing it straight at
the area as shown (arrow) until the lock tab clicks.
Make sure the connector is locked securely.
j
[3]
• Always clean around and keep any foreign material away from the
connector before disconnecting it.
• A faulty ABS is often related to poorly connected or corroded
connections. Check those connections before proceeding.
• In testing at ABS modulator 18P {Black) connector terminals (wire
harness side; except No. 1, No. 9, No, 10 and No. 18 terminals), always
use the test probe [1] . Insert the test probe into the connector terminal,
then connect the digital multimeter probe to the test probe.
1
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110 '
J
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TERMINAL LAYOUT:
~ 8 7 6 5 4 3 2 ~
~ 17 16 15 14 13 12 11 G
(Terminal side of the wire harness)
20-8
ABS OTC INDEX
NOTE:
• The ABS indicator might blink in the following cases. Correct the problem.
- Incorrect tire pressure.
- Tires not recommended for the motorcycle were installed (incorrect tire size).
- Deformation of the wheel or tire.
• The ABS indicator might blink while riding under the following conditions. This is a temporary failure. Be sure to erase the OTC
(page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph) and check the OTC (page 20-7). Ask the rider for the riding conditions in detail
when the motorcycle is brought in for inspection.
- The motorcycle has a continuous run on bumpy roads.
- The front wheel leaves the ground for a long time when riding (wheelie).
- Only either the front or rear wheel rotates.
- The ABS operates continuously.
- The ABS control unit has been disrupted by an extremely powerful radio wave (electromagnetic interference).
Detection Refer
DTC Function failure Symptom/Fail-safe function
ABS indicator malfunction

A B
. ABS indicator never comes
to
20-11
r
-
..
• ABS modulator voltage input line
Indicator related wires . ON at all
ABS indicator stays ON at all
..
Meter
ABS modulator
20-11
Sub fuse ABS MAIN 10 A
1-1 .
Front wheel speed sensor circuit malfunction
0 0
. Stops ABS operation 20-13
Wheel speed sensor or related wires
Front wheel speed sensor malfunction
.
. Stops ABS operation
Wheel speed sensor, pulser ring or related
1-2 0 20-13
. wires
Electromagnetic interference
.
1-3 .
Rear wheel speed sensor circuit malfunction
Wheel speed sensor or related wires 0 0
Stops ABS operation
20-15
.
1-4
.
Rear wheel speed sensor malfunction
Wheel speed sensor, pulser ring or related
0
Stops ABS operation
20-15
. wires
Electromagnetic interference
2-1
Front pulser ring
. 0
Pulser ring or related wires
2-3 .
Rear pulser ring
0
3-1
Pulser ring or related wires
Solenoid valve malfunction (ABS modulator) . Stops ABS operation
3-2
0 0 20-17
3-3
3-4
Front wheel lock . Stops ABS operation
4- 1 . Riding condition 0
20-13
4-2 .
Front wheel lock (Wheelie)
Riding condition 0
Rear wheel lock
4-3 . Riding condition 0 20-15
.
5-1 ..
Pump motor lock
Pump motor (ABS modulator) or related wires 0 0
Stops ABS operation
20-17
r' ABS-M 30 A fuse
.
5-2 .
Motor stuck off
Pump motor (ABS modulator) or related wires 0 0
Stops ABS operation
20-17
• ABS-M 30 A fuse
.
5-3 .
Motor stuck on
0 0
Stops ABS operation
20-17
Pump motor (ABS modulator) or related wires
Fail-safe relay malfunction
. . Stops ABS operation
5-4 Fail-safe relay (ABS modulator) or related wires 0 0 20-18
. Sub fuse ABS FSR+ 20 A
Power circuit under voltage
.
6-1 Input voltage (too low) 0 0
. Sub fuse ABS MAIN 10 A 20-19
6-2 .
Power circuit over voltage
0 0
Input voltage (too high)
20-9
DTC Function failure

Detection
Symptom/Fail-safe function
Refer
II
7-1 .
Tire malfunction
A B
0
to
20-20
1l
f
Tire size
.
8-1 .
ABS control unit malfunction
ABS modulator 0 0
.
Stops ABS operation
20-20
Rear ABS off indicator Rear ABS off mode function
8-2 . Rear ABS off indicator (meter) or related wire 0 0 does not work
20-20 l
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8-3 ..
IMU malfunction
Acceleration sensor 0 0
.
Stops ABS operation
20-22
Gyro sensors Stops ABS operation
8-4 . 0 0 l
IMU installation status
.
8-5
8-6
.
IMU circuit malfunction
IMU or related wires
CAN communication malfunction
0
0
0
0
.
Stops ABS operation
Stops ABS operation

20-23
4-60 l
l
CAN communication error . ABS level does not change

4-63
4-60
l
8-7
(A) Pre-start self-diagnosis (page 20-6)

0 0 4-64
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(B) Ordinary self-diagnosis: diagnoses while the motorcycle is running (after pre-start self-diagnosis)
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20-10 !•
ABS INDICATOR CIRCUIT
TROUBLESHOOTING
r ABS INDICATOR DOES NOT COME ON
(when the ignition switch turned ON)
NOTE:
• Before starting this inspection, check the initial
function of the meter (page 22-16).
1. Indicator Operation Inspection
Disconnect the ABS modulator 18P (Black)
Check the ABS indicator.
Does the ABS indicator come on?
YES - Faulty ABS modulator
NO - GO TO STEP 2.
,.
2. Indicator Signal Line Short Circuit Inspection
[1]
18P (Black) connector [1] and ground.
TOOL:
, Is there continuity?
YES - Short circuit in the White/blue wire
NO - Faulty meter
ABS INDICATOR STAYS ON (Indicator

does not go off when the motorcycle is
running, but DTC is not stored)
1. Service Check Line Short Circuit Inspection
[1]
TOOL:

NO - GO TO STEP 2.
20-11
2. Indicator Signal Line Open Circuit Inspection
Short the wire harness side 18P (Black) connector
[1]
[1] to the ground with a jumper wire [2].
TOOL:
Turn the ignition switch ON. [2]

Check the ABS indicator.
Does it go off?
YES - GO TO STEP 3.
NO - • Open circuit in the White/blue wire
• Faulty meter (if the White/blue wire is
OK)
3. Modulator Ground Line Open Circuit Inspection
[1]
Remove the jumper wire.
CONNECTION: 10- Ground a1:::
YES - GO TO STEP 4.
4. Fuse Inspection
Open the fuse box cover.
Check for a blown sub fuse ABS MAIN 10 A [1].
Is the fuse blown?
YES - GO TO STEP 5.
NO - GO TO STEP 6.
5. Power Input Line Short Circuit Inspection

With the sub fuse ABS MAIN 10 A removed, check
for continuity between the wire harness side 18P
[1]
,
I
(Black) connector [1] and ground.
TOOL:
YES - Short circuit in Red/green wire
NO - Intermittent failure. Replace the sub fuse
ABS MAIN 10 A with a new one and
recheck.
20-12
6. Power Input Line Open Circuit Inspection
Install the sub fuse ABS MAIN 10 A.
[1)
TOOL:
7
CONNECTION: 7 (+) - Ground (-)
NO - Open circuit in Red/green wire
ABS DTC TROUBLESHOOTING

NOTE:
• Perform inspection with the ignition switch OFF,
unless otherwise specified.
• All connector diagrams in the troubleshooting are
viewed from the terminal side.
• When the ABS modulator assembly is detected to be
faulty, recheck the wire harness and connector
connections closely before replacing it.
• After diagnostic troubleshooting, erase the DTC
(page 20-8).
Then test-ride the motorcycle to check that the ABS
indicator operates normally during pre-start self-
diagnosis (page 20-6).
DTC 1-1/1-2/2-1/4-1/4-2 (Front Wheel

Speed Sensor Circuit/Front Wheel
Speed Sensor/Front Pulser Ring/Front
Wheel Lock)
NOTE:
• The ABS indicator might blink under unusual riding
conditions (page 20-9). This is temporary failure.
Erase the DTC (page 20-8).
Then test-ride the motorcycle above 10 km/h (6
mph} to check that the ABS indicator operates
normally (page 20-6).
• If DTC 4-1 is indicated, check the front brake for
drag.
1. Front Wheel Speed Sensor Clearance Gap
Inspection
Check the clearance gap between sensor bracket
and pulser ring (page 20-26).
Is the clearance gap correct?
YES - GO TO STEP 2 .
• NO - Check the related parts for deformation

and looseness, or damage and repair if
necessary. Recheck the clearance gap.
20-13
2. Front Wheel Speed Sensor Condition Inspection
Inspect the area around the front wheel speed
sensor:
Check for iron or other magnetic deposits between
the pulser ring and wheel speed sensor and check
the pulser ring slots for obstructions.
Check the installation condition of the pulser ring or
wheel speed sensor for looseness.
Check the pulser ring and sensor tip for deformation
or damage.
Are the sensor and pulser ring in good
condition?
YES - GO TO STEP 3.
NO - Remove any deposits. Install properly or
replace faulty part.
3. Front Wheel Speed Sensor Short Circuit
Inspection
Disconnect the front wheel speed sensor 2P (Black)
connector (page 20-24 ).
Check for continuity between each terminal of the
sensor side 2P {Black) connector [1] and ground . Bu
Blue - Ground
YES - Faulty front wheel speed sensor
NO - GO TO STEP 4.
4. Front Wheel Speed Sensor Line Short Circuit

Inspection
Disconnect the ABS modulator 18P {Black)
[1]\
wire harness side 2P (Black) connector [1] and
ground . Bu W
White - Ground
NO - GO TO STEP 5.
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20-14 l
5. Front Wheel Speed Sensor Line Open Circuit
Inspection
Short the wire harness side 18P {Black) connector
[2) [1)
[1) terminals with a jumper wire [2) .
CONNECTION: 8 - 17
2P (Black) connector [3) terminals.
[3]
CONNECTION: Blue - White
YES - GO TO STEP 6.
NO - Open circuit in the Blue or White wire
6. Failure Reproduction with a Known Good Front

Wheel Speed Sensor
Replace the front wheel speed sensor with a known
good one (page 20-24 ).
Connect the 18P {Black) and front wheel speed
sensor 2P (Blue) connectors.
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the OTC (page 20-7).
Is the DTC 1-1, 1-2, 2-1, 4-1 or 4-2 indicated?
NO - Faulty original front wheel speed sensor
OTC 1-3/1-4/2-3/4-3 (Rear Wheel Speed

Sensor Circuit/Rear Wheel Speed
Sensor/Rear Pulser Ring/Rear Wheel
Lock)
NOTE:
mph) to check that the ABS indicator operates
• If OTC 4-3 is indicated, check the rear brake for
drag.
1. Rear Wheel Speed Sensor Clearance Gap
Inspection
Check the clearance gap between sensor bracket
and pulser ring (page 20-26).
t Is the clearance gap correct?

YES - GO TO STEP 2.
NO - Check the related parts for deformation
and looseness, or damage and repair if
necessary. Recheck the clearance gap.
20-15
2. Rear Wheel Speed Sensor Condition Inspection
Inspect the area around the rear wheel speed
sensor:
Check for iron or other magnetic deposits between
the pulser ring and wheel speed sensor and check
the pulser ring slots for obstructions.
Check the installation condition of the pulser ring or
wheel speed sensor for looseness.
Check the pulser ring and sensor tip for deformation
or damage.
Are the sensor and pulser ring in good
condition?
YES - GO TO STEP 3.
NO - Remove any deposits. Install properly or
replace faulty part.
3. Rear Wheel Speed Sensor Short Circuit
Inspection
Disconnect the rear wheel speed sensor 2P {Black)
sensor side 2P {Black) connector [1] and ground . Bu
Blue - Ground
YES - Faulty rear wheel speed sensor
NO - GO TO STEP 4.
4. Rear Wheel Speed Sensor Line Short Circuit

Inspection
wire harness side 2P (Black) connector [1] and
ground.
w
White-Ground
NO - GO TO STEP 5.
20-16
,
[ ANTI-LOCK BRAKE SYSTEM (ABS)
5. Rear Wheel Speed Sensor Line Open Circuit
I Inspection
Short the wire harness side 18P (Black) connector
[1 ]
r [1] terminals with a jumper wire [2].
CONNECTION: 6-15
f
t 2P (Black) connector [3) terminals.
[3]
CONNECTION: Blue - White
YES - GO TO STEP 6.
NO - Open circuit in the Blue or White wire
6. Failure Reproduction with a Known Good Rear

Wheel Speed Sensor
Replace the rear wheel speed sensor with a known
good one (page 20-25).
Connect the 18P (Black) connector.
~ Test-ride the motorcycle above 10 km/h (6 mph).
[ Recheck the DTC (page 20-7).
l
I
Is the DTC 1-3, 1-4, 2-3, or 4-3 indicated?
I NO - Faulty original rear wheel speed sensor
DTC 3-1/3-2/3-3/3-4 (Solenoid Valve)

r 1. Failure Reproduction
r Erase the DTC (page 20-8).
Recheck the DTC (page 20-7).
Is the DTC 3-1, 3-2, 3-3 or 3-4 indicated?
NO - Solenoid valve is normal (intermittent
failure).
DTC 5-1/5-2/5-3 (Pump Motor)

1. Fuse Inspection
Remove the starter relay switch cover (page 6-9)
and check for a blown ABS-M 30 A fuse [1].
Is the fuse blown?
,I YES - GO TO STEP 2.
NO - GO TO STEP 3.
20-17
2. Motor Power Input Line Short Circuit Inspection
[1]
With the ABS-M 30 A fuse removed, check for
continuity between the wire harness side 18P
(Black) connector [1] terminal and ground.
1::: :::1a
YES - Short circuit in the Red/yellow wire
between the starter relay switch and 18P
(Black) connector
NO - Intermittent failure. Replace the ABS-M 30
A fuse with a new one and recheck.
3. Motor Power Related Line Open Circuit

Inspection
Install the ABS-M 30 A fuse.
Measure the voltage between the wire harness side [1] 8
18P (Black) connector [1] terminals.
CONNECTION: 9 (+) - 1 (-)
YES - GO TO STEP 4.
NO - • Open circuit in the Black or Red/yellow
wire between the battery and 18P I : : : : : : I
(Black) connector
• Open circuit in the Green wire between
the 18P (Black) connector and ground
terminal
4. Failure Reproduction
Connect the 18P (Black) connector.
Is the OTC 5-1, 5-2, or 5-3 indicated?
NO - Pump motor is normal (intermittent failure)
OTC 5-4 (Fail-safe Relay)

1. Fuse Inspection
Remove the fuse case cover and check for a blown
sub fuse ABS FSR+ 20 A [1].
Is the fuse blown?
YES - GO TO STEP 2.
NO - GO TO STEP 3.
20-18
2. Solenoid Power Input Line Short Circuit
Inspection
[1]
With the sub fuse ABS FSR+ 20 A removed, check
for continuity between the wire harness side 18P
(Black) connector [1] terminal and ground .
CONNECTION: 18 - Ground 1::::::1a
YES - Short circuit in the Red/green wire
between the sub fuse ABS FSR+ 20 A
terminal and 18P (Black) connector
NO - Intermittent failure. Replace the sub fuse
ABS FSR+ 20 A with a new one and
recheck.
3. Solenoid Power Input Line Open Circuit
Inspection
Install the sub fuse ABS FSR+ 20 A.
Disconnect the ABS modulator 18P (Black) [1 J
18P (Black) connector [1] terminal and ground .
CONNECTION: 18 (+) - Ground(-) 1::::::1a
Is there battery voltage? 18
YES - GO TO STEP 4.
NO - Open circuit in the Black, White, Red , or
Red/green wires between the battery and
18P (Black) connector
Connect the ABS modulator 18P (Black) connector.
Is the DTC 5-4 indicated?
NO - Fail-safe relay is normal (intermittent
failure).
DTC 6-1/6-2 (Power Circuit)

1. Battery Voltage Inspection
Inspect the battery voltage (page 21-7).
Is the battery voltage normal?
YES - GO TO STEP 2.
NO - Replace the battery (page 21-6).
2. Charging Voltage Inspection
Inspect the battery charging voltage (page 21-8).
Is the voltage above 15.5 V?
YES - Faulty regulator/rectifier
NO - GO TO STEP 3.
20-19
Is the DTC 6-1 or 6-2 indicated?
NO - Power circuit is normal (intermittent failure)
DTC 7-1 (Tire Size)

NOTE :
• Check the following and correct the faulty part.
- Incorrect tire pressure
- Tires not recommended for the motorcycle were
installed (incorrect tire size)
- Deformation of the wheel or tire
If the above items are normal, recheck the OTC as
follows:
•.
J
NO - Tire size is normal (intermittent failure) l
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DTC 8-1 (ABS Control Unit)
NO - ABS control unit (ABS modulator) is
normal (intermittent failure)
DTC 8-2 (Rear ABS Off Indicator)

1. Rear ABS Off Indicator Inspection 1
Turn the ignition switch ON and check the rear ABS
off indicator.
Is the rear ABS off indicator indicated?
YES - GO TO STEP 2.
NO - GO TO STEP 3.
20-20
r 2. Rear ABS Off Indicator Line Short Circuit
Inspection
[1 J
Disconnect the meter 20P connector (page 22-14).
Check tor continuity between the wire harness side
18P (Black) [1] connector and ground .
TOOL:

YES - Short circuit in the White/green wire
NO - Replace the meter with a new one and
recheck (page 22-14).
3. Rear ABS Off Indicator Inspection 2

Ground the wire harness side 18P (Black) connector
[1 J
[1] with a jumper wire [2].
TOOL:

Check the rear ABS off indicator.
Is the rear ABS off indicator off mode indicated?
YES - GO TO STEP 4. [2]
NO - GO TO STEP 5.
Recheck the DTC (page 20-7).
NO - ABS control unit is normal (intermittent
failure)
5. Rear ABS Off Indicator Line Open Circuit
Inspection
Disconnect the meter 20P connector (page 22-14). [1 J
Check tor continuity between the wire harness side
18P (Black) [1] and 20P [2] connectors.
TOOL:
Test probe, 2 pack 07ZAJ-RDJA 110 16
CONNECTION: 16 - White/Green
WIG
YES - Replace the meter with a new one and
recheck (page 22-14 ).
NO - Open circuit in the Wh ite/green wire
[2]
20-21
OTC 8-3/8-4 (IMU)
NOTE:
mph) and check that the ABS indicator operates
1. IMU System Inspection
YES - GO TO STEP 2.
NO - GO TO STEP 3.
2. IMU Input Voltage Inspection
[1]
Disconnect the IMU 4P (Black) connector (page 22-
52).
Measure the voltage between the 4P (Black)
connector [1] terminals.
CONNECTION: Black/red(+)- Green/blue(-)
Does the battery voltage exist?
YES - Faulty IMU
NO - • Open circuit in Black/red wire
• Open circuit in Green/blue wire
YES - GO TO STEP 4.
NO - IMU is normal (intermittent failure)
4. IMU Installation Inspection
Check the correct IMU installation (page 4-67).
Is the /MU installed correctly?
YES - Faulty IMU
NO - Faulty IMU stay
20-22
'
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It ANTI-LOCK BRAKE SYSTEM (ABS)
'
r OTC 8-5 (IMU CIRCUIT)
1. PGM-FI OTC Check
r Check the PGM-FI OTC (page 4-6).
Does the ECM store the OTC U0125 (103-3)?
YES - Perform the OTC U0125 troubleshooting
(page 4-63).
NO - GO TO STEP 2.
2. ABS Control Unit CAN Line Open Circuit
Inspection
[1 J
- ABS modulator 18P (Black) connector (page 20-
8)
- IMU 4P (Black) connector (page 22-52)
Check for continuity between the 18P (Black)
connector [1 ] and 4P (Black) connector [2].
TOOL:
CONNECTION: 2 - Black/red
11 - Black
[2]
YES - GO TO STEP 3.
3. IMU Inspection
Replace the IMU with a known good one (page 4-
67).
Is the OTC 8-5 indicated?
OTC 8-6 (CAN COMMUNICATION

MALFUNCTION)
Refer to PGM-FI troubleshooting:
- OTC U0001 : (page 4-60)
- OTC U0121 : (page 4-63)
OTC 8-7 (CAN COMMUNICATION

ERROR)
Refer to PGM-FI troubleshooting OTC U0155 (page 4-
64).
20-23
WHEEL SPEED SENSOR
NOTE:
I
Refer to procedure for the pulser ring removal/
installation:
- Front: (page 17-17)
- Rear: (page 18-7)
FRONT WHEEL SPEED SENSOR
Remove the front fender (page 2-23).
Disconnect the front wheel speed sensor 2P (Black)
connector [1] from the clip and disconnect it.

