SHOP MANUAL

CRF1100A/AL/A2/AL2/A4/
AL4/D/DL/D2/DL2/D4/DL4

CRF1100A/AL/A2/AL2/A4/AL4/D/DL/D2/DL2/D4/DL4
 dummyhead

HOW TO USE THIS MANUAL

A Few Words About Safety
HOW TO USE THIS MANUAL

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.

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.

Failure to properly follow instructions and

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

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the 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.

0-1
dummyhead

HOW TO USE THIS MANUAL

How To Use This Manual
This manual describes the service procedures for the CRF1100A/AL/A2/AL2/A4/AL4/D/DL/D2/DL2/D4/DL4.
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 23 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.

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

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

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

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

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

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.

© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: May, 2020

0-2
 dummyhead

HOW TO USE THIS MANUAL

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).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example:
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example:
• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Pro Honda M-77 Assembly Paste (Moly) (U.S.A. only)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Moly Paste 500 manufactured by Sumico Lubricant, Japan

Use silicone grease.

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use fork or suspension fluid.

0-3
dummyhead

CONTENTS
GENERAL INFORMATION 1
FRAME/BODY PANELS/EXHAUST SYSTEM 2
MAINTENANCE 3
PGM-FI SYSTEM 4
IGNITION SYSTEM 5
ELECTRIC STARTER 6
FUEL SYSTEM 7
ENGINE/ELECTRICAL

COOLING SYSTEM 8
LUBRICATION SYSTEM 9
CYLINDER HEAD/VALVE/CAMSHAFT 10
ALTERNATOR/STARTER CLUTCH 11
CLUTCH/GEARSHIFT LINKAGE (MT model) 12
DUAL CLUTCH TRANSMISSION (DCT model) 13
CRANKCASE/TRANSMISSION/BALANCER 14
CRANKSHAFT/PISTON/CYLINDER 15
ENGINE REMOVAL/INSTALLATION 16
FRONT WHEEL/SUSPENSION/STEERING 17
CHASSIS

REAR WHEEL/SUSPENSION 18
HYDRAULIC BRAKE 19
ANTI-LOCK BRAKE SYSTEM (ABS) 20
ELECTRICAL

BATTERY/CHARGING SYSTEM 21
FRAME

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC 22
IMMOBILIZER SYSTEM (HISS) 23
WIRING DIAGRAMS 24
INDEX
dummyhead

MEMO
dummytext

1. GENERAL INFORMATION

SERVICE RULES ··········································1-2 SPECIAL TOOL LIST ································· 1-30

MODEL IDENTIFICATION ····························1-3 CABLE & HARNESS ROUTING················· 1-32

SPECIFICATIONS ·········································1-6 EMISSION CONTROL SYSTEMS ·············· 1-79

TORQUE VALUES ······································1-16 TECHNICAL FEATURES···························· 1-82

LUBRICATION & SEAL POINTS················1-28

1-1
 dummyhead

GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION

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.
4. Install new gaskets, O-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 1-32).
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
BCU Body Control Unit
CAN Controller Area Network
CKP sensor Crankshaft Position sensor
DCT Dual Clutch Transmission
DLC Data Link Connector
DRL Daytime running light
DTC Diagnostic Trouble Code
ECM Engine Control Module
ECT sensor Engine Coolant Temperature sensor
ECV Exhaust Control Valve
ECV POT Exhaust Control Valve Potentiometer
EGCA Exhaust Gas Control Actuator
EOP sensor Engine Oil Pressure sensor
EOP switch Engine Oil Pressure switch
EOT sensor Engine Oil Temperature sensor
ESS Emergency Stop Signal
EVAP Evaporative Emission
GP sensor Gear Position sensor
GST Generic Scan Tool
HSTC Honda Selectable Torque Control
HISS Honda Ignition Security System
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
OBD 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
dummyhead

GENERAL INFORMATION
DESTINATION CODE
Throughout this manual, the following codes are used to identify individual models for each region.
DESTINATION CODE REGION
CH, IICH China
ED, IIED European direct sales
FO, IIFO Taiwan
GS, IIGS Gulf countries
ID, II ID India
II IN Indonesia
KO, IIKO Korea
IIMA Malaysia
TH, IITH Thailand
U, IIU Australia, New Zealand

MODEL IDENTIFICATION
CRF1100D4 shown:

1-3
 dummyhead

GENERAL INFORMATION
SERIAL NUMBERS/LABELS
The vehicle Identification Number (V.I.N) [1] is stamped on The engine serial number [1] is stamped on the crankcase as
the right side of the steering head. shown.
[1]

[1]
The throttle body identification number [1] is stamped on the The color label [1] (except ID) is attached on the top side of
left side of the throttle body as shown. the rear fender B. When ordering color-coded parts, always
specify the designated color code.
ED, U models shown:

[1]

[1]

The emission information label [1] (KO only) is attached on

the top side of the rear fender B.

[1]

1-4
dummyhead

GENERAL INFORMATION
TYPES
MANUAL TRANSMISSION (MT)
DUAL CLUTCH TRANSMISSION (DCT)
LOW DOWN
HAZARD
EMERGENCY STOP SIGNAL (ESS)
DAYTIME RUNNING LIGHT (DRL)
DESTINATION
TYPE CODE CORNERING LIGHT
CODE
TUBELESS TIRE
BIG FUEL TANK
ACCESSORY SOCKET
GRIP HEATER
ELECTRONIC
SUSPENSION
CRF1100A ED, IIED, IIGS,
– – – – – – – –
KO, IIKO, U, IIU
CRF1100AL CH, IICH – – – – – – – – – –
IIMA, TH, IITH – – – – – – –
CRF1100D ED, IIED, IIGS,
– – – – – – – –
KO, IIKO, IIU
CRF1100DL IICH – – – – – – – – – –
FO, IIFO, IIMA – – – – – – –
CRF1100A2 ED, IIED, GS, IIU – – –
CRF1100AL2 IICH – – – – –
II ID – –
II IN – – –
CRF1100D2 ED, IIED, GS,
– – –
KO, IIKO, IIU
CRF1100DL2 CH, IICH – – – – –
ID – –
II IN – – –
CRF1100A4 ED, IIED, IIGS – –
CRF1100AL4 IIMA –
CRF1100D4 ED, IIED, IIGS,
– –
KO, IIKO, IIU
CRF1100DL4 IICH – – – –
IIMA, IITH –

1-5
 dummyhead

GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length CRF1100A/A2/A4/D/D2/D4 2,330 mm (91.7 in)
CRF1100AL/AL2/AL4/DL/
2,310 mm (90.9 in)
DL2/DL4
Overall width 960 mm (37.8 in)
Overall height CRF1100A/D 1,395 mm (54.9 in)
CRF1100AL/DL 1,355 mm (53.3 in)
CRF1100A2/ Screen high
1,620 mm (63.8 in)
A4/D2/D4 position
Screen low
1,560 mm (61.4 in)
position
CRF1100 Screen high
1,580 mm (62.2 in)
AL2/AL4/ position
DL2/DL4 Screen low
1,520 mm (59.8 in)
position
Wheelbase CRF1100A/A2/A4/D/D2/D4 1,575 mm (62.0 in)
CRF1100AL/AL2/AL4/DL/
1,560 mm (61.4 in)
DL2/DL4
Seat height CRF1100A/ Standard
870 mm (34.3 in)
A2/A4/D/D2/ position
D4 Low
850 mm (33.5 in)
position
CRF1100AL/ Standard
830 mm (32.7 in)
AL2/AL4/DL/ position
DL2/DL4 Low
810 mm (31.9 in)
position
Footpeg height CRF1100A/A2/A4/D/D2/D4 352 mm (13.9 in)
CRF1100AL/AL2/AL4/DL/
312 mm (12.3 in)
DL2/DL4
Ground clearance CRF1100A/A2/A4/D/D2/D4 250 mm (9.8 in)
CRF1100AL/AL2/AL4/DL/
210 mm (8.3 in)
DL2/DL4
Curb weight CRF1100A/ Except KO 226 kg (498 lbs)
AL KO 225 kg (496 lbs)
CRF1100D/ Except KO 236 kg (520 lbs)
DL KO 235 kg (518 lbs)
CRF1100A2/AL2 238 kg (525 lbs)
CRF1100D2/ Except KO 248 kg (547 lbs)
DL2 KO 250 kg (551 lbs)
CRF1100A4/AL4 240 kg (529 lbs)
CRF1100D4/DL4 250 kg (551 lbs)
Maximum weight capacity CRF1100A/ Except KO/
220 kg (485 lbs)
AL/D/DL TH
KO 200 kg (441 lbs)
TH 180 kg (397 lbs)
CRF1100A2/ Except ID/
218 kg (481 lbs)
AL2/A4/AL4/ IN/KO/TH
D2/DL2/D4/ ID/TH 178 kg (392 lbs)
DL4 IN 188 kg (414 lbs)
KO 198 kg (437 lbs)

1-6
dummyhead

GENERAL INFORMATION
ITEM SPECIFICATIONS
FRAME Frame type Semi double cradle
Front suspension Telescopic fork
Front axle travel CRF1100A/A2/A4/D/D2/D4 204 mm (8.0 in)
CRF1100AL/AL2/AL4/DL/
164 mm (6.5 in)
DL2/DL4
Rear suspension Swingarm
Rear axle travel CRF1100A/A2/A4/D/D2/D4 220 mm (8.7 in)
CRF1100AL/ Except CH/
181 mm (7.1 in)
AL2/AL4/DL/ IN
DL2/DL4 CH/IN 180 mm (7.1 in)
Front tire size 90/90-21M/C 54H
Rear tire size 150/70R18M/C 70H
Front tire brand CRF1100A/AL/D/DL AX41TF G (BRIDGESTONE)
KAROO STREET (METZELER)
CRF1100A2/AL2/A4/AL4/D2/ AX41TF L (BRIDGESTONE)
DL2/D4/DL4 KAROO STREET (METZELER)
Rear tire brand CRF1100A/AL/D/DL AX41TR G (BRIDGESTONE)
KAROO STREET (METZELER)
CRF1100A2/AL2/A4/AL4/D2/ AX41TR L (BRIDGESTONE)
DL2/D4/DL4 KAROO STREET (METZELER)
Front brake Hydraulic double disc
Rear brake Hydraulic single disc
Caster angle Except CH/
27° 30’
KO/MA
CH/KO/MA 27.5°
Trail length 113 mm (4.4 in)
Fuel tank capacity CRF1100A/AL/D/DL 18.8 liters (4.97 US gal, 4.14 Imp gal)
CRF1100A2/AL2/A4/AL4/D2/
24.8 liters (6.55 US gal, 5.46 Imp gal)
DL2/D4/DL4
ENGINE Cylinder arrangement 2 cylinders in-line, slant angle 22.5°
Bore and stroke 92.0 x 81.5 mm
(3.62 x 3.21 in)
Displacement 1,084 cm3 (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)
DCT model 74.9 kg (165.1 lbs)
Firing order 1-2
FUEL Type PGM-FI
DELIVERY Throttle bore 46 mm (1.8 in)
SYSTEM

1-7
 dummyhead

GENERAL INFORMATION
ITEM SPECIFICATIONS
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 Except CH/
2.625 (42/16)
IN
CH/IN 2.470 (42/17)
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
(DCT model) Clutch operation system Automatic
Transmission Constant mesh, 6-speeds
Primary reduction 1.863 (82/44)
Final reduction Except CH/
2.625 (42/16)
IN
CH/IN 2.470 (42/17)
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

1-8
dummyhead

GENERAL INFORMATION
PGM-FI SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
IAT sensor resistance (at 40°C/104°F) 1.0 – 1.3 kΩ
Fuel injector resistance (at 20°C/68°F) 11 – 13 Ω
A/F sensor heater resistance (at room temperature) 3.6 – 6.0 Ω
EVAP purge control solenoid valve resistance
30 – 34 Ω
(at 20°C/68°F)
PAIR control solenoid valve resistance (at 20°C/68°F) 24 – 28 Ω
ECT sensor resistance 40°C (104°F) 1.0 – 1.3 kΩ
100°C (212°F) 0.14 – 0.18 kΩ

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

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 cm3 (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/cm2, 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 Except IN/MA/TH High quality ethylene glycol antifreeze containing
silicate-free corrosion inhibitors
IN/MA/TH Honda PRE-MIX coolant
Standard coolant concentration Except IN/MA/TH 1:1 mixture with distilled water

1-9
 dummyhead

GENERAL INFORMATION
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
4.0 liters (4.2 US qt, 3.5 Imp qt) –
filter change
After disassembly 4.8 liters (5.1 US qt, 4.2 Imp qt) –
DCT model 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 Honda "4-stroke motorcycle oil" or an
equivalent motor oil.
API service classification: SG or higher –
JASO T903 standard: MA
Viscosity: SAE 10W-30
Oil pressure (at oil filter cartridge) 614 kPa (6.3 kgf/cm2, 89 psi)
–
at 5,000 r/min (80°C/176°F)
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)

CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 500 r/min 1.4 MPa (14.3 kgf/cm2, 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 stem end and
0.30 ± 0.03 (0.012 ± 0.001) –
adjusting 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 O.D. 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 I.D. EX 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)
Shaft O.D. 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)
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss O.D. 57.749 – 57.768 (2.2736 – 2.2743) –
I.D. 44.000 – 44.016 (1.7323 – 1.7329) –

1-10
dummyhead

GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (MT model)
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
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 (0.10)
Plate warpage – 0.20 (0.008)
Primary driven gear I.D. 41.958 – 41.983 (1.6519 – 1.6529) –
Clutch outer guide O.D. 34.975 – 34.991 (1.3770 – 1.3776) –
I.D. 28.000 – 28.021 (1.1024 – 1.1032) –
Mainshaft O.D. at clutch outer guide 27.967 – 27.980 (1.1011 – 1.1016) –

DUAL CLUTCH TRANSMISSION SPECIFICATIONS (DCT model)

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
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 kΩ –

CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS
MT model:
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
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) –

1-11
 dummyhead

GENERAL INFORMATION
DCT model:
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
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) –

CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
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 O.D. 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 I.D. 22.002 – 22.008 (0.8662 – 0.8665) 22.02 (0.867)
Piston pin O.D. 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 I.D. 22.026 – 22.040 (0.8672 – 0.8677) 22.050 (0.8681)

1-12
dummyhead

GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire Driver only 225 kPa (2.25 kgf/cm2, 33 psi) –
pressure Driver and passenger 225 kPa (2.25 kgf/cm2, 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 CRF1100A/A2/D/D2 433.7 (17.07) 425.0 (16.73)
length CRF1100AL/AL2/DL/DL2 394.2 (15.52) 386.3 (15.21)
CRF1100A4 412.0 (16.22) 403.8 (15.90)
CRF1100D4 415.0 (16.34) 406.7 (16.01)
CRF1100AL4/DL4 378.0 (14.88) 370.4 (14.58)
Recommended fork fluid Fork Fluid (viscosity: 10W) –
Fluid level CRF1100A/A2/D/D2 93 (3.7) –
CRF1100AL/AL2/DL/DL2 104 (4.1) –
CRF1100A4/D4 R: 139 (5.5)
–
L: 69 (2.7)
CRF1100AL4/DL4 R: 130 (5.1)
–
L: 59 (2.3)
Fluid CRF1100A/A2/D/D2 708 ± 2.5 cm3
–
capacity (23.9 ± 0.1 US oz, 24.9 ± 0.1 Imp oz)
CRF1100AL/AL2/DL/DL2 698 ± 2.5 cm3
–
(23.6 ± 0.1 US oz, 24.6 ± 0.1 Imp oz)
CRF1100A4/D4 R: 637 ± 2.5 cm3
(21.5 ± 0.1 US oz, 22.4 ± 0.1 Imp oz)
–
L: 664 ± 2.5 cm3
(22.5 ± 0.1 US oz, 23.4 ± 0.1 Imp oz)
CRF1100AL4/DL4 R: 630 ± 2.5 cm3
(21.3 ± 0.1 US oz, 22.2 ± 0.1 Imp oz)
–
L: 663 ± 2.5 cm3
(22.4 ± 0.1 US oz, 23.3 ± 0.1 Imp oz)
Pre-load CRF1100A 2 turns from the full soft position –
adjuster CRF1100D/A2 5 turns from the full soft position –
standard CRF1100AL/DL 6 turns from the full soft position –
position CRF1100D2
8 turns from the full soft position –
CRF1100AL2/DL2
10 1/2 turns from the full soft position –
Rebound CRF1100A/D 2 3/4 turns from full hard position –
damping CRF1100AL/AL2/DL/DL2
adjuster 2 1/2 turns from full hard position –
standard CRF1100A2/D2
position 2 1/4 turns from full hard position –
Compression CRF1100A/D 9 clicks from full hard position –
damping CRF1100AL/AL2/DL/DL2
adjuster 12 clicks from full hard position –
standard CRF1100A2/D2
position 7 clicks from full hard position –

1-13
 dummyhead

GENERAL INFORMATION
REAR WHEEL/SUSPENSION SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire Driver only 250 kPa (2.50 kgf/cm2, 36 psi) –
pressure Driver and passenger 280 kPa (2.80 kgf/cm2, 41 psi) –
Axle runout – 0.2 (0.01)
Wheel rim runout Radial – 1.0 (0.04)
Axial – 1.0 (0.04)
Wheel balance weight – 60 g (2.1 oz) max.
Drive Slack CRF1100A/A2/A4/D/D2/
chain D4 35 – 45 (1.4 – 1.8) –

CRF1100AL/AL2/AL4/
DL/DL2/DL4 30 – 40 (1.2 – 1.6) –

Size/link DID: 525HV3-124LE –

Shock Pre-load adjuster standard position 7 clicks from full soft position
–
absorber (first click is "0" position)
Rebound CRF1100A/A2/D/D2
8 clicks from full hard position –
damping
adjuster CRF1100AL/AL2/DL/
standard DL2 15 clicks from full hard position –
position
Compression CRF1100A/A2/D/D2
12 clicks from full hard position –
damping
adjuster CRF1100AL/AL2/DL/
standard DL2 9 clicks from full hard position –
position

HYDRAULIC BRAKE SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Front Specified brake fluid 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 DOT 4 brake fluid –
Master cylinder push rod length 73.0 – 75.0 (2.87 – 2.95) –
Brake disc thickness 5.8 – 6.2 (0.23 – 0.24) 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 Fully charged 13.5 – 14.0 V
(20°C/68°F) Needs charging Below 10.8 V
Alternator Capacity 0.49 kW/5,000 r/min
Charging coil resistance (20°C/68°F) 0.1 – 1.0 Ω

1-14
dummyhead

GENERAL INFORMATION
LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight Hi LED
Lo LED
DRL (Except CH/IN) LED
Position light (CH/IN) LED
Cornering light
(CRF1100A2/AL2/A4/ LED
AL4/D2/DL2/D4/DL4)
Brake/taillight LED
Front turn with position light
LED
signal light (Except CH/IN)
without position light
LED
(CH/IN)
Rear turn signal light LED
License light LED
Instrument light LED
ABS indicator LED
Alarm indicator (ED only) LED
Auto cruise set indicator LED
Auto cruise ON indicator LED
DRL indicator (Except CH/IN) LED
Fog light indicator LED
Fuel reserve indicator LED
High beam indicator LED
Coolant temperature indicator LED
HISS indicator LED
Low oil pressure indicator LED
MIL LED
Neutral indicator LED
Parking brake indicator (DCT model) LED
Rear ABS indicator LED
Suspension indicator
LED
(CRF1100A4/AL4/D4/DL4)
Torque control indicator LED
Torque control OFF indicator LED
Turn signal indicator LED
Fuse Main fuse 30 A
Main2 fuse 30 A
FI fuse 15 A
ABS-M fuse 30 A
DCT-M fuse (DCT model) 30 A
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 kΩ
Fuel level CRF1100A/AL/D/DL Full 6 – 10 Ω
sensor Empty 434 – 446 Ω
resistance CRF1100A2/AL2/A4/ Full 6 – 10 Ω
AL4/D2/DL2/D4/DL4 Empty 328 – 338 Ω
Grip heater resistance (25°C/77°F)
1.7 – 2.1 Ω
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)

1-15
 dummyhead

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 (CRF1100A/AL/D/DL) 4 5 0.42 (0.04, 0.3)
Windscreen screw 6 5 0.42 (0.04, 0.3)
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
Lock plate mounting bolt 4 4 1.8 (0.2, 1.3)
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
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 1 6 12.0 (1.2, 9)
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
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 4 8 35 (3.6, 26)
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
Rear carrier bolt 2 8 35 (3.6, 26)
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
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/AL/D/DL) 4 6 9.0 (0.9, 6.6)
Exhaust pipe cover B bolt 4 6 9.0 (0.9, 6.6)
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
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)
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)
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
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

1-16
dummyhead

GENERAL INFORMATION
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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 3-12
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)
(DCT 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
and seating surface.
Self-lock nut
Oil bolt 5 10 34 (3.5, 25)
Brake pipe joint nut 4 10 14 (1.4, 10) Apply brake fluid to the threads.
Parking brake adjuster lock nut 1 8 17.2 (1.8, 13)
(DCT model)
Front spoke (CRF1100A/AL/D/DL) 36 BC 3.5 3.7 (0.4, 2.7)
Front spoke (CRF1100A2/AL2/A4/ 40 BC 4.0 5.0 (0.5, 3.7) Replace with a new one.
AL4/D2/DL2/D4/DL4)
Rear spoke (CRF1100A/AL/D/DL) 32 BC 3.5 3.7 (0.4, 2.7)
Rear spoke (CRF1100A2/AL2/A4/ 36 BC 3.5 5.0 (0.5, 3.7) Replace with a new one.
AL4/D2/DL2/D4/DL4)
PGM-FI SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
IMU mounting bolt/washer 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
and seating surface.
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
DIA. (mm) N·m (kgf·m, lbf·ft)
Timing hole cap 1 14 6.0 (0.6, 4.4) Apply grease to the threads.
ELECTRIC STARTER
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Starter motor cable terminal nut/ 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)

1-17
 dummyhead

GENERAL INFORMATION
FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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 7-14
Insulator band screw 2 5 – See page 7-16
Fuel injector assembly mounting 4 5 5.1 (0.5, 3.8)
bolt
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
DIA. (mm) N·m (kgf·m, lbf·ft)
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 8-7
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 1-27
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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 1-27

CYLINDER HEAD/VALVE/CAMSHAFT
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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 1-27
Cam chain tensioner pivot bolt 1 8 23 (2.3, 17) Apply locking agent to the threads.
(*1) See page 1-27
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)

1-18
dummyhead

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 1-27
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 1-27

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 1-27
Shift drum center bolt 1 8 23 (2.3, 17) Apply locking agent to the threads.
(*2) See page 1-27
Gearshift spindle set plate bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
(*1) See page 1-27
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

1-19
 dummyhead

GENERAL INFORMATION
DUAL CLUTCH TRANSMISSION (DCT model)
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 1-27
Linear solenoid valve body 4 6 12 (1.2, 9)
mounting 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 3 6 14 (1.4, 10)
bolt
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 1-27
Drum shifter guide plate/drum shifter 2 6 12 (1.2, 9) Apply locking agent to the threads.
assembly mounting bolt (*1) See page 1-27
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.
Shift spindle switch terminal nut 1 4 1.7 (0.2, 1.3)
Neutral switch terminal nut 1 4 1.7 (0.2, 1.3)
CRANKCASE/TRANSMISSION/BALANCER
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Front balancer bearing set plate bolt 3 6 12 (1.2, 9) Apply locking agent to the threads.
(*1) See page 1-27
Front balancer shaft bolt 1 10 103 (10.5, 76) Apply engine oil to the threads and
seating surface.
Rear balancer shaft holder bolt 3 8 29 (3.0, 21)

Mainshaft bearing set plate bolt 3 6 12 (1.2, 9) Apply locking agent to the threads.
(*1) See page 1-27
Shift drum bearing setting bolt/ 2 6 12 (1.2, 9) Apply locking agent to the threads.
washer (*1) See page 1-27
Crankcase main journal bolt 6 10 43 (4.4, 32) Apply molybdenum oil solution to
the threads and seating surface.
Crankcase 10 mm bolt 1 10 39 (4.0, 29)

Crankcase 8 mm bolt 9 8 24 (2.4, 18)

1-20
dummyhead

GENERAL INFORMATION
CRANKSHAFT/PISTON/CYLINDER
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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
the threads and seating surface.
Crankpin bearing cap bolt 4 9 22 (2.2, 16) + 90° Apply engine oil to the threads
(retightening) and seating surface.
ENGINE REMOVAL/INSTALLATION
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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)
Neutral switch terminal nut 1 4 1.7 (0.2, 1.3)
Shift spindle switch terminal nut 1 4 1.7 (0.2, 1.3)
Alternator cover bolt 12 6 12 (1.2, 9)

1-21
 dummyhead

GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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
(CRF1100A/AL/D/DL) one.
Pulser ring bolt 3 5 7.0 (0.7, 5.2) ALOC bolt: replace with a new
(CRF1100A/AL/D/DL) one.
Front spoke (CRF1100A/AL/D/DL) 36 BC 3.5 3.7 (0.4, 2.7)
Front brake disc bolt (CRF1100A2/ 10 6 20 (2.0, 15) ALOC bolt: replace with a new
AL2/A4/AL4/D2/DL2/D4/DL4) one.
Pulser ring bolt (CRF1100A2/AL2/ 5 5 7.0 (0.7, 5.2) ALOC bolt: replace with a new
A4/AL4/D2/DL2/D4/DL4) one.
Front spoke (CRF1100A2/AL2/A4/ 40 BC 4.0 5.0 (0.5, 3.7) Replace with a new one.
AL4/D2/DL2/D4/DL4)
Front tire valve nut (CRF1100A2/ 1 8V1 6.5 (0.7, 4.8)
AL2/A4/AL4/D2/DL2/D4/DL4)
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
suspension model left side) threads.
Fork damper lock nut 2 10 20 (2.0, 15)
(conventional suspension model)
Fork damper lock nut (electronic 1 10 20 (2.0, 15)
suspension model left side)
Fork bolt 2 – 35 (3.6, 26)
Suspension solenoid (electronic 1 – 15 (1.5, 11)
suspension model left side)
Inner fork bolt (electronic suspension 1 – 90 (9.2, 66)
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 17-49
Steering stem nut 1 24 100 (10.2, 74) See page 17-49

1-22
dummyhead

GENERAL INFORMATION
REAR WHEEL/SUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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
(CRF1100A/AL/D/DL) one.
Rear brake disc bolt (CRF1100A2/ 5 8 42 (4.3, 31) ALOC bolt: replace with a new
AL2/A4/AL4/D2/DL2/D4/DL4) 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
(CRF1100A/AL/D/DL) one.
Pulser ring bolt (CRF1100A2/AL2/ 3 5 7.0 (0.7, 5.2) ALOC bolt: replace with a new
A4/AL4/D2/DL2/D4/DL4) one.
Rear spoke (CRF1100A/AL/D/DL) 32 BC 3.5 3.7 (0.4, 2.7)
Rear spoke (CRF1100A2/AL2/A4/ 36 BC 3.5 5.0 (0.5, 3.7) Replace with a new one.
AL4/D2/DL2/D4/DL4)
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
one.
Drive chain guard bolt 2 6 10 (1.0, 7)
Swingarm pivot nut 1 16 80 (8.2, 59) Apply engine oil to the threads and
seating surface.
Self-lock nut

1-23
 dummyhead

GENERAL INFORMATION
HYDRAULIC BRAKE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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
(DCT model) one.
Parking brake pad pin 2 8 17.2 (1.8, 13) ALOC bolt: replace with a new
(DCT model) one.
Drive chain guard bolt 2 6 10 (1.0, 7)
(DCT model)
Parking brake caliper cover bolt 2 6 9.0 (0.9, 6.6)
(DCT 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
Rear master cylinder push rod lock 1 8 17.2 (1.8, 13)
nut
Front brake caliper assembly torx 6 8 27 (2.8, 20) Apply locking agent to the threads.
bolt
Rear brake caliper pin bolt 1 12 27 (2.8, 20)
Parking brake stopper stay HEX bolt 1 4 2.3 (0.2, 1.7)
(DCT model)
Parking brake stopper stay flange 1 6 11.9 (1.2, 9)
bolt (DCT model)
Parking brake lock lever pivot bolt 1 6 6.9 (0.7, 5.1)
(DCT model)
Parking brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
(DCT model)
Parking brake lever pivot nut 1 6 5.9 (0.6, 4.4)
(DCT model)
Parking brake switch mounting 1 4 1.2 (0.1, 0.9) Apply locking agent to the threads.
screw (DCT model)
Parking brake caliper pin bolt 1 8 22 (2.2, 16) Apply locking agent to the threads.
(DCT model)
Parking brake adjuster lock nut 1 8 17.2 (1.8, 13)
(DCT model)

ANTI-LOCK BRAKE SYSTEM (ABS)

THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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.

