TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START 1. Fuel Line Inspection Check fuel flow to carburetor. Does fuel reach the carburetor? IMO - • Clogged fuel hose or …
WIRING DIAGRAM
WIRING DIAGRAM WIRING DIAGRAM
STARTER SWITCH
INSPECTION '05 - '07: Remove the front visor. - '05 -'07: (page 3-5) - After '07: (page 3-6) Disconnect the starter switch 2P (Black) connector. STARTER SWITCH Check for continuity …
TAIL LIGHT
INSPECTION Start the engine and check the tail light illumination. If any LED does not turn on, replace the tail light unit. CLAMPS STAY CONNECTORS SCREWS TAIL LIGHT UNIT REMOVAL/INSTALLATION …
COMPONENT LOCATION
STARTER SWITCH SERVICE INFORMATION GENERAL NOTICE • A halogen headlight bulb becomes very hot while the headlight is ON, and remain hot for a while after it is turned OFF. …
STARTER RELAY SWITCH
INSPECTION STARTER RELAY SWITCH Remove the left side cover (page 3-3). Shift the transmission into neutral. Pull the clutch lever fully, and push the engine starter switch. If the starter …
ASSEMBLY
O-RING DUST SEAL WASHER INSULATED WASHER SHIM ARMATURE BRUSH FRONT COVER SEAL RINGS SHIMS BRUSH SPRING WASHER INSULATORS O-RING MOTOR CASE BRUSH HOLDER INSULATOR TERMINAL BOLT INSULATOR PLATE REAR COVER …
STARTER MOTOR
REMOVAL • Remove the negative cable at the battery before servicing the starter motor. STARTER MOTOR CABLE Remove the cylinder (page 10-5). Remove the rubber cap from the starter motor …
IGNITION CONTROL MODULE (ICM)
ICM CONNECTORS REMOVAL/INSTALLATION Remove the left side cover (page 3-3). Disconnect the ICM connectors. Remove the ICM from the rear fender. Installation is in the reverse order of removal. IGNITION …
IGNITION SYSTEM INSPECTION
DIGITAL MULTIMETER (impedance 10 Mi^/DCV minimum) PEAK VOLTAGE ADAPTOR • If there is no spark at the plug, check all connections for loose or poor contact before measuring each peak …
IGNITION SYSTEM
COMPONENT LOCATION 05 - '07 shown: THROTTLE POSITION SENSOR IGNITION CONTROL MODULE (ICM) IGNITION PULSE GENERATOR ENGINE STOP BUTTON ALTERNATOR IGNITION COIL SPARK PLUG SYSTEM DIAGRAM G/BIBI/Y I I- &VG …
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION (+) PROBE Remove the seat (page 3-3). Disconnect the negative (-) cable from the battery. Connect the ammeter (+) probe to the negative (-) cable and ammeter …
BATTERY/CHARGING SYSTEM
COMPONENT LOCATION '05 - '07 shown: ALTERNATOR REGULATOR/RECTIFIER BATTERY FUSE 15 A G : Green R : Red W : White Y : Yellow SYSTEM DIAGRAM SERVICE INFORMATION GENERAL A …
BRAKE PEDAL
REMOVAL PIVOT BOLT Remove the clip, brake pedal pivot bolt, washer and dust seals. COTTER BRAKE PEDAL JOINT PIN Remove the return spring. Remove and discard the cotter pin. Remove …
REAR BRAKE CALIPER
REMOVAL Drain the rear brake hydraulic system (page 16-6). Remove the brake pads (page 16-10). Remove the bolts and brake caliper guard. Loosen the oil bolt. Remove the rear wheel …
FRONT BRAKE CALIPER
REMOVAL Drain the front brake hydraulic system (page 16-6). Remove the brake pads (page 16-10). Remove the brake hose oil bolt, sealing washers and brake hose eyelet. PAD SPRING CALIPER …
REAR MASTER CYLINDER
REMOVAL Drain the rear brake hydraulic system (page 16-6). Remove the brake pedal (page 16-24). When removing the Remove the brake hose oil bolt, sealing washers brake hose oil bolt, …
FRONT MASTER CYLINDER