[1] [1]
Release the front wheel speed sensor wire [2] from the
clamps [3].
Remove the wire clips [4] .
;
Remove the wire clips [1].
;
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20-24
Remove the bolt [1] and front wheel speed sensor [2] .
Clean around the mounting area of the caliper bracket
., thoroughly and be sure that no foreign material is
allowed to enter the mounting hole .
NOTE:
• Always replace the front wheel speed sensor bolt
with a new one.
• After installation, check the clearance gap (page 20-
26).
REAR WHEEL SPEED SENSOR

Remove the rear wheel (page 18-6).
Disconnect the rear wheel speed sensor 2P (Black)
connector [1].
Release the rear wheel speed sensor wire [2] from the
guide [3] .
Remove the clip [1].

, Remove the bolt [2].
Release the brake hose guide [3] from the frame.
Remove the rear wheel speed sensor wire [4] from the
brake hose guide.
Remove the brake hose clamp screw [1] and brake

hose clamp [2].
Remove the brake hose guide screws [3] and brake
hose guide [4].
Remove the clips [7].
20-25
Remove the clip [1].
Remove the rear wheel speed sensor bolt [2] and rear
wheel speed sensor [3]. ,
Clean around the mounting area of the caliper bracket
thoroughly and be sure that no foreign material is
allowed to enter the mounting hole.
TORQUE:
Brake hose guide screw:
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
Brake hose clamp screw:
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
NOTE:
• Always replace the rear wheel speed sensor bolt
with a new one.
• Replace the brake hose guide screw and brake hose
clamp screws with new one.
• Route the hose, cable, and wire properly (page 1-
26).
• After installation, check the clearance gap (page 20-
26).
j
CLEARANCE GAP INSPECTION

Support the motorcycle securely using a hoist or - - --~.-.-
equivalent and raise the front or rear wheel off the
ground .
Measure the clearance gap between the sensor bracket
and pulser ring at several points by turning the wheel
slowly.
It must be within specification. .
STANDARD:
FRONT: 0.40-1.15 mm (0.016- 0.045 in)
REAR: 0.40-1.06 mm (0.016- 0.042 in)
The sensor clearance gap cannot be adjusted.
If it is not within specification, check each installation
part for deformation, looseness, or damage.
20-26
ABS MODULATOR
'
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I
I NOTICE I
Spilled fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
NOTE:
• Be careful not to bend or damage the brake pipes.
Drain the brake fluid from the brake hydraulic system
(page 19-6).
- EVAP canister (page 7-23)
Disconnect the ABS modulator 18P (Black) connector
(page 20-8).
- Bolt/washers [1]
- Collars [2]

- Oil bolts [1]
- Sealing washers [2]
- Rear brake hose A [3]
- Rear brake hose B [4]
Open the clamp [5] .
Release the front brake pipe B [6] and front brake pipe
C[7].
Loosen the brake pipe joint nuts [8].
Remove the front brake pipes from the ABS modulator
[9].
Remove the ABS modulator.
TORQUE:
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf-ft)
Brake pipe joint nut:
14 N·m (1.4 kgf·m, 10 lbf·ft)
NOTE:
• Apply brake fluid to the joint nut threads.
• Replace the sealing washers with new ones.
7).
20-27
MEMO
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21. BATTERY/CHARGING SYSTEM
SERVICE INFORMATION···· .. ················ 21-2 BATTERy ........................................... 21-6
TROUBLESHOOTING · ·· · ·· · ··· · ·· · ·· · · · · ·· · · ·· 21-3 CHARGING SYSTEM INSPECTION ........ 21-8
SYSTEM LOCATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · 21-5 REGULATOR/RECTIFIER ............ · · .. · · .. · 21-9
SYSTEM DIAGRAM .... · · .. · · .............. · · · .. 21-5 ALTERNATOR CHARGING COIL·· .. · .... · 21-10
- I
21-1
BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
GENERAL
• If electrolyte gets on your skin or clothes, flush with clean water such as tap water etc. immediately.
• If electrolyte gets on your eyes, flush with large quantities of water immediately and consult an eye doctor.
NOTICE I
• Do not jump-start the motorcycle. It may blow out the built-in fuse in the lithium ion battery.
• Always turn OFF the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 21-3).
• For alternator/stator servicing (page 11-2).
Be= Beige Bl= Black Br= Brown Bu= Blue G = Green Gr= Gray J
Lb = Light blue Lg = Light green 0 = Orange P = Pink R= Red V = Violet ;
W =White Y = Yellow
• For extended storage, remove the battery and store it in a cool space.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for a long period. These same conditions
contribute to shortening the "life span" of the battery.
l
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery at a suitable time to prevent
it from discharging. l
J
LITHIUM-ION BATTERY CHARGING '
~
• These models are equipped with the Lithium Ion (Li-Ion) battery. To charge the battery, use only the specified battery charger:
(OptiMATE Lithium LFP 4s-5A (U.S.A. only) or C1401 B manufactured by ELIIY Power Co., Ltd.). Follow the manufacturer's
instructions.
• Quick charging should only be done in an emergency; slow charging is preferred.
LITHIUM-ION BATTERY TESTING
Refer to the instruction in the Operation Manual for the recommended battery tester for details about battery testing .
The recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
Lithium-ion battery tester/charger: C-1401B manufactured by ELIIY Power Co., Ltd.

TOOLS
OptiMATE Lithium 4s-5A battery charger
TMNTM291 (U.S.A. only)
,
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21-2 f
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST (Except U.S.A.)
Remove the battery (page 21-6).
Check the battery condition using the recommended battery tester.
Recommended battery tester:
C-1401B manufactured by ELIIY Power Co., Ltd.
Is the battery good condition?
YES - GO TO STEP 2.
NO - Faulty battery
2. CURRENT LEAKAGE TEST
Install the battery (page 21-6).
Check the battery current leakage test (page 21-8).
Is the current leakage below 0.4 mA?
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTOR
Disconnect the regulator/rectifier 3P (Black) connector and recheck the battery current leakage.
Is the current leakage below 0.4 mA?
YES - Faulty regulator/rectifier
i
r NO - • Shorted wire harness
iI • Faulty ignition switch
r. 4. ALTERNATOR CHARGING COIL INSPECTION

f Check the alternator charging coil (page 21-10).
Is the alternator charging coil resistance within 0.1- 1.0 fl (20°C/68°F)?
YES - GO TO STEP 5.
NO - Faulty charging coil
5. CHARGING VOLTAGE INSPECTION
Measure and record the battery voltage using a digital multimeter (page 21-7).
t Start the engine.
I
t Measure the charging voltage (page 21-8).
r Compare the measurement to result of the following calculation .
r STANDARD:
Measured BV < Measured CV< 15.5 V
• BV = Battery Voltage
• CV = Charging Voltage
Is the measured charging voltage within the standard voltage?
YES - Faulty battery
r NO - GO TO STEP 6.
r 6. REGULATOR/RECTIFIER SYSTEM INSPECTION
r
Check the voltage and resistance at the regulator/rectifier connector (page 21-9).
' Are the results of checked voltage and resistance correct?
.r YES
NO
- Faulty regulator/rectifier
- • Open circuit in related wire
Shorted wire harness
,,
f
• Loose or poor contacts of related terminal
'
r
21-3
BATTERY/CHARGING SYSTEM j
ELECTRICAL SYSTEM DOES NOT TURNED ON WHEN THE IGNITION SWITCH IS TURNED ON OR
STARTER MOTOR CANNOT BE TURNED
1. ELECTRICAL SYSTEM INSPECTION
Connect a fully charged 12 V battery and turn the ignition switch ON .
Is the electrical system turned ON? 4
YES - GO TO STEP 2. I
NO Check the following:

j
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- Main fuse 30 A
- MAIN2 fuse 30 A j
- Fl 15 A J
- Fl relay
- Sub fuses
l
- Related wires
2. STARTER SYSTEM INSPECTION
Check that the starter motor can be turned .
Can the starter motor be turned?
YES - GO TO STEP 3.
NO - Check the starter system (page 6-2).
3. BATTERY CONDITION INSPECTION t
Check the battery for cracked or deformed case, electrolyte leakage, nasty smell or heat generation.
Is the battery in above conditions?
YES - Follow the emergency manual.
NO - GO TO STEP 4.
1
4. BATTERY VOLTAGE INSPECTION f
l
Leave the battery for 30 minutes and check the battery voltage.
Is the voltage below 6 Vor above 14.6 V?
J
YES - Replace the battery (page 21-6). i'
NO - GO TO STEP 5. f
5. CHARGING CONDITION INSPECTION

Charge the battery using the specified battery charger (C-14018 manufactured by ELIIY Power Co., Ltd.). l
Is the battery charged? 1
YES - Battery is normal.
NO - Replace the battery (page 21-6).
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21-4
!r BATTERY/CHARGING SYSTEM
SYSTEM LOCATION
t
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IGNITION SWITCH STARTER RELAY SWITCH
- MAIN FUSE 30 A
BATTERY
REGULATOR/RECTIFIER
SYSTEM DIAGRAM
MAIN FUSE 30 A
,
If
Bl Bl/Gr
G
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R y y y
,
f
EB 8
BATTERY REGULATOR/RECTIFIER
Bl: Black ALTERNATOR

G: Green
R: Red
Y: Yellow
Gr: Gray
21-5
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BATTERY
BATTERY REMOVAL/INSTALLATION
Remove the bolt [1] and disconnect the battery negative
(-) cable [2] first.
Then remove the bolt [3] and disconnect the battery
positive(+) cable [4] . '
Open the battery holder [6].
Remove the battery [7].
Install the battery in the reverse order of removal.
NOTE:
• Connect the battery positive (+) cable first and then
the negative(-) cable.
BATTERY BOX
Disconnect the battery negative(-) cable (page 21-6).
- Junction 1 24 P (White) connector [1]
- Junction 2 24 P (White) connector [2]
Fl relay [3]
- Starter relay [4]
Release the following from the battery box:

- Starter relay switch [1]
- Fuse box [2]
- Fuse box 4P connector [3]
21-6
Remove the bolt [1] and disconnect the battery positive
(+) cable [2].
Remove the battery [3] .
Remove the socket bolt [4].
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Release the battery box bosses [1] from the grommets

[2] of the frame.
Remove the battery box [3] to the left side.
Remove the battery box lid [4] from the battery box.
NOTE:
• Route the battery positive (+) cable [5] and battery
negative(-) cable [6] as shown .
[
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VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital multimeter.
VOLTAGE (20°C/68°F):
Fully charged: 13.5-14.0 V
Needs charging: Below 10.8 V
BATTERY TESTING
Refer to the instructions that are appropriate to the
battery testing equipment available to you .
TOOL:
Battery tester / C-1401 B manufactured by
charger ELIIY Power Co., Ltd.
Battery charger OptiMATE Lithium 4s-5A
battery charger (U.S.A only).
21-7
BATTERY CHARGING (U.S.A. only)
Refer to the instructions that are appropriate to the
battery charging equipment available to you.
TOOL:
Battery charger OptiMATE Lithium 4s-5A
battery charger.
CHARGING SYSTEM INSPECTION

CURRENT LEAKAGE TEST
Disconnect the battery negative(-) cable (page 21-6).
Connect the ammeter (+) probe [1] to the battery
negative H cable [2] and the ammeter H probe [3] to
the battery H terminal [4].
With the ignition switch OFF, check for current leakage.
NOTE:
• When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the range
selected may blow the fuse in the tester.
• While measuring current, do not turn the ignition
switch ON. A sudden surge of current may blow the
fuse in the tester.
SPECIFIED CURRENT LEAKAGE:

0.4mAmax.
If current leakage exceeds the specified value, a
shorted circuit is the probable cause.
Locate the short by disconnecting connections one by
one and measuring the current.
CHARGING VOLTAGE INSPECTION
NOTE:
• Make sure the battery is in good condition before
performing this test.
Start the engine and warm it up to the operating
temperature; then stop the engine.
Connect the multimeter between the battery positive(+)
terminal [1] and negative H terminal [2].
NOTE:
• To prevent a short, make absolutely certain which
are the positive and negative terminals or cable.
• Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tester or electrical components.
With the headlight on high beam, restart the engine.
Measure the voltage on the multimeter when the engine
runs at 5,000 r/min.
STANDARD:
Measured BV < Measured CV< 15.5 V
• BV = Battery Voltage (page 21-7)
• CV = Charging Voltage
If the charging voltage reading is out of the
specification, inspect the regulator/rectifier (page 21-9).
21-8
REGULATOR/RECTIFIER
Disconnect the alternator 3P (Gray) connector [1] and
regulator/rectifier 3P (Black) connector [2].
Remove the bolts [3] and regulator/rectifier [4].
SYSTEM INSPECTION
Check connectors for loose contact or corroded
terminals.
, Inspect the following items:

-
-
Battery charging line (page 21-9)
Ground line (page 21-9)
- Charging coil (page 21-10)
If all components of the charging system are normal
and there are no loose connections at the alternator and
regulator/rectifier connectors, replace the regulator/
rectifier.
BATTERY CHARGING LINE
INSPECTION
[1]
Disconnect the regulator/rectifier 3P (Black) connector
(page 21-9).
R
Measure the voltage between the regulator/rectifier 3P
(Black) connector [1] at the wire side and ground .
CONNECTION: Red (+) - Ground (-)
There should be battery voltage at all times.
GROUND LINE INSPECTION

[1]
Disconnect the regulator/rectifier 3P (Black) connector
(page 21-9). G
Check for continuity between the regulator/rectifier 3P
(Black) connector [1] at the wire side and ground .
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21-9
ALTERNATOR CHARGING COIL

CHARGING COIL INSPECTION
Disconnect the alternator 3P (Gray) connector (page
21-9).
Measure the resistance at the stator side 3P (Gray)
connector [1].
CONNECTION: Yellow - Yellow
STANDARD: 0.1-1.00 (20°C/68°F)
[1]
Check for continuity between the alternator 3P (Gray)

connector [1] terminals at the stator side and ground. [1]

STANDARD: No continuity
i
Replace the stator if the resistance is out of
specification, or if any wire has continuity to ground .
For stator replacement (page 11-5).
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21-10 I
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22. LIGHTS/METERS/SWITCHES/ELECTRONIC SUSPENSION
SERVICE INFORMATION··· ············ .. ····· 22-2 HORN ···············································22-47
SYSTEM LOCATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22-4 HSTC················································22-47
Apple CarPlay™ TROUBLESHOOTING··· 22-5 ACCESSORY SOCKET

(CRF11 OOA4/D4) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22-48
HEADLIGHT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22-7
GRIP HEATER {CRF11 OOA4/D4) · · · · · · · · · · · 22-48
TURN SIGNAL LIGHT ·························22-12
BCU ·················································22-52
LICENSE LIGHT································· 22-13
BODY CONTROL SYSTEM
TROUBLESHOOTING INFORMATION · · · 22-54
BRAKE/TAILLIGHT····························· 22-13
BODY CONTROL SYSTEM DIAGRAM · · · 22-55

METER/MID ·······································22-14
BODY CONTROL SYSTEM DTC

r OPEN AIR TEMPERATURE SENSOR ····22-24
INDEX···············································22-56
EOP SWITCH {MT model) · · · · · · · · · · · · · · · · · · · · 22-25

TROUBLESHOOTING · ·· · ···· ···· · ·· · ··· · ···· · 22-57
FUEL LEVEL SENSOR························ 22-25
scu ·················································22-80
IGNITION SWITCH······························ 22-26
ELECTRONIC SUSPENSION SYSTEM
LEFT HANDLEBAR SWITCH················ 22-27 TROUBLESHOOTING INFORMATION · · · 22-81
RIGHT HANDLEBAR SWITCH·············· 22-34 ELECTRONIC SUSPENSION SYSTEM I

SYMPTOM TROUBLESHOOTING · · ···· · ·· 22-82 -
BRAKE SWITCH ································22-41
CLUTCH SWITCH {MT model)·············· 22-44 DIAGRAM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22-83
" PARKING BRAKE SWITCH ELECTRONIC SUSPENSION SYSTEM DTC

{DCT model) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22-44 INDEX··············································· 22-84
NEUTRAL SWITCH {MT model) ············22-45 ELECTRONIC SUSPENSION SYSTEM DTC

TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · 22-85
SIDESTAND SWITCH··························22-45
GPS ANTENNA·································· 22-96
22-1
LIGHTS/METERS/SWITCHES/ELECTRONIC SUSPENSION
SERVICE INFORMATION
GENERAL
• Check the battery condition before performing any inspection that requires proper battery voltage .
• A continuity test can be made with the switches installed on the motorcycle.
Lb = Light blue Lg = Light green 0 = Orange P = Pink R= Red V = Violet
• Only iPhone 5 or newer versions with iOS 10 or later are compatible with Apple CarPlay™. For details on countries and regions
where Apple CarPlay™ is available, as well as information pertaining to function , refer to the Apple homepage.
• Apple CarPlay™'s features and services may be discontinued without notice due to operating system , hardware, software, Apple
CarPlay™'s specification change or newly defined regulation or regulatory amendment. Honda has no warranty as to the
mechanism and function of Apple CarPlay™ provided by Apple.
• If Apple CarPlay™ can not be used, check the following items.
- Is it an Apple CarPlay™ compatible model?
- Is iPhone version up to date?
- Is the Bluetooth® headset connected?
- Is Apple CarPlay™ running with the main switch on?
- Is there a defective contact of the USB cable?
- Is the communication of the mobile network unstable?
- Is there a battery exhaustion or communication failure in the headset?
- Is it connected to USB?
- Is it using an Apple certified USB cable?
- Is the use of Apple CarPlay™ permitted on the equipment use confirmation screen?
- Is the setting on the iPhone side allowed to use Apple CarPlay™?
• Some audio devices and Bluetooth® audio devices may not be compatible.
• Connected Bluetooth® device may be unsupported device. Check the supported Bluetooth® version/profiles.
Supported Bluetooth® version/profiles
Bluetooth® version Bluetooth 2.1 + EDR ;
Bluetooth® profiles HFP (Hand Free Profile) ver. 1.5 1
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(For iPhone, mobile phone or Bluetooth® device) A2DP (Advanced Audio Distribution Profile) ver. 1.2
AVRCP (AudioNideo Remote Control Profile) ver. 1.4
PBAP (Phone Book Access Profile) ver. 1.0
Bluetooth® profiles (For rider and passenger headsets) HFP (Hand Free Profile) ver. 1.7
A2DP (Advanced Audio Distribution Profile) ver. 1.2 J
• You cannot pair a Bluetooth® device and Bluetooth® headsets while the motorcycle is moving. l
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When pairing , park your motorcycle in a safe place. j
• Bluetooth® connection cannot be established while launching Apple CarPlay™. j

• Your motorcycle is not equipped an with intercom function . If you want to use the intercom function , use the intercom function of
your headset.
• Some local governments prohibit the use of a headset by the operator of a motor vehicle .
Always obey applicable laws and regulations.
• Do not use hard disks, card readers, and memory readers which may damage the device and data. If you accidentally connect
the one of them , turn the ignition switch OFF and remove it.
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22-2 '
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TOOL
Test probe, 2 pack
07ZAJ-RDJA 110
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22-3
SYSTEM LOCATION
IGNITION SWITCH
MID USB CONNECTOR
METER
FRONT BRAKE/CRUISE CANCEL SWITCH

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- CLUTCH SWITCH
(MT model)
- CLUTCH CRUISE
CANCEL SWITCH
(MT model) DLC J
- PARKING BRAKE JI
SWITCH J
(OCT model) J
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LEFT
HANDLEBAR
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SWITCH
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HORN
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SIDESTAND SWITCH
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22-4 l
Apple CarPlay™ TROUBLESHOOTING

Apple CarPlay™ Does Not Start-up
- Lightning cable to USB
- Lightning cable to iPhone
To start-up Apple CarPlay™, refer to the motorcycle
Owner's Manual.
1. Power
Check iPhone display.
Is your iPhone turned ON?
YES - GO TO STEP 2.
NO - Turn ON the power switch.
2. Charge status
Is your iPhone charged?
YES - GO TO STEP 3.
NO - Check the Lightning cable.
3. USB connection
Check for USB connection .
Is your iPhone connected to the USB?
YES - GO TO STEP 4.
NO - Apple CarPlay™ only works through USB.
4. Operation message
Does the display show any operation instruction
message?
YES - Set your iPhone operational in its
agreement screen.
NO - GO TO STEP 5.
5. Head set connection
Check for head set connection.
Is the rider's head set connected?
YES - GO TO STEP 6.
NO - Connect the head set and then reconnect
the Lightning cable.
6. MID unit configuration
Check MID unit configuration display.
Is the mode set to Apple CarPlay™?
YES - GO TO STEP 7.
( NO - Set the mode to Apple CarPlay™ and
reconnect the Lightning cable.
22-5
7. iOS version
Check iOS version . J
Does your device have the latest version of iOS?