1-24
dummyhead

GENERAL INFORMATION
LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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 1 PT 1/8 12 (1.2, 9) Apply sealant to the threads.
(MT model) See page 22-24
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 1 10 12 (1.2, 9) Apply engine oil to the thread and
(MT model) 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.

1-25
 dummyhead

GENERAL INFORMATION
OTHERS
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
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) 1 14 18 (1.8, 13) Apply locking agent to the threads.
(DCT 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 ±
0.04 in) from bolt end
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 ±
0.04 in) from bolt end
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)
Right crankcase cover inner cover 6 6 12 (1.2, 9) Apply locking agent to the threads.
bolt (DCT model) (*1) See page 1-27
Upper crankcase sealing bolt 1 8 23 (2.3, 17) Apply locking agent to the threads.
(8 mm) Coating width: 5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
0.04 in) from bolt end
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 ±
0.04 in) from bolt end
Lower crankcase sealing bolt 2 18 29 (3.0, 21) Apply locking agent to the threads.
(18 mm) Coating width: 5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
0.04 in) from bolt end
Lower crankcase sealing bolt 1 22 30 (3.1, 22) Apply locking agent to the threads.
(22 mm) Coating width: 4.5 ± 1 mm (0.2 ±
0.04 in) except 2 ± 1 mm (0.1 ±
0.04 in) from bolt end

1-26
dummyhead

GENERAL INFORMATION
*1: Apply locking agent to the threads as shown.
6.5 ± 1.0 mm 2.0 ± 1.0 mm
(0.26 ± 0.04 in) (0.08 ± 0.04 in)

Apply this area.

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)

Apply this area.

The bolt shown is typical.

1-27
 dummyhead

GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Sealant Crankcase mating surface See page 14-26
(TB1207B manufactured Alternator cover mating surface See page 11-4
by ThreeBond or an Alternator wire grommet mating surface of alternator cover See page 11-5
equivalent) Right crankcase cover mating surface MT model: See page 12-6
DCT model: See page 13-44
Linear solenoid valve wire grommet See page 13-49
Sealant Cylinder head cover packing See page 10-6
(TB5211C 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, C5, 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 O-ring entire surface (DCT 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 O-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 1-27
Cam chain guide plate bolt threads Coating width:
(*1) See page 1-27
UNIREX N3 manufactured Shift reduction gear teeth and journal (DCT model) 2 – 4 g (0.07 – 0.14 oz)
by ExxonMobil or
equivalent

1-28
dummyhead

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 O-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 grip pipe-to-APS contacting area See page 17-7
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 an Left handlebar grip rubber matching surface
equivalent (CRF1100A/AL/D/DL)
Left grip heater matching surface 1.0 g (0.04 oz) minimum
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
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 (DCT 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 (DCT 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
(DCT model)
DOT 4 brake fluid Brake master piston and cups
Brake caliper piston
Brake caliper piston seals
Rear master cylinder connector O-ring
Fork fluid Fork cap O-ring
Fork dust seal and oil seal lips
Dive chain lubricant Drive chain whole surface
designed specifically for O-
ring chains or SAE #80-90
gear oil
Locking agent Main step rubber bolt

1-29
 dummyhead

GENERAL INFORMATION
SPECIAL TOOL LIST
TITLE TOOL No TOOL NAME
MAINTENANCE 07708-0030400 Valve adjusting wrench
07HAA-PJ70101 Oil filter wrench
07HMH-MR10103 Drive chain tool set
PGM-FI SYSTEM 070MZ-0010300 SCS short connector
07ZAJ-RDJA110 Test probe
IGNITION SYSTEM 07HGJ-0020100 Peak voltage adaptor
07ZAJ-RDJA110 Test probe
FUEL SYSTEM 07406-0040004 Fuel pressure gauge
070MJ-K260100 Pressure gauge attachment set
07ZAJ-S5A0130 Hose attachment, 6 mm/9 mm
07ZAJ-S7C0100 Hose attachment, 8 mm/9 mm
07ZAJ-S7C0200 Attachment joint, 8 mm/9 mm
07ZAJ-S5A0150 Attachment joint, 6 mm/9 mm
LUBRICATION SYSTEM 070MJ-0010101 Oil pressure gauge attachment
07HAA-PJ70101 Oil filter wrench
07506-3000001 Oil pressure gauge set
07406-0030000 Oil pressure gauge attachment
07936-1660101 Bearing remover shaft set, 12 mm
07741-0010201 Remover weight
07936-3710100 Remover handle
07746-0041300 Pilot, 16 mm
07749-0010000 Driver
07746-0040400 Pilot, 17 mm
CYLINDER HEAD/VALVE/CAMSHAFT 070MG-0010100 Tensioner holder B
07757-0010000 Valve spring compressor
07742-0010100 Valve guide driver, 5.5 mm
07743-0020000 Valve guide driver
07984-2000001 Valve guide reamer, 5.5 mm
07781-0010101 Cutter holder, 5.5 mm
07780-0010500 Seat cutter, 40 mm (45° IN)
07780-0010400 Seat cutter, 35 mm (45° EX)
07780-0012400 Flat cutter, 38.5 mm (32° IN)
07780-0012900 Flat cutter, 33 mm (32° EX)
07780-0014100 Interior cutter, 37.5 mm (60° IN)
07780-0014700 Interior cutter, 34 mm (60° EX)
ALTERNATOR/STARTER CLUTCH 07725-0040001 Flywheel holder
07733-0020001 Rotor puller
CLUTCH/GEARSHIFT LINKAGE 07724-0050002 Clutch center holder P.D. 48 – 135
(MT model) 07724-0010100 Gear holder, 2.5
DUAL CLUTCH Transmission (DCT model) 07ZAJ-RDJA110 Test probe
07741-0010201 Remover weight
07JAC-PH80200 Bearing remover shaft
07JAC-PH80100 Adjustable bearing puller, 20 – 40 mm
07936-3710600 Bearing remover set, 20 mm
07936-3710100 Remover handle
07749-0010000 Driver
07746-0010400 Attachment, 52 x 55 mm
07746-0040900 Pilot, 40 mm
07746-0040500 Pilot, 20 mm
07724-0010100 Gear holder, 2.5
CRANKCASE/TRANSMISSION/BALANCER 07724-0010100 Gear holder, 2.5
07936-ZV10100 Bearing remover shaft set, 25 mm
07741-0010201 Remover weight
07949-3710001 Driver, 15 x 280L
07746-0010400 Attachment, 52 x 55 mm
07746-0040600 Pilot, 25 mm
07746-0040200 Pilot, 12 mm
07PPD-YE10100 Seal driver, 14 x 22 mm

1-30
dummyhead

GENERAL INFORMATION
TITLE TOOL No TOOL NAME
FRONT WHEEL/SUSPENSION/STEERING 07746-0050600 Bearing remover head, 20 mm
07746-0050100 Bearing remover shaft
07749-0010000 Driver
07746-0010300 Attachment, 42 x 47 mm
07746-0040500 Pilot, 20 mm
070MA-MKS0100 Fork bolt wrench
07WMA-KZ30100 Lock nut wrench, 50 mm
070MF-MBZC110 Spring collar holder
070MF-MBZC130 Stopper plate
070MA-MKS0200 Pin type wrench
070MB-MKS0100 Rod guide wrench
07KMD-KZ30100 Fork seal driver, 45.2 mm
070MF-MBZC120 Damper rod holder
07916-KA50100 Steering stem socket
07JAC-PH80100 Adjustable bearing puller, 20 – 40 mm
07JAC-PH80200 Bearing remover shaft
07741-0010201 Remover weight
07946-3710500 Bearing remover
07946-MB00000 Inner driver, 30 x 36 x 300 L
07746-0010400 Attachment, 52 x 55 mm
REAR WHEEL/SUSPENSION 07749-0010000 Driver
07746-0010800 Attachment, 22 x 24 mm
07746-0040500 Pilot, 20 mm
07746-0050600 Bearing remover head, 20 mm
07GGD-0010100 Bearing remover shaft
07746-0010300 Attachment, 42 x 47 mm
07946-1870100 Attachment, 28 x 30 mm
07746-0010400 Attachment, 52 x 55 mm
070MA-MKS0200 Pin type wrench
07741-0010201 Remover weight
07936-3710100 Remover handle
07936-3710300 Bearing remover set, 17 mm
07936-3710600 Bearing remover set, 20 mm
07949-3710001 Driver, 15 x 280L
07746-0040400 Pilot, 17 mm
07746-0010100 Attachment, 32 x 35 mm
07MAD-PR90200 Pilot, 32 mm
07746-0040600 Pilot, 25 mm
07746-0041000 Pilot, 22 mm
ANTI-LOCK BRAKE SYSTEM (ABS) 07ZAJ-RDJA110 Test probe
LIGHT/METERS/SWITCHES/OTHER 07ZAJ-RDJA110 Test probe
ELECTRONIC CONTROL UNITS
IMMOBILIZER SYSTEM (HISS) 070MZ-0010300 SCS short connector
07ZAJ-RDJA110 Test probe

1-31
 dummyhead

GENERAL INFORMATION
CABLE & HARNESS ROUTING
CRF1100A/AL/D/DL:

FRONT SUB HARNESS

FRONT SUB HARNESS

(to left turn signal light)

MID 7P CONNECTOR

USB CONNECTOR GPS CONNECTOR

METER 20P
CONNECTOR

USB CONNECTOR

GPS WIRE

FRONT SUB HARNESS

10 mm (0.4 in)

GPS

FRONT SUB HARNESS

(to right fog light and open air
temperature sensor)
USB WIRE

FRONT SUB HARNESS

(to right front turn signal light)

1-32
dummyhead

GENERAL INFORMATION
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:

FRONT SUB HARNESS

FRONT SUB HARNESS

(to left turn signal light)

MID 7P
CONNECTOR GPS CONNECTOR

USB CONNECTOR

METER 20P
CONNECTOR

FRONT SUB HARNESS

USB CONNECTOR

GPS WIRE

10 mm (0.4 in)

GPS

FRONT SUB HARNESS

(to right fog light and open air
temperature sensor)
USB WIRE

FRONT SUB HARNESS

(to right front turn signal light)

1-33
 dummyhead

GENERAL INFORMATION
CRF1100A/AL/D/DL:

FRONT SUB HARNESS

RIGHT FOG LIGHT (option) OPEN AIR TEMPERATURE RIGHT FRONT TURN SIGNAL LIGHT
2P CONNECTOR 2P (Black) CONNECTOR 2P (Orange) CONNECTOR

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:

OPEN AIR TEMPERATURE

2P (Black) CONNECTOR

USB CONNECTOR

FRONT SUB
HARNESS

RIGHT FOG LIGHT (option) RIGHT FRONT TURN SIGNAL LIGHT

2P CONNECTOR 2P (Orange) CONNECTOR

1-34
dummyhead

GENERAL INFORMATION
CRF1100A/AL/D/DL:

HEADLIGHT 6P CONNECTOR

FRONT SUB HARNESS

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:

HEADLIGHT 6P CONNECTOR

CORNERING LIGHT
6P CONNECTOR

FRONT SUB HARNESS

(to headlight)

FRONT SUB HARNESS

(to cornering light)

1-35
 dummyhead

GENERAL INFORMATION
CRF1100A/AL/D/DL:

ACCESSORY SOCKET (option)

2P CONNECTOR

FRONT SUB HARNESS 1

12P (Black) CONNECTOR

FRONT SUB HARNESS FRONT SUB HARNESS 3

12P (Black) CONNECTOR

LEFT FRONT TURN SIGNAL LIGHT LEFT FOG LIGHT (option) FRONT SUB HARNESS 2
2P (Light blue) CONNECTOR 2P CONNECTOR 4P (Black) CONNECTOR

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:

ACCESSORY SOCKET
2P CONNECTOR

FRONT SUB HARNESS 3

12P (Black) CONNECTOR

LEFT FRONT TURN SIGNAL LIGHT

2P (Light blue) CONNECTOR

FRONT SUB HARNESS 1

12P (Black) CONNECTOR

FRONT SUB HARNESS LEFT FOG LIGHT (option) FRONT SUB HARNESS 2
2P CONNECTOR 4P (Black) CONNECTOR

1-36
dummyhead

GENERAL INFORMATION
CRF1100A/AL/D/DL:

FRONT BRAKE HOSE A

MT model: CLUTCH CABLE

DCT model: PARKING BRAKE CABLE
MT model: CLUTCH CABLE
DCT model: PARKING BRAKE CABLE

LEFT HANDLEBAR SWITCH

WIRE Front

130 mm (5.1 in)

FRONT BRAKE HOSE A

30 mm (1.2 in)

Front

RIGHT HANDLEBAR SWITCH WIRE

RIGHT HANDLEBAR SWITCH WIRE

(Grip APS)

1-37
 dummyhead

GENERAL INFORMATION
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:

FRONT BRAKE HOSE A

MT model: CLUTCH CABLE

DCT model: PARKING BRAKE CABLE
MT model: CLUTCH CABLE
DCT model: PARKING BRAKE CABLE

LEFT GRIP HEATER WIRE

LEFT HANDLEBAR SWITCH

WIRE Front

130 mm (5.1 in)

30 mm (1.2 in) FRONT BRAKE HOSE A

Front

RIGHT HANDLEBAR SWITCH WIRE

RIGHT GRIP
HEATER WIRE

RIGHT HANDLEBAR SWITCH WIRE

(Grip APS)

1-38
dummyhead

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

switch connector (Black/green wire side).

CLUTCH SWITCH

CRUISE CANCEL SWITCH

1-39
 dummyhead

GENERAL INFORMATION
DCT model:

White paint

LEFT HANDLEBAR
SWITCH WIRE

LEFT GRIP HEATER WIRE

5 mm (0.2 in)
maximum

PARKING BRAKE SWITCH

1-40
dummyhead

GENERAL INFORMATION

Install the wire band by

aligning with the front
brake switch end.

5 mm (0.2 in)
maximum
FRONT BRAKE SWITCH
RIGHT HANDLEBAR CONNECTORS
SWITCH WIRE

RIGHT GRIP HEATER WIRE CRUISE CANCEL

SWITCH CONNECTORS

1-41
 dummyhead

GENERAL INFORMATION
CRF1100A/AL/D/DL:

RIGHT HANDLEBAR SWITCH WIRE

LEFT HANDLEBAR SWITCH WIRE
FRONT BRAKE HOSE A

RIGHT HANDLEBAR
SWITCH WIRE (Grip APS) Left
LEFT GRIP HEATER (option)
2P CONNECTOR

Front

RIGHT HANDLEBAR
SWITCH WIRE

RIGHT HANDLEBAR
SWITCH WIRE (Grip APS)

1-42
dummyhead

GENERAL INFORMATION
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:
*: Electronic suspension model

LEFT GRIP HEATER

2P CONNECTOR

FRONT SUSPENSION SOLENOID WIRE* LEFT GRIP HEATER WIRE

FRONT SUSPENSION SOLENOID

2P CONNECTOR* LEFT HANDLEBAR
SWITCH WIRE
FRONT SUSPENSION
FRONT SUSPENSION STROKE SOLENOID WIRE*
SENSOR WIRE*

RIGHT HANDLEBAR
SWITCH WIRES

RIGHT GRIP Left

HEATER WIRE
FRONT SUSPENSION LEFT GRIP
HEATER WIRE Front
STROKE SENSOR
2P CONNECTOR*

FRONT SUSPENSION
STROKE SENSOR WIRE*

RIGHT HANDLEBAR
SWITCH WIRE
Left

GRIP HEATER WIRE

RIGHT HANDLEBAR
SWITCH WIRE Front
(Grip APS)

FRONT BRAKE HOSE A

LEFT GRIP HEATER

2P CONNECTOR

FRONT SUSPENSION
STROKE SENSOR
2P CONNECTOR*

FRONT SUSPENSION
SOLENOID 2P CONNECTOR*

1-43
 dummyhead

GENERAL INFORMATION

FRONT BRAKE HOSE D

FRONT WHEEL SPEED

SENSOR WIRE
FRONT BRAKE PIPE C

FRONT WHEEL SPEED

SENSOR WIRE

FRONT
BRAKE
HOSE D

HORN CONNECTORS

FRONT BRAKE HOSE D

FRONT WHEEL SPEED

SENSOR WIRE

1-44
dummyhead

GENERAL INFORMATION

FRONT WHEEL SPEED SENSOR WIRE

FRONT WHEEL SPEED SENSOR WIRE

FRONT BRAKE
HOSE D
FRONT BRAKE HOSE D

Front

Front

FRONT WHEEL SPEED

SENSOR WIRE

FRONT WHEEL SPEED

SENSOR WIRE

FRONT BRAKE HOSE D

1-45
 dummyhead

GENERAL INFORMATION

FRONT WHEEL SPEED SENSOR WIRE

FRONT BRAKE HOSE D

FRONT BRAKE HOSE D

1-46
dummyhead

GENERAL INFORMATION

LEFT HANDLEBAR
SWITCH 8P CONNECTOR

LEFT HANDLEBAR
SWITCH 12P CONNECTOR

FRONT SUSPENSION SOLENOID

2P CONNECTOR
(Electronic suspension model)

LEFT HANDLEBAR
SWITCH WIRE

GROUND TERMINAL IMMOBILIZER RECEIVER

4P (Black) CONNECTOR

IMMOBILIZER RECEIVER
IGNITION SWITCH WIRE
WIRE

1-47
 dummyhead

GENERAL INFORMATION

LEFT FAN MOTOR 2P CONNECTOR

LEFT FAN MOTOR WIRE

LEFT RADIATOR SHROUD

AIR CLEANER
DRAIN HOSE

LEFT A/F AIR CLEANER

SENSOR WIRE HOUSING

MAIN WIRE
HARNESS MAIN WIRE HARNESS

ECT SENSOR 2P
(Black) CONNECTOR
AIR CLEANER
DRAIN HOSE

LEFT A/F SENSOR

4P CONNECTOR AIR CLEANER
DRAIN HOSE

CRF1100A/AL/
D/DL: No.1-2 SPARK PLUG CAP
LEFT A/F SENSOR

LEFT A/F SENSOR

4P CONNECTOR

1-48
dummyhead

GENERAL INFORMATION

DCT model shown:

MT model: CLUTCH CABLE

DCT model: PARKING BRAKE CABLE

SIPHON HOSE

AIR CLEANER DRAIN HOSE

LINEAR SOLENOID VALVE

WIRE (DCT model)

DCT model:

MAIN WIRE
HARNESS

RIGHT A/F SENSOR

1-49
 dummyhead

GENERAL INFORMATION

DCT model shown:

RIGHT FAN MOTOR RIGHT GRIP HEATER
2P CONNECTOR 2P CONNECTOR

GRIP APS 8P CONNECTOR RIGHT HANDLEBAR SWITCH

4P CONNECTOR
(Brake/cruise cancel switch)

LINEAR SOLENOID VALVE 4P

(Black) CONNECTOR
(DCT model)
RIGHT HANDLEBAR SWITCH
12P CONNECTOR

RIGHT A/F SENSOR

4P CONNECTOR

RIGHT FAN MOTOR WIRE

LINEAR SOLENOID VALVE WIRE

(DCT model)

MAIN WIRE HARNESS

(DCT model)

RIGHT RADIATOR
SHROUD

RIGHT A/F AIR CLEANER

No.2-2 SPARK PLUG WIRE SENSOR WIRE DRAIN HOSE

SIPHON HOSE

MAIN WIRE HARNESS

(DCT model)

LINEAR SOLENOID VALVE WIRE

(DCT model)

1-50
dummyhead

GENERAL INFORMATION

FRONT BRAKE HOSE A

MT model: CLUTCH CABLE

DCT model: PARKING BRAKE CABLE

FRONT BRAKE PIPE C

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

(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)

1-51
 dummyhead

GENERAL INFORMATION

RADIATOR HOSE A

Yellow paint
White paint

Rear
10 – 14 mm Rear
(0.4 – 0.6 in)

45°
Lower Lower

30° 30°

UPPER
RADIATOR HOSE

White paint

Left

60°
SIPHON HOSE
Lower
30°

1-52
dummyhead

GENERAL INFORMATION

LOWER RADIATOR HOSE

RADIATOR HOSE B
30°

45°
Left
Left

Lower 30°
30°
40° 40°

Lower

1-53
 dummyhead

GENERAL INFORMATION

DCT model:

BYPASS HOSE
Yellow paint
BYPASS HOSE

45°
Front
35°
90° Front

Lower White paint Lower

45°

Insert the bypass hose

until the indent mark of
the joint pipe.

Insert the bypass hose

until the indent mark of
the water pipe.

MT model:

Insert the bypass hose

until the indent mark of
the joint pipe.
Insert the bypass hose
until the indent mark of
the joint pipe.

Yellow paint BYPASS HOSE

90°
Front
45°
White paint
90°

Front
Lower
45°
Lower

BYPASS HOSE

1-54
dummyhead

GENERAL INFORMATION

FRONT WHEEL SPEED SENSOR

2P (Black) CONNECTOR

PAIR CONTROL SOLENOID RADIATOR HOSE A

VALVE 2P (Black) CONNECTOR

MT model: CLUTCH CABLE

DCT model: PARKING BRAKE
CABLE

AIR SUPPLY HOSE

IAT SENSOR Front

2P (Blue)
CONNECTOR

Lower

TBW MOTOR 2P
CONNECTOR AIR SUCTION HOSE

IMMOBILIZER
RECEIVER 4P
(Black)
CONNECTOR

IGNITION SWITCH 4P IGNITION SUB HARNESS

(Brown) CONNECTOR 6P CONNECTOR

1-55
 dummyhead

GENERAL INFORMATION

IGNITION SUB HARNESS

No.2-1 IGNITION COIL
IGNITION SUB HARNESS
6P CONNECTOR

Front

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

Front

IGNITION SUB HARNESS

No.1-1 IGNITION COIL

No.1-2 IGNITION COIL

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

IGNITION SUB HARNESS

6P CONNECTOR

1-56
dummyhead

GENERAL INFORMATION

MAIN WIRE HARNESS

FRAME

CRANKCASE BREATHER HOSE AIR SUPPLY HOSE

5 mm (0.2 in) maximum

45°

Right

Front

Right

Front

CRANKCASE
BREATHER HOSE

AIR CLEANER
DRAIN HOSE

AIR CLEANER No.1-2 SPARK PLUG CAP

DRAIN HOSE

No.2-2 SPARK PLUG CAP No.1-1 SPARK PLUG CAP

No.2-1 SPARK PLUG CAP

1-57
 dummyhead

GENERAL INFORMATION
MT model:

ALTERNATOR WIRE
UPPER RADIATOR HOSE
MAIN WIRE HARNESS
MAIN WIRE HARNESS
(to VS sensor)

Rear
SIDESTAND
SWITCH WIRE
VS SENSOR 3P (Black)
Left CONNECTOR

ALTERNATOR WIRE
45°

MAIN WIRE
HARNESS

SIDESTAND
SWITCH WIRE

ALTERNATOR WIRE

MAIN WIRE
HARNESS

SIDESTAND
SWITCH WIRE

SHIFT STROKE
SENSOR (option)
4P CONNECTOR

CKP SENSOR 3P (Gray)

CONNECTOR

SIDESTAND SWITCH
EOP SWITCH
EVAP CANISTER DRAIN HOSE

RADIATOR RESERVE TANK

SIDESTAND SWITCH WIRE DRAIN HOSE

FUEL TANK DRAIN HOSE

1-58
dummyhead

GENERAL INFORMATION
DCT model:

UPPER RADIATOR HOSE

Rear VS SENSOR 3P (Black)

CONNECTOR

Left OUTER MAINSHAFT SENSOR

MAIN WIRE HARNESS 3P (Black) CONNECTOR

45°

ALTERNATOR WIRE

GEAR CHANGE
SWITCH (option)
3P (Black)
CONNECTOR

SIDESTAND
SWITCH WIRE
CKP SENSOR 3P (Gray)
CONNECTOR

SHIFT CONTROL
MOTOR 2P (Black)
CONNECTOR
MAIN WIRE HARNESS

SIDESTAND SWITCH

EVAP CANISTER DRAIN HOSE

RADIATOR RESERVE TANK

SIDESTAND SWITCH WIRE DRAIN HOSE
ALTERNATOR WIRE
Install the wire band in
FUEL TANK DRAIN HOSE
position as shown.
EOP SENSOR 3P
Put the wire band end
(Black) CONNECTOR
inside the frame.