REMOVAL SEALING WASHERS OIL BOLT Drain the front brake hydraulic system (page 16-6). Remove the brake hose oi and brake hose eyelet. bolt, sealing washers When removing the brake hose …
BRAKE PAD/DISC
BRAKE PAD REPLACEMENT BOLTS DISC COVER For front brake, remove the bolts and brake disc cover. Push the caliper pistons all the way in to allow installation of new brake …
BRAKE FLUID REPLACEMENT/AIR BLEEDING
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. • Once the hydraulic system …
HYDRAULIC BRAKE
COMPONENT LOCATION SERVICE INFORMATION GENERAL A WARNING Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health. • Avoid breathing dust particles. • Never …
BEARING REPLACEMENT
DRIVER ATTACHMENT /PILOT ATTACHMENT/PILOT Press the needle bearings out of the swingarm using the special tools and a hydraulic press. TOOLS: 07949-3710001 07746-0010700 07746-0041000 07746-0030300 Driver ATTACHMENT DRIVER i-11.5 mm …
SWINGARM
REMOVAL BRAKE CALIPER Remove the following: - Rear wheel (page 15-8) - Brake pedal (page 16-24) Do not disconnect Remove the rear brake caliper from the slide rail on the …
BEARING REPLACEMENT
SHOCK ARM NEEDLE BEARING Press the needle bearings (shock link side and swingarm side) out of the shock link using the special tools and a hydraulic press. TOOLS: 07949-3710001 07746-0010700 …
SHOCK LINKAGE
REMOVAL Remove the cotter pin, washer, joint pin, spring and left step. LEFT STEP WASHER Remove the step bracket mounting bolts and step bracket assembly. Remove the nut and drive …
SPHERICAL BEARING REPLACEMENT
DUST SEALS Remove the dust seals. Check the spherical bearing for wear or damage. If it is worn or damaged, it must be replaced. STOPPER RING COLLAR Press the spherical …
ROD GUIDE CASE INSPECTION
REBOUND RUBBER METAL DUST SEAL Inspect the rebound rubber and dust seal lips for wear or damage and replace the rod guide case with a new one if necessary. Visually …
PISTON RING REPLACEMENT
PISTON RING GUIDE Apply fork oil to new O-rings and piston ring. Place the piston ring guide attachment over the piston and install new O-rings and piston ring into place …
DAMPER DISASSEMBLY
Point the valve away from you to prevent debris getting in your eyes. Depress the valve core to release the nitrogen from the reservoir (page 15-15). AWARNING The chamber cap …
BLADDER REPLACEMENT
• Set the rebound adjuster and compression adjuster counterclockwise to the softest position. • Replace the bladder when oil leaks around the chamber cap or oil spills out when releasing …
SHOCK ABSORBER
REMOVAL SUB-FRAME Remove the seat (page 3-3). Remove the fuel tank (page 3-8). Raise the rear wheel off the ground by placing a workstand or equivalent under the engine. Loosen …
REAR WHEEL
REMOVAL Raise the rear wheel off the ground by placing a workstand or equivalent under the engine. Loosen the axle nut. Loosen the drive chain adjuster lock nuts and turn …
COMPONENT LOCATION
SERVICE INFORMATION GENERAL AWARNING • Use only nitrogen to pressurize the shock absorber. The use of an unstable gas can cause a fire or explosion resulting in serious injury. • …
STEERING STEM
REMOVAL BOLTS/COLLARS Remove the following: - Front visor ('05 - '07: page 3-5, After '07: page 36) - Handlebar (page 14-32) - Front wheel (page 14-8) After '07: Remove the …
HPSD (Honda Progressive Steering Damper): After ’07
REMOVAL/INSTALLATION Clean and apply a locking agent to the steering damper mounting bolts. Install the steering Install the steering damper, collars and bolts. • The upper side collar is shorter …