YES - GO TO STEP 8.
NO - Apple CarPlay™ works only with iPhone 5
or later with iOS 10 or later.
8. iPhone configuration
Check configuration screen.
Is Apple CarPlayr"' enabled in your iPhone's
configuration screen?
YES - GO TO STEP 9.
NO - Set Apple CarPlay™ operational in your
iPhone's configuration screen.
9. License agreement
Check license agreement. ~
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Do you accept the agreement to use Apple 1
CarPlay™? j
YES - The MID unit or its related circuit is faulty.
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NO - If you do not accept the agreement, you
cannot use Apple CarPlay™.
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22-6
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l LIGHTS/METERS/SWITCHES/ELECTRONIC SUSPENSION
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HEADLIGHT
Disconnect the GPS connector [1].
r Remove the wire band [2] .
Disconnect the headlight 6P connector [4] .
CRF1100A4/D4: Disconnect the cornering light 6P connector [5].
' Remove the headlight unit [6].

Remove the collars [7] and grommets [8] from the
headlight unit.
Remove the GPS antenna if necessary (page 22-96).
NOTE:
CRF11 OOD4 shown :
[2]
[4]
22-7
INSPECTION
Check the following before inspection:
- Battery condition
- Blown sub fuse HEAD LIGHT 15 A
- Blown sub fuse HORN/STOP 10 A
- OTC indicated
Check the following lighting condition:
CRF1100A4/D4 shown:
-
-
Headlight [1]
Cornering light (CRF11 OOA4/D4) [2]
~
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NOTE:
• If any LED in the headlight unit does not turn on,
replace the headlight unit as an assembly.
• When the headlight or cornering light does not light
properly, check the following :
- No OTC in the ABS and IMU system
- Headlight power/ground line (page 22-10)
- Faulty circuit between the headlight unit and BCU.
• The cornering light lights up the direction of travel of
the motorcycle when cornering.
MANUALLY ACTIVATING CORNERING LIGHT

To manually activate the cornering light lights, perform
the procedure as follows:
1. Pull and hold the page switch [1 J or touch the clock
area [2] of the MID.
~[2]
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6 8 10
22-8
2. Select the "Cornering Light Service Mode" [1] by
"Cornering Light Service Mode":
using the sel up switch [2], sel down switch [3], sel
[1]
left/right switch [4], ENT switch [5] and back switch
[6] or touch the MID.
NOTE:
Select the display in the following order to the
"Cornering Light Service Mode" :
"Settings" > "Service" > "Service Mode" >
"Cornering Light Service Mode"
3. Check that each light is on .
NOTE:
• In the cornering light service mode, you can switch
left and right by operating the turn signal switch [7] .
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22-9
HEADLIGHT DRIVER
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: BI/Y
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IGNITION
SWITCH
IGN 1 BI/Y - - - - -- Y/B, - - < l . / 0 - R/BI

HEAD LIGHT 15 A
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HEADLIGHT l
DRIVER I
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GND
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1. Headlight Power Input Line Inspection t
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Disconnect the headlight 6P connector (page 22-7).
Measure the voltage at the wire harness side 6P
connector terminal and ground.
CONNECTION: Black/yellow(+) - Ground (-)
STANDARD: Battery voltage
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YES
NO
- GO TO STEP 2.
- • Open circuit in the Black/yellow or
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Yellow/blue wire
• Blown sub fuse HEAD LIGHT 15 A j
2. Headlight Ground Line Open Circuit Inspection J

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6P connector terminal and ground. J
CONNECTION: Green - Ground 1
Is there continuity? J
YES - Faulty headlight unit J
NO - Open circuit in the Green wire 1
22-10
CORNERING LIGHT DRIVER (CRF1100A4/D4)
:BI/W~ftl3
CORNERING LIGHT 6P CONNECTOR
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IGNITION
SWITCH
IGN2 BI/W - - - -Y/W 0./0- - - ~BI

CORNER LIGHT/
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ACC 10 A
CORNERING
LIGHT DRIVER
GND
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f• 1. Cornering light Power Input Line Inspection
Disconnect the cornering light 6P connector (page
22-7).
, connector terminal and ground.

CONNECTION: Black/white (+) - Ground (-)
YES - GO TO STEP 2.
, NO Open circuit in the Black/white or

Yellow/white wire
• Blown sub fuse CORNER LIGHT/ACC
r 10 A
2. Cornering light Ground Line Open Circuit
Inspection
6P connector terminal and ground.
t Is there continuity?
YES - Faulty headlight unit
22-11
TURN SIGNAL LIGHT
TURN SIGNAL LIGHT REMOVAL/
INSTALLATION
FRONT
Remove the front turn signal cover (page 2-15).
Remove the following from the front turn signal light
cover [1] :
- Screw/washer [2]
- Collar [3]
- Turn signal light [4]
- Grommet [5]
REAR
Disassemble the rear fender A (page 2-39).
Remove the following from the rear fender A [1 ]:
- Screw/washer [2]
- Collar (3] J
- Turn signal light [4] I
- Grommet [5] )
AUTO CANCEL TURN SIGNAL

SYSTEM INSPECTION I
Check the following :
[1] ;
- OTC indicated
- Turn signal light
- Left handlebar switch
- Auto cancel turn signal ON/OFF function (MID) [1]
If any parts are OK, replace the BCU with a known good
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one and recheck.
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22-12
LICENSE LIGHT
Disassemble the rear fender A (page 2-39).
[4]
Remove the license light bolts [1] and license light [2].
Remove the following from the rear fender stay [3]:
- Screws [4]
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- Washers [5]
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- Stay [6] [7] - - + ~ [6]
- Grommets [7]
Installation is in the reverse order of removal. ~ ~ [2]
TORQUE:
License light bolt:
2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)
\ [1]
[3]
INSPECTION
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Check that all LEDs in the license light unit illuminate
with the ignition switch turned ON.
r If any LED does not turn on, replace the license light.
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BRAKE/TAILLIGHT
Remove the rear center cowl (page 2-35).
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?[3[
Disconnect the brake/taillight 3P (Black) connector [1]. [2]
0
- Bolts [2]
- Washer [3]
- Brake/taillight unit [4]
Remove the collars [5], grommets [6] from the brake/
taillight unit.
[4]
...
[ 22-13
INSPECTION
Check the brake/taillight [1] operation .
Check that all the brake/taillight LEDs illuminate with
the front brake lever and/or rear brake pedal applied .
If any LED does not turn on , replace the brake/ taillight. j
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[1) l
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METER/MID
- USB connector [1] J
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-
GPS connector [2)
MID 7P connector [3)
Meter 20P connector [4)
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Remove the bolts [5) and meter/MID assembly [6) . ;

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22-14
Remove the following from the meter stay [1]:
- Meter/MID screws [2] and washers [3]
- MID[4]
- Meter [5]
- Grommets [6]
TORQUE:
Meter/MID screw:
1.0 N·m (0.1 kgf·m, 0.7 lbHt)
IMETER/MID side [4]
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[3]
[5]
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PROTECTION FILM REPLACEMENT

Remove the protection film from the MID.
NOTE:
• Be careful not to damage the touchscreen.
Install a new protection film [1] in the following
procedure:
1. Clean the touchscreen of the MID.
2. Peel off the end of film A [2] and set the protection
film on the touch screen .
3. Remove the film A slowly as shown.
NOTE:
(
• Be careful not to let air bubbles or dusts between the
touchscreen and the protection film .
• Push out the air bubbles by using a spatula [3] or
equivalent.
4. Remove the film B [4].
22-15
SYSTEM INSPECTION
NOTE:
• Check for loose or poor contact on the MID and
MID:
meter connectors.
Turn the ignition switch ON, check that all the modes
and digital segments are shown.
If the meter and/or MID do not show initial function,
check the power/ground line (page 22-17). J
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METER:
22-16
METER
METER 20P CONNECTOR

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IGNITION MAIN FUSE

~--------- ---------J SWITCH 30A
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METER
IGN BI/R - - - -- -- - - 81/R - 0 / t > - R/81

METER 10 A
BATT R/W ----.......i---- R/W - - - - - - o . . . / ' 0 - - R ------'

CLOCK/TURN/
Gl
FOG/DRL 15 A
GND
MID
--
1. Meter Power Input Line Inspection

Disconnect the meter 20P connector (page 22-14).
20P connector terminal and ground .
., CONNECTION: Black/red (+) - Ground (-)

YES - GO TO STEP 2.
r • Blown sub fuse METER 10 A
2. Meter Back-up Voltage Line Inspection
CONNECTION: Red/white(+) - Ground (-)
, YES - GO TO STEP 3.
r NO - • Open circuit in the Red/white wire
• Blown sub fuse CLOCK/TURN/FOG/
DRL 15A
3. Meter Ground Line Open Circuit Inspection
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20P connector terminal and ground .
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YES - Faulty meter
22-17
MID
MID 7P CONNECTOR
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: BI/R ?--...:
: _5 1 ----,-
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JJ~,--
1___.,--,--'
I R/W G
IGNITION MAIN FUSE
SWITCH 30A
MID
IGN BI/R - - - - - - t t - - - - - BUR -----<l/0--- RIBI

METER 10 A
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BAIT R/W -------<a---<f----- R/W - - - - - - 0 . / 0 - - - - - R - - ~
CLOCK/TURN/
FOG/DRL 15 A
GND G
1 --
METER
1. MID Power Input Line Inspection

Disconnect the MID 7P connector (page 22-14).
CONNECTION: Black/red (+) - Ground (-)
YES - GO TO STEP 2.
• Blown sub fuse METER 10 A
2. MID Back-up Voltage Line Inspection
CONNECTION: Red/white (+) - Ground (-)
YES - GO TO STEP 3.
DRL 15 A J
3. MID Ground Line Open Circuit Inspection .,
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YES - Faulty MID
22-18
INDICATOR TROUBLESHOOTING
METER
When the meter shows the following symptoms, check
the items in the following diagnosis procedure:
Meter function Symptoms Diagnosis procedure
.
ABS INDICATOR Indicator comes on
. Check the OTC
Indicator does not comes on when the . Check the meter

Check the ABS indicator circuit (page
ignition switch turned ON
When the motorcycle is running but .. 20-11)
Check the meter
indicator does not go off (No OTC) Check the ABS modulator
, ALARM INDICATOR Does not operate properly . Check the alarm (option) or its related
circuit
. Check the meter
.
AT INDICATOR Does not operate properly
. Check the CAN communication line
Check the meter
AUTO CRUISE SET Does not operate properly .. Check the CAN communication line
INDICATOR Check the meter
AUTO CRUISE ON Does not operate properly . Check the CAN communication line
INDICATOR . Check the meter
FUEL RESERVE Does not operate properly . Check the fuel reserve sensor (fuel
INDICATOR
.. pump unit) or its related circuit
Check the meter
SHIFT INDICATOR "-" blinks
.. Check the OTC
Check the meter
HIGH BEAM INDICATOR Does not operate properly Check the CAN communication line
. Check the meter
.
COOLANT TEMPERATURE
INDICATOR
Does not operate properly
Check the ECT sensor or its related
circuit
. Check the meter
HISS INDICATOR Does not operate properly . Check the CAN communication line
. Check the meter
I LOW OIL PRESSURE Indicator does not come on with the ignition . Check the open circuit in the EOP switch
INDICATOR
(MT model)
switch turned ON
.. wire
Check the EOP switch
Check the meter
Indicator does not go off with the engine . Check the engine oil level
.
running
. Check the engine oil pressure
Check the short circuit in the EOP switch
wire
. Check the EOP switch
. Check the meter
MIL MIL comes on or blinks
.. Check the OTC
Check the meter
.
When the ignition switch ON, the MIL does
not come on .. Check the CAN communication line
Check the meter
When the ignition switch ON , the MIL does
not go off within a few seconds (No OTC) . Check the CAN communication line
Check the short circuit in the Yellow wire
.. between the ECM and DLC

Check the ECM
Check the meter
NEUTRAL INDICATOR Does not operate properly . Check the CAN communication line
. Check the neutral switch or its related
circuit
l . Check the meter
PARKING BRAKE Indicator does not come on with the parking . Check the open circuit in the parking
INDICATOR (OCT model) brake lever applied brake switch wire
.. Check the parking brake switch

Check the meter
Indicator does not go off with the parking . Check the short circuit in the parking
brake lever released
.. brake switch wire
Check the parking brake switch
Check the meter
22-19
Meter function
REAR ABS INDICATOR
Symptoms
Indicator does not come on in the rear ABS . Diagnosis procedure
Check the open circuit in the rear ABS
OFF mode
.. indicator circuit
Check the meter
Check the ABS modulator
Indicator does not go off in the rear ABS ON . Check the short circuit in the rear ABS
mode indicator circuit
.
.
..
Check the meter
Check the ABS modulator
SUSPENSION INDICATOR Indicator lights or blinks while riding Check the OTC
(Electronic suspension Check the meter
model)
S MODE LEVEL
INDICATOR
Does not operate properly
.. Check the CAN communication line
Check the meter
SPEEDOMETER Speedometer displays "O km/h" while riding .. Check the VS sensor or its related circuit
TORQUE CONTROL Indicator comes ON while riding . Check the meter
Check the CAN communication line
. Check the meter
INDICATOR
TORQUE CONTROL OFF Does not operate properly .. Check the CAN communication line
INDICATOR Check the meter
TURN SIGNAL INDICATOR Does not operate properly .. Check the CAN communication line
Check the meter
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22-20
MID
When the MID shows the following symptoms, check
the items in the following diagnosis procedure:
MID function Symptoms Diagnosis procedure
SPEEDOMETER "---" is displayed and blinks
Unit blinks .. Check the MID
Check the meter
TACHOMETER Does not operate .. Check the CAN communication line
Check the MID
. Check the meter
SHIFT INDICATOR "-" blinks . Check the OTC
. Check the MID
.
r GRIP HEATER INDICATOR Blinks .. Check the meter
Check the OTC
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.. (CRF1100A4/D4)
.. Check the CAN communication line
Check the BCU
Check the MID
. Check the meter
I FUEL GAUGE The fuel gauge flashes in all segments . Check the CAN communication line
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r brink (page 22-25) . Check the fuel level sensor or its related
r
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.. circuit
Check the MID
..
Check the meter
COOLANT TEMPERATURE All segments blink Check the CAN communication line
GAUGE Check the ECT sensor or its related
circuit
. Check the MID
. Check the meter
CRUISE CONTROL SET SPEED Display is not update . Check the CAN communication line
. Check the MID
. Check the meter
.
..
CLOCK "--:--" is displayed and blinks Check the MID
AIR TEMPERATURE GAUGE Display is not update Check the CAN communication line
Check the open air temperature sensor
fr .. or its related circuit
Check the MID
Check the meter
TRIPMETER Display is not update
[TRIP A/BJ
CURRENT FUEL MILEAGE Display is not update
[INST. CONS.]
AVERAGE FUEL MILEAGE Display is not update
[AVG. CONS.]
AVERAGE SPEED Display is not update
[AVG. SPD.] . Check the CAN communication line
FUEL CONSUMPTION Display is not update . Check the MID
[CONS.]
TRIP TIME Display is not update
. Check the meter
[ELAPSED]
AVAILABLE DRIVING DISTANCE Display is not update
[RANGE]
SUBTRACTION TRIP Display is not update
[-TRIP]
BATIERY VOLTAGE Display is not update
[VOLTAGE]
DATE Display is not update . Check the MID
[DATE]
INDICATORS ([P], [EB], [TJ, [G], Indicators ([PJ, [EB], [T], [ABS mode], .. Check the CAN communication line
[ABS mode], [SJ) [SJ) blink
. Check the MID
Check the meter
22-21
MID SOFTWARE UPDATE
PROCEDURE
Connect the USB flash memory [1] to the USB
connector.
NOTE:
• Use the USB flash memory in which only the file to
be updated is stored .
2. The update starts automatically, so wait for it to

[1 J
finish.
NOTE:
• You can check the status of the update on "Software
Update" [1] .
• Select the display in the following order to the
"Software Update":
"Settings" > "Service" > "System Information" >
"Software Update"
3. When updating is complete , MID restarts .

[1 J
NOTE :
j
• You can check the software version on "Software
Version" [1] .
"Software Version" :
"Settings" > "Service" > "System Information" >
"Software Version"
Disconnect the USB flash memory from the USB
connector.
22-22
TOUCHSCREEN CALIBRATION
1. Select the "Touchscreen Calibration" [1].
[1]
NOTE:
"Touchscreen Calibration":
"Settings" > "Service" > "Initialize" > "Touchscreen
Calibration"
2. Touch the centre of each cross [1] once.

[1] [1]
The screen flashes green when calibration is
complete.
If calibration fails, the screen flashes red.
Try step 2 again.
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22-23
OPEN AIR TEMPERATURE SENSOR
CRF1100A/D
Disconnect the open air temperature sensor 2P
connector [1].
Remove the open air temperature sensor screw [2].
Remove the open air temperature sensor [3].
TORQUE:
Open air temperature sensor screw:
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
CRF11 OOA4/D4
Remove the right inner cover (page 2-11 ).
[1)~ (2)
Remove the open air temperature sensor screw [1] and
open air temperature sensor [2].
Installation is in the reverse order of removal. ----------
TORQUE:
Open air temperature sensor screw:
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
)
INSPECTION l
Remove the open air temperature sensor 2P connector. l
- CRF1100ND: (page 22-24) j
- CRF1100A4/D4: (page 2-11) ,j
Measure the resistance at the 2P connector [1] of the ll

sensor side. (1)
STANDARD: 4.9 - 5.1 kO (25°C/77°F) ;'
Replace the open air temperature sensor if
measurement is out of specification.
22-24
EOP SWITCH (MT model)
r Drain the engine oil (page 3-12).
f Remove the bolt/washer [2] and disconnect the EOP
switch terminal [3].
Remove the EOP switch [4].
TORQUE:
EOP switch:
12 N·m (1.2 kgf·m, 9 lbMt)
EOP switch terminal bolt/washer:
2.0 N·m (0.2 kgf·m, 1.5 lbMt)
NOTE:
• Apply sealant (TB 12078 manufactured by
ThreeBond or equivalent) to the EOP switch treads.
Be sure to leave 3 - 4 mm (0.1 - 0.2 in) at the end of
the switch treads free of sealant.
. Fill the engine oil with the recommended engine oil
(page 3-12).
! [4]
FUEL LEVEL SENSOR
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SYSTEM INSPECTION
The fuel meter indicates the warning display
When an open or short circuit occur in the fuel meter
system, all segments of the fuel gauge indicator will
blink as shown with the ignition switch turned ON.
Gold/Bronze image shown:
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Open or short circuit in the Red/blue and/or Blue
wires between the fuel level sensor and meter
Open circuit in the Green wire between the fuel level
sensor and ground
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If they are normal, inspect the fuel level sensor (page
22-26).
If the fuel level sensor is normal, replace the fuel pump
unit with a new one (page 7-8) and recheck.
Fuel meter does not operate properly

NOTE:
• Check the initial operation of the MID first (page 22-
16).
Inspect the fuel level sensor (page 22-26).
If the fuel level sensor is normal, replace the MID and
recheck.
22-25
FUEL LEVEL SENSOR REMOVAL/
INSTALLATION
Remove the nuts (1).
Remove the fuel level sensor (2) and 0-ring (3).
NOTE:
Replace the 0-ring with a new one. J
• Align the sensor plate hole (4) with the tank boss.
FUEL LEVEL SENSOR INSPECTION

Remove the fuel level sensor (page 22-26). (2)
R/Bu G
~
Connect the ohmmeter to the fuel level sensor 2P
(Black) connector (1).
CONNECTION: Red/blue - Green
Measure the resistance with the float (2) at the full and
empty positions.
CRF1100A/D:
FULL EMPTY
IResistance 6-10 0 434-446 0
[1 J
EMPTY
CRF1100A4/D4:
FULL EMPTY
IResistance 6-10 0 328-338 0
If it is out of specification, replace the fuel level sensor

(page 22-26).
IGNITION SWITCH
Remove the top bridge (page 17-47).
Remove the ignition switch mounting bolts (1) and J
ignition switch (2).
NOTE:
• Use a drill or an equivalent tool when removing the
ignition switch mounting bolts.
TORQUE:
Ignition switch mounting bolt:
26 N·m (2.7 kgf·m, 19 lbHt)
NOTE:
• Replace the ignition switch mounting bolts with new
ones.
22-26
INSPECTION
Disconnect the ignition switch 2P connector [1] .
Check for continuity between the ignition switch side
connector terminals in each switch position.
Refer to the wiring diagram for the terminals and switch
status:
r
[1)
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R/BI R

REMOVAL
- Left knuckle guard (page 2-22)
- Left inner cover (page 2-9)
- Left handlebar switch 12P connector [1]
(electronic suspension model only)
Remove the wire band [1] :

Remove the socket bolt [2] and stay [3].
Release the left handlebar switch wire clip [4] from the
stay.
22-27
Remove the left rearview mirror [1].
Remove the wire clamp [1].