1-59
 dummyhead

GENERAL INFORMATION

FUEL TANK DRAIN HOSE

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 FUEL TANK DRAIN HOSE

RADIATOR RESERVE
TANK DRAIN HOSE

1-60
dummyhead

GENERAL INFORMATION
MT model:

RADIATOR HOSE B

Front

Right

45°

CLUTCH CABLE

FUSE BOX 4P CONNECTOR

STARTER RELAY SWITCH

4P (Black) CONNECTOR

STARTER MOTOR CABLE

BATTERY
POSITIVE (+)
CABLE

SIPHON HOSE

1-61
 dummyhead

GENERAL INFORMATION
DCT model:

RADIATOR HOSE B

PARKING BRAKE CABLE Front

Right
FUSE BOX 4P CONNECTOR
45°
STARTER RELAY SWITCH
4P (Black) CONNECTOR 20°

STARTER MOTOR CABLE

LINEAR SOLENOID
VALVE WIRE
BATTERY
POSITIVE (+)
CABLE

SIPHON
HOSE

MAIN WIRE
HARNESS

MAIN WIRE
HARNESS

No.1 CLUTCH EOP

SENSOR 3P (Gray)
CONNECTOR

No.2 CLUTCH EOP SENSOR

3P (Gray) CONNECTOR

EOT SENSOR 2P CLUTCH LINE EOP

(Black) CONNECTOR SENSOR 3P CONNECTOR

1-62
dummyhead

GENERAL INFORMATION

DCT model shown:

MAP SENSOR 3P
(Black) CONNECTOR

TBW UNIT 6P
CONNECTOR

FUEL FEED
HOSE

MAIN WIRE
HARNESS
Front

FUEL TANK
DRAIN HOSE
FUEL LEVEL SENSOR 2P
(Black) CONNECTOR
FUEL PUMP
EVAP PURGE CONTROL
UNIT 3P (Black)
SOLENOID VALVE 2P (Black)
CONNECTOR
CONNECTOR

PARKING BRAKE CABLE

(DCT 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

IMU 4P (Black) CONNECTOR

1-63
 dummyhead

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-THROTTLE BODY
HOSE

ECM

ECM 33P (Gray) CONNECTOR ECM 33P (Black) CONNECTOR

ECM 39P (Black) CONNECTOR

1-64
dummyhead

GENERAL INFORMATION

FUEL FEED HOSE

9 mm (0.4 in)

FUEL TANK
BREATHE HOSE

FUEL TANK
DRAIN HOSE

FUEL LEVEL SENSOR 2P FUEL PUMP UNIT 3P

(Black) CONNECTOR (Black) CONNECTOR

BATTERY POSITIVE (+) CABLE FUSE BOX 4P CONNECTOR

Front

MAIN WIRE HARNESS

FUSE BOX

STARTER RELAY
SWITCH 4P (Black)
CONNECTOR

STARTER RELAY

FI RELAY
JUNCTION 1 24P JUNCTION 2 24P
(White) CONNECTOR (White) CONNECTOR

1-65
 dummyhead

GENERAL INFORMATION

MAIN WIRE HARNESS

BATTERY POSITIVE (+) CABLE

BATTERY NEGATIVE (–) CABLE

MAIN WIRE HARNESS

BATTERY POSITIVE (+) CABLE

BATTERY NEGATIVE (–) CABLE

Front

STARTER MOTOR CABLE

45°±10°

Right

1-66
dummyhead

GENERAL INFORMATION
MT model:

10° 10°

MAIN WIRE HARNESS

SIDESTAND SWITCH 2P
10° 10°
(Black) CONNECTOR

SHIFT STROKE SENSOR

(option) 4P CONNECTOR

SHIFT SPINDLE SWITCH

GP SENSOR 3P (Black)
CONNECTOR

NEUTRAL SWITCH

DCT model:

SIDESTAND SWITCH 2P
(Black) CONNECTOR
10° 10°
MAIN WIRE HARNESS

GEAR CHANGE SWITCH

(option) 3P (Black)
CONNECTOR

NEUTRAL SWITCH
SHIFT SPINDLE ANGLE
SENSOR 3P (Blue)
CONNECTOR

TR SENSOR 3P (Black) INNER MAINSHAFT SENSOR

CONNECTOR 3P (Black) CONNECTOR

1-67
 dummyhead

GENERAL INFORMATION

CRF1100D4 shown:

FRONT BRAKE PIPE C

FRONT BRAKE PIPE B

EVAP CANISTER-to-PURGE
CONTROL SOLENOID VALVE HOSE FUEL TANK BREATHER HOSE

REAR BRAKE SWITCH

IMU 4P (Black) CONNECTOR

REAR WHEEL SPEED
SENSOR WIRE

FRONT BRAKE PIPE B

FRONT BRAKE
PIPE C

Up

Right

MAIN WIRE
HARNESS

BCU

REAR WHEEL SPEED REAR BRAKE HOSE B

SENSOR 2P (Black) REAR BRAKE HOSE A
CONNECTOR

REAR BRAKE
SWITCH 4P
CONNECTOR

BCU 39P (Black) CONNECTOR

1-68
dummyhead

GENERAL INFORMATION

CRF1100D4 shown:

TCM (DCT model)

TCM 33P (Gray) TCM 33P (Black)

CONNECTOR CONNECTOR
(DCT model) (DCT model)

EVAP CANISTER
DRAIN HOSE

ALTERNATOR
WIRE

White paint

MAIN WIRE HARNESS

FUEL TANK
BREATHER HOSE

EVAP CANISTER-to-PURGE CONTROL

SOLENOID VALVE HOSE

1-69
 dummyhead

GENERAL INFORMATION

CRF1100D4 shown:

19°
REAR SUSPENSION LEVEL
ADJUSTER HOSE
(Electronic suspension model)

PARKING BRAKE CABLE

(DCT model)

SIPHON
HOSE

MAIN WIRE
HARNESS
(to shift spindle
angle sensor)
(DCT model)

REAR BRAKE
HOSE A

MAIN WIRE HARNESS (to EOT sensor)

(DCT model)

1-70
dummyhead

GENERAL INFORMATION

CRF1100D4 shown:

MAIN WIRE HARNESS

FUEL TANK BREATHER HOSE

ALTERNATOR WIRE

EVAP CANISTER DRAIN HOSE

ALTERNATOR WIRE

Up

Front

REAR SUSPENSION SOLENOID WIRE

(Electronic suspension model)

- REAR SUSPENSION SOLENOID (option) 2P CONNECTOR

(CRF1100A2/AL2/D2/DL2)
- REAR SUSPENSION SOLENOID 2P CONNECTOR
(Electronic suspension model)

1-71
 dummyhead

GENERAL INFORMATION

REAR BRAKE HOSE B

REAR BRAKE HOSE A

FRONT BRAKE HOSE C

ALTERNATOR WIRE
FRONT BRAKE HOSE B

MAIN WIRE HARNESS

White tape

ALTERNATOR WIRE

MAIN WIRE HARNESS

ABS MODULATOR 18P (Black) CONNECTOR

1-72
dummyhead

GENERAL INFORMATION

CRF1100D4 shown:

FRONT BRAKE PIPE C

REAR BRAKE SWITCH WIRE

FRONT BRAKE PIPE B
REAR WHEEL SPEED SENSOR WIRE

FUEL TANK BREATHER HOSE

EVAP CANISTER-to-PURGE
CONTROL SOLENOID VALVE HOSE

REAR SUSPENSION LEVEL

ALTERNATOR ADJUSTER HOSE
WIRE (Electronic suspension model)

MAIN WIRE
HARNESS

REAR
REAR
WHEEL
WHEEL
SPEED
SENSOR
SPEED
WIRE
SENSOR

REAR BRAKE
HOSE B

PARKING BRAKE CABLE

(DCT model)

FUEL TANK
DRAIN HOSE
SIPHON HOSE

EVAP CANISTER
DRAIN HOSE

MAIN WIRE HARNESS (to EOT sensor)

(DCT model)

RADIATOR RESERVE TANK DRAIN HOSE

1-73
 dummyhead

GENERAL INFORMATION
MT model:

REAR WHEEL SPEED

SENSOR WIRE

REAR BRAKE HOSE B

REAR WHEEL SPEED

SENSOR WIRE
Right

REAR BRAKE HOSE B

Right

REAR BRAKE HOSE B

Right

Right
REAR BRAKE HOSE B
Right
REAR WHEEL SPEED
SENSOR WIRE
REAR BRAKE HOSE B

REAR WHEEL SPEED

REAR BRAKE HOSE B SENSOR WIRE

REAR WHEEL SPEED

SENSOR WIRE

1-74
dummyhead

GENERAL INFORMATION
DCT model:

REAR BRAKE HOSE B

REAR WHEEL SPEED SENSOR WIRE

PARKING BRAKE CABLE

REAR WHEEL SPEED

SENSOR WIRE
Right

REAR BRAKE HOSE B

PARKING BRAKE CABLE

Right

REAR BRAKE HOSE B

Right

Right

Right PARKING BRAKE

CABLE
REAR WHEEL SPEED
SENSOR WIRE
REAR BRAKE HOSE B
REAR BRAKE
REAR WHEEL SPEED HOSE B
REAR BRAKE HOSE B SENSOR WIRE

REAR WHEEL SPEED

SENSOR WIRE

1-75
 dummyhead

GENERAL INFORMATION

CRF1100D4 shown:

POWER BOX

REAR SUSPENSION
POSITION SENSOR 3P
(Gray) CONNECTOR
(Electronic suspension
model)

REAR OPTION 8P
CONNECTOR

DCT RELAY
(DCT model)
SCU 48P (Black)
CONNECTOR
(Electronic
suspension model)
REAR SUSPENSION PRE-LOAD
MOTOR 2P CONNECTOR
(Electronic suspension model)

ABS FSR+ FUSE BOX

MAIN WIRE
HARNESS

SCU
(Electronic suspension model)

SEAT LOCK
CABLE

DLC

1-76
dummyhead

GENERAL INFORMATION

EGCA
EGCA 6P CONNECTOR EGCA CABLE A
EGCA CABLE B

ALTERNATOR 3P (Gray) CONNECTOR

REGULATOR/RECTIFIER 3P (Black) CONNECTOR

LICENSE LIGHT 2P (White) CONNECTOR

LEFT TURN SIGNAL LIGHT RIGHT TURN SIGNAL LIGHT

2P (Orange) CONNECTOR 2P (Light blue) CONNECTOR

BRAKE/TAILLIGHT 3P (Black) CONNECTOR

DLC

MAIN WIRE HARNESS

1-77
 dummyhead

GENERAL INFORMATION

RIGHT REAR TURN SIGNAL LIGHT WIRE

LICENSE LIGHT WIRE

LEFT REAR TURN

SIGNAL LIGHT WIRE

1-78
dummyhead

GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
SOURCE OF EMISSIONS
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 system 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 housing and throttle body.

AIR CLEANER HOUSING

THROTTLE BODY

FRESH AIR
BLOW-BY GAS

1-79
 dummyhead

GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a pulse secondary air supply system, a 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
SOLENOID VALVE

THROTTLE BODY

PAIR REED VALVE

EXHAUST PORT

FRESH AIR
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.

1-80
dummyhead

GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM
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

THROTTLE BODY

EVAP CANISTER

EVAP PURGE CONTROL SOLENOID VALVE

FRESH AIR
FUEL VAPOR

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local low may prohibits 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 new motorcycle for the purpose of noise control prior to its sale or delivery to
the ultimate purchaser or while it is in use; (2) the use of the motorcycle 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. Replacing any moving parts of the motorcycle, or parts of the exhaust or intake system, with parts other then those specified by
the manufacturer.

1-81
 dummyhead

GENERAL INFORMATION
TECHNICAL FEATURES
MOTORCYCLE BODY CONTROL WITH IMU (Inertia Measurement Unit)
MOTORCYCLE BODY BEHAVIOR DETECTION WITH IMU
In this motorcycle, 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.

Yaw angular velocity

Roll angular velocity

Longitudinal
acceleration
IMU

Side
acceleration

Pitch
angular
velocity

Vertical acceleration

IMU
Motorcycle inertia
information (CAN)
Motorcycle inertia
for fall determination
information (CAN)

ABS
ECM
Brake pressure MODULATOR
Motorcycle attitude
control information (CAN)

Motorcycle
Motorcycle attitude attitude DCT model:
information (CAN) information Fall determination
TCM
(CAN) Engine torque control
SCU BCU Shift
control
Damping force
adjustment Lighting control

BRAKES SUSPENSIONS CORNERING LIGHT ENGINE

Electronic suspension model: CRF1100A2/AL2/A4/
AL4/D2/DL2/D4/DL4:

1-82
dummyhead

GENERAL INFORMATION
REAR LIFT MITIGATION
This motorcycle 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

IM
changed for on-road or off-road.

U
Accelerations occur just before rear lift

IM
U
BRAKE CONTROL SUITED FOR ESTIMATED BANK ANGLE
This motorcycle 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 on the bank ABS MODULATOR IMU
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.
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

1-83
 dummyhead

GENERAL INFORMATION
WHEELIE CONTROL
In this system, the ECM makes a wheelie control 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 determines in the wheelie state, the ECM intervenes the wheelie control to stabilize motorcycle attitude.
The wheelie control level changes depending on the wheelie control level manually set.

IMU

REAR WHEEL SPEED SENSOR

Pitch angle

Deceleration

FRONT WHEEL
Acceleration
SPEED SENSOR

GEAR CHANGE MANAGEMENT BY BODY ATTITUDE DETECTION (DCT model)

In the DCT model of this motorcycle, the body attitude information that is detected by the IMU is newly added to shift control during
cornering.
The current motorcycle attitude is calculated from the output signal of the IMU, and the AT shift table is appropriately varied to
achieve AT shift timing closer to the rider's sensitivity.

Roll angle

Vertical acceleration

Longitudinal
Yaw angular acceleration
velocity

IMU
Roll angular velocity

Pitch angular velocity

Side
acceleration
Proper AT shift timing

1-84
dummyhead

GENERAL INFORMATION
COOPERATION SYSTEM OF THE MID (WITH THE TOUCH SCREEN) AND SMARTPHONE
In this motorcycle, Apple CarPlayTM (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)

• 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.
– DTC read out: (page 4-7)
– Daytime running light/cornering light forcibly activate: (page 22-7)
– MID system software update: (page 22-21)
– Touchscreen calibration: (page 22-22)

MID
Bluetooth® HEADSET
(rider side)
ECM

Bluetooth® HEADSET
(passenger side)
FRAME CAN 1

FRAME CAN 2

BCU GPS ANTENNA

HANDLEBAR
SWITCHES

METER

1-85
 dummyhead

GENERAL INFORMATION
DRL (Daytime Running Light) SYSTEM (Except CH/IN)
This motorcycle is equipped with DRL (Daytime Running Light).
When the surroundings are bright, such as daytime, only the DRL lights up. When the surroundings is dark, such as nighttime, the
low beam is turned on, and the DRL is dimmed to the luminance recognized as part of the low beam.
The DRL is automatically controlled by the BCU on the basis of the information from the photo sensor.
If there is a problem with the DRL system, the DRL will dim, and the low beam will illuminate.
For DRL system inspection: (page 22-7)

• For DRL malfunctions, no notifications are made by the indicators or display.

COMPONENT LOCATION:

Hi BEAM
Lo BEAM Lo BEAM

DRL DRL

PHOTOSENSOR

BASIC OPERATION:
BCU: HEADLIGHT UNIT:

PHOTOSENSOR
FRAME
METER CAN DATA Lo BEAM ON
HEADLIGHT
DRL
AUTO DRL SWITCH Hi BEAM ON DRIVER
CONTROL
(in the pop-up
information of the MID)

LEFT HANDLEBAR SWITCH:

DRL ON
DRL ON DRL DRIVER
DIMMER SWITCH
SWITCH
PASSING SWITCH OPERATION

LIGHTING PATTERN:
BCU OUTPUT LIGHTING STATUS
DIMMER AUTO DRL PASSING LIGHTING
Illuminance Lo Hi DRL
SWITCH SWITCH SWITCH PATTERN
Lo such as ON ON ON ON A
ON
daytime OFF OFF OFF ON C
ON ON ON DIMMING A
OFF
OFF ON OFF DIMMING B
such as ON ON ON DIMMING A
–
nighttime OFF ON OFF DIMMING B
Hi – – – ON ON DIMMING A

A: DRIVING BEAM B: PASSING BEAM C: DRL

1-86
dummyhead

GENERAL INFORMATION
CORNERING LIGHT SYSTEM (CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
In the CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4 of this motorcycle is equipped with cornering light.
If there is a problem with the cornering light system, the cornering light will turn off, and the low beam will illuminate.

• For cornering light system malfunctions, no notifications are made by the indicators or display.
• For cornering light system inspection: (page 22-7)
• For cornering light aim adjustment: (page 3-24)
BASIC OPERATION:
BCU: HEADLIGHT UNIT:

FRAME
Estimated bank angle CAN DATA
LIGHTING Lo BEAM ON
HEADLIGHT
Motorcycle speed DETERMINATION Hi BEAM ON DRIVER

LEFT or RIGHT
LIGHT 1
LIGHTING CORNERING
CONTROL LIGHT 2 LIGHT DRIVER
LIGHT 3

Cornering light 1 Cornering light 2 Cornering light 3

turned ON turned ON turned ON

OBD2 (ED/KO only)

This motorcycle complies with OBD2.
Comparison of OBD1 and OBD2:
ITEMS OBD1 OBD2
Threshold diagnosis (Diagnosis of deterioration)
Function diagnosis
or Function diagnosis
Diagnostic
Threshold diagnosis (Diagnosis of deterioration)/
method
Circuit diagnostics For items that can not be function diagnosed,
perform circuit diagnostics
Failure judgment
No stipulation Specified by emission value
criteria
Tool for failure
Not specified Specified in SAE/ISO
diagnosis
Service
No public regulations Published regulations
information
SCS short connector (4P) SCS short connector (6P)
Special tool
070PZ-ZY30100 070MZ-0010300

1-87
dummyhead

MEMO
dummytext

2. FRAME/BODY PANELS/EXHAUST SYSTEM

2
SERVICE INFORMATION ·····························2-2 LEFT REAR COVER ··································· 2-26

TROUBLESHOOTING···································2-2 HEEL GUARD ············································· 2-26

BODY PANEL LOCATIONS ·························2-3 CLUTCH EOP SENSOR COVER

(DCT model) ··············································· 2-27
PILLION SEAT ··············································2-5
RIGHT REAR ENGINE COVER ·················· 2-27
MAIN SEAT ···················································2-5
MAIN STEP ················································· 2-27
TANK FRONT COVER ··································2-6
PILLION STEP ············································ 2-29
MIDDLE COWL ·············································2-7
SEAT CATCH HOOK/SEAT LOCK
INNER COVER ··············································2-9 CYLINDER ·················································· 2-30

FRONT CENTER COWL ·····························2-12 REAR SIDE COWL ····································· 2-30

FRONT SIDE COWL REAR SIDE INNER COVER ······················· 2-33

(CRF1100A/AL/D/DL)··································2-13
REAR SEAT UNDER COVER ···················· 2-34
FRONT LOWER COVER·····························2-14
REAR CENTER COWL ······························· 2-35
FRONT WINKER COVER ···························2-15
PANNIER BRACKET (CRF1100A2/AL2/A4/
INNER PANEL COVER ·······························2-17 AL4/D2/DL2/D4/DL4) ·································· 2-37

WINDSCREEN·············································2-18 REAR CARRIER (CRF1100A2/AL2/A4/AL4/

D2/DL2/D4/DL4) ·········································· 2-37
SCREEN ADJUST RAIL (CRF1100A2/AL2/A4/
AL4/D2/DL2/D4/DL4) ··································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 MUFFLER/EXHAUST PIPE ························ 2-45

(CRF1100A/AL/D/DL)··································2-24
SIDESTAND ················································ 2-54
SKID PLATE················································2-25
FRONT NUMBER STAY (ID/IN only) ········· 2-55
TOOL BOX ··················································2-26
SARI GUARD (ID only)······························· 2-56

2-1
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM

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.

TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler

2-2
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

BODY PANEL LOCATIONS
CRF1100A/AL/D/DL
[14] [15] [16] [17] [18] [19] [1] [20] [21]
[34]
[22]

[2] [33]
[13] [3] [23]
[32]
[4]
[12]
[5]
[31]
[11]
[10] [30] [24]
[9]

[6]
[8] [7] [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)
[7] Inner cover (page 2-9) [18] Front winker cover (page 2-15) [29] Main step (page 2-27)
[8] Clutch EOP sensor cover (DCT 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)
[10] 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.

[13] Pillion seat

[1] Windscreen [34] Tank front cover [10] Pillion step [23] Rear fender A

[3] Front center cowl [16] Middle cowl [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

[4] Front lower cover [18] Front winker cover [24] Rear fender B [33] Seat rail

[7] Inner cover [25] Mud guard

[17] Knuckle guard [6] Skid plate [31] Left rear cover [8] Clutch EOP sensor cover [29] Main step [28] Sidestand
[5] Front fender [32] Tool box [30] Heel guard [9] Right rear engine cover [27] Seat catch hook/seat lock cylinder

2-3
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4
[16] [17] [18] [19] [20] [21]
[1] [35]
[15] [22]
[2]
[34] [23]

[14] [3]
[33]
[4]

[13] [32]
[5]

[6] [31] [24]

[12]

[11] [30] [25]

[10] [29]
[9] [8] [7] [28] [27] [26]

[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 winker 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 [21] Rear side inner cover

[18] Front winker 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

[25] Rear fender B [34] Seat rail

[1] Windscreen
[26] Mud guard

[17] Knuckle guard [7] Skid plate [32] Left rear cover [9] Clutch EOP sensor cover [30] Main step [29] Sidestand
[6] Front fender [33] Tool box [31] Heel guard [10] Right rear engine cover [28] Seat catch hook/seat lock cylinder

2-4
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

PILLION SEAT
REMOVAL/INSTALLATION
PILLION SEAT
Unlock the pillion seat [1] using the ignition key [2].
[1] [3]
Remove the pillion seat.
Installation is in the reverse order of removal.

• Align the pillion seat hooks [3] with the seat rail.

[3]

[2]

SEAT BELT (CRF1100A/AL/D/DL)

Remove the pillion seat (page 2-5).
[3] [1]
Remove the bolts [1], washers [2], and seat belt [3].
Installation is in the reverse order of removal. [2]
[1]

[2]

MAIN SEAT
REMOVAL/INSTALLATION
Remove the pillion seat (page 2-5).
[2]
Remove the main seat [1].
Installation is in the reverse order of removal. [2] [2]

[1]
• Align the main seat hooks [2] with the fuel tank and
seat rail lugs.

2-5
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

TANK FRONT COVER
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the following:
– Tank front cover screws [1]
– Socket bolts [2]
– Trim clips [3]
– Tank front cover [4]
– Well nut [5] [4]
Installation is in the reverse order of removal.
TORQUE: [2] [1]/[5]
Tank front cover screw:
0.42 N·m (0.04 kgf·m, 0.3 lbf·ft) [3]
[2]

[1]/[5]

[5]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the following:
[3] [2] [1] [6]
– Tank front cover screws [1]
– Socket bolts [2]
[2]
– Trim clips [3]
– Tank front cover [4] [1]
– Well nut [5] [4]
Installation is in the reverse order of removal.
[6]
TORQUE:
Tank front cover screw:
0.42 N·m (0.04 kgf·m, 0.3 lbf·ft)
[6]
• Align the tank front cover hooks [6] with the middle
cowl slits.

[5] [5]

2-6
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

MIDDLE COWL
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
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].
Installation is in the reverse order of removal.

Right side shown:

[4]

[2]

[3]
[5]
[1]

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].

2-7
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the slide clips [1] and front side plate [2] from
[1] [1]
the front side cover [3].
Installation is in the reverse order of removal.

[1]
[3]

[2]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
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].
Installation is in the reverse order of removal.

Right side shown: [1]

[5]

[6]

[3]

[4] [6] [2]

2-8
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY
Remove the middle cowl (page 2-7).
[3] [2] [1]
Remove the following from the middle cowl [1]:
– Bolts [2]
– Front side plate [3]
– Nuts [4]

[4]

Remove the slide clips [1].

[6]
Release the middle cowl tabs [2] from the front side
[2]
cover slots [3].
Release the front side cover tabs [4] from the middle [1]
cowl slots [5].
Remove the middle cowl [6] from the front side cover
[7].
Assembly is in the reverse order of disassembly. [3]

[5]

[4]
[7]

INNER COVER
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION (LEFT SIDE)
Remove the front lower cover (page 2-14).
[2] [1]
Release the following:
– Front sub harness 3 12P (Black) connector [1]
– Front sub harness 2 4P (Black) connector [2]
– Left fog light (option) 2P connector [3]

[3]

2-9
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Release the tab [1] of the air cleaner duct from the left
inner cover [2]. [1] [3]

Remove the trim clip [3] and screws [4].

Remove the left inner cover.
Installation is in the reverse order of removal.

[2]

[4]

REMOVAL/INSTALLATION (RIGHT SIDE)

Remove the right middle cowl (page 2-7).
[4] [2]
Release the right fog light (option) 2P connector [1].
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.
Installation is in the reverse order of removal.
[3]

[1]

[5]

2-10
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION (LEFT SIDE)
Remove the left middle cowl (page 2-7).
[4]
Release the following:
– Front sub harness 1 12P (Black) connector [1]
– Front sub harness 2 4P (Black) connector [2]
– Left fog light (option) 2P connector [3]
– Wire clip [4] [1]
– Wire clamp [5] [2]

[5] [3]

Release the tab [1] of the air cleaner duct from the left
[1] [3]
inner cover [2].
Remove the trim clip [3] and screws [4].
Remove the left inner cover.
Installation is in the reverse order of removal.

[2]

[4]

REMOVAL/INSTALLATION (RIGHT SIDE)

Remove the right middle cowl (page 2-7).
[1] [3]
Release the following:
– Open air temperature sensor 2P connector [1]
– Right fog light (option) 2P connector [2]
– Wire clip [3]
Disconnect the open air temperature sensor 2P
connector.

[2]

2-11
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Release the tab [1] of the air cleaner duct from the right
[3] [1]
inner cover [2].
Remove the trim clip [3] and screws [4].
Remove the right inner cover.
Installation is in the reverse order of removal.

[2]

[4]

FRONT CENTER COWL

CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the windscreen (page 2-18).
[1]
Remove the socket bolts [1].
Release the tabs [2] and remove the front center cowl
[3]
[3].
Installation is in the reverse order of removal.

[2]

2-12
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the middle cowls (page 2-7).
[1] [2]
Release the bosses [1] and remove the front center
cowl [2].
Installation is in the reverse order of removal.

• Align the front center cowl tabs [3] with the headlight
unit lugs.

[3]

FRONT SIDE COWL

(CRF1100A/AL/D/DL)
REMOVAL/INSTALLATION
Remove the inner panel cover (page 2-17).
Left side shown:
Remove the trim clip [1].
Remove the front side cowl [2] by releasing its tabs [3]
from the front winker cover and front lower cover. [2]
[1]
Installation is in the reverse order of removal.

[3]

2-13
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

FRONT LOWER COVER
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the front side cowl (page 2-13).
Remove the trim clips [1] and socket bolts [2], and front
lower cover [3].
Installation is in the reverse order of removal.

[2]

[2]

[3] [1]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the middle cowls (page 2-7).
Remove the trim clip [1] and socket bolts [2], and front
lower cover [3].
Installation is in the reverse order of removal. [2]

[3] [1] [2]

2-14
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY
Remove the front lower cover (page 2-14).
[3]
Remove the slide clip [1]. [1]
Remove the front spoiler [2] from the front lower cover
[3].
Assembly is in the reverse order of disassembly.

