Content

General information

Periodic maintenance

• Periodic maintenance schedule
• Periodic maintenance chart
• Lubrication points
• Maintenance and tune-up procedures
• Air cleaner
• Spark plug
• Valve clearance
• Fuel hose
• Engine oil and oil filter
• Engine idle speed
• Throttle cable play
• Throttle valve synchronization
• Evaporative emisson control system (for e-33 only)
• Pair (air supply) system
• Clutch
• Cooling system
• Final gear oil
• Brake
• Tire
• Steering
• Front fork
• Rear suspension
• Exhaust pipe bolt
• Chassis bolt and nut
• Compression pressure check
• Compression test procedure
• Oil pressure check
• Oil pressure test procedure
• SDS check

Engine

• Engine components removable with engine in place
• Engine removal and installation
• Engine removal
• Engine installation
• Engine disassembly
• Engine components inspection and servicing
• Cylinder head cover
• Camshaft
• Cam chain tensioner and guide
• Cylinder head
• Cylinder
• Piston
• Conrod/crankshaft
• Clutch
• Generator/signal generator/ starter clutch
• Oil pump
• Transmission
• Gearshift fork
• Oil jet
• Crankcase
• Engine reassembly

Shaft drive

• Secondary bevel gears
• Construction
• Removal
• Disassembly
• Inspection
• Secondary gear shims adjustment
• Reassembly
• Installation
• Final bevel gears
• Construction
• Final gear case removal
• Final gear case disassembly
• Final gear shims adjustment
• Final gear case reassembly
• Final gear case installation

FI system

• Precautions in servicing
• Connector/coupler
• Fuse
• ECM/various sensors
• Electrical circuit inspection procedure
• Using the multi-circuit tester
• Fi system technical features
• Injection time (injection volume)
• Compensation of injection time (volume)
• Injection stop control
• Fi system parts location
• Fi system wiring diagram
• ECM terminal
• Self-diagnosis function
• User mode
• Dealer mode
• Tps adjustment
• Fail-safe function
• FI system troubleshooting
• Customer complaint analysis
• Visual inspection
• Self-diagnostic procedures
• Self-diagnosis reset procedure
• Use of SDS diagnostic procedures
• Use of SDS diagnosis reset procedure
• Show data when trouble (displaing data at the time of DTC)
• Malfunction code and defective condition
• “c12” (p0335) ckp sensor circuit malfunction
• “c13” (p1750) or “c17” (p0105) iap sensor circuit malfunction
• “c14” (p0120-h/l) TP sensor circuit malfunction
• “c15” (p0115-h/l) ECT sensor circuit malfunction
• ECT sensor inspection
• “c21” (p0110-h/l) iat sensor circuit malfunction
• “c23” (p1651-h/l) to sensor circuit malfunction
• “c24” (p0351) or “c25” (p0352) ignition system malfunction
• “c28” (p1655) STV actuator circuit malfunction
• “c29” (p1654-h/l) STP sensor circuit malfunction
• “c31” (p0705) GP switch circuit malfunction

Fuel system and throttle body

• Fuel delivery system
• Fuel system
• Fuel tank removal
• Fuel tank installation
• Fuel pressure inspection
• Fuel pump inspection
• Fuel discharge amount inspection
• Fuel pump relay inspection
• Fuel pump removal and disassembly
• Fuel mesh filter inspection and cleaning
• Fuel pump reassembly and installation
• Throttle body
• Construction
• Air cleaner box removal
• Air cleaner box installation
• Throttle body removal
• Throttle body disassembly
• Throttle body cleaning
• Inspection
• Throttle body reassembly
• Throttle body installation
• Stp sensor adjustment
• Fuel injector removal
• Fuel injector inspection
• Fuel injector installation
• Fast idle
• Fast idle adjustment
• Throttle valve synchronization
• Throttle position sensor (TPS) setting

Cooling and lubrication system

• Engine coolant
• Cooling circuit
• Cooling circuit inspection
• Radiator and water hoses
• Radiator removal
• Radiator cap inspection
• Radiator inspection and cleaning
• Radiator remounting
• Water hose and reservoir tank inspection
• Cooling fan
• Cooling fan thermo-switch
• Engine coolant temperature sensor
• Thermostat
• Water pump
• Lubrication system
• Oil pressure
• Oil filter
• Oil pressure regulator
• Oil strainer
• Oil jet
• Oil pump
• Oil pressure switch
• Engine lubrication system chart

Chassis

• Exterior parts
• Front wheel
• Front fork
• Handlebar
• Steering
• Steering tension adjustment
• Rear wheel
• Rear suspension
• Rear shock absorber disposal
• Suspension setting
• Front brake

Electrical system

• Cautions in servicing
• Connector
• Coupler
• Clamp
• Fuse
• Semi-conductor equipped part
• Battery
• Connecting the battery
• Wiring procedure
• Using the multi-circuit tester
• Location of electrical components
• Charging system
• Starter system and side-stand/ignition interlock system
• Starter motor
• Starter relay inspection
• Side stand/ignition interlock system parts inspection
• Ignition system
• Speedometer and pilot lamp box
• Lamps
• Headlight, brake light/taillight, license plate light and turn signal light
• Relays
• Turn signal/side-stand relay
• Starter relay
• Fuel pump relay

Servicing information

• Troubleshooting
• Fi system malfunction code and defective condition
• Engine
• Radiator (cooling system)
• Chassis
• Shaft drive
• Brakes
• Electrical
• Battery
• Wiring harness, cable and hose routing
• Wiring harness routing
• Cable routing
• Throttle body installation
• Cooling system hose routing
• Front brake routing
• Speed sensor harness routing
• Front turn signal installation
• Front turn signal lead wire routing
• Muffler and exhaust pipe installation
• Handlebar balancer
• Battery protector
• Lubrication points
• Fuel tank installation
• Rear combination lamp installation
• Frame head cover cushion installation
• Left side cover cushion installation
• Rear fender cushion installation
• Left side cover installation
• Lid cushion instsallation
• Tail lamp installation
• Pair (air supply) system diagram
• Pair (air supply) system hose routing
• Special tools
• Tightening torque
• Engine
• Secondary and final
• Fi system and intake air system
• Cooling system
• Chassis
• Tightening torque chart
• Service data

Emission control information

• Emission control systems
• Fuel injection system
• Exhaust emission control system (pair system)
• Noise emission control system
• Evaporative emission control system (only for e-33)
• Pair (air supply) system inspection
• Hoses
• Pair reed valve
• Pair control solenoid valve
• Pair (air supply) system hose routing
• Heated oxgen sensor (ho2s) inspection (for e-02, 19, 24)
• Evaporative emission control system inspection (only for e-33)
• Hoses (EVAP hose)
• EVAP canister
• EVAP canister hose routing (only for e-33)

Wiring diagram