Release the wire clip [2] from the stay.
- Left grip heater 2P connector [3]
(electronic suspension model only} ;
I
I
MT model: Remove the wire clamps [1].

- Clutch switch connectors (upper side} [2]
- Cruise cancel switch connectors (lower side} [3] .•
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~
OCT model: Remove the wire clamps [1].
Disconnect the parking brake switch connectors [2].
'
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J
•
22-28
MT model: Remove the bolts [1] ,
assembly [3].
OCT model: Remove the bolts [1] , h_older [2], and parking brake
lever assembly [3].

Remove the left handlebar switch screws [2].
Separate the left handlebar switch housing [3].

Remove the left handlebar switch front housing [2] by
opening the setting plate [3].
[1]
22-29
INSTALLATION
Install the left handlebar switch front housing [1] .
NOTE:
Install the left handlebar switch rear housing [1].

Install and tighten the left handlebar switch screws [2] to
Install a new wire band [3].
MT model: Install the clutch lever assembly [1] by aligning its end
the lower bolt [5].
OCT model: Install the parking brake lever assembly [1] by aligning I
its end with the paint mark on the handlebar. J
Install the holder [2] with its punch mark [3] facing up. 1
Install the bolts, and tighten the upper bolt [4] first, then j
the lower bolt [5] . l
j
l
.'
22-30
MT model: Connect the following:
OCT model: Connect the parking brake switch connectors [1].

Install the wire clip [1].

Install the wire clamp [2].
- Left grip heater 2P connector [3]
Install the left rearview mirror [1].
22-31
Install the left handlebar switch wire clip [1] to the stay.
Install the stay [2] and socket bolt [3] .
NOTE:
• Align the stay tab with the frame hole.
Tighten the socket bolt securely.

Left handlebar switch 12P connector [1]
Left knuckle guard (page 2-22)
- Left inner cover (page 2-9)
22-32
INSPECTION
NOTE:
• Before inspection, check that there is no DTCs.
Measure the resistance between the left handlebar
switch side 12P connector [1] terminals when each
switch is operated .
[1]
[9] [8] [5] [2)
[7] [10] [3] [6) [4)
CONNECTION: STANDARD (at 25°C/77°F):

Blue [2] - Green/blue [3] Headlight dimmer switch: 95.5 - 105.5 0
Passing light control switch: 338.9 - 374.7 0
White/black [4]- Green/blue [3] Page switch : 1609.6-1779.1 0
Voice control switch: 736.1-813.7 0
Function lever (up): 95.5 - 105.5 0
Function lever (down): 338.9 - 374.7 0
White/blue [5] - Green/blue [3] Sel left switch: 95.5 - 105.5 0
Back switch: 338.9 - 374.7 0
Sel up switch: 736.1-813.7 0
Sel down switch: 1609.6-1779.1 0
White/red [6] - Green/blue [3] Sel right switch: 95.5 - 105.5 0
ENT switch: 338.9 - 374.7 0
Skip switch: 736.1 - 813.7 0
Goes back switch : 1609.6-1779.1 0
White/green [7] - Green/blue [3] Horn switch: 95.5 - 105.5 0
Favorite switch : 338.9 - 374.7 0
White/yellow [8] - Green/blue [3] Turn signal left switch: 736.1-813.70
Turn signal right switch: 1609.6-1779.1 0
Turn signal cancel switch: 338.9- 374.7 0
Hazard switch : 95.5 -105.5 0
DCT model only:

Black/blue [9] - Green/white [1 OJ Shift up switch (+) : I 406.9 - 449.8 0
Shift down switch(-) : I 267.8 - 296.1 0
Replace the left handlebar switch if any switch
resistance is not standard value.
!
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22-33
RIGHT HANDLEBAR SWITCH
REMOVAL
Right knuckle guard (page 2-22)
- Right inner cover (page 2-9)
Right handlebar switch 4P connector [2]
Grip APS 8P connector [3]
- Right grip heater connector (4]
Remove the wire band A clip [1] and wire band B clip [2]
from the stays.
Remove the right rearview mirror [1].

[1J
Remove the wire clamp [1]. J

Electronic Disconnect the front suspension stroke sensor J
suspension model connector [2].
only:
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4
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22-34
Remove the wire clamp [1] .
Front brake switch connectors (upper side} [2]
Remove the bolts [1] , holder [2] , and front master

cylinder [3].
NOTE:
• Keep the front master cylinder upright to prevent air
from entering the hydraulic system.

Remove the right handlebar switch screws [2].
Separate the right handlebar switch housing [3].
CRF1100A4/D4: Release the wire clip [4] .
Remove the screw [1] .

Remove the right handlebar switch housing [2] and
throttle grip pipe [3].
22-35
[2]
Remove the grip APS [2] by opening the setting plate
[3].
DISASSEMBLY
Remove the right handlebar switch (page 22-34 ).
[1] [4]
- Wire band A [1]
- Wire band B [2]
- Wire protector [3]
Remove the grip APS [4] from the right handlebar
switch rear housing [5].
[2] [3] [5]

J
ASSEMBLY i
Temporarily set the following to the right handlebar

[1 ] [2]
switch rear housing [1]:
- Grip APS [2]
- Throttle grip pipe [3]
[3]
Secure the following wires with new wire band A [1] to

[2]: 360 ± 10 mm (14.2 ± 0.4 in)
specified range as shown.
[3]: 355 ± 10 mm (14.0 ± 0.4 in)
- Grip APS wire [2]
- Right handlebar switch wire [3]
- Right grip heater wire [4] (CRF11 OOA4/D4)
NOTE:
• Install the wire band A so that its clip is in the
direction as shown.
[1 ]
[4] : 365 ± 10 mm
(14.4 ± 0.4 in)
22-36
Secure the following wires with new wire band B [1] and
wire protector [2] to specified range from the wire band [4]: 230 ± 5 mm (9.1 ± 0.2 in)
A [3] as shown. [5]: 215 ± 5 mm (8.5 ± 0.2 in)
[6]: 225 ± 5 mm (8.9 ± 0.2 in)
- Grip APS wire [4]
- Right handlebar switch wire [5]
- Right grip heater wire [6] (CRF11 OOA4/D4) [2] [4] [5]
NOTE:
· • Install the wire band B so that its clip is in the
direction as shown.
Remove the following from the right handlebar switch
rear housing:
- Grip APS [1] [6] [3]
- Throttle grip pipe
INSTALLATION
Install the grip APS [1].
[1]
NOTE:
Install and tighten the screw [3] securely:
Apply grease to the throttle grip pipe [1] and APS [2]
contact area as shown.
3mm -Siim
,
·---pS: 3mm
(0.1 in)
r• [2]
...~
3mm
(0.1 in)
---fiimi
5mm
~
(0.2 in)
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! 22-37
Install the throttle grip pipe [1] as shown .
[1]
NOTE:
• Align the throttle grip pipe tabs [2] with the grip APS
grooves [3].
Install the right handlebar switch rear housing [1].

NOTE:
• Align the rear housing tabs with the holes.
,•.
Install the right handlebar switch front housing [1]. I

I
NOTE:
1
• Align the front housing boss with the hole.
I
Install and tighten the right handlebar switch screws [2]
to the specified torque. l
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) I
j
Install a new wire band [3] .
i
l
CRF1100A4/D4: Install the wire clip [4] .
Install the front master cylinder [1] by aligning its end

Install the front master cylinder holder [2] with its "UP"
mark [3] facing up.
Install the front master cylinder bolts, and tighten the
upper bolt [4] first, then the lower bolt [5] to the specified
torque.
J
22-38

Electronic Connect the front suspension stroke sensor connector
suspension model [2].
only:
Install the right rearview mirror [1] .

[1]
Install wire band A clip [1] and wire band B clip [2] to the
stays.
[2]
22-39
Connect the following :
- Grip APS 8P connector [3]
- Right grip heater connector [4]
- Right knuckle guard (page 2-22)
- Right inner cover (page 2-9)
NOTE:
• Route the hoses and wires properly (page 1-26). l
INSPECTION
'
1
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NOTE:
• Before inspection, check that there is no DTCs.
STARTER SWITCH INSPECTION
I )
(page 22-34 ). [1]

;
Check the continuity between the switch side 12P
connector [1] terminals. . l
•
CONNECTION: Black - Green/black t
There should be continuity only when the starter switch j
is pushed. I
If the starter switch is OK, check the following:
- Open circuit in the Gray wire between the ECM 39P 1
:
(Black) connector and right handlebar switch 12P I
(Black) connector
- Open circuit in the Gray wire between the right J
handlebar switch 12P and ECM 33P (Black) '----- - - - - - - - - - - - -- - -~
J
connectors
- Open circuit in the Gray wire between the ECM 33P J
(Gray) and right handlebar switch 12P connectors
- Engine stop switch function (page 22-40) J
If the wires are OK, replace the ECM with a known good l
J
one and recheck. •'"i
ENGINE STOP SWITCH INSPECTION
.I
[1] I
(page 22-34 ).
)
Check the continuity between the switch side 12P
connector [1] terminals. '
CONNECTION: White/blue - Green/black
j
There should be no continuity only when the engine .
stop switch is OFF.
If the engine stop switch is OK, check the following : J'
- Open circuit in the White wire between the ECM 33P I
-
Open circuit in the Gray wire between the right
handlebar switch 12P and ECM 33P (Black)
J
,
connectors
Short circuit in the White wire between the ECM 33P
'.
)
•
If the wire is OK, replace the ECM with a known good )
one and recheck.
j
•
22-40
OTHER SWITCHES INSPECTION
Measure the resistance between the right handlebar
switch side 12P connector [1 ] terminals when each
switch is operated.
[1]
[3] [5] [4] [8]

t
Green/blue [2] - Blue [3] Function switch: 95.5-105.5 Q
t
'
White/black [4] - Green/black [5] Cruise control main switch: 85.2-94.1 Q
SET/- Cruise control lever: 187.2 - 207.0 Q
White [6] - Green/black [5] RES/+ Cruise control lever: 87.8-97.0 0
DCT model only:
Black/blue [7] - Green/white [8] N switch: 85.2- 94.1 0
D-S switch: 187.2 - 207.0 Q
AIM switch: 372.4-411 .70
Replace the right handlebar switch if any switch
resistance are not standard value.
BRAKE SWITCH
FRONT
Refer to front master cylinder service (page 19-15).
REAR
Remove the front cross plate (page 7-8).
Disconnect the rear brake switch 4P connector [1].
Release the rear brake switch wire from the guide [2].
22-41
l
Disconnect the rear brake switch spring [1 ].
[3]
Remove the boot [2].
Remove the rear brake switch [3].
Remove the adjust nut [4].
Installation is in the reverse order of removal. (4)
,,f
NOTE:
• Route the wire properly (page 1-26). (2)
[1)
INSPECTION
FRONT
Disconnect the front brake switch connectors (upper
side) [1] .
Check for continuity between the front brake switch side
terminals.
There should be continuity with the brake lever applied,
and there should be no continuity with the brake lever
released.
I
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J
;
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Disconnect the cruise cancel switch connectors (lower
side) [1]. j
!
Check for continuity between the front brake switch side I
l
terminals. 4
There should be no continuity with the brake lever
applied, and there should be continuity with the brake I
lever released . ~=s ..
1
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22-42 'j
REAR
Disconnect the rear brake switch 4P connector [1] .
Check for continuity between the rear brake switch side
4P connector terminals.
CONNECTION:
Brake switch side: Black - Black
There should be continuity with the brake pedal applied,
and there should be no continuity with the brake pedal
released .
CONNECTION:
Cruise cancel switch side: White - Green
There should be no continuity with the brake pedal ~ - - -......-
applied, and there should be continuity with the brake
pedal released.
[1]
22-43
CLUTCH SWITCH (MT model)
Refer to clutch lever service (page 12-26). I
J
INSPECTION
Disconnect the clutch switch connectors (upper side) p i - . . , . ~ ~ ~ ~ ~
[1 ).
Check for continuity between the clutch switch side
terminals.
There should be continuity with the clutch lever applied,
and there should be no continuity with the clutch lever
released.
Disconnect the cruise cancel switch {lower side) [1) .

Check for continuity between the cruise cancel switch
side terminals.
There should be continuity with the clutch lever applied,
and there should be no continuity with the clutch lever
released .
PARKING BRAKE SWITCH (DCT model) j

l
REMOVAL/INSTALLATION l
Refer to parking brake lever service (page 19-24 ).
•
INSPECTION ;
Disconnect the parking brake switch connectors [1) and l
check for continuity between the terminals. l
There should be continuity with the parking brake lever •
applied , and there should be no continuity with the
parking brake lever released.
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22-44
'
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i-- LIGHTS/METERS/SWITCHES/ELECTRONIC SUSPENSION
'
NEUTRAL SWITCH (MT model)
" Release the rubber cap [1].
Remove the nut [2] and disconnect the neutral switch
terminal [3].
Remove the neutral switch [4] and sealing washer [5].
l- TORQUE:
~
Neutral switch:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Neutral switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
NOTE:
• Apply engine oil to the neutral switch threads and
seating surface.
SIDESTAND SWITCH
r
I
'I Remove the battery box (page 21-6).
MT model: Remove the shift spindle cover (page 12-20).
OCT model: Remove the following:
- Left rear cover (page 2-26)
Disconnect the sidestand switch 2P (Black) connector
[1].
MT model: Remove the clamp [1].
22-45
Remove the sidestand switch bolt [1] and sidestand _.,--,.._.......,..-:---:::= --:-""""!11:::-..-
switch [2].
,'
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J
,
i
Remove the left main step bracket bolts [1] and left
main step bracket [2] .
1
1
J
.
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TORQUE:
Left main step bracket bolt:
35 N·m (3.6 kgf·m, 26 lbf·ft) ,.'
Sidestand switch bolt:
10 N·m (1.0 kgf·m, 7 lbf·ft) J
NOTE:
;
hole [2].
spring holding pin [4] .
Replace the sidestand switch bolt [5] with a new ===-- - = ' - - - - - - - -- - -- - - ---'
one.
INSPECTION
Disconnect the sidestand switch 2P (Black) connector
(page 22-45). [1) .'• I
Check for continuity at the switch side 2P (Black) I

CONNECTION: Green/white - Green
There should be continuity with the sidestand retracted G/W G
. ~
and no continuity with the sidestand lowered.

'
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, .
'
;
,
,;
22-46
'
f
HORN
Disconnect the horn connectors [1] from the horn [2] .
Remove the bolt [3] and horn .
NOTE:
• Rest the horn stay [4] against the stopper [5] .
INSPECTION
Disconnect the horn connectors from the horn (page
22-47).
Connect the 12 V battery to the horn [1] terminal
directly.
The horn is normal if it sounds when the 12 V battery is
connected across the horn terminals.
BATTERY
',.
HSTC
, NOTE:
The HSTC system utilizes various PGM-FI/ABS
components. If any of the related items and/or circuit
has problem, the system will fail and the torque
control indicator remains on in order to notify the
rider of the problem.
• If any OTC is indicated, repair the malfunctioned
part(s) first.
• Do not change the drive/driven sprocket gear teeth
number and tier size. It may cause incorrect HSTC
operation .
SYSTEM INSPECTION
PRE-START SELF-DIAGNOSIS PROCEDURE
1. Turn the ignition switch ON and engine stop switch
"O".
2. The torque control indicator turns ON .
3. Start the engine.
4. Test ride the motorcycle and increase the
motorcycle speed to approximately 10 km/h (6 mph).
5. The system is normal if the indicator goes off.
22-47
ACCESSORY SOCKET (CRF1100A4/D4)
REMOVAL/INSTALLATION I•
.:
j
Remove the ring nut [1]. J
Remove the accessory socket [2] from the inner panel
cover [3].
-l
i
Installation is in the reverse order of removal. l
;
NOTE:
''
• Align the accessory socket boss [4] with the inner
[2]
panel cover groove [5]. ;
.
<j
;
SYSTEM INSPECTION
Disconnect the accessory socket 2P connector (page 2-
[1]
18).
.'•
Y/W G
CONNECTION: Yellow/white (+) - Green (-)
There should be battery voltage with the ignition switch 8
turned ON.
If there is no battery voltage, inspect the following:
- Open circuit in the Yellow/white or Green wire
- Blown sub fuse CORNER LIGHT/ACC 10 A
If the circuits are OK, replace the accessory socket ~ - -- - - - - - - - - - - -- ~
(page 22-48).
GRIP HEATER (CRF1100A4/D4)

REPLACEMENT
LEFT GRIP HEATER
Remove the left knuckle guard (page 2-22).
Release the wire clamp [1] .
.
Disconnect the left grip heater 2P connector [2].
'
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,;
.
J
22-48
Separate the left handlebar switch (page 22-27).
[2]
Remove the left grip heater [2].
Clean the outside surface of the left handlebar [1] and

inside surface of the new left grip heater [2]. Apply Honda Bond A or Pro Honda
Handgrip Cement (U.S.A. only).
Apply 1.0 g (0.04 oz) of Honda Bond A or Pro Honda
Handgrip Cement (U.S.A. only) to the outside surface of
the left handlebar and inside surface of the left grip
heater.
\
,
[1]
Apply Honda Bond A or Pro Honda

Handgrip Cement (U.S.A. only).
[2].,
,
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22-49
Spray isopropyl alcohol over the outside of the
Spray isopropyl alcohol.
handlebar [1] and inside of the grip heater [2].
,,
~\~
Install the left grip heater to the handlebar.
I NOTICE I
• Do not tap the grip end with a hammer and do not
twist the grip with force to insert the left grip heater
\
onto the handlebar, as it can damage the element. i
• If the grip gets stuck halfway during installation, l
apply isopropyl alcohol to the gap between the grip I
heater and handlebar. Do not try to remove the left
[1)
grip heater using force or tools as the grip heater
element can be damaged. Spray isopropyl alcohol.
NOTE:
• Push the left grip heater in tight against the left
handlebar switch housing.
• Align the left grip heater wire end with the left J
handlebar switch front housing groove.
• Allow the adhesive to dry for at least 1 hour before !
~
touching or checking the heater operation.
• When checking the heater operation, do not set the [2]
',
heater level higher than level 2.
• Make sure to turn off the heater switch after the
operation check.
'
#
• Do not set the heater level higher than level 2 for the
first week after installation.
Install a new wire band [3].
i
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[3]
Install the left handlebar switch (page 22-30).

Install the wire clamp [1]. I
Connect the left grip heater 2P connector [2].
•
j
I
RIGHT GRIP HEATER

Refer to the right handlebar switch servicing (page 22- ...
34 ).
22-50
FAILURE SYMPTOM CHECK
NOTE:
• If there is a malfunction in the grip heater system,
the grip heater indicator (1) blinks as shown.
If there is a malfunction, check the following :
- Body control system OTC (page 22-54)
- Grip heater resistance (page 22-51)
The grip heaters and their circuits are OK, check the [1]
following :
- MID (page 22-14)
- BCU (page 22-52)
GRIP HEATER RESISTANCE

INSPECTION
,
I Disconnect the following :
[1]
- Left grip heater 2P (Black) connector (page 22-28)

- Right grip heater 2P (Black) connector (page 22-34)
Disconnect the left grip heater 2P (Black) connector
and right grip heater 2P (Black) connector.
Measure the resistance between the grip heater
connector (1) terminals at the grip heater side.
CONNECTION:
Left: Black - Black
Right: Black - Black
STANDARD: 1.7 - 2.1 0 (at 25°C/77°F)
If the resistance is out of specification, replace the grip

heater.
.,
I
22-51
BCU {Body Control Unit)
BCU
IMU 4P (Black) connector [1]
- Rear brake switch 4P connector [2]
- Rear wheel speed sensor 2P (Black) connector [3]
Release the rear brake switch wire, rear wheel speed
sensor wire, and main wire harness from the guides [4].
Release the main wire harness clip [5] .
Disconnect the BCU 39P (Black) connector [1]. ,I

Release the tabs [2].
Open the cover [3] and remove the BCU [4].
l
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1
)
BCU TRAY
- BCU: (page 22-52)
- TCM (OCT model only): (page 13-65)
Remove the trim clip [1]. J
I
Release the tab [2]. !
I
Remove the BCU tray [3] and collars [4]. l
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22-52
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BCU 39P (Black) CONNECTOR
G/Bu~ R/Bu 1
i ~!Illfl IJJnt::
I
~------- --------------J
IGNITION
SWITCH
MAIN FUSE
30A
_J
'
BCU
IGN - - - - - - ----<a....,'"'Q>----- R/BI R
METER 10 A
BAT1
•
I BAT2
rI G HEATER 10 A
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I
GND G/B,
1
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1. BCU Power Input Line Inspection
Disconnect the BCU 39P (Black) connector (page
22-52).
r Measure the voltage between the wire harness side
39P (Black) connector terminal and ground.
r
TOOL:

I Is there battery voltage?