[2]

FRONT WINKER COVER

CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the front side cowl (page 2-13).
Remove the socket bolt [1].
Release the front winker 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
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].

Right side shown:

[3] [5]

[1]

[2] [4]

2-15
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Right side: Remove the USB socket [1] by releasing its tabs [2]
[3]
from the right front winker cover [3].
Remove the collar [4].
Installation is in the reverse order of removal.

• Install the USB socket as shown.

[1]

Right

Rear

[4] [1]

[2] [4] [3]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the middle cowl (page 2-7).
Left side shown:
Remove the trim clip [1] and socket bolts [2].
Disconnect the front turn signal light 2P connector [3].
[6]
– Left side: 2P (Orange) connector [3]
– Right side: 2P (Light blue) connector
Remove the front winker cover [4].
Installation is in the reverse order of removal.

• Align the front winker cover groove [5] with the inner [2]
panel cover tab [6].
[5] [1]

[2]
[4] [2]

2-16
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

INNER PANEL COVER
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the front center cowl (page 2-12).
Remove the middle cowl (page 2-7).
Release the open air temperature sensor 2P connector
[1].
[3]
Remove the trim clip [2] and socket bolts [3].
Remove the right inner panel cover [4] by releasing its
boss [5] from the left inner panel cover grommet.

[5]

[1]
[2]
[3]
[4]

Remove the trim clip [1] and socket bolts [2].

Remove the left inner panel cover [3].
Installation is in the reverse order of removal.
[2]

[3]

[2] [1]

2-17
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the front winker covers (page 2-15). [3]
Release the accessory socket 2P connector [1] and [4]
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].

[5] [1] [2]

Release the open air temperature 2P connector [1] from [5] [8] [6] [2]
the inner panel cover [2].
Release the inner panel cover tab [3] from the front [3]
upper cover slot [4].
Remove the USB socket [5] rearward by releasing its
tabs from the inner panel cover.
Release the cover [6].
Disconnect the USB connector [7].
Remove the inner panel cover.
Installation is in the reverse order of removal. [7]

• Align the USB connector tab [8] with the USB socket
groove.
• Install the USB socket with USB connector tab
facing up. [1] [4]

WINDSCREEN
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the following:
[1] [2] [3] [4]
– Windscreen screws [1]
– Plastic washers A [2]
– Rubber washers [3] [5]
– Windscreen [4]
Remove the well nuts [5] and plastic washers B [6]. [6]

Installation is in the reverse order of removal.

TORQUE:
Windscreen screw:
0.42 N·m (0.04 kgf·m, 0.3 lbf·ft)

2-18
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the following:
[3]
– Windscreen screws [1] [2]
[1] [4]
– Plastic washers A [2]
– Rubber washers [3]
– Windscreen [4]
Remove the well nuts [5] and plastic washers B [6]. [5] [6]
Installation is in the reverse order of removal.
TORQUE:
Windscreen screw:
0.42 N·m (0.04 kgf·m, 0.3 lbf·ft)

SCREEN ADJUST RAIL (CRF1100A2/

AL2/A4/AL4/D2/DL2/D4/DL4)
• Do not apply grease to the screen adjust rail slide
portions.

ADJUSTMENT
If you feel that the windscreen does not move smoothly,
[1]
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] 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).

[1]

2-19
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

REMOVAL/INSTALLATION
Remove the windscreen (page 2-18).
[2]
Remove the inner panel cover (page 2-17).
Remove the screen adjust rail bolts [1] and screen
adjust rail [2].
Installation is in the reverse order of removal.

[1]

DISASSEMBLY/ASSEMBLY

Left side shown:

LEVER SPRING

SCREEN ADJUST
BRACKET

SPRING PIN

LOCK LEVER

SLIDER GUIDES

LOCK
PLATE
COLLARS

E-RINGS
SCREEN ADJUST
RAIL RAIL GUIDES WASHERS
LOCK PLATE MOUNTING BOLTS
1.8 N·m (0.2 kgf·m, 1.3 lbf·ft)

• 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
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

FRONT UPPER COVER
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the inner panel cover (page 2-17).
[3]
Remove the trim clip [1]. [2]
Remove the bolts [2] and front upper cover [3].
Installation is in the reverse order of removal.

[1]

DISASSEMBLY/ASSEMBLY
Remove the front upper cover (page 2-21). [1] [3]
Remove the bolts [1].
Remove the windscreen stays [2] and collars [3].
Remove the front upper cover [4] by releasing its
bosses [5] from the stay [6].
Installation is in the reverse order of removal.

[2]

[6]

[4]

[3] [2] [5]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the screen adjust rail (page 2-19).
[2] [3]
Remove the front center cowl (page 2-12).
Remove the trim clip [1].
Release the bosses [2] and remove the front upper
cover [3].
[1]
Installation is in the reverse order of removal.

2-21
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

KNUCKLE GUARD
REMOVAL/INSTALLATION
Remove the handlebar weight (page 17-12).
Left side shown:
Remove the following:
[5]
– Screws [1]
– Knuckle guard B [2] (CRF1100A2/AL2/A4/AL4/D2/ [4]
DL2/D4/DL4)
– Knuckle guard A [3]
– Well nuts [4]
– Plastic washers [5]
Installation is in the reverse order of removal.
[3]

[5]

[4]

[1] [2] [1]

2-22
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

FRONT FENDER
REMOVAL/INSTALLATION
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 [10] from the front fender covers.
Installation is in the reverse order of removal.
TORQUE:
Front side reflector nut:
1.8 N·m (0.2 kgf·m, 1.3 lbf·ft)

• Route the wire and hoses properly (page 1-32).

• Align the front side reflector boss with the front
fender cover hole.

[10]
[9]
[7]
[1]

Align [2]
[8]

[3]

[4]

[6]

[3]

[5]

2-23
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY

FRONT FENDER A TAPPING SCREWS

FRONT FENDER B

TANK SIDE COVER

(CRF1100A/AL/D/DL)
REMOVAL/INSTALLATION
Remove the middle cowl (page 2-7).
Right side shown:
Remove the following: [4]
– Socket bolt A [1] [2]
– Socket bolt B [2]
Release the tank side cover bosses [3] from the
grommets [4].
Remove the tank side cover [5].
Installation is in the reverse order of removal.

[3] [5] [3] [1]

2-24
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

SKID PLATE
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the following:
[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]
Installation is in the reverse order of removal.
TORQUE:
Skid plate bolt A:
26.0 N·m (2.7 kgf·m, 19 lbf·ft) [6]
[4] [1]

• Align the grommet B of the skid plate with the boss

[8] of the frame.
[2]

[2]

[3]
[1] [7]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the following:
[8]/[9]/[10]
– Skid plate bolt A [1]
– Washers A [2]
– Clip nuts A [3]
– Collars A [4]
– Grommets A [5]
– Skid plate bolts B [6] [13]
– Washer B [7]
– Clip nut B [8]
– Collar B [9] [6]
– Grommet B [10]
– Skid plate [11]
– Grommet C [12]
Installation is in the reverse order of removal. [7]
[3]/[4]/[5]
TORQUE: [5] [4]
Skid plate bolt A:
26.0 N·m (2.7 kgf·m, 19 lbf·ft)
Skid plate bolt B:
12.0 N·m (1.2 kgf·m, 9 lbf·ft) [2]

[2]
• Align the grommet C of the skid plate with the boss
[13] of the frame. [1]

[1] [11] [12]

2-25
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

TOOL BOX
REMOVAL/INSTALLATION
Remove the socket bolts [1] and tool box [2].
[1] [4]
Installation is in the reverse order of removal.

• Align the tool box slots [3] with the battery box tabs
[4].

[2]

[3]

[1]

LEFT REAR COVER

REMOVAL/INSTALLATION
MT model only: Remove the gearshift arm (page 12-21).
Remove the left rear cover bolts [1], left rear cover [2]
[2]
and drive chain guide plate [3].
Release the sidestand wire clip [4] and sidestand wire
[5] from the left rear cover.
[3]
Installation is in the reverse order of removal.
TORQUE:
Left rear cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft) [1]

• Align the chain guide plate holes with the left rear
cover bosses.
• Route the wires properly (page 1-32).

[1]

Align

[5]
[4]

HEEL GUARD
REMOVAL/INSTALLATION
Remove the socket bolt [1] and heel guard [2].
Right side shown:
Installation is in the reverse order of removal.
[1]

[2]

2-26
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CLUTCH EOP SENSOR COVER (DCT
model)
REMOVAL/INSTALLATION
CRF1100D2/DL2/ Remove the exhaust pipe cover B (page 2-45).
[2]
D4/DL4:
Remove the socket bolts [1] and release the clutch EOP
sensor cover boss [2].
Remove the clutch EOP sensor cover [3]. [3]

Installation is in the reverse order of removal.

TORQUE:
Clutch EOP sensor cover socket bolt:
10 N·m (1.0 kgf·m, 7 lbf·ft)

[1]

RIGHT REAR ENGINE COVER

REMOVAL/INSTALLATION
Remove the right rear engine cover bolts [1] and right
MT model shown:
rear engine cover [2].
Installation is in the reverse order of removal.
[1]
TORQUE:
Right rear engine cover bolt:
10 N·m (1.0 kgf·m, 7 lbf·ft)

[2]

MAIN STEP
REMOVAL/INSTALLATION
LEFT MAIN STEP BRACKET
Remove the sidestand switch bolt [1] and sidestand
switch [2].

[1] [2]

2-27
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the left main step bracket bolts [1] and left
[1]
main step bracket [2].
For main step disassembly/assembly (page 2-29)

[1] [2]

Installation is in the reverse order of removal.

[2] [4] [5]
TORQUE:
Left main step bracket bolt:
35 N·m (3.6 kgf·m, 26 lbf·ft) [3]
Sidestand switch bolt:
10 N·m (1.0 kgf·m, 7 lbf·ft)

• Route the wires properly (page 1-32).

• Align the sidestand switch tab [1] with the sidestand
hole [2].
• Align the sidestand switch groove [3] with the return
spring holding pin [4].
[1]
• Replace the sidestand switch bolt [5] with a new
one.
RIGHT MAIN STEP BRACKET
Remove the exhaust pipe (page 2-45).
[2]
Remove the following:
– Right main step bracket lower bolt [1]
– Right main step bracket upper bolt [2] [3]
– Right main step bracket [3]
For main step disassembly/assembly (page 2-29)
Installation is in the reverse order of removal.
TORQUE:
Right main step bracket upper bolt:
69 N·m (7.0 kgf·m, 51 lbf·ft)
Right main step bracket lower bolt:
32 N·m (3.3 kgf·m, 24 lbf·ft) [1]

2-28
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY

Left side shown:

JOINT PIN MAIN STEP BRACKET
MAIN STEP RUBBER

STEP RUBBER
SET PLATE WASHER

COTTER PIN

MAIN STEP RETURN SPRING

MAIN STEP RUBBER BOLT

PILLION STEP
REMOVAL/INSTALLATION
Remove the pillion step bracket bolts [1] and pillion step
Right side shown:
assembly [2].
Installation is in the reverse order of removal.
TORQUE:
Pillion step bracket bolt:
32 N·m (3.3 kgf·m, 24 lbf·ft) [2]

• Apply grease to the pillion step joint pin sliding area.

[1]

2-29
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

SEAT CATCH HOOK/SEAT LOCK
CYLINDER
REMOVAL/INSTALLATION
SEAT CATCH HOOK
Remove the pillion seat (page 2-5).
[1]
Remove the bolt [1].
Disconnect the seat lock cable [2] from the seat catch
hook [3] and remove the seat catch hook. [5] [4]
Installation is in the reverse order of removal.

• Apply grease to the seat catch hook sliding area.

• Align the seat catch hook boss [4] with the seat rail
hole [5].

[2] [3]

SEAT LOCK CYLINDER

Remove the left fender B cover (page 2-43).
[2]
Disconnect the seat lock cable [1] from the seat lock
cylinder [2].
Remove the lock spring [3], seat lock cylinder, and stay
[4].
Installation is in the reverse order of removal.
[5]
[3]
• Align the seat lock cylinder lug [5] with the left fender
B cover groove [6] and stay groove [7].
[6]

[4]

[1] [7]

REAR SIDE COWL

CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
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.
[4]
Installation is in the reverse order of removal.

[2] [3]

2-30
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY
Remove the rear side cowl (page 2-30). [3]
Remove the twist clip [1].
Remove the rear cowl lid [2] from the side cowl [3].

[1]

[2]

Remove the trim clip [1]. [4] [1]

Remove the rear side cowl A [2] by releasing its tabs [3]
from the rear side cowl B [4].
Installation is in the reverse order of removal.

[3]

[2]

2-31
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the main seat (page 2-5).
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].
Installation is in the reverse order of removal.

• Align the rear side cowl tabs [6] with the rear fender
B and rear fender B cover lugs.

Left side shown:

[1]

[5]

[2]

[3]
[6]
[4]

2-32
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

REAR SIDE INNER COVER
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the main seat (page 2-5).
[2] [1] [1]
Remove the following:
– Trim clips [1]
– Rear side inner cover screw A [2] [3]
– Rear side inner cover screw B [3]
– Rear side inner cover [4]
Installation is in the reverse order of removal.
TORQUE:
Rear side inner cover screw A: [4]
0.42 N·m (0.04 kgf·m, 0.3 lbf·ft)

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the main seat (page 2-5).
Remove the following:
– Trim clips [1]
– Rear side inner cover screw A [2]
– Rear side inner cover screw B [3]
– Rear side inner cover [4]
Installation is in the reverse order of removal.
TORQUE:
Rear side inner cover screw A:
0.42 N·m (0.04 kgf·m, 0.3 lbf·ft)

• Align the rear side inner cover tabs [5] and slots [6]
with the rear side cowl slots and lugs.

Left side shown: [1] [5]

[2] [1]
[4]
[3]

[6]

[5]

2-33
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

REAR SEAT UNDER COVER
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the rear side inner cover (page 2-33).
Left side shown: [4] [3] [1]
Release the tank side cover boss [1] from the rear seat [2]
under cover grommet [2].
Remove the socket bolts [3] and screw [4].
Release the rear seat under cover tab [5] from the rear [3]
fender B cover slot [6].
[7]
Remove the rear seat under cover [7].
Installation is in the reverse order of removal.

[5]
[6]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the rear side inner cover (page 2-33).
Left side shown:
Remove the socket bolt [1] and screw [2].
Release the rear seat under cover grommet [3] from the [3]
rear side cowl boss [4]. [1]
[2]
Release the rear seat under cover tab [5] from the rear
fender B cover slot [6].
Remove the rear seat under cover [7]. [7] [4]
Installation is in the reverse order of removal.

[5]
[6]

2-34
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

REAR CENTER COWL
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the rear side cowl (page 2-30).
[2] [1]
Remove the rear side inner cover (page 2-33).
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.
Installation is in the reverse order of removal.

DISASSEMBLY/ASSEMBLY
Remove the rear center cowl (page 2-35).
[2] [1] [3]
Release the tabs [1] by pulling the rear side cowls C [2]
rearward.
Remove the rear side cowls C from the rear center cowl
[3].
Installation is in the reverse order of removal.

[2]

2-35
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the rear side cowl (page 2-30).
[2]
Remove the rear side inner cover (page 2-33).
[1]
Remove the rear center cowl A [1] by releasing its tabs
[2] from the rear center cowl B slots.

Remove the tapping screws [1].

[3] [1]
Remove rear center cowl B [2] by releasing its tabs [3] [2]
from the rear fender B slots.
Installation is in the reverse order of removal.

[1]

[1]

2-36
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

PANNIER BRACKET (CRF1100A2/AL2/
A4/AL4/D2/DL2/D4/DL4)
REMOVAL/INSTALLATION
Remove the rear side cowl (page 2-30).
[5] [4]
Remove the rear side inner cover (page 2-33).
Remove the following: [3]
– Pannier bracket bolt A [1]
[2]
– Pannier bracket bolt B [2]
– Washers [3]
– Pannier bracket [4]
– Collars [5]
Installation is in the reverse order of removal.
TORQUE:
Pannier bracket bolt A/B:
35 N·m (3.6 kgf·m, 26 lbf·ft)
[1]

REAR CARRIER (CRF1100A2/AL2/A4/

AL4/D2/DL2/D4/DL4)
REMOVAL/INSTALLATION
Remove the rear center cowl B (page 2-35).
[3] [4]
Remove the following:
– Pannier bracket bolts A [1]
– Washers [2]
– Rear carrier bolts [3]
– Rear carrier [4]
[5]
– Rear center rubbers [5]
Installation is in the reverse order of removal.
TORQUE: [1]
Pannier bracket bolt A:
35 N·m (3.6 kgf·m, 26 lbf·ft) [2]
Rear carrier bolt:
35 N·m (3.6 kgf·m, 26 lbf·ft)

[3]
[2]

[1]

2-37
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

MUD GUARD
REMOVAL/INSTALLATION
Remove the following:
– Trim clips [1]
– Socket bolts [2]
– Mud guard [3]
Installation is in the reverse order of removal.
[3] [2]

[2] [1]

REAR FENDER A
REMOVAL/INSTALLATION
Remove the pillion seat (page 2-5).
Release the connector cover [1] from the stay.
Disconnect the following: [1]
– Right rear turn signal light 2P (Light blue) connector [4]
[2]
– License light 2P (White) connector [3]
– Left rear turn signal light 2P (Orange) connector [4]

[3]

[2]

Remove the following:

– Bolts [1]
– Washers [2]
– Rear fender A [3]
– Collars [4]
Installation is in the reverse order of removal.

• Route the wires properly (page 1-32).

[4]

[2]

[1]

[3]

2-38
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY

TAPPING SCREWS

REAR FENDER STAY

REAR FENDER A

Align

REAR REFLECTOR

REAR REFLECTOR NUT

1.8 N·m (0.2 kgf·m, 1.3 lbf·ft)

SOCKET BOLTS

• Align the rear reflector boss with the rear fender A

hole.
• For rear turn signal light removal/installation (page
22-11)
• For license light removal/installation (page 22-12)

2-39
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

REAR FENDER B
CRF1100A/AL/D/DL
REMOVAL/INSTALLATION
Remove the following:
– 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:
[1]
– Wire clamp [1]
– ABS FSR+ fuse box [2]
– DCT relay (DCT model) [3]
– Power box [4] [2]

[3]

[4]

Release the EVAP canister mounting rubber [1] from

[1]
the rear fender B stay [2].

[2]

Release the following from the rear fender B:

[2] [1]
– DLC [1]
– Wire clamps [2]
Disconnect the seat lock cable [3].
[3]

[2]

2-40
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the following:
– Socket bolts A [1]
– Socket bolts B [2]
– Socket bolts C [3]
– Rear fender B [4]
Installation is in the reverse order of removal.

• Place the rear fender B hooks [5] onto the seat rail.
• Route the wires properly (page 1-32).

[2]
[5]

[3]

[2] [1] [3] [4]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/
DL4
REMOVAL/INSTALLATION
Remove the following:
– Mud guard (page 2-38)
– Muffler (page 2-45)
– SCU (Electronic suspension model) (page 22-83)
– EVAP canister (page 7-22)
– 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:
[1]
– Wire clamp [1]
– ABS FSR+ fuse box [2]
– DCT relay (DCT model) [3]
– Power box [4] [2]

[3]

[4]

2-41
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Release the following from the rear fender B:
[1]
– DLC [1]
– Wire clamps [2]
Disconnect the seat lock cable [3].

[2]
[3]

Electronic Release the rear suspension pre-load motor 2P

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

[2]

Remove the following:

– Socket bolts A [1]
– Socket bolts B [2]
– Rear fender B [3]
Installation is in the reverse order of removal.

• Place the rear fender B hooks [4] onto the seat rail.
• Route the wires properly (page 1-32).

[4]
[1]

[2]

[4]

[1] [2] [3]

2-42
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

SEAT RAIL
REMOVAL/INSTALLATION
Remove the following:
• CRF1100A/AL/D/DL:
– Heel guard (page 2-26)
– Pillion steps (page 2-29)
– Seat catch hook (page 2-30)
– Regulator/rectifier (page 21-9)
– EGCA (page 4-76)
– ABS modulator (page 20-27)
– Rear fender B (page 2-40)
• CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:
– 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 4-76)
– ABS modulator (page 20-27)
– Rear suspension level adjuster bracket (electronic
suspension model) (page 18-13)
– Rear fender B (page 2-40)
Remove the trim clip [1].
Electronic suspension model shown:
Electronic Release the wire clip [2].
suspension model: Release the rear suspension solenoid 2P connector [3]
and disconnect it.

[3] [2] [1]

Remove the rear master cylinder reservoir mounting

bolt [1] and release the rear master cylinder reservoir
[2].
[2]

• Keep the rear master cylinder reservoir upright to [1]

prevent air from entering the hydraulic system.

2-43
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the following:
[2]/[3] [4] [4] [2]/[3]
– Seat rail bolts (short) [1]
– Seat rail bolts (long) [2]
– Washers [3]
– Nuts [4]
– Seat rail [5]
[4] [4]

[1]/[3] [5] [1]/[3]

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]
Installation is in the reverse order of removal.
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)

[2]
• Route the hose, wire, and cable properly (page 1-
32). [4]
[3]
• For IMU removal/installation (page 4-73) [4] [2] [1]
• For seat lock cylinder removal/installation (page 2-
30)

2-44
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

MUFFLER/EXHAUST PIPE
FRONT EXHAUST PIPE COVER
REMOVAL/INSTALLATION (CRF1100A/AL/D/DL)
Remove the exhaust pipe (page 2-50).
Remove the catalyst cover bolts [1] and washers [2].
[3]
Fully loosen the exhaust pipe cover band screw [3] and
remove the catalyst cover [4].
Installation is in the reverse order of removal.
TORQUE:
Catalyst cover bolt: [2]
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)

• Set the exhaust pipe cover band screw in position as

shown. [1]
[4]

Up

Left

[4]

15°

15°

[3]

REMOVAL/INSTALLATION (CRF1100A2/AL2/A4/
AL4/D2/DL2/D4/DL4)
Remove the exhaust pipe cover B bolts [1] and exhaust
pipe cover B [2].
Remove the grommet [3].
Installation is in the reverse order of removal.
TORQUE:
Exhaust pipe cover B bolt:
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)

[1]

[3]
[2]

2-45
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

REAR EXHAUST PIPE COVER
REMOVAL/INSTALLATION
Remove the exhaust outer cover bolt [1].
[4]
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]

[1]
[5]

Remove the exhaust pipe cover C bolts [1] and exhaust

pipe cover C [2].
Remove the grommets [3].
Installation is in the reverse order of removal.
TORQUE:
Exhaust outer cover bolt:
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
Exhaust pipe cover C bolt:
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
[3]

[2] [1]

2-46
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

MUFFLER
MUFFLER REMOVAL/INSTALLATION
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]. [1]
Fully slacken the EGCA cable by turning the adjusting
bolt [2] while holding the adjusting nut [3].
[2]

Remove the valve guide cover bolts [1] and valve guide
[2]
cover [2].
Make sure that the ignition switch is turned OFF.
[1]
Loosen the lock nuts [3] and remove the cable joints [4]
from the valve guide body [5] of the muffler.
Disconnect EGCA cable B [6] from the valve cable
guide [7]. [1]

Turn the valve cable guide counterclockwise and

disconnect EGCA cable A [8].
[4]
[3]

[6]
[8]

[5]
[7]

2-47
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

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]

[5]

[4]

[7]

[6]
[9]

[8]

40°
[6]

Installation is in the reverse order of removal.

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)

• 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 1-32).
• 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
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

VALVE CABLE GUIDE REMOVAL/INSTALLATION
Disconnect the EGCA cables (page 2-47).
[2]
Straighten the lock washer [1] tabs.
[1]
Remove the following:
– Nut [2]
– Lock washer [3]
– Valve cable guide [3]
– Return spring [4]
[4]
Installation is in the reverse order of removal.

• 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]
and muffler stopper tab [8].
• Replace the lock washer with a new one.
[6] [3]

[7]

[4]

[5]
[8]

MUFFLER DISASSEMBLY/ASSEMBLY

TAIL CAP COVER MUFFLER COVER SCREW

9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
RUBBER WASHER

RUBBER
WASHER

RUBBER WASHERS MUFFLER MUFFLER COVER

TAIL CAP COVER BOLTS
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)

• Align the tail cap cover and muffler cover slots with
the muffler bosses.

2-49
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

EXHAUST PIPE REMOVAL
Remove the following:
[1]
– Middle cowl (page 2-7)
– Exhaust pipe cover B (CRF1100A2/AL2/A4/AL4/D2/
DL2/D4/DL4) (page 2-45)
– Muffler (page 2-47)
Open the clamp [1] and release the left A/F sensor wire [2]
[2].
Disconnect the left A/F sensor 4P connector [3].
Release the wire clip [4].

[3] [4]

Open the clamp [1] and release the right A/F sensor
wire [2].
Disconnect the right A/F sensor 4P connector [3].
[3]

• 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 [1]
connectors to prevent the misconnection.
Release the wire clip [4]. [2]
[4]

Remove the exhaust pipe mounting nut [1], collar [2],

[3]/[4]
washer [3], and bolt/washer [4].

[2]

[1]

Remove the exhaust pipe joint nuts [1], exhaust pipe

Right side: Left side:
[2], and gaskets [3]. [3]
Remove the A/F sensors if necessary (page 4-73). [3]

[1] [2] [1]

2-50
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

EXHAUST PIPE INSTALLATION

CRF1100D4 shown:

EXHAUST PIPE MOUNTING NUT

GASKETS

BOLT/WASHER

WASHER

MOUNTING RUBBER

EXHAUST PIPE JOINT NUTS

20 N·m (2.0 kgf·m, 15 lbf·ft)

EXHAUST PIPE COVER B

STAY BOLT*
COLLAR 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)

RUBBER WASHER*

EXHAUST PIPE COVER B STAY*

EXHAUST PIPE EXHAUST PIPE

COVER A
*: CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4
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 4-73).

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4 shown:
CRF1100A2/AL2/ Install the exhaust pipe cover B stay [1], rubber washer
A4/AL4/D2/DL2/D4/ [2], and exhaust pipe cover B stay bolt [3] and tighten [1]
DL4: the bolt to the specified torque. [2]/[3]
[4]
TORQUE: 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
Loosely install the exhaust pipe cover A [4] and exhaust
pipe cover bands [5].

[5]

2-51
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Install new gaskets [1] to the exhaust ports of the
Right side: Left side: [1]
cylinder head.
Loosely install the following:
[1]
– Exhaust pipe [2]
– Exhaust pipe joint nuts [3]
– Washer [4]
– Bolt/washer [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 lbf·ft) [3] [2] [3]

[4]/[5]

[6]

[7]

Tighten the muffler band bolts [1] to the specified

torque.
TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft)

[1]

Tighten the exhaust pipe mounting nut [1] securely.

[1]

2-52
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Tighten the muffler mounting bolt [1] securely.
[1]

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)
Left

• Set the exhaust pipe cover band screws and [2]

exhaust pipe cover A [2] in position as shown.
15°

15°

[1]

[2]
6.2 mm (0.24 in)

Connect the right A/F sensor 4P connector [1].

Front
Install the wire clip [2].
Secure the right A/F sensor wire [3] with the clamp [4]. Right
[1]

[4]
[2]
[3]

[1]

2-53
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

Connect the left A/F sensor 4P connector [1].
[4]
Install the wire clip [2].
Secure the left A/F sensor wire [3] with the clamp [4].
Adjust the EGCA cable freeplay (page 3-17).
Install the following:
[3]
– Front exhaust pipe cover (page 2-45)
– Exhaust outer cover (page 2-46)
– Middle cowl (page 2-7)

• Route the hose, wire, and cable properly (page 1-

32).
[1] [2]

STUD BOLT REPLACEMENT

Remove the exhaust pipe (page 2-50).
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
switch [2].

[1] [2]

Support the motorcycle securely using a hoist or

equivalent.
Remove the sidestand return spring [1]. [5]
Remove the sidestand pivot nut [2] and bolt [3], then
remove the sidestand [4] and collar [5]. [2]
[3]

[4] [1]

2-54
dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

INSTALLATION
Apply molybdenum disulfide grease to the sidestand
pivot bolt [1] sliding surface and collar [2] outer surface.
Install the sidestand [3] and collar. [2]
Install and tighten the sidestand pivot bolt to the
specified torque. [4]
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) [1]

After tightening the pivot bolt, return the pivot bolt 45° to
90°. Up
Install and tighten the sidestand pivot nut [4] to the
specified torque while holding the sidestand pivot bolt. Rear

TORQUE: 42 N·m (4.3 kgf·m, 31 lbf·ft)

[3] [5]
Install the sidestand return spring [5] in the direction as
shown.
Install the sidestand switch [1] and new sidestand
[4] [6] [2]
switch bolt [2].
Tighten the sidestand switch bolt to the specified
torque.
[5]
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

• Align the sidestand switch tab [3] with the sidestand

hole [4].
• Align the sidestand switch groove [5] with the return
spring holding pin [6].
• Replace the sidestand switch bolt with a new one.
[3] [1]

FRONT NUMBER STAY (ID/IN only)

REMOVAL/INSTALLATION
Remove the following from the front cowl stay:
– Nuts [1]
– Bolts [2]
– Front number stay [3]
Installation is in the reverse order of removal.

• The number plate guard [4] must be removed and

installed from the front number stay together with the
number plate.

[4]

[3]

[2]

[1]

2-55
 dummyhead

FRAME/BODY PANELS/EXHAUST SYSTEM

SARI GUARD (ID only)
REMOVAL/INSTALLATION

SARI GUARD RUBBER C

Front
SARI GUARD RUBBER B

Rear

Front
SARI GUARD STAY

SARI GUARD RUBBER A

FLANGE BOLTS

SOCKET BOLT

Front
COLLAR

LEFT PILLION STEP CAP RUBBER SARI GUARD

• Install the sari guard rubber A, B, and C in direction

as shown.

2-56
dummytext

3. MAINTENANCE

SERVICE INFORMATION ·····························3-2 EXHAUST GAS CONTROL ACTUATOR

CABLE ························································ 3-17
MAINTENANCE SCHEDULE························3-2
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 NUTS, BOLTS, FASTENERS ····················· 3-33

SECONDARY AIR SUPPLY SYSTEM········3-15 WHEELS/TIRES ·········································· 3-33

EVAPORATIVE EMISSION CONTROL STEERING HEAD BEARINGS ··················· 3-33

SYSTEM ······················································3-16

3-1
 dummyhead

MAINTENANCE
SERVICE INFORMATION
MAINTENANCE

GENERAL
• Place the motorcycle on level surface before starting any work.

MAINTENANCE SCHEDULE
ED, FO, KO, U
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 (NOTE 1)
ANNUAL REGULAR REFER TO
ITEMS NOTE x 1,000 km 1 12 24 36 48
CHECK REPLACE PAGE
x 1,000 mi 0.6 8 16 24 32
* FUEL LINE I I I I I 3-4
* THROTTLE OPERATION I I I I I 3-4
* AIR CLEANER NOTE 2 R R 3-5
CRANKCASE BREATHER NOTE 3 C C C C 3-5
* SPARK PLUG I R 3-6
* VALVE CLEARANCE I I 3-7
ENGINE OIL R R R R R R 3-11
ENGINE OIL FILTER R R R 3-12
CLUTCH OIL FILTER NOTE 6 R R R 3-13
* ENGINE IDLE SPEED I I I I I 3-14
RADIATOR COOLANT NOTE 5 I I I I I 3 years 3-14
* COOLING SYSTEM I I I I I 3-15
* SECONDARY AIR SUPPLY SYSTEM I I 3-15
EVAPORATIVE EMISSION CONTROL
* I I 3-16
SYSTEM
EXHAUST GAS CONTROL
** I I 3-17
ACTUATOR CABLE
DRIVE CHAIN NOTE 4 EVERY 1,000 km (600 mi) I, L 3-18
DRIVE CHAIN SLIDER NOTE 4 I I I I 3-21
BRAKE FLUID NOTE 5 I I I I I 2 years 3-21
BRAKE PADS WEAR I I I I I 3-22
BRAKE SYSTEM I I I I I 3-22
BRAKE LIGHT SWITCH I I I I I 3-23
* BRAKE LOCK OPERATION NOTE 6 I I I I 3-23
HEADLIGHT AIM I I I I I 3-24
CLUTCH SYSTEM NOTE 7 I I I I I 3-25
SIDESTAND I I I I I 3-26
* SUSPENSION I I I I I 3-26
* NUTS, BOLTS, FASTENERS NOTE 4 I I I I I 3-33
** WHEELS/TIRES NOTE 4 EVERY 6,000 km (4,000 mi) I I 3-33
** STEERING HEAD BEARINGS I I I I I 3-33
* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Service more frequently when riding OFF-ROAD.
5. Replacement requires mechanical skill.
6. DCT type only
7. Except DCT Type

3-2
dummyhead

MAINTENANCE
CH, GS, ID, IN, MA, TH
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 (NOTE 1)
ANNUAL REGULAR REFER TO
ITEMS NOTE x 1,000 km 1 6 12 18 24 30 36
CHECK REPLACE PAGE
x 1,000 mi 0.6 4 8 12 16 20 24
* FUEL LINE I I I I 3-4
* THROTTLE OPERATION I I I I 3-4
* AIR CLEANER NOTE 2 R R 3-5
CRANKCASE BREATHER NOTE 3 C C C C C C 3-5
EVERY 24,000 km (16,000 mi) I,
* SPARK PLUG 3-6
EVERY 48,000 km (24,000 mi) R
* VALVE CLEARANCE I 3-7
ENGINE OIL R R R R R 3-11
ENGINE OIL FILTER R R 3-12
CLUTCH OIL FILTER NOTE 6 R R 3-13
* ENGINE IDLE SPEED I I I I 3-14
RADIATOR COOLANT NOTE 5 I I I I 3 years 3-14
* COOLING SYSTEM I I I I 3-15
SECONDARY AIR SUPPLY
* I 3-15
SYSTEM
EVAPORATIVE EMISSION
* I 3-16
CONTROL SYSTEM
EXHAUST GAS CONTROL
** I 3-17
ACTUATOR CABLE
DRIVE CHAIN NOTE 4 EVERY 1,000 km (600 mi) I, L 3-18
DRIVE CHAIN SLIDER NOTE 4 I I I 3-21
BRAKE FLUID NOTE 5 I I I I I I I 2 years 3-21
BRAKE PADS WEAR I I I I I I I 3-22
BRAKE SYSTEM I I I I 3-22
BRAKE LIGHT SWITCH I I I I 3-23
* BRAKE LOCK OPERATION NOTE 6 I I I I I I 3-23
HEADLIGHT AIM I I I I 3-24
CLUTCH SYSTEM NOTE 7 I I I I I I I 3-25
SIDESTAND I I I I 3-26
* SUSPENSION I I I I 3-26
* NUTS, BOLTS, FASTENERS NOTE 4 I I I I 3-33
** WHEELS/TIRES NOTE 4 I I I I I I I 3-33
STEERING HEAD
** I I I I 3-33
BEARINGS
* Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Service more frequently when riding OFF-ROAD.
5. Replacement requires mechanical skill.
6. DCT type only
7. Except DCT Type

3-3
 dummyhead

MAINTENANCE
FUEL LINE
CRF1100A/AL/D/ Remove the following:
CRF1100D4 shown:
DL:
– Tank side cover (page 2-24)
– Rear seat under cover (page 2-34) [3]

CRF1100A2/AL2/ Remove the middle cowl (page 2-7). [4] [4]

A4/AL4/D2/DL2/D4/
DL4: [5]
Remove the bolt [1] and washer [2].
[5]
Lift the fuel tank [3] by releasing its grooves [4] from the [1]/[2]
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.

[1]

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 22-33).

[1]

3-4
dummyhead

MAINTENANCE
AIR CLEANER
• The viscous paper element type air cleaner can not
Right side shown:
be cleaned because the element contains a dust
adhesive. [6] [5]
• If the motorcycle is used in unusually wet or dusty
areas, more frequent inspections are required.
Remove the middle cowl (page 2-7).
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].
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 3-2).
Also replace the air cleaner element any time if it is
excessively dirty or damaged.
Install the removed parts in the reverse order of
removal.
TORQUE:
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].
Left side: [1]
[1]
• 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. [2]
[2]
Reinstall the plugs securely.

Right side:

[1]

[2]

3-5
 dummyhead

MAINTENANCE
SPARK PLUG
REMOVAL/INSTALLATION

• 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 5-9).
[1]
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

[1]
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 3-2).
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 lbf·ft)

• Replace new spark plugs as a set.

Install the ignition coil tray (page 5-9).

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

• This motorcycle's spark plugs are equipped 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
dummyhead

MAINTENANCE
Check the gap between the center and side electrodes
[1]
with a wire type feeler gauge [1].

• To prevent damaging the iridium center electrode,

use a wire type feeler gauge to check the spark plug
gap.
Make sure that the Φ 1.0 mm (0.04 in) plug gauge can
not be inserted between the gap.

• Do not adjust the spark plug gap. If the gap is out of

specification, replace it with a new one.

VALVE CLEARANCE
• Inspect and adjust the valve clearance while the
engine is cold (below 35°/95°F).
Remove the cylinder head cover (page 10-4).
[1] [2]
Remove the crankshaft hole cap [1] and the timing hole
cap [2].

Turn the crankshaft counterclockwise and align the "T1"

[1] [2]
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.

[4]

[3]

3-7
 dummyhead

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

[1]

Turn the crankshaft counterclockwise 270° and align

[1] [2]
the "T2" mark [1] on the flywheel with the index mark [2]
of the alternator cover.
Make sure that the punch mark [3] on the cam sprocket
aligns with the upper surface of the cylinder head as
shown.

[3]

Check the No.2 cylinder intake valve clearances by

inserting a feeler gauge [1] between the valve lifter and
cam lobe (page 1-10).
Adjust the valve clearance by changing the valve lifter
shim (page 3-10).

[1]

3-8
dummyhead

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

Adjust the No.2 cylinder exhaust valve clearance by

[4] [2]
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 [1]

Apply engine oil to the adjusting screw and lock nut

threads and seating surface.
Hold the adjusting screw and tighten the lock nut.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
After tightening the lock nut, recheck the valve [3]
clearance.
Rotate the crankshaft counterclockwise approximately
[1] [2]
252.5° and align the "E1" mark [1] with the index mark
[2].
Make sure that the " " mark [3] on the cam sprocket
align with the upper surface of the cylinder head as
shown.

[3]

3-9
 dummyhead

MAINTENANCE
Check the No.1 cylinder exhaust valve clearances by
[1]
inserting a feeler gauge [1] between the locker arm
roller and cam lobe (page 1-10).

Adjust the No.1 cylinder exhaust valve clearance by

[4] [3]
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
Apply engine oil to the adjusting screw and lock nut
threads and seating surface. [2]

Hold the adjusting screw and tighten the lock nut.

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
After tightening the lock nut, recheck the valve [1]
clearance.
Coat new O-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 [3] [2]
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 lbf·ft)
Crankshaft hole cap:
[1] [1]
8.0 N·m (0.8 kgf·m, 5.9 lbf·ft)
Install the cylinder head cover (page 10-6).

INTAKE VALVE CLEARANCE

ADJUSTMENT
Remove the valve lifter and shim (page 10-12).
[1]
Clean the valve shim contact area in the valve lifter [1]
with compressed air.

3-10
dummyhead

MAINTENANCE
Measure the shim [1] thickness and record it.
[1]

• Fifty-one different shim thicknesses are available in

increments of 0.025 mm (from 1.200 mm to 2.450
mm).

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

• Make sure of the correct shim thickness by

measuring the shim with the micrometer.
• 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 10-15).
Rotate the crankshaft counterclockwise several times
and recheck the valve clearances.

ENGINE OIL
OIL LEVEL INSPECTION
Place the motorcycle on its sidestand.
[1]/[5]
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 [4]
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].
[2] [3]/[5]
RECOMMENDED ENGINE OIL:
Honda "4-stroke motorcycle oil" or an equivalent
motor oil.
API service classification: SG or higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
Check that the O-rings [5] of the oil filler cap and
dipstick are in good condition, and replace them if
necessary.
Apply engine oil to the O-rings.
Install the oil filler cap and dipstick.

3-11
 dummyhead

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.

• 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. [1]/[2] [1]/[2]
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
DCT model:
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
5.2 liters (5.5 US qt, 4.6 Imp qt) at disassembly
Check the engine oil level (page 3-11).
Make sure that there are no oil leaks.
Install the skid plate (page 2-25).

ENGINE OIL FILTER

• DCT 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.
TOOL:
Oil filter wrench 07HAA-PJ70101

[1]

3-12
dummyhead

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]
• If the oil filter boss is removed, apply locking agent
to the oil filter boss threads as shown and install it.

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
O-ring.
Install and tighten the oil filter cartridge [1] to the
specified torque using the special tool.
TOOL:
Oil filter wrench 07HAA-PJ70101

TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft)

Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-12).
[1]

CLUTCH OIL FILTER (DCT model)

• Replace the engine oil filter when the clutch oil filter
is replaced.

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.
Drain the engine oil (page 3-12).
[6]
Remove the following:
– Bolts [1]
– Clutch oil filter cover [2]
– O-ring [3]
– Spring [4]
– Clutch oil filter [5]
Install a new clutch oil filter with the "OUT SIDE" mark
[6] facing outside.

• Installing the oil filter backwards will result in severe

engine damage.
Apply engine oil to a new O-ring and install it to the oil
filter cover. [5]
Install the spring and oil filter cover.
Tighten the bolts to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[1] [2] [3] [4]
Fill the crankcase with the recommended engine oil and
check that there are no oil leaks (page 3-12).

3-13
 dummyhead

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 10-2).

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:
Except IN/MA/TH:
High quality ethylene glycol antifreeze
containing silicate-free corrosion inhibitors
IN/MA/TH:
Honda PRE-MIX coolant

RECOMMENDED MIXTURE (Except IN/MA/TH): [1]

1:1 mixture with distilled water

[2]

Remove the reserve tank cap [1] and add the coolant to
[1]
the "UPPER" level line.
Reinstall the cap.
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
dummyhead

MAINTENANCE
COOLING SYSTEM
Check the radiator air passages for clogging or
damage.
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 8-7).

SECONDARY AIR SUPPLY SYSTEM

Remove the air cleaner housing (page 7-14).
Check the PAIR hoses for deterioration, damage or
loose connections. [3] [2]
Also, check that the hoses are not kinked, pinched or
cracked.
– Air suction hose [1] (between the air cleaner housing
[2] and PAIR control solenoid valve [3]) [1]
– 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 7-20).
For secondary air supply system inspection (page 7-19)

[4]

[5]

FRESH AIR
EXHAUST GAS

3-15
 dummyhead

MAINTENANCE
EVAPORATIVE EMISSION CONTROL
SYSTEM
Remove the BCU tray (page 22-51).
[1] [2]
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 and Harness Routing for hose
connections and routing (page 1-32). [3]

[4]

FRESH AIR
FUEL VAPOR

Open the fuel filler cap [1].

Check the breather seal [2] in the fuel filler cap for
deterioration, cracks or damage. Replace it if
necessary.

• Always replace the breather seal with a new one

when the fuel filler cap is removed for service.
[1]

[2]

3-16
dummyhead

MAINTENANCE
EXHAUST GAS CONTROL ACTUATOR
CABLE
OPERATING INSPECTION
Remove the following:
[2]
– Valve guide cover bolts [1]
– Valve guide cover [2]

[1]

[1]

Turn the ignition switch ON.

[1] [2]
The EGCA operates and the index line [1] on the valve
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 3-17).
Install the removed parts in the reverse order of
removal.

CABLE ADJUSTMENT
Remove the mud guard (page 2-38).
[1] [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].
Install the mud guard (page 2-38). [2]

[3] [4]

3-17
 dummyhead

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:
CRF1100A/A2/A4/D/D2/D4:
35 – 45 mm (1.4 – 1.8 in)
CRF1100AL/AL2/AL4/DL/DL2/DL4:
30 – 40 mm (1.2 – 1.6 in)

• Excessive chain slack, 60 mm (2.4 in) or more, may

damage the frame.
ADJUSTMENT
Loosen the rear axle nut [1] and drive chain adjuster
[4]
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.

• 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.
TORQUE: 100 N·m (10.2 kgf·m, 74 lbf·ft)
Seat the drive chain adjusting bolts snugly against the
adjusting plate [5]. [5] [1] [3] [2]

Tighten the drive chain adjuster lock nuts to the

specified torque while holding the drive chain adjusting [4] [6] [7]
bolts.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)
Recheck the drive chain slack and free wheel rotation
(page 3-18). [4]
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).
[2] [3] [5]

3-18
dummyhead

MAINTENANCE
CLEANING AND LUBRICATION
Clean the drive chain [1] with a chain cleaner designed
specifically for O-ring chains. Use a soft brush if the
drive chain is dirty.

[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 O-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 [2]
lubricating.
Lubricate the drive chain with drive chain lubricant [2].
RECOMMENDED LUBRICANT:
Dive chain lubricant designed specifically for O-
ring chains or SAE #80-90 gear oil

Do not use a chain lubricant NOT designed specifically

for use with O-ring chains to lubricate the drive chain.
Wipe off the excess oil or drive chain lubricant.

SPROCKET INSPECTION
Remove the left rear cover (page 2-26).
Inspect the drive and driven sprocket teeth for wear or WEAR
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.

DAMAGE NORMAL

Check the drive sprocket bolt [1] and driven sprocket

[1] [2]
nuts [2] on the drive and driven sprockets.
If any are loose, torque them.
TORQUE:
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).

3-19
 dummyhead

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.
1 LINK
• When using the special tool, follow the
manufacturer's instruction.
TOOL:
Drive chain tool set 07HMH-MR10103
Remove the excess drive chain links from a new drive
chain with the drive chain tool set. 124 LINKS

STANDARD LINKS: 124 LINKS

REPLACEMENT CHAIN
DID: 525HV3-130ZB
Insert a new master link [1] with new O-rings [2] from
[3]
the inside of the drive chain.
Install a new plate [3] and O-rings with the identification [2]
mark facing the outside.
Assemble the master link, O-rings and plate.
TOOL:
Drive chain tool set 07HMH-MR10103

• Never reuse the old drive chain, master link, master

link plate, or O-rings.

[1]

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.

Make sure that the pins are staked properly by

[1]
measuring the diameter of the staked area using a slide
caliper [1].

DIAMETER OF THE STAKED AREA:

5.50 – 5.80 mm (0.217 – 0.228 in)
After staking, check the staked area of the master link
for cracks.
If there is any cracking, replace the master link, O-rings,
and plate.

3-20
dummyhead

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 [1]
drive chain slider replacing (page 18-23).

BRAKE FLUID

Spilled fluid can damage painted, plastic or rubber

parts. Place a rag over these parts whenever the
system is serviced.

• 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:
Front: [1]
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).

[2]

Rear:

[3]

3-21
 dummyhead

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
[1]
air has entered the system.
If the lever or pedal feels soft or spongy when operated,
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.
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)
Replace hoses and fittings as required.

BRAKE LEVER ADJUSTMENT

The distance between the brake lever and the grip can
[1]
be adjusted by turning the adjuster [1].

• Align the " " mark [2] on the brake lever with the
index number on the adjuster.

[2]

3-22
dummyhead

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.

[2]
• The front brake switch does not require adjustment.

[1]
[1]

BRAKE LOCK OPERATION (DCT

model)
INSPECTION
Support the motorcycle using a safety stand or hoist
[2] [1]
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
[1] [2]
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.

• 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
 dummyhead

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 lbf·ft) [2]
Recheck the parking brake operation.
Install the parking brake caliper cover (page 19-12).

[1]

HEADLIGHT AIM
HEADLIGHT AIM
Place the motorcycle on a level surface.
Left side shown:
Adjust the headlight beams vertically by turning the
vertical beam adjuster [1] on right side and left side. [1]

• Adjust the headlight beam as specified by local laws

and regulations.

CORNERING LIGHT AIM (CRF1100A2/

AL2/A4/AL4/D2/DL2/D4/DL4)

• 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. 0.10 m
[2]

• The Lo beam cut line is 0.10 m below the headlight

mounting position [2].

[1]

10 m

3-24
dummyhead

MAINTENANCE
3. Set the cornering light forcibly activate mode (page
[1]
22-7).
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 cornering light forcibly activate mode.
Right side shown:
[6] [5]
• Adjust the cornering light beam as specified by local
laws and regulations. [2]

[3] 0.10 m

1.46 m

[4]
3m

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
(0.4 – 0.8 in)

Minor adjustment is made with the upper adjuster at the

[1] [2]
clutch lever.

• 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
 dummyhead

MAINTENANCE
Major adjustment is made with the lower adjusting nut
[1] at the clutch lifter arm.
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 12-8).

[2] [1]

SIDESTAND
Check the sidestand spring [1] for damage or loss of
[1] [2]
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
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 22-45).

SUSPENSION
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.

• Loose, worn or damaged suspension parts impair

the motorcycle’s stability and control.
Tighten all nuts and bolts.
Refer to the fork service (page 17-20).

3-26
dummyhead

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
CRF1100D/A2: 5 turns
CRF1100AL/DL: 6 turns
CRF1100D2: 8 turns
CRF1100AL2/DL2: 10 1/2 turns

[1]

REBOUND DAMPING ADJUSTER

Rebound damping can be adjusted by turning the
adjuster [1].

TURN CLOCKWISE:
Increases the damping force (harder)
TURN COUNTERCLOCKWISE:
Decreases the damping force (softer)

ADJUSTABLE RANGE: 3 – 4 turns

STANDARD POSITION
(from full hard position):
CRF1100A/D: 2 3/4 turns
CRF1100AL/AL2/DL/DL2: 2 1/2 turns
CRF1100A2/D2: 2 1/4 turns

[1]

3-27
 dummyhead

MAINTENANCE
COMPRESSION DAMPING ADJUSTER
Compression damping can be adjusted by turning the
adjuster [1].

TURN CLOCKWISE:
Increases the damping force (harder)
TURN COUNTERCLOCKWISE:
Decreases the damping force (softer)

ADJUSTABLE RANGE: 12 clicks or more

STANDARD POSITION
(from full hard position):
CRF1100A/D: 9 clicks
CRF1100AL/AL2/DL/DL2: 12 clicks
CRF1100A2/D2: 7 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.

• Loose, worn or damaged suspension parts impair

the motorcycle’s stability and control.
Tighten all nuts and bolts.
Refer to shock absorber service (page 18-9).
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 18-21).

REAR SUSPENSION ADJUSTMENT

(CONVENTIONAL SUSPENSION
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)
TURN COUNTERCLOCKWISE:
Decreases the spring pre-load (softer)

ADJUSTABLE RANGE: 35 clicks

STANDARD POSITION (from full soft position):

7 clicks (first click is "0" position)

[1]

3-28
dummyhead

MAINTENANCE
REBOUND DAMPING ADJUSTER

• 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].
TURN CLOCKWISE:
Increases the damping force (harder)
TURN COUNTERCLOCKWISE:
Decreases the damping force (softer)

ADJUSTABLE RANGE: 21 clicks

STANDARD POSITION
(from full hard position):
CRF1100A/A2/D/D2: 8 clicks
CRF1100AL/AL2/DL/DL2: 15 clicks

COMPRESSION DAMPING ADJUSTER

• 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
[1]
adjuster [1].

TURN CLOCKWISE:
Increases the damping force (harder)
TURN COUNTERCLOCKWISE:
Decreases the damping force (softer)

ADJUSTABLE RANGE: 24 clicks

STANDARD POSITION
(from full hard position):
CRF1100A/A2/D/D2: 12 clicks
CRF1100AL/AL2/DL/DL2: 9 clicks

3-29
 dummyhead

MAINTENANCE
ELECTRONIC SUSPENSION
ADJUSTMENT (ELECTRONIC
SUSPENSION model)
RIDING MODE SELECTING
Select the riding mode [1] by pushing the sel up switch
[1]
[2] and sel down switch [3].

• 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]

3-30
dummyhead

MAINTENANCE
REAR SPRING PRELOAD

• 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 [1]
area" [2] of the MID.
Select the "Gold image display".

• Select the display in the following order to the Gold

image display:
"Settings" > "Display" > "Display Mode" > "TOUR"

Gold image display: [2]

2. Select the "Page 4" [1] by using the sel up switch [2],
Page 4: [1]
sel down switch [3], sel left/right switch [4], ENT
switch [5] and back switch [6] or touch the MID.
Press the ENT switch.
3. Select the "PRELOAD" [7] by using the sel up
switch, sel down switch, ENT switch and back switch
or touch the MID.
Push the sel left/right switch or touch the MID until
the desired value is displayed.
STANDARD POSITION: Rider only

• 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
 dummyhead

MAINTENANCE
FRONT/REAR SUSPENSION DAMPING

• The front/rear 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 MID.

[2]

2. Select the "User 1" [1] or "User 2" [2] by using the
User 1 or User 2: [1]
sel up switch [3], sel down switch [4], sel left/right
switch [5], ENT switch [6] and back switch [7] or
touch the MID.

• 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 left/right
switch, ENT switch and back switch or touch the
MID.
[2]
STANDARD POSITION:
Overall Front Rear [3] [5]
User 1 OFFROAD STD STD
User 2 MEDIUM STD STD

• Push and hold the sel left/right switch to advance the

figure fast.

[6]

[4] [7]

3-32
dummyhead

MAINTENANCE
NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-16).
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
wheel off the ground.
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 17-13).
Support the motorcycle securely and raise the rear
wheel off the ground.
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 18-4).
Check the tire pressure with a tire pressure gauge when
the tires are cold.
– Front tire pressure (page 1-13)
– Rear tire pressure (page 1-14)
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:
CRF1100A/AL/D/DL (FRONT/REAR):
3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4
(FRONT/REAR):
5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:
• Tighten the spokes with a ball point wrench.
• When removing the spokes replace them with new
ones.