YES - GO TO STEP 2.
,
r
•I
2. BCU Back-up Voltage Line Inspection
,
t 39P (Black) connector terminal and ground.
TOOL:
t CONNECTION:
,
l
;
Back-up 1: Red/white (+) - Ground (-)
Back-up 2: Red/blue (+) - Ground (-)
,, Is there battery voltage?

YES - GO TO STEP 3.
r NO Back-up 1 side:
! - Open circuit in the Red/white wire

- Blown sub fuse CLOCK/TURN/FOG/
DRL 15 A
' • Back-up 2 side:
- Open circuit in the Red/blue wire
- Blown sub fuse G HEATER 10 A
22-53
3. BCU Ground Line Open Circuit Inspection
39P (Black) connector terminal and ground .
TOOL:
CONNECTION: Green/blue - Ground

YES - Faulty BCU
NO - Open circuit in the Green/blue wire
BODY CONTROL SYSTEM

TROUBLESHOOTING INFORMATION
MCS INFORMATION
DTC READOUT
NOTE:
• If the MIL blinks, check the PGM-FI OTC (page 4-6).
If there is any problem in the PGM-FI system,
troubleshoot it first. Then recheck the body control
system after erasing the PGM-FI OTC.
Read the OTC and stored data with the MCS .
To read the OTC with the MID, refer to the PGM-FI
system (page 4-7).
Perform the troubleshooting procedure by following the
body control system OTC index (page 22-56).
ERASING DTC
22-54
BODY CONTROL SYSTEM DIAGRAM

BCU
RIGHT HANDLEBAR SWITCH
y
Gr 2 sw1 1
(M F SEL SW)1
ALTERNATOR f f i REGULATOR G
/RECTIFIER
II
FUNCTION 10
SWITCH lO j_
r :
CLOCK/TURN
lRR -
r
LEFT HAN DLEBAR SWITCH C
/FOG/DRL 15A R
~ W 19 sw2 1 R/W R Bl
t
I'
""°''G"'~
DIMMER
(DI MMER) I 39 BAT1
%
G HEATER
" MAIN FUSE
I SWITCH 30A l+I 1-1
PASS ING LIGHT R/Bu 10A R
I
CONTROL 1lo
I 13 BAT2
- "- IBATIERYI
SWITCH • METER
t W/BI
24 sw~ I BI/R 10A R/BI
INGSW
r FUNCTION ~0
LEVER
(MF UP) I 26 ING '
R/BIO ~
-=-=
-
r (UP)
FUNCTION 0 I-
l LEVER 1
(DOWN) IC2..._• HORN/STOP
VOICE IOI,... BI/R 10A R/BI
127 HORN IN
CONTROL ~ L
SWITCH '
~-
11 HORN OUT
PAGE~O .... R/BI R/BI Y/W
SWITCH )Q : '-_
-~
Br 22 CORN ER LIGHT
sw; I /ACC 10A
SEL LEFT 16 (SEL LEFT)
HEAD LIGHT 15A
SWITCH
Y/Bu Y/Bu
i- ~
BACK 1 0 ':!.-
r
14 H/L LO
SWITCH IL
SELUP 1 0
SWITCH IL
'""I
120 H/L HI
-
Bu
HEADLIGHT
r'
I
SELDOWN 1 0 -
SWITCH JO I ------- I
~6
W/R
21 sw1 l ...E I
I
BI/W I
I
SEL RIGHT (SEL RIGHT)
V - , Br/Bu I
SWITCH
.... I 31
H
CL 1
I
I
!r
p Br/Bl
ENT~O I 30 CL_2
I CORNERI NG
SWTICH l L
SKIP~O
i-• 129
q:
CL 3
y I
I
Bl LIGHT
SWITCH l L Be I
Br
12s CL LR
GOEs 1 0 '- I
f BACK ~
SWITCH lo n 11 6 W/L FR
Lb Lb d ' G RIGHT FRONT
I
I ...E
HAZARD ~6
Lg 23 sw~ I
(HAZ/TURN) 11 7 0 0
~
d' G
TURNSIGNAL LIGHT
LEFT FRONT
1
-
------------ CRF1 100A4/0 4
W/L FL
SWITCH ~ TURNSIGNAL LIGHT
Lb Lb d ' G RIGHT REAR
TURN SIGNAL ~0
i- ~
f 18 W/L RR ......,, TURNSIGNAL LIGHT
CANCEL SWITCH IL 0 0 d' G LEFT REAR
f32 ......,,
TURN SIGNAL 10
.... t
W/L RL
_-....TURNSIGNAL LIGHT
LEFT SWITCH l<L_

-
TURN SIGNAL ~0 ._
RIGHT SWITCH 10
Bl
SW~ I
S (HORN/FAVORITE)
"0"~
SWITCH ,-------,
GRIP HEATER
- Y-
f7 GH Bl
FAVORITE~
SWITCH JO
. ,ll
I
-CRF1100A4/D4-
I
.l...
rr
Gr
10 SG I
Fl RELAY
-
w
' [--~
137 K LI NE
t
BI/R
Bl
14
15
F_CAN_HI
F CANL I 112 LG
G/Bu
1T W I
I l.- .
G/Bu
y
: DLC
I
' -. - ·- - - -·
I
I I 1nl
I I I
........ . ~ I
.d:..:l.,, ....LL 1 ~ ~
..I .. . .
I . 39 38 37 36 35 34 33 32 31 30 29 28 27 Bl
Be
Black
Beige
Lg · Lightgreen
0 : Orange
.. ..
ABS
I I 26 25 24 23 22 21 20 19 18 17 16 15 14 p : Pink
ECM
.___
.
I
TCM
·.___
l! ____ _I
MODULATOR
.·~1
I
scu
l! ____ _ ~
IMU METER MID
L---
13 12 11 10 9 8 7 6 5 4 3 2 1
'-,'-i. i___r, /
Br
Bu
G
Brown
Blue
Green
R : Red
V : Violet
Gr Gray W : White
OCT CRF1100A4/04 Lb Light blue Y : Yellow
model BCU 39P (Black) CONN ECTOR (BCU SIDE)
,
t
I
I
• 22-55
BODY CONTROL SYSTEM DTC INDEX
NOTE:
• After confirming the MID displays, perform the
troubleshooting according to the OTC index.
MID Honda MIL Refer to

DTC DTC name
displays code blinks page
1-1 - - Ignition power failure (low voltage) 22-57
81
1-2 - - Ignition power failure (high voltage) 22-57
3-1 - - Back-up 1 failure (low voltage) 22-58
83
3-2 - - Back-up 1 failure (high voltage) 22-58
4-1 - - Back-up 2 failure {low voltage) 22-59
84 4-2 - - Back-up 2 failure (high voltage) 22-59
4-3 - - Back-up 2 malfunction 22-60
- Headlight dimmer/passing light control switch failure
11-1 - 22-61
{low voltage)
811
- Headlight dimmer/passing light control switch failure
11-2 - 22-62
(high voltage)
12-1 - - Turn signal switch failure (low voltage) 22-63
812
12-2 - - Turn signal switch failure {high voltage) 22-64
817
17-1 - - Horn switch/Favorite switch failure (low voltage) 22-65
17-2 - - Horn switch/Favorite switch failure (high voltage) 22-66
21-1 - - Right front turn signal light failure {short circuit) 22-67
821
21-2 - - Right front turn signal light failure (open circuit) 22-68
22-1 - - Left front turn signal light failure {short circuit) 22-67
822
22-2 - - Left front turn signal light failure (open circuit) 22-68
23-1 - - Right rear turn signal light failure (short circuit) 22-67
823
23-2 - - Right rear turn signal light failure (open circuit) 22-68
24-1 - - Left rear turn signal light fai lure (short circuit) 22-67
824
24-2 - - Left rear turn signal light failure (open circuit) 22-68
34-1 - - Grip heater load failure (short circuit) 22-69
834 34-2 - - Grip heater load failure (open circuit) 22-70
835
34-3
35-1
35-2
-
-
-
-
-
-
Grip heater load failure (internal circuit malfunction)
Horn relay failure (short circuit)
Horn relay failure (open circuit)
22-71
22-71
22-71
'
81-1 - - Function switch failure (low voltage) 22-72
881
81-2 - - Function switch failure (high voltage) 22-73
Function lever/voice control switch/page switch failure
82-1 - -
(short circuit)
22-74
882
Function lever/voice control switch/page switch failure
82-2 - - 22-75
(open circuit)
Sel left switch/Back switch/Se! up switch/Sel down switch J
83-1 - - 22-76 I
failure (short circuit)
883
Sel left switch/Back switch/Se! up switch/Sel down switch l
83-2 - - 22-77
failure (open circuit)
Sel right switch/ENT switch/Skip switch/Goes back switch
84-1 - - 22-78
884
failure (short circuit) l
Sel right switch/ENT switch/Skip switch/Goes back switch .i
84-2 - - 22-79
failure (open circuit)
891 101-2 - - BCU EEPROM malfunction 22-79
103-1 CAN communication malfunction
893 103-2 U0001 103 4-60
103-3
J
,
22-56 I
j
TROUBLESHOOTING
NOTE:
• Before starting the troubleshooting, check for loose
or poor contact in the BCU related circuit.
DTC B1 IGNITION POWER FAILURE
DTC 81 (1-1) IGNITION POWER FAILURE (LOW
VOLTAGE)
Probable cause:
• Faulty battery or its related circuit
• Charging system malfunction
• Faulty BCU or its power/ground line
• Body control system works normally
1. Recheck DTC
Read the OTC.
Is the DTC 81 (1-1) indicated?
YES - GO TO STEP 2.
NO - Intermittent failure
2. 8CU power/ground line Inspection
Check the BCU power/ground line (page 22-53).
Is the power/ground line normally?
YES - GO TO STEP 3.
NO - Repair the faulty parts.
3. Charging System Inspection
Check the charging system (page 21-8).
Is the charging system normally?
YES - Faulty BCU
DTC 81 (1-2) IGNITION POWER FAILURE (HIGH

VOLTAGE)
Probable cause:
' • Faulty battery

• Faulty BCU
• Body control system works normally
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
YES - Faulty BCU
22-57
I
l
~
l
DTC B3 BACK-UP 1 FAILURE 1
DTC 83 (3-1) BACK-UP 1 FAILURE (LOW VOLTAGE)
Probable cause:
• Blown sub fuse CLOCK/TURN/FOG/ORL 15 A
• Headlight/turn signal light/fog light works normally
1. Recheck DTC
Read the OTC. J
Is the OTC 83 (3-1) indicated?
YES - GO TO STEP 2.
2. BCU power/ground line Inspection
YES - GO TO STEP 3.
YES - Faulty BCU
DTC 83 (3-2) BACK-UP 1 FAILURE (HIGH 1

VOLTAGE)
Probable cause:
Faulty battery
• Faulty BCU
• Headlight/turn signal light/fog light does not work
1. Recheck DTC
Read the OTC.
Is the OTC 83 (3-2) indicated? i
YES - GO TO STEP 2. '
NO - Intermittent failure '
Check the charging system (page 21 -8).
YES - Faulty BCU
..
22-58
DTC B4 BACK-UP 2 FAILURE
DTC B4 (4-1) BACK-UP 2 FAILURE (LOW VOLTAGE)
Probable cause:
• Blown sub fuse G HEATER 10 A
• Grip heater works normally
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
2. BCU power/ground line Inspection
YES - GO TO STEP 3.
YES - Faulty BCU
DTC B4 (4-2) BACK-UP 2 FAILURE (HIGH

VOLTAGE)
Probable cause:
• Faulty battery
• Faulty BCU
• Grip heater works normally
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
YES - Faulty BCU
22-59
OTC 84 (4-3) BACK-UP 2 FAILURE
Probable cause:
• Faulty battery
• Faulty BCU
• Grip heater does not work
1. Recheck OTC
Read the OTC.
YES - GO TO STEP 2. I
YES - Faulty BCU
j
j
22-60
DTC B11 HEADLIGHT DIMMER/
PASSING LIGHT CONTROL SWITCH
FAILURE

12P CONNECTOR BCU 39P (Black) CONNECTOR
r--------------,
W I
r------------------------,
1J 1I11J ~
Gr~ 1
L------------ -.1
w SW 2 (DIMMER) BCU
HEADLIGHT
DIMMER ~
, SWITCH
r'
PASSING
r LIGHT
f
CONTROL ~
SWITCH Gr SG
OTC 811 (11-1)

HEADLIGHT DIMMER/PASSING LIGHT CONTROL
SWITCH FAILURE {LOW VOLTAGE)
Probable cause:
• Short circuit in the related wire
• Faulty switch
• Faulty BCU
• Headlight works normally
1. Recheck OTC
(
Read the OTC.
YES - GO TO STEP 2.
2. Headlight Dimmer/Passing Light Control Switch
Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
, Test probe, 2 pack 07ZAJ-RDJA110
i CONNECTION: White - Ground
:
NO - • Faulty left handlebar switch (headlight
dimmer/passing light control switch)
• Faulty BCU
I
22-61
DTC B11 (11-2)
HEADLIGHT DIMMER/PASSING LIGHT CONTROL
SWITCH FAILURE (HIGH VOLTAGE)
Probable cause:
• Open circuit in the related wire
• Faulty switch
• Faulty BCU
• Headlight works normally
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
2. Headlight Dimmer/Passing Light Control Switch
Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black) J
.
connector and left handlebar switch 12P connector.
TOOL:
CONNECTION: White - White

Gray-Gray
YES - • Faulty left handlebar switch (headlight
dimmer/passing light control switch) ...
• Faulty BCU
NO - Open circuit in the White or Gray wire
..
f
22-62
DTC 812 TURN SIGNAL SWITCH
FAILURE

r-------------------,
I
1 I CJ l~ G r
i I~
1III UIJiillL
"----------
HAZARD
SWITCH ~ t-----Lg SW6
(HAZARD/TURN)
TURN SIGNAL
CANCEL SWITCH ~
BCU
TURN SIGNAL
LEFT SWITCH ~
~
TURN SIGNAL 1--- - - Gr - -- - - ; SG
RIGHT SWITCH
DTC B12 (12-1)

TURN SIGNAL SWITCH FAILURE (LOW VOLTAGE)
Probable cause:
• Faulty switch
• Faulty BCU
• Turn signal light works normally
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
2. Turn Signal Switch Line Short Circuit Inspection
I connector and ground.
f TOOL:
,
[
~
Test probe, 2 pack

07ZAJ-RDJA 110
rf
NO Faulty left handlebar switch (turn signal
left/right switch , turn signal cancel
switch, or hazard switch)
• Faulty BCU
22-63
OTC B12 (12-2)
TURN SIGNAL SWITCH FAILURE (HIGH VOLTAGE)
Probable cause:
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function: l
j
• Turn signal light works normally l
1. Recheck OTC l
•
Read the OTC.
Is the DTC 812 (12-2) indicated? 1
YES - GO TO STEP 2.
'I
I
NO - Intermittent failure I
I
2. Turn Signal Switch Line Open Circuit Inspection
Check for continuity between the BCU 39P {Black)
TOOL:
Test probe, 2 pack 07ZAJ-ROJA 110
CONNECTION: Light green - Light green

'
)
j
l
Gray-Gray
J
Is there continuity? l
YES - • Faulty left handlebar switch (turn signal j
left/right switch, turn signal cancel •
switch, or hazard switch) j
• Faulty BCU
l
NO - Open circuit in the Light green or Gray wire !
l
l
;
'
J
•I
;
;
.J
22-64
DTC 817 HORN SWITCH FAILURE
,
f
' LEFT HANDLEBAR SWITCH
r BCU 39P (Black) CONNECTOR
12P CONNECTOR
t
t Bl
rI
Gr~
0 1T1tl ~ 1
I
SW?
HORN
SWITCH ~ (HORN/FAVORITE)
r BCU
,.
I
FAVORITE
SWITCH ~
SG
rI
1
1
f
r
DTC B17 (17-1)
HORN SWITCH FAILURE (LOW VOLTAGE)
[ Probable cause:
• Faulty switch
t • Faulty BCU
t • Horn does not work
r',. 1. Recheck DTC
t
I
Read the OTC.
YES - GO TO STEP 2.
~ NO - Intermittent failure
l
2. Horn Switch Line Short Circuit Inspection
r Check for continuity between the BCU 39P (Black)
TOOL:
I'
t
I
Test probe, 2 pack

07ZAJ-RDJA 110

NO - • Faulty left handlebar switch (horn
switch or favorite switch)
[ • Faulty BCU
r 22-65
DTC B17 (17-2)
HORN SWITCH FAILURE (HIGH VOLTAGE) .
Probable cause:
J
1
• Faulty switch J
• Faulty BCU
Symptom/Fail-safe function : 'j
• Horn does not work I
I
1. Recheck DTC 'l
Read the DTC.
l
Is the DTC 817 (17-2) indicated? j
YES - GO TO STEP 2.
2. Horn Switch Line Open Circuit Inspection
TOOL: J
Test probe, 2 pack 07ZAJ-RDJA110 J
I
CONNECTION: Black- Black
;
Gray-Gray
YES - • Faulty left handlebar switch (horn
switch or favorite switch)
• Faulty BCU
.l
j
NO - Open circuit in the Black or Gray wire
J
J
j'
J
l
j
'l
j
j
,
lj
J
JI
I
22-66 ]
DTC 821/822/823/824
, TURN SIGNAL LIGHT FAILURE
BCU 39P {Black) CONNECTOR TURN SIGNAL LIGHT 2P CONNECTORS

r-----------------------,
Lb (Right front) Lb (Right rear)
G~b~rde) 0 (Left side)
dt1If1
~
1~1
0 (Left front) 0 (Left rear)
CONNECTOR COLLAR:
- 0 (Left side)
- Lb (Right side)
II I ]
..
W/L_FR Lb - - - - - - - Lb -+-- Lb
RIGHT FRONT TURN
, - G • G
SIGNAL LIGHT
W/L_FL 0 - LEFT FRONT TURN

0. ~.Y SIGNAL LIGHT
BCU i..._G : G "
I
I
~
~
I
W/L_RR Lb Lb
G _DJ~~ RIGHT REAR TURN

SIGNAL LIGHT
W/L_RL 0 0
G _DJ~~ LEFT REAR TURN

SIGNAL LIGHT
- - - -
DTC 821 (21-1 )/822 (22-1 )/823 (23-1 )/824 (24-1)
,
I
TURN SIGNAL LIGHT FAILURE (SHORT CIRCUIT)
Probable cause:
I • Faulty turn signal light
• Faulty BCU
'
~
• Turn signal light does not work
• Normal units blink two times faster than usual
1. Recheck DTC
Read the OTC.
Is the DTC B21 (21-1)!822 (22-1)/B23 (23-1)/B24
r (24-1) indicated?
I YES - GO TO STEP 2.
t NO - Intermittent failure
t
r
22-67
2. Turn Signal Light Line Short Circuit Inspection
TOOL:
CONNECTION:
Left side: Orange - Ground
Right side: Light blue - Ground
YES - Short circuit in the Orange or Light blue
wire
NO - • Faulty turn signal light
• Faulty BCU
DTC 821 (21-2)/822 (22-2)/823 (23-2)/824 (24-2)

TURN SIGNAL LIGHT FAILURE (OPEN CIRCUIT)
Probable cause:
J
J
• Faulty turn signal light
• Faulty BCU
• Normal units blink two times faster than usual
1. Recheck DTC
Read the OTC. i
l
Is the DTC 821 (21-2)/822 (22-2)/823 (23-2)/824 J
(24-2) indicated?
YES - GO TO STEP 2.
2. Turn Signal Light Line Open Circuit Inspection
connector and each turn signal light 2P connector.
Check for continuity between each turn signal light
2P connector and ground. ;'
TOOL: f
CONNECTION:
Left side: Orange - Orange
Green - Ground
Right side: Light blue - Light blue j
Green - Ground
J
YES - • Faulty turn signal light
• Faulty BCU
NO - Open circuit in the Orange, Light blue or
Green wire
J
j
22-68
DTC B34 GRIP HEATER LOAD
FAILURE
BCU 39P (Black) CONNECTOR RIGHT GRIP HEATER

I I
2P CONNECTOR
!1i 11It1 01±rmrBI I:y~m I

I I
i ~Bl:
L----------- -------J
BCU GH Bl~
y B1 -L__j
RIGHT GRIP
HEATER
D=
LEFT GRIP
BI
Bl
Y/R
HEATER
r
: -A-
I G ~ Y/R
I
I
L----------J
LEFT GRIP HEATER 2P CONNECTOR
DTC 834 (34-1) GRIP HEATER LOAD FAILURE

(SHORT CIRCUIT)
Probable cause:
r • Short circuit in the related wire
• Faulty grip heater
t • Faulty BCU
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
2. Grip Heater Line Short Circuit Inspection
Check for short circuit in the following wires:
'I - Black wire between the BCU 39P (Black)

connector and right grip heater 2P connector
- Yellow and Yellow/red wires between the right
r grip heater 2P connector and left grip heater 2P
connector
r,. Are the wires OK?
t YES - GO TO STEP 3.
NO - Short circuit in the Black, Yellow, or
( Yellow/red wire
22-69
l
3. Grip Heater Resistance Inspection
Measure the grip heater resistance (page 22-51 ). ;
Is the grip heater OK?
I
YES - Faulty BCU J
NO - Replace the faulty grip heater.
'
DTC 834 (34-2) GRIP HEATER LOAD FAILURE
(OPEN CIRCUIT)
Probable cause:
• Faulty BCU
I
Symptom/Fail-safe function : J
I
1. Recheck DTC j
Read the DTC.
YES - GO TO STEP 2. ,
NO - Intermittent failure l
2. Grip Heater Line Open Circuit Inspection
Check for open circuit in the following wires:
- Black wire between the BCU 39P (Black)
connector and right grip heater 2P connector
1
- Yellow and Yellow/red wires between the right ii
grip heater 2P connector and left grip heater 2P 1
connector ;
- Green wire between the left handlebar switch ,,J
12P connector and ground
TOOL:
Are the wires OK?
YES - GO TO STEP 3.
NO - Open circuit in the Black, Yellow, Yellow/
red, or Green wire
1
3. Grip Heater Resistance Inspection J
Measure the grip heater resistance (page 22-51 ).