STEERING HEAD BEARINGS

Support the motorcycle securely and raise the front
wheel off the ground.
Check that the handlebar moves freely from side to
side. Make sure the control cables do not interfere with
the handlebar rotation.
If the handlebar moves unevenly, binds, or has vertical
movement, inspect the steering head bearings (page
17-45).

3-33
dummyhead

MEMO
dummytext

4. PGM-FI SYSTEM

SERVICE INFORMATION ·····························4-2 IAT SENSOR··············································· 4-75

SYSTEM LOCATION·····································4-3 ECT SENSOR ············································· 4-75

PGM-FI TROUBLESHOOTING EGCA ·························································· 4-76

INFORMATION··············································4-5
ECM ····························································· 4-77
PGM-FI SYMPTOM
TROUBLESHOOTING···································4-9 VS SENSOR················································ 4-79

PGM-FI SYSTEM DTC INDEX ····················4-10 GP SENSOR (MT model) ··························· 4-79

PGM-FI SYSTEM DTC SHIFT SPINDLE SWITCH (MT model) ······ 4-80
TROUBLESHOOTING·································4-17
GRIP APS···················································· 4-80
MIL CIRCUIT TROUBLESHOOTING··········4-72
FI RELAY ···················································· 4-81
IMU·······························································4-73
TBW RELAY ··············································· 4-82
A/F SENSOR ···············································4-73
SUB VB RELAY ·········································· 4-83
MAP SENSOR ·············································4-74
CKP SENSOR ············································· 4-83

4-1
 dummyhead

PGM-FI SYSTEM
SERVICE INFORMATION
PGM-FI SYSTEM

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 ECM is replaced, perform the following procedure.
– Crank pulse initialize learning procedure (page 4-84) (ED, KO only)
– Key Registration Procedure (page 23-5)
• If the TCM is replaced, perform the Clutch Initialize Learning Procedure (DCT model) (page 13-68).
• If the CKP sensor is removed, perform the crank pulse initialize learning procedure (page 4-83) (ED, KO only).
• 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:
– MT model: (page 24-8)
– DCT model: (page 24-9)
• Use a digital tester for PGM-FI system inspection.
• 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 O = Orange P = Pink R = Red V = Violet
W = White Y = Yellow

4-2
dummyhead

PGM-FI SYSTEM
SYSTEM LOCATION
MT model:

GRIP APS

TBW UNIT
MID
– TBW MOTOR
– TP SENSOR

METER MAP SENSOR

– MIL

FUEL PUMP UNIT

IGNITION SWITCH
FUSE BOX
ECM
– FI 15 A
– MAIN2 30 A
IAT SENSOR DLC
IMU POWER BOX
PAIR CONTROL
SOLENOID VALVE – TBW RELAY
– FAN RELAY
IGNITION COILS – FUEL RELAY
– SUB VB RELAY
FUEL
– TBW 10 A
INJECTORS
– ST-MAG 10 A
– METER 10 A
ECT SENSOR – HORN/STOP 10 A
– DIODE
EVAP PURGE
CONTROL FI RELAY
SOLENOID
VALVE

FRONT WHEEL
SPEED SENSOR
EGCA

A/F SENSORS

CKP SENSOR REAR WHEEL

SPEED SENSOR
EOP SWITCH
STARTER RELAY SWITCH
VS SENSOR
– MAIN FUSE 30 A
GP SENSOR
SHIFT SPINDLE SWITCH
NEUTRAL SWITCH
SIDESTAND SWITCH

4-3
 dummyhead

PGM-FI SYSTEM
DCT model:

GRIP APS

TBW UNIT
MID
– TBW MOTOR
– TP SENSOR

METER MAP SENSOR

– MIL POWER BOX
– TBW RELAY
– FAN RELAY
FUEL PUMP UNIT
– FUEL RELAY
IGNITION SWITCH
– SUB VB RELAY
FUSE BOX
ECM – TBW 10 A
– FI 15 A
– ST-MAG 10 A
– MAIN2 30 A
IAT SENSOR – METER 10 A
– DCT-M 30 A
– HORN/STOP 10 A
– DIODE
PAIR CONTROL IMU
SOLENOID VALVE DLC
IGNITION COILS
FUEL
INJECTORS DCT RELAY

ECT SENSOR

EVAP PURGE
CONTROL FI RELAY
SOLENOID
VALVE

FRONT WHEEL
SPEED SENSOR
EGCA

A/F SENSORS

CKP SENSOR REAR WHEEL

SPEED SENSOR
EOP SENSOR EOT SENSOR
STARTER RELAY SWITCH
VS SENSOR
– MAIN FUSE 30 A
TR SENSOR

NEUTRAL SWITCH
SIDESTAND SWITCH

4-4
dummyhead

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-diagnostic 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 SCS 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 4-72).
CURRENT DTC/STORED DTC
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
 dummyhead

PGM-FI SYSTEM
GST (Generic Scan Tool) INFORMATION
• The GST can readout the DTC, stored data, current data and other ECM condition.
How to connect the GST
Turn the ignition switch OFF.
[1]
Remove the main seat (page 2-5). [2]
Remove the dummy connector [1] from the DLC [2].
Connect the special tool to the DLC.
Connect the GST to the DLC.
Turn the ignition switch ON.
Check the DTC and stored data.
OBD harness circuit connection
(General allocation in ISO 15031-3)
DLC 6P 16P
Signal ground A 5
CAN_H B 6
Discretionary (SCS line) C 9
K-line D 7
CAN_L E 14
Permanent positive battery F 16

MCS INFORMATION
• The MCS can readout the DTC, stored data, current data, and other ECM condition.
How to connect the MCS
Turn the ignition switch OFF.
Remove the dummy connector from the DLC (page 4-6).
Connect the MCS to the DLC.
Turn the ignition switch ON and check the DTC and stored data.

• Stored data indicates the engine conditions when the malfunction was first detected.

DTC READOUT
Start the engine and check the MIL.
If the MIL stays on, connect the GST to the DLC (page 4-6) or connect the MCS to the DLC (page 4-6).
Read the DTC, stored data and follow the DTC index (page 4-10).
To read the DTC by the MIL blinks, refer to the following procedure.
Reading DTC with the MIL
Turn the ignition switch OFF.
Remove the main seat (page 2-5).
Remove the dummy connector [1] from the DLC.
Short the DLC terminals using a special tool.
TOOL:
SCS short connector [2] 070MZ-0010300

CONNECTION: Yellow – Green/blue

Turn the ignition switch ON, read, note the MIL blinks and refer to the DTC
index (page 4-10).

[1] [2]

4-6
dummyhead

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.
[1]
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.

[3]

[4]

[2]

[5]

3. Read the DTC [1].

• For returning to the riding information, previous screen, or Home screen:

– Pull the page switch
– Touch the return icon [2] on the touch screen of the MID

[2]

[1]

4-7
 dummyhead

PGM-FI SYSTEM
ERASING STORED DTC

• When the ERASING DTC procedure is performed, the DTCs of DCT system are erased at the same time.
Erase the DTC with the GST or MCS while the engine is stopped.
To erase the DTC without GST or MCS, refer to the following procedure.
How to clear the DTC with SCS short connector
1. Connect the SCS connector to the DLC (page 4-6).
[2]
2. Turn the ignition switch ON.
3. Disconnect the SCS short connector [1] from the DLC [2].
Reconnect the SCS short connector to the DLC while the MIL stays ON
about 5 seconds (reset receiving pattern).
4. The stored DTC 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 [1]
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 07ZAJ-RDJA110

[1]

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]
– ECM 33P (Gray) connector C [3]

[1]

[2]/[3]

4-8
dummyhead

PGM-FI SYSTEM
PGM-FI SYMPTOM TROUBLESHOOTING
When the motorcycle has one of these symptoms, check if the DTC or MIL is blinking, then refer to the DTC index (page 4-10) and
begin the appropriate troubleshooting procedure. If there is no DTC 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 DTC 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
4). – 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 FI relay or related circuit
(No fuel pump operation sound (page 4-77) • 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, 1. Check the idle speed (page 3-14). • Contaminated/deteriorated fuel
rough idling 2. Inspect the fuel supply system (page 7-4). • Intake air leak
3. Inspect the battery charging system (page • 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
Idle speed is below 1. Inspect the fuel supply system (page 7-4).
specifications or fast idle too low 2. Check the idle speed (page 3-14).
(No DTC 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
specifications or fast idle too 2. Check the throttle operation (page 3-4). • Intake air leak
high (No DTC and MIL blinking) • Engine top-end problem
• Air cleaner condition
MIL never comes on at all 1. Check the CAN line circuit.
2. Inspect the meter (page 22-13).
MIL stays on but no DTCs set Inspect the MIL circuit (page 4-72).
• DLC circuit malfunction
• CAN line circuit malfunction

4-9
 dummyhead

PGM-FI SYSTEM
PGM-FI SYSTEM DTC INDEX
• When using GST or MCS, check the lighting or blinking state of the MIL and shift indicator, and then refer to DTC index.
• Follow the prior diagnosis notes before performing the troubleshooting, refer to the PRIOR DIAGNOSIS (page 4-17).

MID Detected
Shift
displays/ D/C Refer to
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
C0520 99 – 1 IMU Malfunction 4-18
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)
4-18
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
P00D1 38 – 1
(Left A/F Sensor Heater Control Circuit Range/
performance)
4-20
A/F Sensor Heater Control Circuit Performance
Problem
P00D3 39 – 1
(Right A/F Sensor Heater Control Circuit Range/
performance)
MAP Sensor Circuit
P0105 1 – 2 4-20
(MAP Sensor Stuck)
MAP Sensor Circuit Range Problem
P0106 1 – 2 4-20
(MAP Sensor Circuit Range/performance)
MAP Sensor Circuit Low
P0107 1 – 1
(MAP Sensor Circuit Low Voltage)
4-21
MAP Sensor Circuit High
P0108 1 – 1
(MAP Sensor Circuit High Voltage)
IAT Sensor Circuit High Range Problem
P0111 9 – 2 4-22
(IAT Sensor Circuit Range/performance)
IAT Sensor Circuit Low
P0112 9 – 1
(IAT Sensor Circuit Low Voltage)
4-22
IAT Sensor Circuit High
P0113 9 – 1
(IAT Sensor Circuit High Voltage)
ECT Sensor Circuit
P0115 7 – 2 4-24
(ECT Sensor Stuck)
ECT Sensor Circuit Low
P0117 7 – 1
(ECT Sensor Circuit Low Voltage)
4-24
ECT Sensor Circuit High
P0118 7 – 1
(ECT Sensor Circuit High Voltage)
ECT Sensor Intake Air Temperature Correlation
P011B 132 – 2 4-25
(Engine Coolant Temperature Correlation)
TP Sensor 1 Circuit Range Problem
P0121 71 – 1 4-26
(TP Sensor 1 Circuit Range/performance)
TP Sensor Circuit Low
P0122 71 – 1
(TP Sensor 1 Low Voltage)
4-26
TP Sensor Circuit High
P0123 71 – 1
(TP Sensor 1 High Voltage)
Insufficient Coolant Temperature for Closed Loop Fuel
P0125 7 – 2 4-28
Control
O2/AF Sensor Circuit Low Voltage
P0131 36 – 1
(Left A/F Sensor Circuit Low Voltage)
4-28
O2/AF Sensor Circuit High Voltage
P0132 36 – 1
(Left A/F Sensor Circuit High Voltage)
O2/AF Sensor Circuit No Activity Detected
P0133 36 – 2
(Left A/F Sensor Circuit Slow Response)
4-30
O2/AF Sensor Circuit No Activity Detected
P0134 36 – 1
(Left A/F Sensor Circuit No Activity Detected)

4-10
dummyhead

PGM-FI SYSTEM
MID Detected
Shift
displays/ D/C Refer to
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
O2/AF Sensor Circuit Low Voltage
P0151 37 – 1
(Right A/F Sensor Circuit Low Voltage)
4-28
O2/AF Sensor Circuit High Voltage
P0152 37 – 1
(Right A/F Sensor Circuit High Voltage)
O2/AF Sensor Circuit Slow Response Problem
P0153 37 – 2
(Right A/F Sensor Circuit Slow Response)
4-30
O2/AF Sensor Circuit No Activity Detected
P0154 37 – 1
(Right A/F Sensor Circuit No Activity Detected)
DCT model:
P0197 – 44 – EOT Sensor Circuit Low
(EOT Sensor Low Voltage)
13-13
DCT model:
P0198 – 44 – EOT Sensor Circuit High
(EOT Sensor High Voltage)
Cylinder 1 Injector Circuit
P0201 12 – 1
(No. 1 (Left) Fuel Injector Malfunction)
4-30
Cylinder 2 Injector Circuit
P0202 13 – 1
(No. 2 (Right) Fuel Injector Malfunction)
TP Sensor 2 Circuit Range Problem
P0221 72 – 1 4-32
(TP Sensor 2 Circuit Range/performance)
TP Sensor 2 Circuit Low
P0222 72 – 1
(TP Sensor 2 Low Voltage)
4-32
TP Sensor 2 Circuit High
P0223 72 – 1
(TP Sensor 2 High Voltage)
Random/multiple Cylinder Misfire Detected
133 – 1 (Random/multiple Cylinder Misfire Detected A)
(When the MIL is blinking)
P0300 4-33
Random/multiple Cylinder Misfire Detected
133 – 2 (Random/multiple Cylinder Misfire Detected B)
(When the MIL is lighting)
CKP Sensor Variation Not Learned
P0315 142 – 1 4-34
(Crankshaft Position System Variation Not Learned)
Ignition Coil 1 Primary Control Circuit Open
P0351 91 – 1 (No.1-1 (No.1 Cylinder Main) Ignition Coil Circuit
Malfunction)
Ignition Coil 2 Primary Control Circuit Open
P0352 92 – 1 (No.2-1 (No.2 Cylinder Main) Ignition Coil Circuit
Malfunction)
4-35
Ignition Coil 3 Primary Control Circuit Open
P0353 93 – 1 (No.1-2 (No.1 Cylinder Sub) Ignition Coil Circuit
Malfunction)
Ignition Coil 4 Primary Control Circuit Open
P0354 94 – 1 (No.2-2 (No.2 Cylinder Sub) Ignition Coil Circuit
Malfunction)
AIR System Switching Valve Circuit
P0412 89 – 1 4-37
(PAIR Control Solenoid Valve Malfunction)
EVAP System Purge Control Valve Circuit
P0443 88 – 1 4-38
(EVAP Purge Control Solenoid Valve Malfunction)
EX Pressure Control Valve
P0475 35 – 2 4-39
(EGCA Malfunction)
EX Pressure Control Valve Intermittent
P0479 35 – 2 4-40
(EGCA Motor Lock)
EX Pressure Control Valve Position Sensor Circuit Low
P048D 34 – 1
(EGCA Position Sensor Circuit Low)
EX Pressure Control Valve Position Sensor Circuit High
P048E 34 – 1
(EGCA Position Sensor Circuit High) 4-41
EX Pressure Control Valve Position Sensor Circuit
P048F 35 – 2 Intermittent
(EGCA Position Sensor Stuck)
VSP Sensor 1 Malfunction
P0500 67 67 1 4-42
(Front Wheel Speed Sensor Malfunction)

4-11
 dummyhead

PGM-FI SYSTEM
MID Detected
Shift
displays/ D/C Refer to
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
DCT model:
P0501 – 66 1 Vehicle Speed Sensor Range Performance Error 13-14
(Front Wheel Pulser Ring Malfunction)
Brake Switch Malfunction
P0504 145 – – 4-43
(Brake Cruise Cancel Switch Correlation Failure)
DCT model:
P0522 83 – 1 EOP Sensor Low
(EOP Sensor Low Voltage)
13-14
DCT model:
P0523 83 – 1 EOP Sensor High
(EOP Sensor High Voltage)
System Voltage
P0562 126 37 1 4-44
(Sub VB Relay Malfunction)
Cruise Control Switch Circuit Low
P0567 119 – – 4-46
(RES/+ Cruise Control Lever Short Circuit)
Cruise Control Related Malfunction
P0574 121 – – 4-47
(Cruise Vehicle Speed Correlation Failure)
Cruise Control Related Malfunction
P0580 118 – – (Cruise Main Switch, SET/– Cruise Control Lever Short
Circuit)
4-47
Cruise Control Related Malfunction
P0581 118 – – (Cruise Main Switch, SET/– Cruise Control Lever Open
Circuit)
Control Module Processor
P0606 84 84 1 4-48
(CPU in the ECM Malfunction)
ICM EEPROM Error
P062F 33 – 1 4-48
(ECM EEPROM Malfunction)
ICM O2 Sensor CPU Performance Problem
P064D 131 – 1
(Left A/F Sensor IC Circuit Abnormal)
4-49
ICM O2 Sensor Processor Performance Problem
P064E 144 – 1
(Right A/F Sensor IC Circuit Abnormal)
ECM/PCM Power Relay Control Circuit Low
P0686 126 37 1
(Ignition Hold Relay Stuck OFF)
4-44
ECM/PCM Power Relay Control Circuit High
P0687 126 37 1
(Ignition Hold Relay Stuck ON)
MT model:
P0704 113 – 1 Clutch Switch Input Circuit Malfunction 4-49
(Clutch Switch Circuit Low Voltage)
DCT model:
P0715 – 53 1 Input Speed Sensor 1 Circuit 13-16
(Inner Mainshaft Speed Low)
DCT model:
P0721 – 67 1 Output Speed Sensor Range Performance Error 13-17
(Rear Wheel Speed Sensor Circuit No Signal)
OS Sensor Circuit No Signal
P0722 11 11 1 4-50
(VS Sensor Circuit No Signal)
DCT model:
– 55 1 Pressure Control Solenoid Malfunction
(No.1 Linear Solenoid Valve Current Failure)
P0745 13-17
DCT model:
– 55 1 Pressure Control Solenoid Malfunction
(No.1 Linear Solenoid Valve Driver in the TCM Failure)
DCT model:
– 56 1 Pressure Control Solenoid 2 Malfunction
(No.2 Linear Solenoid Valve Current Failure)
P0775 13-18
DCT model:
– 56 1 Pressure Control Solenoid 2 Malfunction
(No.2 Linear Solenoid Valve Driver in the TCM Failure)

4-12
dummyhead

PGM-FI SYSTEM
MID Detected
Shift
displays/ D/C Refer to
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
DCT model:
P0851 – 52 – Park/Neutral Switch Input Circuit Low
(Neutral Switch Stuck OFF)
13-19
DCT 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))
4-52
TBW Switch Malfunction (OFF Side)
P1659 85 – 1
(TBW Relay Failure (OFF Side))
TBW Switch Malfunction
P1684 77 – 1 4-53
(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 4-55
(GP Sensor Low Voltage)
P1702
DCT model:
– 51 1 TR Sensor Circuit Low 13-21
(TR Sensor Low Voltage)
MT model:
41 – 1 GP Sensor Circuit High 4-55
(GP Sensor High Voltage)
P1703
DCT model:
– 51 1 TR Sensor Circuit High 13-21
(TR Sensor High Voltage)
DCT model:
P1704 – 47 1
No.1 Clutch EOP Sensor Low Voltage
DCT model:
P1705 – 47 1
No.1 Clutch EOP Sensor High Voltage
13-22
DCT model:
P1706 – 48 1
No.2 Clutch EOP Sensor Low Voltage
DCT model:
P1707 – 48 1
No.2 Clutch EOP Sensor High Voltage
MT model:
108 – 1 Shift Spindle Angle Sensor Low Voltage 4-56
P1708 (Shift Spindle Switch Circuit Low Voltage)
DCT model:
– 21 1 13-23
Shift Spindle Angle Sensor Low Voltage
MT model:
108 – 1 Shift Spindle Angle Sensor High Voltage 4-56
P1709 (Shift Spindle Switch Circuit High Voltage)
DCT model:
– 21 1 13-23
Shift Spindle Angle Sensor High Voltage
DCT model:
P170A – 24 1
Shift Control Motor Drive Circuit
13-25
DCT model:
P170B – 31 1
Shift Control Motor Low Voltage
MT model:
P170D 107 – 1 Shift Sensor Ground Fault
(Shift Stroke Sensor Circuit Low Voltage)
4-57
MT model:
P170E 107 – 1 Shift Sensor Open Circuit
(Shift Stroke Sensor Circuit High Voltage)
DCT model:
P170F – 33 1 Learning Value Area Malfunction 13-26
(TCM EEPRPM Malfunction)

4-13
 dummyhead

PGM-FI SYSTEM
MID Detected
Shift
displays/ D/C Refer to
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
DCT model:
P1712 84 84 1 TCM CPU Malfunction 4-58
(CPU in the ECM/TCM Malfunction)
DCT model:
Spindle Operation During Shifter Stop
P1713 – 22 1 13-26
(Shift Spindle Operation Malfunction (After Operating
Gearshift Mechanism))
DCT model:
P1714 – 27 1 13-27
Shift Drum Position Malfunction
DCT model:
P1716 – 9 –
Clutch Line EOP Sensor High Voltage
13-27
DCT model:
P1717 – 9 –
Clutch Line EOP Sensor Low Voltage
DCT model:
P1718 – 49 – Shift Control Motor Drive Circuit 13-29
(Clutch Line Low Oil Pressure)
DCT model:
P1719 – 68 1 Clutch (1) Being Dysversion 13-29
(No.1 Clutch Operation Malfunction (Clutch Slips))
DCT model:
P171A – 69 1 Clutch (2) Being Dysversion 13-30
(No.2 Clutch Operation Malfunction (Clutch Slips))
DCT model:
Clutch Bite Crowded (Clutch 1 No Opening)
P171B – 58 –
(No.1 Clutch Does Not Disengage (When Shifting
Gear))
13-30
DCT model:
Clutch Bite Crowded (Clutch 2 No Opening)
P171C – 59 –
(No.2 Clutch Does Not Disengage (When Shifting
Gear))
DCT model:
P171D – 61 – Clutch Bite Crowded (1) Pressure No Opening
(No.1 Clutch Oil Pressure Canceling Malfunction)
DCT model:
Clutch (1) Hydraulic Pressure Malfunction
P171E – 61 1
(No.1 Clutch Oil Pressure Malfunction (at Clutch Initial
Diagnosis))
DCT model:
P171F – 61 1 Clutch (1) No Pressure
(No.1 Clutch No Oil Pressure)
DCT model:
P1720 – 61 1 Clutch (1) Hydraulic Pressure Low
(No.1 Clutch Oil Pressure Degradation)
DCT model:
P1721 – 62 – Clutch (1) Hydraulic Pressure Rise
(No.1 Clutch Oil Pressure High)
13-31
DCT model:
P1722 – 63 – Clutch Bite Crowded (2) Pressure No Opening
(No.2 Clutch Oil Pressure Canceling Malfunction)
DCT model:
Clutch (2) Hydraulic Pressure Malfunction
P1723 – 63 1
(No.2 Clutch Oil Pressure Malfunction (at Clutch Initial
Diagnosis))
DCT model:
P1724 – 63 1 Clutch (2) No Pressure
(No.2 Clutch No Oil Pressure)
DCT model:
P1725 – 63 1 Clutch (2) Hydraulic Pressure Low
(No.2 Clutch Oil Pressure Degradation)
DCT model:
P1726 – 64 – Clutch (2) Hydraulic Pressure Rise
(No.2 Clutch Oil Pressure High)

4-14
dummyhead

PGM-FI SYSTEM
MID Detected
Shift
displays/ D/C Refer to
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
DCT model:
P1728 – 57 1 Shifter Malfunction
(Gearshift Mechanism Malfunction)
13-31
DCT model:
P1729 – 57 1 Shifter Setting Malfunction
(Gear Position Malfunction (Jumps Out of Gear))
DCT 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
(Shift Pedal Angle Sensor (Option) Malfunction)
DCT model:
P172C – 46 – N-D Switch Signal Malfunction 13-33
(N-D Switch Malfunction)
DCT model:
P172D – 45 – Shifter Driven in Spindle Inactive 13-34
(Shift Switch Malfunction)
DCT model:
P172E – 32 1 FSR Malfunction 13-35
(Fail Safe Relay Circuit Malfunction)
DCT model:
Spindle No Operation During Shifter Drive
P172F – 23 1 13-36
(Shift Spindle Operation Malfunction (While Operating
Gearshift Mechanism))
Throttle Actuator Circuit Performance Problem
P2101 79 – 1
(TBW System Control Correlation Failure)
4-58
Throttle Actuator Current Performance Problem
P2118 78 – 1
(TBW Motor Malfunction)
APS 1 Sensor Circuit Range Problem
P2121 74 – 1 4-59
(APS 1 (TCP) Circuit Range/performance)
APS 1 Sensor Circuit Low
P2122 74 – 1
(APS 1 (TCP) Low Voltage)
4-60
APS 1 Sensor Circuit High
P2123 74 – 1
(APS 1 (TCP) High Voltage)
APS 2 Sensor Circuit Range Problem
P2126 75 – 1 4-59
(APS 2 (TCP) Circuit Range/performance)
APS 2 Sensor Circuit Low
P2127 75 – 1
(APS 2 (TCP) Low Voltage)
4-61
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 4-62
TP Sensor 1/2 Voltage Correlation
73 – 1
(TP Sensors 1 and 2 Short Circuit)
APS 1/2 Sensor Voltage Correlation
P2138 76 – 1 4-63
(APS 1 – 2 (TCP) Voltage Correlation Malfunction)
VSP Sensor 2 Malfunction
P2158 66 66 1 4-64
(Rear Wheel Speed Sensor Malfunction)
O2/AF Sensor Signal Biased/stuck Lean
P2195 36 – 2
(Left A/F Sensor Signal Biased/stuck Lean)
O2/AF Sensor Signal Biased/stuck Rich
P2196 36 – 2
(Left A/F Sensor Signal Biased/stuck Rich)
4-65
O2/AF Sensor Signal Biased/stuck Lean
P2197 37 – 2
(Right A/F Sensor Signal Biased/stuck Lean)
O2/AF Sensor Signal Biased/stuck Rich
P2198 37 – 2
(Right A/F Sensor Signal Biased/stuck Rich)
DCT model:
P2765 – 54 1 Input Speed Sensor 2 Circuit 13-37
(Outer Mainshaft Speed Low)

4-15
 dummyhead

PGM-FI SYSTEM
MID Detected
Shift
displays/ D/C Refer to
DTC indicator DTC name
MIL (Driving page
blinks
blinks Cycle)
O2/AF Sensor Circuit Range Problem
P2A00 36 – 2
(Left A/F Sensor Circuit Range/performance)
4-65
O2/AF Sensor Circuit Range Problem
P2A03 37 – 2
(Right A/F Sensor Circuit Range/performance)
U0001 103 – 1 CAN Communication Malfunction 4-66
CAN Communication Malfunction (PCM-ABS)
U0121 103 – 1 4-68
(ABS CAN Communication Malfunction)
CAN Communication Malfunction (IMU)
U0125 103 – 1 4-69
(IMU CAN Communication Malfunction)
CAN Communication Malfunction (TCM-GCM)
U0155 103 – 1 4-70
(Meter CAN Communication Malfunction)
CAN Communication Malfunction (PTCAN)
U019E 112 – 1 4-70
(Power train CAN Communication Malfunction)

4-16
dummyhead

PGM-FI SYSTEM
PGM-FI SYSTEM DTC
TROUBLESHOOTING
PRIOR DIAGNOSIS
Before processing the DTC troubleshooting, check as
follows:
• Check for loose or poor contact on the DTC related
connectors (each sensor, solenoid, unit etc.), then
recheck the DTC.
• Erase the DTC (page 4-8) and recheck it.
• Refer to probable cause of each detected DTC and
check the listed items first. If possible, correct the
abnormally.

• Always turn the ignition switch OFF when checking

the continuity of the circuit and before disconnecting
the connectors.
• Some DTCs have a recheck function, so that the
priority DTC is detected when the ignition switch is
switched from OFF to ON. Wait for 10 seconds and
check the DTC again.

COMMON TROUBLESHOOTING
INFORMATION

• Always use the test probe when inspecting at the

ECM, TCM, ABS modulator, BCU, and SCU
connectors.
TOOL:
Test probe 07ZAJ-RDJA110
• If the ECM is replaced, perform the following:
– CKP sensor initialize learning procedure (page 4-
84)
– Key Registration Procedure (page 23-5)
• If the TCM is replaced, perform the Clutch Initialize
Learning Procedure (page 13-68).
• If the Left crankcase cover or CKP sensor is
removed, perform the crank pulse initialize learning
procedure (page 4-83) (ED, KO only).
• 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.

4-17
 dummyhead

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 GST or 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
Symptom/Fail-safe function:
• Fuel consumption deterioration
• Detected value feedback stops
1. A/F Sensor Heater Line Open Circuit Inspection
Disconnect the ECM 39P connector (page 4-77).
[1] [2]
Disconnect the ECM 33P (Gray) connector (page 4-
77).
Disconnect the A/F sensor connector (page 4-73).
Check for continuity between the wire harness side
left A/F sensor connector [1] and ECM 39P
connector [2]. W
CONNECTION: White – A14 A14
Check for continuity between the wire harness side
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

4-18
dummyhead

PGM-FI SYSTEM
2. A/F Sensor Heater Ground Line Open Circuit
Inspection
Check for continuity between the wire harness side
[1]
A/F sensor connector [1] and ground.
CONNECTION: Green – Ground
Is there continuity?
YES – GO TO STEP 3. G
NO – Open circuit in the Green wire

3. A/F Sensor Heater Output Line Short Circuit

Inspection
Check for continuity between the wire harness side
[1]
A/F sensor connector [1] and ground.
CONNECTION: White – Ground
Is there continuity?
YES – Short circuit in the White wire W
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 DTC.
Start the engine and wait for a minute.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original A/F sensor

4-19
 dummyhead

PGM-FI SYSTEM
DTC P00D1/DTC P00D3
Probable cause:
• Faulty A/F sensor heater or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Fuel consumption deterioration
• Detected value feedback stops
1. A/F Sensor Inspection
Replace the A/F sensor with a new one.
Erase the DTC.
Start the engine and wait for a minute.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original A/F sensor

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
Symptom/Fail-safe function:
• Rough idling
• Driveability deterioration
1. MAP Sensor Inspection
Replace the MAP sensor with a new one.
Erase the DTC.
Start the engine and wait for three seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original MAP sensor

DTC P0106
Probable cause:
• Faulty MAP sensor or its related circuit
• Contaminated intake manifold or throttle bore
• Faulty ECM
Symptom/Fail-safe function:
• Rough idling
• Driveability deterioration
1. MAP Sensor Inspection
Replace the MAP sensor with a new one.
Erase the DTC.
Start the engine and wait for three seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original MAP sensor

4-20
dummyhead

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 4-74).
[1]
Turn the ignition switch ON.
Measure the voltage at the wire harness side MAP
sensor connector [1].
CONNECTION: Yellow (+) – Gray (–)
Is the voltage within 4.75 – 5.25 V?
Gr Y
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

Disconnect the ECM 39P connector (page 4-77).
[2] [1]
Check for continuity between the wire harness side
MAP sensor connector [1] and ECM 39P connector
[2].
CONNECTION: Light green – A15
Is there continuity?
YES – GO TO STEP 3.
A15 Lg
NO – Open circuit in the Light green wire

3. MAP Sensor Signal Line Short Circuit Inspection

Check for continuity between the wire harness side
[1]
MAP sensor connector [1] and ground.
CONNECTION: Light green – Ground
Is there continuity?
YES – Short circuit in the Light green wire
Lg
NO – GO TO STEP 4.

4-21
 dummyhead

PGM-FI SYSTEM
4. MAP Sensor Inspection
Replace the MAP sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original MAP sensor

DTC P0111
Probable cause:
• Faulty IAT sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. IAT Sensor Inspection
Replace the IAT sensor with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original IAT sensor

DTC P0112/DTC P0113

Probable cause:
• Faulty IAT sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. IAT Sensor Output Line Open Circuit Inspection
Disconnect the ECM 39P connector (page 4-77).
[2] [1]
Disconnect the IAT sensor connector (page 7-14).
Check for continuity between the wire harness side
IAT sensor connector [1] and ECM 39P connector
[2].
CONNECTION: Yellow – A17
Is there continuity?
YES – GO TO STEP 2.
A17 Y
NO – Open circuit in the Yellow wire

4-22
dummyhead

PGM-FI SYSTEM
2. IAT Sensor Output Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
IAT sensor connector [1] and ground.
CONNECTION: Yellow – Ground
Is there continuity?
YES – Short circuit in the Yellow wire
Y
NO – GO TO STEP 3.

3. IAT Sensor Ground Line Open Circuit Inspection

Disconnect the ECM 33P (Black) connector (page
[2] [1]
4-77).
Check for continuity between the wire harness side
IAT sensor connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Gray – B23
Is there continuity?
YES – GO TO STEP 4. B23 Gr
NO – Open circuit in the Gray wire

4. IAT Sensor Inspection

Replace the IAT sensor with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original IAT sensor

4-23
 dummyhead

PGM-FI SYSTEM
DTC P0115
Probable cause:
• Faulty ECT sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Hard to start at a low temperature
• Exhaust gas too lean or too rich
• Fuel consumption deterioration
• Driveability deterioration
1. ECT Sensor Inspection
Replace the ECT sensor with a new one.
Erase the DTC.
Start the engine and wait for 10 minutes.
Stop the engine and wait an hour.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original ECT sensor

DTC P0117/DTC P0118

Probable cause:
• Faulty ECT sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Hard to start at a low temperature
• Driveability deterioration
1. ECT Sensor Output Line Open Circuit Inspection
Disconnect the ECM 33P (Black) connector (page
[1] [2]
4-77).
Disconnect the ECT sensor connector (page 4-75).
Check for continuity between the wire harness side
ECT sensor connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Light green – B20
Is there continuity?
Lg B20
YES – GO TO STEP 2.
NO – Open circuit in the Light green wire

2. ECT Sensor Output Line Short Circuit Inspection

Check for continuity between the wire harness side
[1]
ECT sensor connector [1] and ground.
CONNECTION: Light green – Ground
Is there continuity?
YES – Short circuit in the Light green wire
NO – GO TO STEP 3. Lg

4-24
dummyhead

PGM-FI SYSTEM
3. ECT Sensor Ground Line Open Circuit
Inspection
Check for continuity between the wire harness side
[2] [1]
ECT sensor connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Gray – B23
Is there continuity?
YES – GO TO STEP 4.
NO – Open circuit in the Gray wire B23 Gr

4. ECT Sensor Inspection

Replace the ECT sensor with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original ECT sensor

DTC P011B
Probable cause:
• Faulty ECT sensor or its related circuit
• Insufficient coolant
• Faulty thermostat
• Faulty water pump
• Clogged coolant passage
• Faulty IAT sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Hard to start at a low temperature
• Exhaust gas too lean or too rich
• Fuel consumption deterioration
• Driveability deterioration

• Before processing the DTC troubleshooting, stop the

engine and wait for 6 hours if the motorcycle is
running.
• Do not disconnect the battery cable.
1. ECT Sensor Inspection
Replace the ECT sensor with a new one.
Erase the DTC.
Turn the ignition switch OFF and wait for 6 hours.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – GO TO STEP 2.
NO – Faulty original ECT sensor

4-25
 dummyhead

PGM-FI SYSTEM
2. IAT Sensor Inspection
Replace the IAT sensor with a new one.
Erase the DTC.
Turn the ignition switch OFF and wait for 6 hours.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original IAT sensor

DTC P0121
Probable cause:
• Faulty TP sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Driveability deterioration
• Motorcycle speed is limited: approximately 120 km/h
(75 mph)
• HSTC does not operate
1. TP Sensor 1 Inspection
Replace the throttle body (TP sensor).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TP Sensor

DTC P0122/DTC P0123

Probable cause:
• Faulty TP sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed
• HSTC does not operate
1. TP Sensor 1 Input Voltage Inspection
Disconnect the TBW unit connector (page 7-16).
[1]
Turn the ignition switch ON.
Measure the voltage at the wire harness side TBW
unit connector [1].
CONNECTION: Yellow (+) – Light green (–)
Is about 5 V indicated? Y Lg
YES – GO TO STEP 2.
NO – • Open or short circuit in the Yellow wire
• Open circuit in the Light green wire
• If the wire is OK, replace the ECM with
a new one, and recheck.

4-26
dummyhead

PGM-FI SYSTEM
2. TP Sensor 1 Output Line Open Circuit
Inspection
Disconnect the ECM 33P (Black) connector (page
[2]
4-77).
Check for continuity between the wire harness side
TBW unit connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Blue/black – B27
B27
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Blue/black wire
Bu/Bl

[1]

3. TP Sensor 1 Output Line Short Circuit

Inspection
Check for continuity between the wire harness side
[1]
TBW unit connector [1] and ground.
CONNECTION: Blue/black – Ground
Is there continuity?
YES – Short circuit in the Blue/black wire Bu/Bl

NO – GO TO STEP 4.

4. TP Sensor 1 Inspection
Replace the throttle body (TP sensor).
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TP sensor

4-27
 dummyhead

PGM-FI SYSTEM
DTC P0125
Probable cause:
• Faulty ECT sensor or its related circuit
• Insufficient coolant
• Faulty thermostat
• Faulty water pump
• Clogged coolant passage
• Faulty ECM
Symptom/Fail-safe function:
• Hard to start at a low temperature
• Exhaust gas too lean or too rich
• Fuel consumption deterioration
• Driveability deterioration
1. ECT Sensor Inspection
Replace the ECT sensor with a new one.
Erase the DTC.
Warm up the engine until the coolant temperature is
above 25°C (77°F) and wait for 10 minutes.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original ECT sensor

DTC P0131/DTC P0132/DTC P0151/

DTC P0152
Probable cause:
• Faulty A/F sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Fuel consumption deterioration
• Detected value feedback stops
1. A/F Sensor Output Line Open Circuit Inspection
Disconnect the A/F sensor connector (page 4-73).
[1]
Disconnect the ECM connectors:
– Left A/F sensor: ECM 39P connector (page 4-77)
– Right A/F sensor: ECM 33P (Gray) connector
(page 4-77)
Left A/F sensor: Check for continuity between the
wire harness side A/F sensor connector [1] and
ECM 39P connector [2]. Bl A25
Right A/F sensor: Check for continuity between the
wire harness side A/F sensor connector [3] and
[2]
ECM 33P (Gray) connector [4].
CONNECTION:
Left A/F sensor: Black – A25
Right A/F sensor: Black – C32 [3]

Is there continuity?
YES – GO TO STEP 2.
NO – Open circuit in the Black wire

Bl C32

[4]

4-28
dummyhead

PGM-FI SYSTEM
2. A/F Sensor Output Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
A/F sensor connector [1] and ground.
CONNECTION: Black – Ground
Is there continuity?
YES – Short circuit in the Black wire Bl
NO – GO TO STEP 3.

3. A/F Sensor Ground Line Open Circuit Inspection

Left A/F sensor: Check for continuity between the
wire harness side A/F sensor connector [1] and [1] [2]
ECM 39P connector [2].
Right A/F sensor: Check for continuity between the
wire harness side A/F sensor connector [3] and
ECM 33P (Gray) connector [4].
CONNECTION:
Left A/F sensor: Gray – A36
Right A/F sensor: Gray – C21
Is there continuity?
YES – GO TO STEP 4.
Gr A36
NO – Open circuit in the Gray wire
[3] [4]

Gr C21

4. A/F sensor Inspection

Replace the A/F sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Start the engine and wait for a minute.
Stop the engine.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original A/F sensor

4-29
 dummyhead

PGM-FI SYSTEM
DTC P0133/DTC P0134/DTC P0153/
DTC P0154
Probable cause:
• Faulty A/F sensor or its related circuit
• Faulty A/F sensor heater or its related circuit
• There is an exhaust leak
• Faulty ECM
Symptom/Fail-safe function:
• Fuel consumption deterioration
• Exhaust gas too lean or too rich
• Driveability deterioration
• Detected value feedback stops
1. A/F sensor Inspection
Replace the A/F sensor with a new one.
Erase the DTC.
Warm up the engine until the coolant temperature is
above 50°C (122°F) and keep the engine revolution
at 2,000 – 8,100 r/min with no 100 r/min variation a
second.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original A/F sensor

DTC P0201/DTC P0202

Probable cause:
• Faulty fuel injector or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine does not start (Fuel injectors, fuel pump and
ignition shut down)
1. Fuel Injector Input Voltage Inspection
Disconnect the fuel injector connector (page 7-17).
[1]
Turn the ignition switch ON.
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

4-30
dummyhead

PGM-FI SYSTEM
2. Fuel Injector Signal Line Open Circuit Inspection
Disconnect the ECM 33P (Black) connector (page
[1] [2]
4-77).
Check for continuity between the wire harness side
fuel injector connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: B8
P
No.1: Blue – B7
No.2: Pink – B8
Bu
Is there continuity?
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

Check for continuity between the wire harness side
[1]
fuel injector connector [1] and ground.
CONNECTION:
No.1: Blue – Ground
No.2: Pink – Ground
Is there continuity? No.1: Bu
YES – • No.1: Short circuit in the Blue wire No.2: P
• 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.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original fuel injector

4-31
 dummyhead

PGM-FI SYSTEM
DTC P0221
Probable cause:
• Faulty TP sensor
• Faulty ECM
Symptom/Fail-safe function:
• Driveability deterioration
• Motorcycle speed is limited: approximately 120 km/h
(75 mph)
• HSTC does not operate
1. TP Sensor 2 Inspection
Replace the throttle body (TP sensor).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TP Sensor

DTC P0222/DTC P0223

Probable cause:
• Faulty TP sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed
1. TP Sensor 2 Input Voltage Inspection
Disconnect the TBW unit connector (page 7-16).
[1]
Turn the ignition switch ON.
Measure the voltage at the wire harness side TBW
unit connector [1].
CONNECTION: Yellow (+) – Light green (–)
Is about 5 V indicated? Y Lg
YES – GO TO STEP 2.
NO – • Open or short circuit in the Yellow wire
• Open circuit in the Light green wire
• If the wire is OK, replace the ECM with
a new one, and recheck.

2. TP Sensor 2 Output Line Open Circuit

Inspection
Disconnect the ECM 33P (Black) connector (page
[2]
4-77).
Check for continuity between the wire harness side
TBW unit connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: Blue/white – B28
B28
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Blue/white wire
Bu/W

[1]

4-32
dummyhead

PGM-FI SYSTEM
3. TP Sensor 2 Output Line Short Circuit
Inspection
Check for continuity between the wire harness side
[1]
TBW unit connector [1] and ground.
CONNECTION: Blue/white – Ground
Is there continuity?
YES – Short circuit in the Blue/white wire Bu/W
NO – GO TO STEP 4.

4. TP Sensor 2 Inspection
Replace the throttle body (TP sensor).
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TP Sensor

DTC P0300
Probable causes:
• Faulty ignition system
• Faulty fuel supply system
• Faulty air supply system
• Faulty cylinder compression
• Faulty MAP sensor, IAT sensor, ECT sensor, CKP
sensor, APS, TP sensor, and/or A/F sensor
Symptom/Fail-safe function:
• Engine operates at restricted speed
• Driveability deterioration

• When other DTC is displayed, together with P0300,

troubleshoot it first.

1. Parts Status Inspection

Check and replace the following:
– Related fuse(s)
– Ignition system
– Fuel line
– Intake air related parts (e.g. air cleaner, insulator,
throttle body)
– Cylinder compression
– Related sensors
Erase the DTC.
Perform the test ride (page 4-17).
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Checked and replaced parts failure

4-33
 dummyhead

PGM-FI SYSTEM
DTC P0315
Probable cause:
• Faulty CKP sensor
• Faulty crank pulse initialize learning
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally

• This DTC is erased at the 1 D/C (driving cycle) after

detecting the system normally.
1. CKP Sensor Circuit Inspection
Erase the DTC.
Check for CKP sensor circuit (page 5-8).
Are the CKP sensor or its circuits normally?
YES – GO TO STEP 2.
NO – Open or short circuit in CKP sensor related
circuit
2. CKP Sensor Related Parts Inspection
Check the following:
– Iron or other magnetic deposits between the
crank pulser plate and CKP sensor
– Crank pulser plate slits for obstruction
– Installation condition of the crank pulser plate or
CKP sensor for looseness
– Crank pulser plate and CKP sensor tip for
deformation or damage
Are the crank pulser plate and CKP sensor in
good condition?
YES – GO TO STEP 3.
NO – Replace abnormal parts
3. Crank Pulse Initialize Learning (ED, KO only)
Perform the crank pulse learning (page 4-83).
Turn the ignition switch ON and wait 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – ECM or crank pulse initialization failure

4-34
dummyhead

PGM-FI SYSTEM
DTC P0351/DTC P0352/DTC P0353/
DTC P0354
Probable cause:
• Faulty Ignition coil or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• 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-
9).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
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]
4-77).
Check the continuity between the wire harness side
No.1-2:
ignition coil wire connector [1] and ECM 33P (Black)
Bu/W
connector [2].
B11
CONNECTION: No.2-1:
No.1-1: Blue/black – B33 Bu/R B22
No.2-1: Blue/red – B22
No.1-2: Blue/white – B11 No.1-1:
No.2-2: Blue/yellow – B10 Bu/Bl B33 B10

Is there continuity? No.2-2:

YES – GO TO STEP 3. Bu/Y

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

4-35
 dummyhead

PGM-FI SYSTEM
3. Ignition Coil Primary Coil Signal Line Short
Circuit Inspection
Check for continuity between the wire harness side
[1]
ignition coil wire connector [1] and ground.
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?
YES – Replace the ECM with a new one, and
recheck.
NO – GO TO STEP 5.
5. Ignition Coil Inspection
Replace the Ignition coil with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original ignition coil

4-36
dummyhead

PGM-FI SYSTEM
DTC P0412
Probable cause:
• Faulty PAIR control solenoid valve or its related
circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. PAIR Control Solenoid Valve Input Voltage
Inspection
Disconnect the PAIR control solenoid valve
[1]
connector (page 7-20).
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 (–)
Is there battery voltage?
YES – GO TO STEP 2.
NO – Open circuit in the Brown wire

2. PAIR Control Solenoid Valve Signal Line Open

Circuit Inspection
Disconnect the ECM 33P (Black) connector (page
[2]
4-77).
Check for continuity between the wire harness side
PAIR control solenoid valve connector [1] and ECM
33P (Black) connector [2].
B2
CONNECTION: Yellow/blue – B2
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Yellow/blue wire

Y/Bu
[1]

3. PAIR Control Solenoid Valve Signal Line Short

Circuit Inspection
Check for continuity between the wire harness side
[1]
PAIR control solenoid valve connector [1] and
ground.
CONNECTION: Yellow/blue – Ground Y/Bu

Is there continuity?
YES – Short circuit in the Yellow/blue wire
NO – GO TO STEP 4.

4-37
 dummyhead

PGM-FI SYSTEM
4. PAIR Control Solenoid Valve Inspection
Replace the PAIR control solenoid valve with a new
one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original PAIR control solenoid valve

DTC P0443
Probable cause:
• Faulty EVAP purge control solenoid valve or its
related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. EVAP Purge Control Solenoid Valve Input
Voltage Inspection
Disconnect the EVAP purge control solenoid valve
[1]
connector (page 7-22).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
EVAP purge control solenoid valve connector [1]
and ground.
Br
CONNECTION: Brown (+) – Ground (–)
Is there battery voltage?
YES – GO TO STEP 2.
NO – Open circuit in the Brown wire

2. EVAP Purge Control Solenoid Valve Signal Line

Open Circuit Inspection
Disconnect the ECM 33P (Black) connector (page
[2]
4-77).
Check for continuity between the wire harness side
EVAP purge control solenoid valve connector [1]
and ECM 33P (Black) connector [2].
CONNECTION: Yellow – B1 B1

Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Yellow wire

Y
[1]

4-38
dummyhead

PGM-FI SYSTEM
3. EVAP Purge Control Solenoid Valve Signal Line
Short Circuit Inspection
Check for continuity between the wire harness side
[1]
EVAP purge control solenoid valve connector [1]
and ground.
CONNECTION: Yellow – Ground
Is there continuity? Y
YES – Short circuit in the Yellow wire
NO – GO TO STEP 4.

4. EVAP Purge Control Solenoid Valve Inspection

Replace the EVAP purge control solenoid valve with
a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original EVAP purge solenoid valve

DTC P0475
Probable cause:
• Faulty EGCA motor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Driveability deterioration
1. EGCA Motor Line Open Circuit Inspection
Disconnect the EGCA connector (page 4-76).
[2]
Disconnect the ECM 33P (Gray) connector (page 4-
77).
Check for continuity between the wire harness side
EGCA connector [1] and ECM 33P (Gray) connector
[2]. C1
CONNECTION:
Bu
Blue – C1
Red – C12
Is there continuity? C12 R
YES – GO TO STEP 2.
NO – • Open circuit in the Blue wire
• Open circuit in the Red wire [1]

4-39
 dummyhead

PGM-FI SYSTEM
2. EGCA Motor Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
EGCA connector [1] and ground.
CONNECTION:
Blue – Ground R Bu
Red – Ground
Is there continuity?
YES – • Short circuit in the Blue wire
• Short circuit in the Red wire
NO – GO TO STEP 3.

3. EGCA Motor Inspection

Replace the EGCA motor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original EGCA motor

DTC P0479
Probable cause:
• Faulty EGCA motor
• Faulty ECV or its related parts
• Faulty ECM
Symptom/Fail-safe function:
• Driveability deterioration
1. EGCA Motor Inspection
Replace the EGCA motor with a new one.
Erase the DTC.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original EGCA motor

4-40
dummyhead

PGM-FI SYSTEM
DTC P048D/DTC P048E/DTC P048F
Probable cause:
• Faulty EGCA position sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Driveability deterioration
1. ECV POT Input Voltage Inspection
Disconnect the EGCA connector (page 4-76).
[1]
Turn the ignition switch ON.
Measure the voltage between the wire harness side
EGCA connector [1].
CONNECTION: Yellow (+) – Gray (–) Y Gr

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. ECV POT Output Line Open Circuit Inspection

Turn the ignition switch OFF.
[1] [2]
Disconnect the ECM 33P (Gray) connector.
Check for continuity between the wire harness side
EGCA connector [1] and ECM 33P (Gray) connector
[2].
CONNECTION: Black/red – C29 Bl/R
Is there continuity?
C29
YES – GO TO STEP 3.
NO – Open circuit in Black/red wire

3. ECV POT Output Line Short Circuit Inspection

Check for continuity between the wire harness side
[1]
EGCA connector [1] and ground.
CONNECTION: Black/red – Ground
Is there continuity?
YES – Short circuit in Black/red wire Bl/R
NO – GO TO STEP 4.

4-41
 dummyhead

PGM-FI SYSTEM
4. ECV POT Inspection
Replace the EGCA with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original EGCA

DTC P0500
Probable cause:
• Faulty front wheel speed sensor or its related circuit
• ABS modulator has DTC (CAN lines included)
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally

• When other DTC 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 4-77)
Check for continuity between the wire harness side
ABS modulator connector [1] and ECM 33P (Black) Bu/Y
connector [2].
CONNECTION: Blue/yellow – B14
Is there continuity?
YES – GO TO STEP 2.
NO – Open circuit in the Blue/yellow wire B14

[2]

2. Front Wheel Speed Sensor Signal Output Line

Short Circuit Inspection
Check for continuity between the wire harness side
[1]
ECM 33P (Black) connector [1] and ground.
CONNECTION: B14 – Ground
Is there continuity?
YES – Short circuit in the Blue/yellow wire
NO – GO TO STEP 3.
B14

4-42
dummyhead

PGM-FI SYSTEM
3. ECM Inspection
Replace the ECM with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Perform the test ride (page 4-17).
Check the DTC with GST or MCS.
Is same DTC indicated?
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
Symptom/Fail-safe function:
• Cruise control does not operate
1. Cruise Cancel Switch Input Line Input Voltage
Inspection
Disconnect the right handlebar switch 4P connector
[1]
(page 22-33).
Turn the ignition switch ON.
Measure the voltage at the wire harness side right
handlebar switch 4P connector [1] and ground.
CONNECTION: Brown (+) – Ground (–) Br

Is there battery voltage?