YES - Faulty BCU
J
!
j
.,l
'
22-70
DTC B34 (34-3) GRIP HEATER LOAD FAILURE
(INTERNAL CIRCUIT MALFUNCTION)
Probable cause:
• Faulty BCU
• Grip heater does not turn OFF
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
2. Grip Heater Resistance Inspection
Measure the grip heater resistance (page 22-51 ).
YES - Faulty BCU
,
OTC B35 HORN RELAY LOAD
FAILURE
DTC B35 (35-1) HORN RELAY LOAD FAILURE
(SHORT CIRCUIT}
,
r Probable cause:
• Faulty horn
r • Faulty BCU
t
• Horn does not turn OFF
1. Horn Inspection
Replace the horn with a known good one and
recheck.
YES - Faulty BCU
NO - Faulty original horn
DTC B35 (35-2) HORN RELAY LOAD FAILURE

(OPEN CIRCUIT)
Probable cause:
• Faulty BCU
, • Horn does not work
1. Recheck DTC
Read the OTC.
YES - Faulty BCU
(
'
22-71
DTC B81 FUNCTION SWITCH FAILURE
'J
RIGHT HANDLEBAR J
SWITCH 12P CONNECTOR BCU 39P (Black) CONNECTOR
l
G;(SW7) ~ : 1 Gr 'j
: (SW?) ~ I l
~j
CJ
fl l~ :
Gr(SG) 1
I
i I~ IJII Li IJOOIG,(SG)
1
~----------- --------------~
i----- Gr (SW?) -----< SW? '

(HORN/FAVORITE)
l
FUNCTION J
'
SWITCH l BCU
l
I
l
t---- Gr (SG) ---------1 SG '
J
l
J
I
OTC 881 (81-1) FUNCTION SWITCH FAILURE J

(SHORT CIRCUIT)
Probable cause:
• Faulty switch
• Faulty BCU
• DRL and fog light work normally
1. Recheck OTC
Read the OTC.
YES - GO TO STEP 2.
2. Function Switch Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black) )
connector and ground .
)
TOOL:
Test probe, 2 pack 07ZAJ-ROJA110
CONNECTION: Gray (SW7) - Ground

Gray (SG) - Ground
YES - Short circuit in the Gray wire
NO - • Faulty right handlebar switch (function J
switch) J
• Faulty BCU i
~
22-72
DTC 881 (81-2) FUNCTION SWITCH FAILURE
(OPEN CIRCUIT)
Probable cause:
• Faulty switch
• Faulty BCU
1. Recheck DTC
Read the DTC.
YES - GO TO STEP 2.
.. NO - Intermittent failure
2. Function Switch Line Open Circuit inspection
connector and right handlebar switch 12P
connector.
TOOL:
CONNECTION:
Signal line: Gray (SW7) - Gray (SW7)
Ground line: Gray (SG) - Gray (SG)
YES - • Faulty right handlebar switch (function
switch)
• Faulty BCU
r NO - Open circuit in the Gray wire
,.
.,..
r
22-73
l
LIGHTS/METERS/SWITCHES/ELECTRONIC SUSPENSION I
DTC 882 FUNCTION LEVERNOICE
CONTROL SWITCH/PAGE SWITCH
FAILURE

r--------------,
I
W/BI "" f1l : , J CJ [~ G r
Gr~
iJ ITI 11 : 1
I
! I~ :!Ill LI IJJfflL., J
.J
FUNCTION
LEVER (UP) ~ W/BI SW 3 (MF UP)
FUNCTION
LEVER (DOWN) ~ J
BCU l
VOICE CONTROL •'
SWITCH ~
j
PAGE SWITCH ~ Gr SG
(
.'';
DTC 882 (82-1) FUNCTION LEVERNOICE
.
CONTROL SWITCH/PAGE SWITCH FAILURE
(SHORT CIRCUIT)
J
Probable cause:
• Faulty switch
I•
• Faulty BCU
Symptom/Fail-safe function : ~
.j
• DRL and fog light work normally j
1. Recheck DTC
Read the OTC. J
YES - GO TO STEP 2.
'
2. Function LeverNoice Control Switch/Page I
Switch Line Short Circuit Inspection :
Check for continuity between the BCU 39P (Black) j
;.
TOOL:
J
CONNECTION: White/black- Ground J
YES - Short circuit in the White/black wire
J
NO - • Faulty left handlebar switch (function
lever/voice control switch/page switch) I
•
• Faulty BCU
J
22-74 •t
OTC 882 (82-2) FUNCTION LEVERNOICE
CONTROL SWITCH/PAGE SWITCH FAILURE (OPEN
CIRCUIT)
Probable cause:
• Faulty switch
• Faulty BCU
1. Recheck OTC
Read the DTC.
r
I
YES - GO TO STEP 2.
r NO - Intermittent failure
r 2. Function LeverNoice Control Switch/Page
Switch Line Open Circuit Inspection
TOOL:
Test probe, 2 pack 07ZAJ-ROJA110
CONNECTION: White/black - White/black

Gray-Gray
YES - • Faulty left handlebar switch (function
lever/voice control switch/page switch)
• Faulty BCU
NO - Open circuit in the White/black or Gray
' wire
t
r
,r
I
22-75
DTC B83 SEL LEFT SWITCH/BACK
SWITCH/SEL UP SWITCH/SEL DOWN
SWITCH FAILURE

12P CONNECTOR BCU 39P {Black) CONNECTOR )
I I
• Br -............. _ •
: j1JJ1 11 :
• Gr
I
1.-------- ---J
•
I
11IL1
! 1~ B 1
H m[
L--------- ---------J I
I
J
j
J
J
SEL LEFT SWITCH 1 SW 4 (MF_LEFT)
BACK SWITCH
1 BCU
SEL UP SWITCH
1
SEL DOWN SWITCH
1 SG
I
'I
DTC 883 (83-1) SEL LEFT SWITCH/BACK SWITCH/
SEL UP SWITCH/SEL DOWN SWITCH FAILURE
.J.
(SHORT CIRCUIT) )
Probable cause:
-
• Faulty switch
• Faulty BCU •
J
~
•
• Sel left switch/back switch/sel up switch/sel down
switch do not work
1. Recheck DTC '
Read the OTC. " I
'
YES
NO
- GO TO STEP 2.
- Intermittent failure
2. Sel Left Switch/Back Switch/Sel Up switch/Se!
)
'
l
r
Down Switch Line Short Circuit Inspection
:
connector and ground. j
TOOL: -J
CONNECTION: Brown - Ground J

YES - Short circuit in the Brown wire ~
•
NO Faulty left handlebar switch (sel left
'
'
switch/back switch/sel up switch/sel
down switch)
• Faulty BCU i
)
22-76 •
f
DTC 883 (83-2) SEL LEFT SWITCH/BACK SWITCH/
SEL UP SWITCH/SEL DOWN SWITCH FAILURE
(OPEN CIRCUIT)
Probable cause:
• Fau lty switch
• Faulty BCU
'• • Sel left switch/back switch/sel up switch/sel down
r switch do not work
1. Recheck DTC
Read the OTC.
Is the DTC B83 (83-2) indicated?
,- YES - GO TO STEP 2.
2. Sel Left Switch/Back Switch/Sel Up switch/Sel
Down Switch Line Open Circuit inspection
~ Check for continuity between the BCU 39P (Black)

I
TOOL:
r Test probe, 2 pack 07ZAJ-RDJA 110
CONNECTION: Brown - Brown

I" Gray-Gray
i Is there continuity?
r YES - • Faulty left handlebar switch (sel left
switch/back switch/sel up switch/sel
down switch)
• Faulty BCU
NO - Open circuit in the Brown or Gray wire
,,,
t
I
•
I
f
r
r
-
~
I
.,. 22-77
i
DTC 884 SEL RIGHT SWITCH/ENT
SWITCH/SKIP SWITCH/GOES BACK
SWITCH FAILURE '
1

'
r--------------------,
I
J
1 f CJ ~ Gr
I~ 1IJIILi +IIIDLR
i~--------- ----------~ 1
~
j
~
~
SEL RIGHT SWITCH

~
'
SW 5 (SEL_RIGHT) J
ENT SWITCH
~ ,
BCU
SKIP SWITCH
~ j,'
l
GOES BACK SWITCH ~ SG
I
DTC B84 (84-1) SEL RIGHT SWITCH/ENT SWITCH/

SKIP SWITCH/GOES BACK SWITCH FAILURE
'
J
(SHORT CIRCUIT)
Probable cause:
• Faulty switch
• Faulty BCU
'
• Sel right switch/ENT switch/skip switch/goes back
switch do not work
1. Recheck DTC
Read the OTC.
Is the DTC B84 (84-1) indicated?
YES
NO
- GO TO STEP 2.
- Intermittent failure '
2. Sel Right Switch/ENT Switch/Skip Switch/Goes
Back Switch Line Short Circuit Inspection
'
TOOL:
CONNECTION: White/red - Ground

YES - Short circuit in the White/red wire
NO Faulty left handlebar switch (sel right
switch/ENT switch/skip switch/goes
back switch) ,
• Faulty BCU l
22-78
DTC B84 (84-2) SEL RIGHT SWITCH/ENT SWITCH/
•' SKIP SWITCH/GOES BACK SWITCH FAILURE
(OPEN CIRCUIT)
Probable cause:
• Faulty switch
• Faulty BCU
• Sel right switch/ENT switch/skip switch/goes back
switch do not work
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
2. Sel Right Switch/ENT Switch/Skip Switch/Goes
Back Switch Line Open Circuit Inspection
TOOL:
,
I CONNECTION: White/red -White/red
Gray-Gray
YES - • Faulty left handlebar switch (sel right
switch/ENT switch/skip switch/goes
back switch)
• Faulty BCU
NO - Open circuit in the White/red or Gray wire
DTC B91 (101-2) BCU EEPROM

MALFUNCTION
Probable cause:
f • Faulty BCU
'l
,, • Body control system works normally
'
1. Recheck DTC
.. Read the OTC.
"' Is the DTC 891 (101-2) indicated?
YES - Faulty BCU
r NO - Intermittent failure
..
,r
:
I
.
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'
22-79
'
SCU (Suspension Control Unit)
Release the rubber band [1].
Disconnect the SCU 48P {Black) connector (2) and
remove the SCU (3).
Installation is in the reverse order of removal. . t
SCU 48P (Black) CONNECTOR

r--------------------,
;
MAIN FUSE
30A
•
)
scu BATT t - - ~ ~ ~ R/W ~ ~ ~~----io,.....,-o~~ ~ - R ~ ~ ~ ~ ~ ~-----'

CLOCK/TURN/
,I
GND
- G-1 FOG/DRL 15 A
1. SCU power input line inspection

Disconnect the SCU 48P (Black) connector (page
•J
22-80).
TOOL:

YES - GO TO STEP 2.
• Blown sub fuse HORN/STOP 10 A .
#
•
;
22-80
2. SCU back-up voltage line inspection
TOOL:
CONNECTION: Red/white(+) - Ground (- )

YES - GO TO STEP 3.
DRL 15 A
3. SCU ground line open circuit inspection
TOOL:

YES - Faulty SCU

r
f
TROUBLESHOOTING INFORMATION
MCS INFORMATION
DTC READOUT
NOTE:
• If the MIL blinks, check the PGM-FI DTC (page 4-6).
If there is any problem in the PGM-FI system,
troubleshoot it first. Then recheck the electronic
t suspension system after erasing the PGM-FI OTC .
•
,t If the suspension indicator [1] lights or blinks, read the
OTC and stored data with the MCS.
t To read the OTC with the MID, refer to the PGM-FI
,
I
system (page 4-7).
Perform the troubleshooting procedure by following the
r' electronic suspension system OTC index (page 22-84).
[1]
ERASING DTC
Refer to the PGM-FI system (page 22-54 ).
22-81
ELECTRONIC SUSPENSION SYSTEM •
SYMPTOM TROUBLESHOOTING
,,
When the suspension indicator lights up, but the MID
does not display the electronic suspension system
.
OTC, check the following:
Unusual condition Probable cause
SCU can not start up . Faulty SCU
(Related wires are OK) )
Power is not suppled to the SCU . Open circuit in the power input line and/or back-up
. voltage line
Faulty battery
. Faulty SCU
SCU can not output CAN information .. Faulty CAN communication '•
Faulty SCU
)
J
' I
J'
'
J
, 4
J
J
-
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)
'
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.
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22-82 J
,.. ELECTRONIC SUSPENSION SYSTEM
DIAGRAM
,
t ~
Bl
- R R -"-- RfW
MAIN FUSE CLOCK/TURN

30A /FOG/DRL 15A
-,
Bl/Gr
1-1 I +I
..!..o
IGNITION
R/BI
-" -
HORN/STOP
BI/R 9
IGNI 143 BATI
RfW
SWITCH 10A
I BATIERY I
-=-=- 121
131
RR_SOL(-)
RR SOL(+)
y
Gr
: REAR SUSPENSION
SOLENOID
I
I
FRONT SUSPENSION
STROKE SENSOR
I Br
Bl
39
40
FR_STRK_SEN2
FR_STRK_SEN1
1 11
'33
FR_SOL(-)
FR_SOL(+)
Br
Bl : FRONT SUSPENSION
SOLENOID
I
I
Bl
6 svcc Br
y I 19 MOT(-)
REAR SUSPENSION
POSITION SENSOR Br
14 JACK_STRK_SEN
22 SGND
I 35 MOT(+)
Bl I
M REAR SUS PENSION
PRE-LOAD MOTOR
BI/R BI/R
10 CAN2_H
DLC Bl Bl
11 CAN2_LI
BI/R BI/R
1 CAN1-HI
Bl Bl
2 CAN1 -L
ECM BI/R
Bl
BI/R
ABS r;-
,• MODULATOR
BI/R I scu I
r IMU r;-
• BI/R
~ BCU r;-
~
Bl GND G
13
I METER J_
.r
BI/R
Bl -
~
f
MID R
Bl Black
Br Brown
G Green
Gr Gray
R Red
,
f SCU 48P (Black) CONNECTOR (SCU SIDE)
w White
,
;"'
22-83
DTCINDEX
NOTE:
• After confirming the MID displays, perform the
troubleshooting according to the OTC index.
Suspension
MID MIL indicator Refer to
DTC OTC name
displays blinks page
Lights Blinks
U3003-00 - 0 - VBAT too low
S1 U3500-00 - 0 - SCU power input circuit voltage too low 22-85
U3501-00 - 0 - VBU voltage too low
U3003-00 - 0 - VBAT too high
S2 22-86
U3500-00 - 0 - SCU power input circuit voltage too high
U0028-00 103 - 0 CAN communication malfunction 22-86
PGM-FI CAN communication interruption
U0100-00 103 - 0 22-87
malfunction
ABS CAN communication interruption
U0121-00 103 - 0 malfunction
22-87
IMU CAN communication interruption
U0125-00 103 - 0 22-88
malfunction
S3
Meter CAN communication interruption
U0155-00 103 - 0 22-88
malfunction
PGM-FI CAN communication data
U0401-00 103 - 0 22-87
malfunction
U0415-00 103 - 0 Meter CAN communication data malfunction 22-88
U0423-00 103 - 0 ABS CAN communication data malfunction 22-87
U0432-00 103 - 0 IMU malfunction 22-88
S4 C1420-00 - 0 - Front suspension stroke sensor malfunction 22-89
Rear suspension position sensor I
S6 C1430-00 - 0 - 22-90
malfunction
S8 C1412-00 - 0 - Front suspension solenoid malfunction 22-92
S9 C1413-00 - 0 - Rear suspension solenoid malfunction 22-93
S10 C0530-00 - 0 - Rear suspension pre-load motor malfunction 22-94
C1411-00 - 0 - Unspecified solenoid malfunction 22-95
S11
U3000-00 - 0 - SCU malfunction 22-95
;
'
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i
22-84 '
J
' OTC TROUBLESHOOTING
, NOTE:
• Before starting the troubleshooting, check for loose
'
I
or poor contact in the SCU related circuit.
OTC S1 SCU POWER INPUT CIRCUIT

(LOW VOLTAGE)
DTC S1 (U3003-00) VBAT TOO LOW
DTC S1 (U3500-00) SCU POWER INPUT CIRCUIT
VOLTAGE TOO LOW
• DTC S1 (U3501-00) VBU VOLTAGE TOO LOW
Probable cause:
,' • Faulty battery or its related circuit
• Blown sub fuse HORN/STOP 10 A
• Faulty SCU or its power/ground line
• Electronic suspension system does not function
1. Recheck DTC
, Read the OTC.
Is the DTC S1 (U3003-00, U3500-00, U3501-00)
indicated?
YES - GO TO STEP 2.
f
2. SCU power/ground line Inspection
' Check the SCU power/ground line (page 22-80).

YES - GO TO STEP 3.
, Check the charging system (page 21-8).

YES - Faulty SCU
NO - Repair the faulty parts .
.,
,
••
I
22-85
DTC 52 SCU POWER INPUT CIRCUIT
(HIGH VOLTAGE)
DTC S2 (U3003-00) VBAT TOO HIGH
DTC S2 (U3500-00) SCU POWER INPUT CIRCUIT
VOLTAGE TOO HIGH j
Probable cause:
• Faulty battery
• Faulty SCU
• Electronic suspension system does not function
1. Recheck DTC
Read the OTC.
Is the DTC S2 (U3003-00, U3500-00) indicated?
YES - GO TO STEP 2.
NO - Intermittent failure ;
YES - Faulty SCU
DTC 53 CAN COMMUNICATION

MALFUNCTION
DTC S3 (U0028-00) CAN COMMUNICATION
MALFUNCTION
Probable cause:
• Faulty CAN communication line
• Faulty SCU
• Damping control function only operates without
using the CAN information (riding mode fixed)
1. CAN Communication Line Inspection
Check the CAN communication line (page 4-60).
Is the CAN communication line normal?
YES - Faulty SCU
'
)
22-86
:
DTC 53 (U0100-00) PGM-FI CAN COMMUNICATION
' INTERRUPTION MALFUNCTION

DTC 53 (U0401-00) PGM-FI CAN COMMUNICATION
DATA MALFUNCTION
r Probable cause :
, • Faulty ECM
• Faulty SCU
.
I
(
Check the CAN communication line (page 4-60).
YES - • Faulty ECM
• Faulty SCU
'r
DTC 53 (U0121-00) ABS CAN COMMUNICATION
INTERRUPTION MALFUNCTION
DTC 53 (U0423-00) ABS CAN COMMUNICATION
DATA MALFUNCTION
Probable cause:
• Faulty ABS modulator
' • Faulty SCU
t
r • Damping control function only operates without
" 1. CAN Communication Line Inspection
Check the CAN communication line:
,
- CAN communication line (page 4-60)
- ABS CAN communication line (page 4-63)
f Is the CAN communication line normal?
YES - • Faulty ABS modulator
r • Faulty SCU
f
/
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t
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,'
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22-87
DTC 53 (U0125-00) IMU CAN COMMUNICATION
DTC 53 (U0432-00) IMU CAN COMMUNICATION
DATA MALFUNCTION
Probable cause:
• Faulty IMU J
I
• Faulty SCU
J
• Damping control function on ly operates without
1. CAN Communication Line Inspection )
- IMU CAN communication line (page 4-63)
YES - • Faulty IMU
• Fau lty SCU
DTC 53 (U0155-00) METER CAN COMMUNICATION

DTC 53 (U0415-00) METER CAN COMMUNICATION
DATA MALFUNCTION
Probable cause :
• Faulty CAN communication line ',
• Faulty meter
• Faulty SCU i
,J'
- Meter CAN communication line (page 4-64) )
YES - • Faulty meter
• Faulty SCU '
,;
NO. - Repair the faulty parts. j

j
'
.•'
22-88
OTC S4 FRONT SUSPENSION
STROKE SENSOR MALFUNCTION
,
FRONT SUSPENSION STROKE
SCU 48P (Black) CONNECTOR SENSOR2PCONNECTOR
r-------------------, r---------,
: B l / ~Br
~
Br/Bl Br
L-------------
FR_STRK_SEN 1 Bl --11•-- Br t--------i LPS 1-1

FRONT SUSPENSION
scu STROKE SENSOR
FR_STRK_SEN 2 Br ----+- Br/Bl t--------i LPS 1-2
DTC S4 (C1420-00) FRONT SUSPENSION STROKE

SENSOR MALFUNCTION
Probable cause:
• Open or short circuit in the related wire
• Faulty front suspension stroke sensor
• Faulty SCU
• Electronic suspension system does not work
1. Recheck DTC
Read the OTC.
Is the DTC S4 (C1420-00) indicated?
YES - GO TO STEP 2.
2. Front Suspension Stroke Sensor Line
Inspection
r Check the open and short circuit between the SCU
48P (Black) connector and front suspension stroke
sensor 2P connector.
• TOOL:
CONNECTION: Black- Brown

Brown - Brown/black
Are the wires OK?
YES - GO TO STEP 3.
NO - Open or short circuit in the Black, Brown,
or Brown/black wire
3. Front Suspension Stroke Sensor Resistance
Inspection
Measure the resistance at the front suspension
stroke sensor side 2P connector terminals.
Is the sensor resistance within 25 - 45 n?
YES - Faulty SCU
NO - Faulty front suspension stroke sensor
t
,
22-89
DTC 56 REAR SUSPENSION
POSITION SENSOR MALFUNCTION
J
REAR SUSPENSION POSITION
SCU 48P (Black) CONNECTOR SENSOR3PCONNECTOR J'
Bl Y
J
I 7r1"' i
c\ -----------~
~---
svcc
REAR SUSPENSION
SCU JACK_STRK_SEN POSITION SENSOR
SGND
'
''
DTC S6 (C1430-00) REAR SUSPENSION POSITION
SENSOR MALFUNCTION
Probable cause:
• Faulty rear suspension position sensor '
• Faulty SCU '
1. Recheck DTC
Read the OTC .
YES - GO TO STEP 2.
2. Rear Suspension Position Sensor Line
Inspection
Check the open or short circuit between the SCU
I'
48P {Black) connector and rear suspension position
sensor 3P connector. ;
TOOL:
CONNECTION: Black- Black

Yellow - Yellow
Brown - Brown
Are the wires OK?
YES - GO TO STEP 3.
NO - Open or short circuit in the Black, Yellow,
or Brown wire
22-90
3. Rear Suspension Position Sensor Resistance
'•
Inspection 1
Measure the resistance at the rear suspension
'f position sensor side 3P connector terminals .
CONNECTION: Black- Brown
Is the resistance within 3.5 - 6.5 kQ?
YES - GO TO STEP 4.
' NO - Faulty shock absorber (rear suspension

position sensor)
4. Rear Suspension Position Sensor Resistance
Inspection 2
Measure and record the resistance at the rear
suspension position sensor side 3P connector
terminals.
CONNECTION: Black - Yellow
.., Yellow- Brown
•
I
Sum the measured value.
f Is the total value the same as the value in step
3?
'''
YES - Faulty SCU
NO - Faulty shock absorber (rear suspension
r position sensor)
I
;
,
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,
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I,
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'
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~
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tt
22-91
DTC S8 FRONT SUSPENSION
SOLENOID MALFUNCTION
FRONT SUSPENSION
SCU 48P (Black) CONNECTOR SOLENOID 2P CONNECTOR
r-------------------, r---------,
1 Br 1
!11:1:1:1:1:1:1m:1:1:1:1:1:1
.. _____________ _ ,s ! 1 ~
Br/Bl Br
J
J
j
FR_SOL(+) BI---Br/BI 1---------< SOL 1-P

FRONT SUSPENSION
scu SOLENOID
FR_SOL(- ) Br - Br f - - - ------1 SOL1-N
DTC S8 (C1412-00) FRONT SUSPENSION

Probable cause:
• Faulty front suspension solenoid
• Faulty SCU
1. Recheck DTC
Read the OTC.
Is the DTC SB (C1412-00) indicated?
YES - GO TO STEP 2.
2. Front Suspension Solenoid Line Inspection
Check the open circuit between the SCU 48P
(Black) connector and front suspension solenoid 2P
connector.
TOOL:
CONNECTION : Black- Brown/Black

Brown - Brown
Are the wires OK?
YES - GO TO STEP 3.
NO - Open or short circuit in the Black, Brown,
or Brown/black wire
3. Front Suspension Solenoid Resistance
Inspection
Measure the resistance at the front suspension
solenoid side 2P connector terminals.
Is the solenoid resistance within 2 - 6 !l?
YES - Faulty SCU
NO - Faulty front suspension solenoid
22-92
(
DTC S9 REAR SUSPENSION
REAR SUSPENSION
SCU 48P (Black) CONNECTOR SOLENOID 2P CONNECTOR
,
L--------------
~
Y Gr
RR_SOL(+) t--- - Gr-----1 t--- - ---1 SOLO-P

REAR SUSPENSION
scu SOLENOID
, RR_SOL(-) 1------ y - ----1 1 - - - -- - - - 1 SOLO-N
DTC 59 (C1413-00) REAR SUSPENSION SOLENOID

MALFUNCTION
Probable cause:
• Faulty rear suspension solenoid
• Faulty SCU
1. Recheck DTC
Read the OTC.
YES - GO TO STEP 2.
2. Rear Suspension Solenoid Line Inspection
48P (Black) connector and rear suspension solenoid
2P connector.
TOOL:
CONNECTION: Gray - Gray

Yellow - Yellow
Are the wires OK?
YES - GO TO STEP 3.
NO - Open circuit in the Gray or Yellow wire
3. Rear Suspension Solenoid Resistance
Inspection
Measure the resistance at the rear suspension
solenoid side 2P connector terminals.
Is the solenoid resistance within 2 - 6 n?
YES - Faulty SCU
NO - Faulty rear suspension solenoid
22-93
DTC S10 REAR SUSPENSION PRE- ..
LOAD MOTOR MALFUNCTION
REAR SUSPENSION PRE-LOAD

SCU 48P (Black) CONNECTOR MOTOR 2P CONNECTOR
r---------,
Br Bl
MOT(+) >-------< +
REAR SUSPENSION
..
scu PRE-LOAD MOTOR
MOT(-)
DTC 510 (C0530-00) REAR SUSPENSION PRE-

LOAD MOTOR MALFUNCTION
Probable cause:
• Rear suspension pre-load operation malfunction
• Faulty rear suspension pre-load motor
• Faulty SCU
1. Shock Absorber Condition Inspection
Inspect the shock absorber:
- Installation condition
- For bends, damage, or leakage
Is the shock absorber in good condition?
YES - GO TO STEP 2.
NO - Repair the faulty parts
2. Rear Suspension Pre-load Motor Line Inspection
48P (Black) connector and rear suspension pre-load
motor 2P connector.
TOOL:
CONNECTION: Black - Black

Brown - Brown
Are the wires OK?
YES - GO TO STEP 3.
NO - Open or short circuit in the Black or Brown
wire
22-94
3. Rear Suspension Pre-load Motor Resistance
Inspection
f Measure the resistance at the rear suspension pre-
I
•
l load motor side 2P connector terminals.
Is the motor resistance with in 0.5 - 5 fl?
YES - Faulty SCU
,
t
I
NO - Faulty shock absorber (rear suspension
pre-load motor)
DTC 511 SCU MALFUNCTION

DTC S11 (C1411-00) UNSPECIFIED SOLENOID
MALFUNCTION
Probable cause:
• Faulty front suspension solenoid or its circuit
• Faulty rear suspension solenoid or its circuit
• Faulty shock absorber (rear suspension pre-load
motor) or its circuit
• Faulty SCU
1. Probable Cause Parts Inspection
Check the following .
- Front suspension solenoid (page 22-92)
- Rear suspension solenoid (page 22-93)
- Rear suspension pre-load motor (page 22-94)
Are the parts normal?
' YES
NO
- Faulty SCU
- Repair the faulty parts.
DTC S11 (U3000-00) SCU MALFUNCTION
f Probable cause:
• Faulty SCU
r Symptom/Fail-safe function:
t • Electronic suspension system does not work

1. Recheck DTC
t Read the OTC.
I
Is the DTC S11 (U3000-00) indicated?
'
YES - Faulty SCU
I
r..
'{
r
22-95
GPSANTENNA
Release the wire band [1].
Disconnect the GPS connector [2) and remove the GPS
antenna [3] .
NOTE:
• When installing the GPS antenna, clean the GPS
antenna and headlight attaching surface.
• Install the GPS antenna in position as shown.
• Replace the double sided tape [4] with a new one.
Do not allow oil to adhere.
After installation, do not let water splash for 2 days.
..
'.
22-96
23. WIRING DIAGRAMS
r
r
WIRING DIAGRAM (MT model) .. ········ .. ·· 23-2 PGM-FI SYSTEM DIAGRAM · · · · · · · · · · · · · · · · · · 23-8
WIRING DIAGRAM (OCT model) .. ·········· 23-5
I
r
l
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t
23-1
.
,
MEMO
INDEX
A/F SENSOR· ·· ·· ········· ···· ···· ·· ··· ········ ········ ······· ···· 4-67 OCT OTC TROUBLESHOOTING .. ........ .......... .. ... 13-12
ABS OTC INDEX .. ···· ······ ····· ·· ······· ···· ····· ··· ········ ·· · 20-9 OCT RELAY ······· ······ ·· ······ ······ ·· ····· ···· ···· ···· ····· ·· 13-67
ABS OTC TROUBLESHOOTING· .. ········ ······ ········ · 20-13 OCT SYMPTOM TROUBLESHOOTING · · · · · · · · · ·· · · · · · · · 13-4
ABS INDICATOR CIRCUIT TROUBLESHOOTING ·· 20-11 OCT TROUBLESHOOTING INFORMATION ..... .... .. .. 13-8
ABS MODULATOR ···· ············ ····· ·· ··· ··· ······· ···· ·· ·· 20-27 DRIVE CHAIN ·· ·· ··· ... .... .... .................. ........ ........ 3-18
ABS TROUBLESHOOTING INFORMATION· ······ ··· ··· 20-6 DRIVE CHAIN SLIDER········ ·········· ·· ······ ·· ············· 3-21
ACCESSORY SOCKET (CRF11 OOA4/D4) · · · · · · · · · · · · · · 22-48 DUAL CLUTCH/PRIMARY DRIVEN GEAR····· ····· ··· 13-50
AIR CLEANER ···· ··· ··· ····· ······· ···· ······ ·· ·· ···· ········· ··· ·· 3-5 ECM ·········· ···· ··········· ···· ············ ···· ······· ···· ······ ··· 4-71
AIR CLEANER HOUSING· ······· ···· ··· ······ ········ ········ 7-14 ECT SENSOR · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · 4-69
ALTERNATOR CHARGING COIL····· ·· ········ ······ ··· · 21-10 EGCA .... .. ...... ..... ........ ..... .... .... ... ... .... .... .. .. .... ... 4-70
ALTERNATOR COVER · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · 11-4 ELECTRONIC SUSPENSION SYSTEM
Apple CarPlay™ TROUBLESHOOTING· ········ ·········· 22-5 DIAGRAM· ··· ··· ····· ······ ······· ······· ······· ··· ······ ······ ·· 22-83
BALANCER· ····· ·· ·· ··· ······· ········· ···· ······· ·· ··· ····· ····· 14-7 ELECTRONIC SUSPENSION SYSTEM OTC
BATIE RY ··· ··· ····· ·· ··· ····· ···· ······· ···· ··· ···· ·· ··· ·· ····· ··· 21-6 INDEX · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22-84
BCU ······· ····· ······ ····· ···· ···· ·· ······ ···· ··· ···· ······ ······· 22-52 ELECTRONIC SUSPENSION SYSTEM OTC
BODY CONTROL SYSTEM DIAGRAM· ·············· ·· · 22-55 TROUBLESHOOTING · · · · · · · · · · · · · · · · · .. · · ·· · · · · · · · · · · · · · · · · 22-85
BODY CONTROL SYSTEM OTC INDEX · · · · · · · · · · · · · · · 22-56 ELECTRONIC SUSPENSION SYSTEM SYMPTOM
BODY CONTROL SYSTEM OTC TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22-82
TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · 22-57 ELECTRONIC SUSPENSION SYSTEM
BODY CONTROL SYSTEM TROUBLESHOOTING TROUBLESHOOTING INFORMATION ··· ··············· 22-81
INFORMATION· ······· ········· ·· ····························· · 22-54 EMISSION CONTROL SYSTEMS ......... .. ............... 1-72
BODY PANEL LOCATIONS ··· ··········· ····· ····· ··· ·· ·· ·· ·· ·2-3 ENGINE IDLE SPEED ........... ..... ..... . ..... .. .. .... ... ... . 3-14
BRAKE FLUID· ·· ········ ···· ····· ···· ·· ···· ······· ··· ···· ········ 3-21 ENGINE INSTALLATION .. ....... ... .. .. ..... .... ........ ... 16-12
BRAKE FLUID REPLACEMENT/AIR BLEEDING·· ·· ··· 19-6 ENGINE OIL .... .. .. .. .. · .. · .. .. .. ............ .. · .. · · .. ...... .. .. · 3-11
BRAKE LIGHT SWITCH · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-23 ENGINE OIL FILTER ............ ........ .. ........ ... .... .. .... 3-12
BRAKE LOCK OPERATION (OCT model)·· ············ ·· 3-23 ENGINE REMOVAL··· .... ..... ... ... .............. .... .... ..... 16-4
BRAKE PAD/DISC · ·· ···· ·· ····· ·· ··· ······· ······· ·· ·· ·· ···· ·· · 19-8 EOP SENSOR····· ········ ····· ··· ········ ·· .. ···· ··· ·· ····· ··· 13-64
BRAKE PADS WEAR· ····· ···· ······ ········ ·········· · ·· ···· ·· 3-22 EOP SWITCH (MT model) · · · · · ·· · · · · · .. · · · · · .. · · · · · · ·· · .. · · 22-25
BRAKE SWITCH ··· ······ ··· ·········· ·················· ······· 22-41 EOT SENSOR ···· ··· ····· ······· ······· ··· ···· ···· ···· ········· 13-64
BRAKE SYSTEM · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · 3-22 EVAP PURGE CONTROL SOLENOID VALVE/
BRAKE/TAILLIGHT ····· ··· ··· ·· ····· ····· ·········· ··· ··· ···· 22-13 CANISTER ....... ................. ... .. .......... .... .... .... .... . 7-22
CABLE & HARNESS ROUTING·· ···· ···· ····· ··· ········· ·· 1-25 EVAPORATIVE EMISSION CONTROL SYSTEM .... .. 3-16
CAM CHAIN TENSIONER LIFTER ··· ··· ·········· ······· 10-12 EXHAUST GAS CONTROL ACTUATOR CABLE· ·· ···· 3-17
CAMSHAFT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · 10-13 FAN RELAY ··· ····· ···· ····· ·· ········· ··· ···· ··············· ····· 8-12
CHARGING SYSTEM INSPECTION ··· ··· ·· ······ ········· 21-8 Fl RELAY .. ....... ............ .. ..... .... ...... ...... ......... ..... 4_75
CKP SENSOR ·· ·· ····· ······ ····· ·· ··· ······ ··· ··· ··· ······ ···· ·· 4-77 FLYWHEEL · .. · · .. · · · · · .. · .. · · .. · · .. · · · .. · · ·· .... · · .. · .. .. · · ...... 11-6
CLUTCH· ······ ··· ··· ····· ··· ·· ····· ··· ···· ·· ·· ······· ······· ····· ·· 12-9 FORK ···· ······ ···· ···· ··········· ···· ·· ·· ···· ·· ···· ····· ·· ·· ·· ··· 17-22
CLUTCH EOP SENSOR· ·· ··· ······ ··· ··· ······ ·· ·· ····· ···· 13-63 FRONT BRAKE CALIPER ..... .. .. ..... ...... ... ... .... .... . 19-19
CLUTCH EOP SENSOR COVER (OCT model) · · · · · · · · · 2-27 FRONT CENTER COWL · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · 2-12
CLUTCH INITIALIZE LEARNING (TCM) · ·· · · · · · · · · · · · · · 13-67 FRONT CROSS PLATE · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · 7-8
CLUTCH LEVER ·· ···· ··· ···· ··· ······· ······ ··········· ······· 12-25 FRONT FENDER · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · 2-23
CLUTCH OIL FEED PIPE··· ···· ··· ····· ····· ··· ··· ··· ····· · 13-38 FRONT LOWER COVER ...... ..... ... .............. ... . .. .. .. 2-14
CLUTCH OIL FILTER (OCT model) .. ·· .. ·· ··············· ·· 3-13 FRONT MASTER CYLINDER ··· ······ ············· ···· ···· 19-13
CLUTCH SWITCH (MT model) .. ··········· ··· ····· ········ 22-44 FRONT SIDE COWL (CRF1100A/D) ..... .... ...... ..... ... 2-13
CLUTCH SYSTEM (MT model) · · · · · · · · · · · · · ·· · · · · · · · · · · · · .. · 3-25 FRONT UPPER COVER·· ····· ······ ··· ·· ····· .. ·············· 2-21
COMPONENT LOCATION FRONT WHEEL·· ······ ·· ··· ··· ·· ·· ······ ·· ··· ······ ··· ··· · ·· ·· 17-15
ALTERNATOR/STARTER CLUTCH .. .... .............. 11-3 FRONT TURN SIGNAL COVER .. .. ........ ··· ····· ·· ... · .. · 2-15
CLUTCH/GEARSHIFT LINKAGE (MT model) .... .. .. 12-4 FUEL INJECTOR ... ... .. .. .. ....... .... ... .... ... ...... .. .. ... .. 7-17
CRANKCASE/TRANSMISSION/BALANCER· ······ ·· 14-5 FUEL LEVEL SENSOR .... · · · · · · · · .. · · · .. · · · · .. · · · · · · ·· .. · .. 22-25
CRANKSHAFT/PISTON/CYLINDER ·· ········· ·· ····· · 15-3 FUEL LINE · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · 3-4
CYLINDER HEADNALVE/CAMSHAFT· .... .... ...... . 10-4 FUEL LINE INSPECTION ... ... .. ............ ...... ..... ..... ... 7_4
DUAL CLUTCH TRANSMISSION (OCT model) · · · · · 13-5 FUEL PUMP UNIT .... .... ... .. .... . ...... ... .......... .... ... ..... 7-8
ENGINE REMOVAL/INSTALLATION · .. ·· .. · ........ ·· · 16-3 FUEL RELAY·· ···· ... .. .. ... ... ...... ... ....... .... ....... ... ... . 7-14
FRONT WHEEL/SUSPENSION/STEERING .. .. .... . 17-5 FUEL TANK ········· ····· ··· ·· ······· ········ ······ ·· ······ ······ ···7-7
FUEL SYSTEM ··· ······ ·· ···· ······· ·· ·· ·· ············· ····· ··· 7-3 GEARSHIFT ARM/GEARSHIFT PEDAL ...... ... ... .... 12-23
HYDRAULIC BRAKE ..... .. ........ .. ........... ...... ...... 19-3 GEARSHIFT LINKAGE
REAR WHEEL/SUSPENSION···· ··· ·· ·········· ·· ····· ·· 18-5 CLUTCH/GEARSHIFT LINKAGE (MT model)··· ··· 12-20
COOLANT REPLACEMENT·· ······ ········ ····· ···· ········· · ·8-5 DUAL CLUTCH TRANSMISSION (OCT model) · · · 13-57
COOLING SYSTEM··· ··········· ·· ······· ········ ··· ······ ···· · 3-15 GP SENSOR {MT model) .... ... .... .......... ..... .. ........ .. 4-73
CRANKCASE ASSEMBLY· ······· ·· ···· ····· ········· ······ 14-27 GPS ANTENNA · · · · · · · · · · · · · · · · · · · · .. · · · · · · .. · · · · · · .. · · · · · · · · · · 22-96
CRANKCASE BREATHER· ··········· ··· ··· ···· ···· ·········· ··3-5 GRIP APS ...... ..... .... ........... ... ... ..... .... ... .......... .. . 4-74
CRANKCASE SEPARATION .... .. ... . .. .. ... ... .... ... .... 14-12 GRIP HEATER (CRF1100A4/D4) ······ ·· ··· ··········· ··· 22-48
CRANKPIN BEARING .. .... ··· .... ···· .. ··· .. · .. ······ .. · .. ·· .. 15-9 HANDLEBAR ···· ··· ········ ····· ··· ··· ··· ····· ······ ········ ····· 17-6
CRANKSHAFT ·················· ··· ···· ············ ··· ··· ·· ····· · 15-4 HEADLIGHT · · · · · · · · · ··· · · · · · ·· · · ·· · · ·· · · · · · · · · · · · · ·· · · · · · · ··· · · · · 22-7
CUSHION LINKAGE .. ........ ........................ .. ...... 18-19 HEADLIGHT AIM · · · ··· · · · · · ·· · · ·· · ··· · · · · · · .. · · · · · · · · · · · · · ·· · · · · 3-24
CYLINDER COMPRESSION ... ... .............. ....... ..... . 10-5 HEEL GUARD · ...... · · · · · · · · .. ...... · .. · · · · .. · .. · · · · ...... · · .. · · · 2-26
CYLINDER HEAD COVER ········ ············· ······· ········ 10-5 HORN ···· ····· ···· ······ ·· ······ ········· ······ ····· ······· ······ · 22-47
CYLINDER HEAD/CAM CHAIN TENSIONER ......... 10-19 HSTC .. .. ... ........... .. ........ ........ .......... .... ........ ... 22-47
OCT OTC INDEX .... ..... ...................................... 13-10 IAT SENSOR · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-69
INDEX
IGNITION COIL· ··· ·· ········ ·· · ············· ······· ·· ··· ····· ··· 5-10 RIGHT REAR ENGINE COVER .. ··· ·· ··· ············ ···· ··· ·2-27
IGNITION SWITCH ....... .. .. .. ... ...... .. .. ... .... ...... .... . 22-26 ROCKER ARM ···· ··· ··············· ···· ····· ··· ·· ···· ····· ····· ·· 10-9
IGNITION SYSTEM INSPECTION .... ..... .... .... .. ........ 5-7 SCREEN ADJUST RAIL (CRF1100A4/D4) .... ... ... ... ... 2-19
IGNITION TIMING ·· ······ ····· ······· ···· ·· ·· ····· ····· ··· ··· ·· 5-13 SCU· ··· ······ ·· ········· ··· ····· ·· ····· ··········· ··· ···· ····· ····· 22-80
IMU ······· ···· ···· ···· ······ ··· ······· ····· ·· ··· ··· ···· ······ ·.···· ··· 4-67 SEAT CATCH HOOK/SEAT LOCK CYLINDER .... ··· ···2-30
INNER COVER · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-9 SEAT RAIL ·· ····· ······· ··· ·· ··· ·· ········ ··· ····· ····· ······ ······2-43
INNER PANEL COVER· ······ ········ ········· ········ ··· ····· 2-17 SECONDARY AIR SUPPLY SYSTEM
INSULATOR ··· ·· ····· ·· ···· ···· · ········· ··· ··· ··· ····· ·· ·· ····· 10-27 FUEL SYSTEM ...... ...... .. .... ..... .. .. ..... ..... ... .. .... .7-19
KNUCKLE GUARD .... · .. · · ·· .. · · · .. · ...... · .. · · · · · · · · · · · · · · · · · 2-22 MAINTENANCE ....... .......... .. ....... ..... ........ .... ... 3-15
LEFT HANDLEBAR SWITCH · · · · · · · .. .. · · .. · · · · · · · · · · · · · · · · 22-27 SERVICE INFORMATION
LEFT REAR COVER · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-26 ALTERNATOR/STARTER CLUTCH · · · · · · · · · · · · · · · · · · .. 11-2
LICENSE LIGHT ··· ·· ··· ··· ···· ··· ·· ·· ·· ···· ··· ·· ··· ····· ·······22-13 ANTI-LOCK BRAKE SYSTEM (ABS) ············· ·· ··· ·20-2
LINEAR SOLENOID VALVE·· ·· ··· ····· ······· ·· ···· ·· ·· ··· 13-47 BATTERY/CHARGING SYSTEM ... .. ...... ... .... .. ... .21-2
LUBRICATION & SEAL POINTS ·· ······· ··· ·· ········· ·· ··· 1-23 CLUTCH/GEARSHIFT LINKAGE (MT model) .. .. .... 12-2
LUBRICATION SYSTEM DIAGRAM·· ········ ··· ····· · ······ 9-4 COOLING SYSTEM · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · ·· · · · · 8-2
MAIN JOURNAL BEARING · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 15-6 CRANKCASE/TRANSMISSION/BALANCER ··· ··· ··· 14-2
MAIN SEAT ···· ···· ····· ···· ····· ·· ······· ······ ···· ····· ·· ····· ···· 2-5 CRANKSHAFT/PISTON/CYLINDER·· ······ ···· ······· · 15-2
MAIN STEP··· ···· ······· ·· ···· ··· ······ ··· ··· ······· ··· ····· ··· ·· 2-27 CYLINDER HEADNALVE/CAMSHAFT ···· ····· ····· ··10-2
MAINSHAFT SENSOR · · ........ · · · ·· · · .. · ·· · · · · · · ·· .. · · .. · · · 13-61 DUAL CLUTCH TRANSMISSION (OCT model)· ···· ·13-2
MAINTENANCE SCHEDULE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-3 ELECTRIC STARTER ········ ·· ···· ········ ·· ··· ······· ···· ·· 6-2
MAP SENSOR · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· 4-68 ENGINE REMOVAL/INSTALLATION ........... ........ 15_2
METER/MID ·· ···· ········ ·· ····· ······· ········· ···· ·········· ··22-14 FRAME/BODY PANELS/EXHAUST SYSTEM· · .. ..... 2-2
MIDDLE COWL· ······ ········· ····· ··· ··· ····· ··· ·· ···· ······ ··· ·· 2-7 FRONT WHEEL/SUSPENSION/STEERING··· ···· ·· · 17-2
MIL CIRCUIT TROUBLESHOOTING ····· ···· ··········· ·· 4-66 FUEL SYSTEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-2
MODEL IDENTIFICATION· ····· ····· ·· .. ····· ·········· ···· ·· ·· 1-3 HYDRAULIC BRAKE · .. .. .. . ...... .. ·· ·· .... ··· ····· ·· .. .. .. 19-2
MUD GUARD··· ··· ···· ··· ······ ········· ··· ·· ·· ·· ······· ······ ·· · 2-38 IGNITION SYSTEM ······ ····· ···· ···· ······ ···· ····· ···· ··· ·· 5-2
MUFFLER/EXHAUST PIPE · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · 2-45 LIGHTS/METERS/SWITCHES/ELECTRONIC
NEUTRAL SWITCH (OCT model) · · · · · · · · · · · · · · ·· · · · · · · · · · 13-65 SUSPENSION ····· ··· ········ ·· ······· ········ ·· ······ ···· ··· ·22-2
NEUTRAL SWITCH (MT model) · · · · · · · · · ·· · · · · · · · · · · · · · · · · 22-45 LUBRICATION SYSTEM ··· ··· ··· ···· ·· ···· ······· ···· ······ 9-2
NUTS, BOLTS, FASTENERS· ······ ···· ···· ······ ···· ······· 3-33 MAINTENANCE .. · ...... · · · · · · · · ·· · · · · · .. · · ·· · · · · · · · · · · · ·· · · · · 3-2
OIL PRESSURE INSPECTION· ···· ··· ······· ······ ········· ·· 9-6 PGM-FI SYSTEM ···· ·· ·· ·· ··· ····· ·········· ······ ·· ··· ·· ···· · 4-2
OIL PUMP ··· ······· ····· ····· ··· ···· ····· · ····· ·· · ····· ······· ······ 9-6 REAR WHEEL/SUSPENSION ······ .. ··· ······· · ······ ··· 18-2
OIL PUMP DRIVEN GEAR ....... ......... .... .... ............. 9-9 SERVICE RULES .......... ....... ... ...... .. ..... ... ... ... ...... . 1-2
OIL STRAINER · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · 9-10 SHIFT CONTROL MOTOR/REDUCTION GEARS ·· ·· 13-54
OPEN AIR TEMPERATURE SENSOR·· ·· ······ ···· ·· ···22-24 SHIFT SPINDLE ANGLE SENSOR ... ... .... .... ...... ... 13-63
PANNIER BRACKET (CRF1100A4/D4) .. .. .... ... ... .... . 2-37 SHIFT SPINDLE SWITCH (MT model) .. .... ..... .. .... .. ..4_74
PARKING BRAKE CALIPER (OCT model) ···· ··· ······· 19-25 SHOCK ABSORBER·· ··· .. ·· ··· ········ ··· .. ··· ··· ····· ·· ··· · 18-11
PARKING BRAKE LEVER (OCT model) .. ·· ··· ······ ·· ·· 19-23 SIDESTAND
PARKING BRAKE SWITCH (OCT model) .. ···· ·· ...... · 22-44 FRAME/BODY PANELS/EXHAUST SYSTEM ···· ····2-54
PGM-FI SYMPTOM TROUBLESHOOTING ····· ··· ·· ··· ··· 4-9 MAINTENANCE ···· ·· ··········· ·· ·· ···· ·········· ········ ···3-26
PGM-FI SYSTEM DIAGRAM··· ·· ···· ·· ·· ········· ····· ······ 23-8 SIDESTAND SWITCH ··· ·· ·· ····· ···· ······· ··· ··········· ·· · 22-45
PGM-FI SYSTEM OTC INDEX· ····· ······ ····· ······ ·· ···· · 4-10 SKID PLATE ....... ..... .... ..... .. . .. .... ... ....... ... .... .... .... 2-25
PGM-FI SYSTEM OTC TROUBLESHOOTING· ··· ···· · 4-16 SPARK ARRESTER ···· ··· ··· ··········· ····· ····· ········· ···· ·3-33
PGM-FI TROUBLESHOOTING INFORMATION ···· ···· ·· 4-5 SPARK PLUG ···· ··· ·········· ····· ······ ·· ····· ··· ······· ···· ····· 3-6
PILLION SEAT .. ......... .. .... ..... .... ... ..... ..... ....... ...... . 2-5 SPECIFICATIONS ·· ····· ·· ····· ···· ····· ··· ····· ··· ··· ····· ·· ···· 1-5
PILLION STEP· ·· .. ······· · ·· ···· ·· .. ...... ..... .. .. ···· · ·· .. ···· 2-29 STARTER CLUTCH ···· ···· ···· ······ ··· ·· ······· ···· ··· ···· ····11-8
PISTON/CYLINDER ···· ······ ·· ········· ····· ···· ······ ···· ··· 15-12 STARTER MOTOR ···· ·· ··· ·· ·· ···· ··· ········· ·· ·· ······ ··· ···· · 6-7
PRIMARY DRIVE GEAR STARTER RELAY ...... ... ....... ... ........ .... .. ... ... ..... .. .6-11
CLUTCH/GEARSHIFT LINKAGE (MT model)··· ··· 12-18 STARTER RELAY SWITCH ··· ······ ·· ····· ···· ······· ······ ··· 6-9
DUAL CLUTCH TRANSMISSION (OCT model) ···· 13-53 STATOR ............. .... ... ..... ..... ........ ......... .... ...... .. . 11-5
RADIATOR COOLANT ····· ······ ··· ····· ···· ···· ······ ·· ···· · 3-14 STEERING HEAD BEARINGS .... .... ... .... .... ..... ....... 3_34
RADIATOR RESERVE TANK ·· ······· ····· ····· ··· ···· ····· · 8-11 STEERING STEM ···· ·· ···· ···· ·· .... ......... ... ....... ...... . 17-47
RADIATOR/COOLING FAN ····· ··· ···· ········· ·· ····· ··· ···· · 8-7 SUB VB RELAY .. .. .. .... .... .. .... ..... .. ....... ....... ......... 4_77
REAR BRAKE CALIPER .. ...... .. ........ ..... .... .. .... .... 19-21 SUSPENSION · · · · · · ·· · · · · ·· · · · · · · · · · ·· · · ··· · · · · · · ·· · · · · ··· · · ·· · · ·3-26
REAR BRAKE PEDAL· ··· .... .. ·· .. ····· ··· ·· .. ·· .. ···· · .. · .. 19-16 SWINGARM ... .... .... .. .. ............... ...... .... ........ ..... 18-24
REAR CARRIER (CRF11 00A4/D4) ....... ..... .... .... .... 2-37 SYSTEM DIAGRAM
REAR CENTER COWL .. .. .. ···· ····· ··· ······· · .. ···· ····· ·· · 2-35 ANTI-LOCK BRAKE SYSTEM (ABS) · · · · · · · · · · · · · ·· · .. ·20-4
REAR FENDER A· ·········· ··· ········ .. ····· .. ········ ···· ···· 2-38 BATTERY/CHARGING SYSTEM ········· ·· ····· ····· · .. 21-5
REAR FENDER 8 .. ....... ... .. .... ...... ... .. ...... .... ....... . 2-40 DUAL CLUTCH TRANSMISSION (OCT model)· ··· ··13-7
REAR MASTER CYLINDER .. ... .... ...... .... ..... ........ 19-17 ELECTRIC STARTER· ············ ···· ···· ···· ······· ······ ·· 6-5
REAR SEAT UNDER COVER .. .... .... ... .. ............ ... . 2-34 IGNITION SYSTEM ... ..... .............. ..... ...... .. .... .... 5-5
REAR SIDE COWL .... ... .. .... .. .. .. ..... ..... .. .... ...... ... . 2-30 SYSTEM FLOW PATTERN ...... · .. · ·· ·· · · · · · · · · · · · .. ·· ·· · · .. · 8-3
REAR SIDE INNER COVER ...... .......... .. ....... .. ..... . 2-33 SYSTEM LOCATION
REAR WHEEL ..... .. ..... ......... ..... ..... .... ... ........ .... . 18-6 ANTI-LOCK BRAKE SYSTEM (ABS) .... ... .. .......... 20-3
REGULATOR/RECTIFIER· ····· · .. ......... ... ... ...... ...... 21-9 BATTERY/CHARGING SYSTEM ...... ....... .... .. ... ..21-5
RIGHT CRANKCASE COVER DUAL CLUTCH TRANSMISSION (OCT model)···· ··13-6
CLUTCH/GEARSHIFT LINKAGE (MT model) · · · · · · · 12-5 ELECTRIC STARTER· ····· ···· ··· ·· ··· ·· ·· ····· ···· ··· ······ 6-4
DUAL CLUTCH TRANSMISSION (OCT model)···· 13-40 IGNITION SYSTEM .. ·· ·········· ··· ···· · .. ······· .. ······· .. · 5-4
RIGHT HANDLEBAR SWITCH · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22-34
INDEX
LIGHTS/METERS/SWITCHES/ELECTRONIC COOLING SYSTEM·································· ·········8-2
SUSPENSION ················································ 22-4 CRANKCASE/TRANSMISSION/BALANCER ········ 14-4
PGM- FI SYSTEM ··············································4-3 CRANKSHAFT/PISTON/C YLINDER ··················· 15-2
SYSTEM TESTING ···············································8-4 CYLINDER HEADNALVE/CAMSHAFT................ 10-3
TANK FRONT COVER ···········································2-6 ELECTRIC STARTER ········································6-3
TANK SIDEA COVER (CRF1100A/D)..······················ 2-24 FRAME/BODY PANELS/EXHAUST SYSTEM ·········2-2
TBW REL Y ······················································4-76 FRONT WHEEUSUSPENSION/STEERING ········· 17-4
TCM ······························································· 13-65 HYDRAULIC BRAKE ······································· 19-2
TECHNICAL FEATURES....·································· 1-75 IGNITION SYSTEM ···········································5-3
THERM OSTAT ·····················································8-6 LUBRICATION SYSTEM ····································9-3
THROTTLE BODY ·············································· 7-16 REAR WHEEUSUSPENSION ··························· 18-4
THROTTLE OPERATION .......................................3-4 TURN SIGNAL LIGHT........................................ 22-12
TOOL BOX ······································ ·················· 2-26 VALVE CLEARANCE·············································3-7
TORQUE VALUES .............................................. 1-13 VS SENSOR ············ .......······ .......······················ 4-73
TR SENSOR ···················································· 13-62 WATER PUMP ................................................... 8-11
TRANSMISSION··············································· 14-14 WHEEL SPEED SENSOR ·································· 20-24
TROUBLESHOOTING WHEELS/TIRES ················································· 3-33
AL TERNATOR/STARTER CLUTCH···················· 11-2 WINDSCREEN ··················································· 2-18
BATTERY/CHARGING SYSTEM ........................ 21-3 WIRING DIAGRAM (DCT model)..·· ..· ..······· ..·········· 23-5
CLUTCH/GEARSHIFT LINKAGE (MT model)········ 12-3 WIRING DIAGRAM (MT model) ......················· ..· ..· 23-2

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2020

HOW TO USE THIS MANUAL

A Few Words About Safety

For Your Safety

Important Safety Precautions

© Honda Motor Co., Ltd.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

..;1-.ru Apply sealant.

8 Use fork or suspension fluid.

SPECIFICATIONS··················· ··············· 1-5 EMISSION CONTROL SYSTEMS ........... 1-72

TORQUE VALUES ............................... 1-13 TECHNICAL FEATURES ...................... 1-75

PGM-FI SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

LUBRICATION SYSTEM SPECIFICATIONS

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (MT model)

DUAL CLUTCH TRANSMISSION SPECIFICATIONS (DCT model)

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

HYDRAULIC BRAKE SPECIFICATIONS

Caliper piston Upper 30.148 - 30.198 (1 .1869 - 1.1889) -

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ENGINE & FRAME TORQUE VALUES

CLUTCH/GEARSHIFT LINKAGE {MT model)

r Front balancer shaft bolt 1 10 103 (1 0.5, 76)

I Rear balancer shaft holder bolt 3 8 29 (3.0, 21)

., Drive chain guard bolt 2 6 10 (1 .0, 7)

ANTI-LOCK BRAKE SYSTEM (ABS)

Do not apply this area.

The bolt shown is typical.

*2: Apply locking agent to the threads as shown .

ij -1-~ - ~ Apply this area .

The bolt shown is typical.

FRONT SUB HARNESS

FRONT SUB HARNESS

FRONT SUB HARNESS

FRONT SUB HARNESS

FRONT SUB HARNESS

FRONT SUB HARNESS

FRONT SUB HARNESS

FRONT SUB HARNESS

FRONT SUB HARNESS

FRONT SUB HARNESS

OPEN AIR TEMPERATURE SENSOR RIGHT FRONT TURN SIGNAL LIGHT

OPEN AIR TEMPERATURE SENSOR

RIGHT FRONT TURN SIGNAL LIGHT

FRONT SUB HARNESS

FRONT SUB HARNESS

ACCESSORY SOCKET (option)

FRONT SUB HARNESS 3

LEFT FRONT TURN SIGNAL LIGHT FRONT SUB HARNESS 2

FRONT SUB HARNESS 3

LEFT FRONT TURN SIGNAL LIGHT

FRONT BRAKE HOSE A

MT model : CLUTCH CABLE

LEFT HANDLEBAR SWITCH

RIGHT HANDLEBAR SWITCH WIRE

RIGHT HANDLEBAR SWITCH WIRE

FRONT BRAKE HOSE A