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 22-40).
Check for continuity between the wire harness side
right handlebar switch 4P connector [1] and rear
brake switch connector [2].
CONNECTION: White – White
W [2]
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the White wire W

4-43
 dummyhead

PGM-FI SYSTEM
3. Cruise Cancel Switch Output Line Open Circuit
Inspection
Disconnect the ECM 33P (Gray) connector (page 4- [1] [2]
77).
Check for continuity between the wire harness side
rear brake switch 4P connector [1] and ECM 33P
(Gray) connector [2].
CONNECTION: Green – C26
G
Is there continuity? C26
YES – GO TO STEP 4.
NO – Open circuit in the Green wire

4. Cruise Cancel Switch Inspection

Replace the brake switches with new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and apply the brakes.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
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
• Blown MAIN2 30 A fuse
• Faulty TCM
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. Sub VB Relay Power Supply Voltage Inspection
Remove the sub VB relay (page 4-83).
[1]
Turn the ignition switch ON.
Measure the voltage at the wire harness (power
box) side sub VB relay connector [1].
CONNECTION: Red/white (+) – Green (–)
Is there battery voltage?
YES – GO TO STEP 2. G R/W
NO – • Open circuit in the Red/white wire
• Open circuit in the Green wire

4-44
dummyhead

PGM-FI SYSTEM
2. Sub VB Relay Coil Line Open Circuit Inspection
Turn the ignition switch OFF.
[1] [2]
Disconnect the ECM 39P connector (page 4-77).
Check for continuity between the wire harness side
sub VB relay connector [1] and ECM 39P connector
[2].
CONNECTION: Violet/yellow – A27
Is there continuity?
V/Y A27
YES – GO TO STEP 3.
NO – Open circuit in the Violet/yellow wire

3. Sub VB Relay Line Open Circuit Inspection

Check for continuity between the wire harness side
[1] [2]
sub VB relay connector [1] and ECM 39P connector
[2].
CONNECTION: Violet – A8
Is there continuity?
YES – GO TO STEP 4.
V A8
NO – Open circuit in the Violet wire

4. Sub VB Relay Inspection

Replace the sub VB relay with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – • Faulty TCM
• Faulty ECM
NO – Faulty original sub VB relay

4-45
 dummyhead

PGM-FI SYSTEM
DTC P0567
Probable cause:
• Faulty right handlebar switch (RES/+) or its related
circuit
• Faulty ECM
Symptom/Fail-safe function:
• Cruise control does not operate
1. RES/+ Switch Signal Line Open Circuit
Inspection
Disconnect the ECM 33P (Gray) connector (page 4-
[1] [2]
77).
Disconnect the right handlebar switch 12P
connector (page 22-33).
Check for continuity between the wire harness side
right handlebar switch 12P connector [1] and ECM
33P (Gray) connector [2]. W
CONNECTION: White – C31 C31
Is there continuity?
YES – GO TO STEP 2.
NO – Open circuit in the White wire

2. RES/+ Switch Signal Line Short Circuit

Inspection
Check for continuity between the wire harness side
[1]
right handlebar switch 12P connector [1] and
ground.
CONNECTION: White – Ground
Is there continuity? W
YES – Short circuit in the White wire
NO – GO TO STEP 3.

3. RES/+ Switch Inspection

Replace the right handlebar switch with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original right handlebar switch
(RES/+)

4-46
dummyhead

PGM-FI SYSTEM
DTC P0574
Probable cause:
• Faulty VS sensor or its related circuit
• Faulty meter
• Faulty ECM
Symptom/Fail-safe function:
• Cruise control does not operate

• When other DTC is displayed, together with P0574,

troubleshoot it first.
1. Meter Inspection
Replace the meter with a new one.
Erase the DTC.
Perform the test ride with cruise mode.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original meter

DTC P0580/DTC P0581

Probable cause:
• Faulty right handlebar switch (Main, SET/–) or its
related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Cruise control does not operate
1. Cruise Control Main, SET/– Switch Signal Line
Open Circuit Inspection
Disconnect the ECM 33P (Black) connector (page
[1] [2]
4-77).
Disconnect the right handlebar switch 12P
connector (page 22-33).
Check for continuity between the wire harness side
right handlebar switch 12P connector [1] and ECM
33P (Black) connector [2].
W
CONNECTION: White – B29
B29
Is there continuity?
YES – GO TO STEP 2.
NO – Open circuit in the White wire

4-47
 dummyhead

PGM-FI SYSTEM
2. Cruise Control Main, SET/– Switch Signal Line
Short Circuit Inspection
Check for continuity between the wire harness side
[1]
right handlebar 12P connector [1] and ground.
CONNECTION: White – Ground
Is there continuity?
YES – Short circuit in the White wire W

NO – GO TO STEP 3.

3. Cruise Control Main, SET/– Switch Inspection

Replace the right handlebar switch with a new one.
Connect the disconnected connector(s).
Turn the ignition switch ON and wait for 10 seconds.
Erase the DTC.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original right handlebar switch
(Cruise control main, SET/–)

DTC P0606
Probable cause:
• Faulty ECM
Symptom/Fail-safe function:
• Hard to start
Diagnostic procedure:
1. Replace the ECM with a new one.
2. Erase the DTC.
3. Turn the ignition switch ON and wait for 10 seconds.
4. Check the DTC with GST or MCS.
5. If the same DTC is not indicated, faulty original
ECM.

DTC P062F
Probable cause:
• Faulty ECM
Symptom/Fail-safe function:
• Hard to start
• Does not hold the self-diagnosis data
– The MIL come on (the DTC can be readout and
erased only by GST or MCS).
Diagnostic procedure:
1. Replace the ECM with a new one.
2. Erase the DTC.
3. Turn the ignition switch ON and wait for 10 seconds.
4. Check the DTC with GST or MCS.
5. If the same DTC is not indicated, faulty original
ECM.

4-48
dummyhead

PGM-FI SYSTEM
DTC P064D/DTC P064E
Probable cause:
• Faulty A/F sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Fuel consumption deterioration
• Driveability deterioration
1. A/F Sensor Inspection
Replace the A/F sensor with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds
or start the engine and wait a minute.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original A/F sensor

DTC P0704
Probable cause:
• Faulty clutch switch or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. Clutch Switch Output Line Open Circuit
Inspection
Disconnect the left handlebar switch 8P connector
[1] [2]
(page 22-26).
Disconnect the ECM 33P (Gray) connector (page 4-
77).
Check for continuity between the wire harness side
8P connector [1] and ECM 33P (Gray) connector
[2].
CONNECTION: Black/red – C18
Bl/R C18
Is there continuity?
YES – GO TO STEP 2.
NO – Open circuit in the Black/red wire

2. Clutch Switch Output Line Short Circuit

Inspection
Check for continuity between the wire harness side
[1]
8P connector [1] and ground.
CONNECTION: Black/red – Ground
Is there continuity?
Bl/R
YES – Short circuit in the Black/red wire
NO – GO TO STEP 3.

4-49
 dummyhead

PGM-FI SYSTEM
3. Clutch Switch Inspection
Replace the clutch switch with a new one.
Erase the DTC.
Perform the test ride (page 4-17).
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original clutch switch

DTC P0722
Probable cause:
• Faulty VS sensor or its circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. VS Sensor Ground Line Open Circuit Inspection
Disconnect the VS sensor connector (page 4-79).
[1]
Check for continuity between the wire harness side
VS sensor connector [1] and ground.
CONNECTION: Green – Ground
Is there continuity?
YES – GO TO STEP 2. G
NO – Open circuit in the Green wire

2. VS Sensor Input Line Open Circuit Inspection

Temporarily install the removed electrical parts in
[1]
the reverse order of removal.
Turn the ignition switch ON.
Measure the voltage between the wire harness side
VS sensor connector [1] and ground.
CONNECTION: Black/red (+) – Green (–)
Bl/R G
Is there battery voltage?
YES – GO TO STEP 3.
NO – Open circuit in the Black/red wire or its
related circuit

4-50
dummyhead

PGM-FI SYSTEM
3. VS Sensor Signal Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
VS sensor connector [1] and ground.
CONNECTION: Pink – Ground
Is there continuity?
YES – Short circuit in the Pink wire
P
NO – GO TO STEP 4.

4. VS Sensor Signal Line Open Circuit Inspection

Disconnect the ECM 33P (Gray) connector (page 4-
[1] [2]
77).
Check for continuity between the wire harness side
VS sensor connector [1] and ECM 33P (Gray)
connector [2].
CONNECTION: Pink – C16
Is there continuity? P
C16
YES – GO TO STEP 5.
NO – Open circuit in the Pink wire

5. VS Sensor Inspection
Replace the VS sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Perform the test ride (page 4-17).
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original VS sensor

4-51
 dummyhead

PGM-FI SYSTEM
DTC P1658/DTC P1659
Probable cause:
• Faulty TBW relay or its related circuit
• Blown sub fuse TBW 10 A
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. TBW Relay Input Voltage Inspection
Remove the TBW relay (page 4-82).
[1]
Measure the voltage at the wire harness (power
box) side TBW relay connector [1]. G
CONNECTION: Red/blue (+) – Green (–)
Is there battery voltage? R/Bu
YES – GO TO STEP 2.
NO – • Open circuit in the Red/blue wire
• Open circuit in the Green wire

2. TBW Relay Line Open Circuit Inspection

Disconnect the ECM 39P and ECM 33P (Gray)
[2]
connectors (page 4-77).
Check for continuity between the wire harness side
TBW relay connector [1] and ECM 39P connector
[2]/ECM 33P (Gray) connector [3]. A1
CONNECTION: Br/G
Brown/green – A1
Yellow/white – C10
Y/W
Is there continuity? C10
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

Check for continuity between the wire harness side
[1]
TBW relay connector [1] and ground.
CONNECTION:
Brown/green – Ground
Yellow/white – Ground Br/G
Y/W
Is there continuity?
YES – • Short circuit in the Brown/green wire
• Short circuit in the Yellow/white wire
NO – GO TO STEP 4.

4-52
dummyhead

PGM-FI SYSTEM
4. TBW Relay Inspection
Replace the TBW relay with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TBW relay

DTC P1684
Probable cause:
• Faulty TBW return spring
• Faulty ECM
Symptom/Fail-safe function:
• 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.
[1]
• The return spring cannot be replaced. If the
return spring is faulty, replace the throttle body.
Remove the throttle body (page 7-16).
Open the throttle valve [1] with your finger.
Does the throttle valve open and return
smoothly?
YES – GO TO STEP 2.
NO – Faulty throttle body (throttle valve and/or
return spring)

4-53
 dummyhead

PGM-FI SYSTEM
2. Throttle Body Inspection
Check the throttle bores [1] and valves visually for
[1]
carbon deposits.
Is there contamination?
YES – Clean the throttle bores and valves
carefully.
NO – GO TO STEP 3.

[1]

3. TBW System Inspection

Replace the throttle body with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original throttle body

4-54
dummyhead

PGM-FI SYSTEM
DTC P1702/DTC P1703
Probable cause:
• Faulty GP sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. GP Sensor Input Voltage Inspection
Disconnect the GP sensor connector (page 4-79).
[1]
Turn the ignition switch ON.
Measure the voltage at the wire harness side GP
sensor connector [1].
CONNECTION: Yellow (+) – Gray (–)
Is the voltage within 4.75 – 5.25 V? Y Gr

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. GP Sensor Signal Line Open Circuit Inspection

Disconnect the ECM 33P (Black) connector (page
[1] [2]
4-77).
Check for continuity between the wire harness side
GP sensor connector [1] and ECM 33P (Black)
connector [2].
CONNECTION: White – B30
Is there continuity?
YES – GO TO STEP 3. W B30

NO – Open circuit in the White wire

3. GP Sensor Output Line Short Circuit Inspection

Check for continuity between the wire harness side
[1]
GP sensor connector [1] and ground.
CONNECTION: White – Ground
Is there continuity?
YES – Short circuit in the White wire W

NO – GO TO STEP 4.

4-55
 dummyhead

PGM-FI SYSTEM
4. GP Sensor Inspection
Replace the GP sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original GP sensor

DTC P1708/DTC P1709

Probable cause:
• Faulty shift spindle switch or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
1. Shift Spindle Switch Input Line Short Circuit
Inspection
Disconnect the ECM 33P (Gray) connector (page 4-
77).
Remove the shift spindle switch terminal (page 4-
80).
Check for continuity between the wire harness side
shift spindle switch terminal and ground.
CONNECTION: Yellow/white – Ground
Is there continuity?
YES – Short circuit in the Yellow/white wire
NO – GO TO STEP 2.
2. Shift Spindle Switch Line Open Circuit
Inspection
Check for continuity between the wire harness side
[1] [2]
shift spindle switch terminal [1] and ECM 33P (Gray)
connector [2].
CONNECTION: Yellow/white – C30
Is there continuity?
YES – GO TO STEP 3. Y/W
NO – Open circuit in the Yellow/white wire C30

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.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original shift spindle switch

4-56
dummyhead

PGM-FI SYSTEM
DTC P170D/DTC P170E
Probable cause:
• Faulty shift stroke sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
• Gearshift function does not work
1. Shift Stroke Sensor Input Voltage Inspection
Disconnect the shift stroke sensor (option)
[1]
connector.
Turn the ignition switch ON.
Measure the voltage at the wire harness side shift Y
stroke sensor connector [1].
CONNECTION: Yellow (+) – Gray (–)
Gr
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. Shift Stroke Sensor Output Line Open Circuit

Inspection
Disconnect the ECM 33P (Gray) connector (page 4-
[2]
77).
Check for continuity between the wire harness side
shift stroke sensor connector [1] and ECM 33P
(Gray) connector [2].
CONNECTION: Black – C28
Is there continuity? [1]
C28
YES – GO TO STEP 3.
NO – Open circuit in the Black wire

Bl

3. Shift Stroke Sensor Output Line Short Circuit

Inspection
Check for continuity between the wire harness side
[1]
shift stroke sensor connector [1] and ground.
CONNECTION: Black – Ground
Is there continuity? Bl

YES – Short circuit in the Black wire

NO – GO TO STEP 4.

4-57
 dummyhead

PGM-FI SYSTEM
4. Shift Stroke Sensor Inspection
Replace the shift stroke sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original shift stroke sensor

DTC P1712
Probable cause:
• Faulty TCM or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Gearshift function does not work
1. TCM Inspection
Replace the TCM with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TCM

DTC P2101/DTC P2118

Probable cause:
• Faulty TBW motor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed
• HSTC does not operate
1. TBW Motor Line Open Circuit Inspection
Disconnect the TBW motor connector (page 7-16).
[1]
Disconnect the ECM 33P (Black) connector (page
4-77).
Check for continuity between the wire harness side Bu R
TBW motor connector [1] and ECM 33P (Black)
connector [2].
CONNECTION:
Red – B3
Blue – B4 B4
B3
Is there continuity?
YES – GO TO STEP 2.
NO – • Open circuit in the Red wire
• Open circuit in the Blue wire [2]

4-58
dummyhead

PGM-FI SYSTEM
2. TBW Motor Line Short Circuit Inspection 1
Check for continuity between the wire harness side
[1]
TBW motor connector [1] and ground.
CONNECTION:
Red – Ground
Blue – Ground
Bu R
Is there continuity?
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).
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TBW motor

DTC P2121/DTC P2126

Probable cause:
• Faulty APS 1 or its related circuit
• Faulty APS 2 or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed
1. APS Inspection
Replace the grip APS with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original grip APS

4-59
 dummyhead

PGM-FI SYSTEM
DTC P2122/DTC P2123
Probable cause:
• Faulty APS 1 or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed
1. APS 1 Input Voltage Inspection
Disconnect the grip APS connector (page 22-33).
Turn the ignition switch ON.
Measure the voltage at the wire harness side grip
APS connector [1].
CONNECTION: Brown (+) – Pink (–)
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – • Open circuit in the Brown wire P Br
• Open circuit in the Pink wire
• If the wires are OK, replace the ECM
with a new one, and recheck.
[1]

2. APS 1 Output Line Open Circuit Inspection

Disconnect the ECM 39P connector (page 4-77).
[2]
Check for continuity between the wire harness side
grip APS connector [1] and ECM 39P connector [2].
CONNECTION: Blue – A26
Is there continuity?
YES – GO TO STEP 3. A26

NO – Open circuit in the Blue wire

Bu

[1]

3. APS 1 Output Line Short Circuit Inspection

Check for continuity between the wire harness side
[1]
grip APS connector [1] and ground.
CONNECTION: Blue – Ground
Bu
Is there continuity?
YES – Short circuit in the Blue wire
NO – GO TO STEP 4.

4-60
dummyhead

PGM-FI SYSTEM
4. APS 1 Inspection
Replace the grip APS (right handlebar switch).
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original APS

DTC P2127/DTC P2128

Probable cause:
• Faulty APS 2 or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed
1. APS 2 Input Voltage Inspection
Disconnect the grip APS connector (page 22-33).
[1]
Turn the ignition switch ON.
Measure the voltage at the wire harness side grip
APS connector [1].
CONNECTION: White (+) – Gray (–) Gr W
Is about 5 V indicated?
YES – GO TO STEP 2.
NO – • Open circuit in the White wire
• Open circuit in the Gray wire
• If the wires are OK, replace the ECM
with a new one, and recheck.

2. APS 2 Output Line Open Circuit Inspection

Disconnect the ECM 39P connector (page 4-77).
[2] [1]
Check for continuity between the wire harness side
grip APS connector [1] and ECM 39P connector [2].
CONNECTION: Yellow – A38
Is there continuity?
YES – GO TO STEP 3.
NO – Open circuit in the Yellow wire Y
A38

4-61
 dummyhead

PGM-FI SYSTEM
3. APS 2 Output Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
grip APS connector [1] and ground.
CONNECTION: Yellow – Ground
Is there continuity?
YES – Short circuit in the Yellow wire Y

NO – GO TO STEP 4.

4. APS 2 Inspection
Replace the grip APS (right handlebar switch).
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original grip APS

DTC P2135
Probable cause:
• Faulty TP sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed

• When other DTC is displayed, together with P0500,

troubleshoot it first.
• Clean the throttle bores and valves carefully.
1. TP Sensor Line Short Circuit Inspection
Disconnect the ECM 33P (Black) connector (page
[1]
4-77).
Disconnect the TBW unit connector (page 7-16).
Check for continuity at the wire harness side TBW
unit connector [1].
CONNECTION: Blue/black – Blue/white Bu/Bl Bu/W
Is there continuity?
YES – Short circuit of the Blue/black-to-Blue/
white wire
NO – GO TO STEP 2.

4-62
dummyhead

PGM-FI SYSTEM
2. TP Sensor Inspection
Replace the throttle body (TP sensor).
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TP sensor

DTC P2138
Probable cause:
• Faulty APS 1 and/or APS 2 or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed
1. APS Line Short Circuit Inspection
Disconnect the ECM 39P connector (page 4-77).
[1]
Disconnect the grip APS connector (page 22-33).
Check for continuity at the wire harness side APS
connector [1].
CONNECTION: Blue – Yellow
Bu
Is there continuity?
YES – Short circuit of the Blue wire-to-Yellow wire
NO – GO TO STEP 2. Y

2. APS Inspection
Replace the grip APS (right handlebar switch).
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original APS

4-63
 dummyhead

PGM-FI SYSTEM
DTC P2158
Probable cause:
• Faulty rear wheel speed sensor or its related circuit
• ABS modulator has DTC (CAN lines included)
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
• HSTC does not operate

• When other DTC is displayed together with P2158,

troubleshoot it first.
1. Rear Wheel Speed Sensor Signal Output Line
Open Circuit Inspection
Disconnect the following:
[2]
– ABS modulator connector (page 20-8)
– ECM 33P (Black) connector (page 4-77)
Check for continuity between the wire harness side
ABS modulator connector [1] and ECM 33P (Black)
B15
connector [2].
CONNECTION: 3 – B15
Is there continuity?
YES – GO TO STEP 2. 3

NO – Open circuit in the Blue/black wire

[1]

2. Rear Wheel Speed Sensor Signal Output Line

Short Circuit Inspection
Check for continuity between the wire harness side
[1]
ECM 33P (Black) connector [1] and ground.
CONNECTION: B15 – Ground
Is there continuity?
YES – Short circuit in the Blue/black wire
NO – GO TO STEP 3.
B15

3. ECM Inspection
Replace the ECM with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Perform the test ride (page 4-17).
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ABS modulator with a new
one, and recheck.
NO – Faulty original ECM

4-64
dummyhead

PGM-FI SYSTEM
DTC P2195/DTC P2196/DTC P2197/
DTC P2198
Probable cause:
• Faulty A/F sensor or its related circuit
• Faulty fuel injector or its fuel pressure too low
• Faulty ECT sensor
• Faulty ECM
Symptom/Fail-safe function:
• Hard to start at a low temperature
• Exhaust gas too lean or too rich
• Intake air or engine vacuum leaks
• Fuel consumption deterioration
• Driveability deterioration
1. A/F sensor Inspection
Replace the A/F sensor with a new one.
Erase the DTC.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original A/F sensor

DTC P2A00/DTC P2A03

Probable cause:
• Faulty A/F sensor or its related circuit
• There is an exhaust leak
• Faulty ECM
Symptom/Fail-safe function:
• Hard to start at a low temperature
• Exhaust gas too lean or too rich
• Intake air or engine vacuum leaks
• Fuel consumption deterioration
• Driveability deterioration
1. A/F sensor Inspection
Replace the A/F sensor with a new one.
Erase the DTC.
Start the engine and wait a minute.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original A/F sensor

4-65
 dummyhead

PGM-FI SYSTEM
DTC U0001

• When other DTC is displayed, together with U0001,

troubleshoot it first.
Probable cause:
• Faulty CAN line(s)
• Faulty CAN connected unit(s)
Symptom/Fail-safe function:
• CAN communication failure
1. CAN Line (ECM-to-BCU) Open Circuit Inspection
Disconnect the following:
[1]
– ECM 39P connector (page 4-77)
– BCU 39P connector (page 22-51)
Check the continuity between the wire harness side
ECM 39P connector [1] and BCU 39P connector [2]. A31 A30
CONNECTION:
A31 – Black/red
A30 – Black
Is there continuity? Bl/R Bl
YES – GO TO STEP 2.
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire [2]

2. CAN Line (ECM-to-SCU) Open Circuit Inspection

Disconnect the SCU 48P connector (page 22-83).
Check the continuity between the wire harness side A31
ECM 39P connector [1] and SCU 48P connector [2].
CONNECTION:
A31 – Black/red
A30 – Black A30
[2]
Is there continuity?
YES – GO TO STEP 3. [1]
Bl
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire

Bl/R

3. CAN Line (ECM-to-IMU) Open Circuit Inspection

Disconnect the IMU connector (page 22-51).
[1] A31
Check the continuity between the wire harness side
ECM 39P connector [1] and IMU connector [2].
CONNECTION:
A31 – Black/red
A30 – Black A30
Is there continuity?
YES – GO TO STEP 4. Bl
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire
Bl/R
[2]

4-66
dummyhead

PGM-FI SYSTEM
4. CAN Line (ECM-to-TCM) Open Circuit Inspection
Disconnect the TCM 33P (Gray) connector (page
[1] A31
13-66).
Check the continuity between the wire harness side
ECM 39P connector [1] and TCM 33P (Gray)
connector [2].
CONNECTION:
A30
A31 – B13
A30 – B2
Is there continuity? B2
YES – GO TO STEP 5.
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire
[2] B13

5. CAN Line (ECM-to-Meter) Open Circuit

Inspection
Disconnect the meter 20P connector (page 22-13).
[1]
Check the continuity between the wire harness side
ECM 39P connector [1] and meter connector [2].
CONNECTION:
A31 – Black/red
A30 – Black A31 A30
Is there continuity? [2]
YES – GO TO STEP 6.
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire Bl

Bl/R

6. CAN Line (ECM-to-ABS Modulator) Open Circuit

Inspection
Disconnect the ABS modulator connector (page 20-
[1]
8). A30
Check the continuity between the wire harness side
ECM 39P connector [1] and ABS modulator
connector [2].
CONNECTION:
A31
A31 – 2
A30 – 11
Is there continuity? 2
YES – GO TO STEP 7.
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire 11
[2]

4-67
 dummyhead

PGM-FI SYSTEM
7. CAN Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
ECM 39P connector [1] and ground.
CONNECTION:
A31 – Ground
A30 – Ground
A31 A30
Is there continuity?
YES – • Short circuit in the Black/red wire
• Short circuit in the Black wire
NO – GO TO STEP 8.

8. Communicated Part Inspection

Connect the disconnected connector(s).
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.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original part

DTC U0121
Probable cause:
• Faulty CAN line(s)
• Faulty CAN connected unit(s)
Symptom/Fail-safe function:
• CAN communication failure
1. CAN Line Open Circuit Inspection
Disconnect the following:
[1]
– ECM 39P connector (page 4-77) A30
– ABS modulator connector (page 20-8)
Check the continuity between the wire harness side
ECM 39P connector [1] and ABS modulator
connector [2]. A31
CONNECTION:
A31 – 2
A30 – 11 2

Is there continuity?
YES – GO TO STEP 2.
11
NO – • Open circuit in the Black/red wire [2]
• Open circuit in the Black wire

4-68
dummyhead

PGM-FI SYSTEM
2. ABS Modulator Inspection
Replace the ABS modulator with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original ABS modulator

DTC U0125
Probable cause:
• Faulty CAN line(s)
• Faulty CAN connected unit(s)
Symptom/Fail-safe function:
• CAN communication failure
1. IMU Input Voltage Inspection
Turn the ignition switch OFF.
[1]
Disconnect the IMU connector (page 22-51).
Turn the ignition switch ON.
Measure the voltage at the wire harness side IMU
connector [1].
CONNECTION: Black/red (+) – Green/blue (–)
G/Bu Bl/R
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open or short circuit in the Black/red
wire
• Open circuit in the Green/blue wire

2. CAN Line Open Circuit Inspection

Disconnect the ECM 39P connector (page 4-77).
[1] A31
Check the continuity between the wire harness side
ECM 39P connector [1] and IMU connector [2].
CONNECTION:
A31 – Black/red
A30 – Black A30
Is there continuity?
YES – GO TO STEP 3. Bl
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire
Bl/R
[2]

3. IMU Inspection
Replace the IMU with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original IMU

4-69
 dummyhead

PGM-FI SYSTEM
DTC U0155
Probable cause:
• Faulty CAN line(s)
• Faulty CAN connected unit(s)
Symptom/Fail-safe function:
• CAN communication failure
1. CAN Line Open Circuit Inspection
Disconnect the following:
[1]
– ECM 39P connector (page 4-77)
– Meter 20P connector (page 22-13)
Check the continuity between the wire harness side
ECM 39P connector [1] and meter connector [2].
A31 A30
CONNECTION:
A31 – Black/red [2]
A30 – Black
Is there continuity?
Bl
YES – GO TO STEP 2.
NO – • Open circuit in the Black/red wire
Bl/R
• Open circuit in the Black wire
2. Meter Inspection
Replace the meter with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original meter

DTC U019E
Probable cause:
• Faulty CAN line(s)
• Faulty CAN connected unit(s)
Symptom/Fail-safe function:
• CAN communication failure
1. Power Train CAN Line Open Circuit Inspection
Disconnect the following:
[1]
– ECM 33P (Gray) connector (page 4-77)
– TCM 33P (Black) connector (page 13-66)
Check for continuity between the wire harness side A21
ECM 33P (Gray) connector [1] and TCM 33P C24
(Black) connector [2].
CONNECTION:
C25 – A33
C24 – A21 C25 A33

Is there continuity?
YES – GO TO STEP 2.
NO – • Open circuit in the Black/red wire [2]
• Open circuit in the Black wire

4-70
dummyhead

PGM-FI SYSTEM
2. Power Train CAN Line Short Circuit Inspection
Check for continuity between the wire harness side
[1]
ECM 33P (Gray) connector [1] and ground.
CONNECTION:
C25 – Ground
C24 – Ground
Is there continuity? C25 C24
YES – • Short circuit in the Black/red wire
• Short circuit in the Black wire
NO – GO TO STEP 3.

3. TCM Inspection
Replace the TCM with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original TCM

4-71
 dummyhead

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 22-16).

When The Ignition Switch ON, The MIL

Does Not Go Off Within A Few
Seconds (Engine Starts)

• 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 4-66).
If the indication is not according to above condition,
check as follows.
Turn the ignition switch OFF.
[1]
Disconnect the ECM 39P connector (page 4-77).
Check for continuity between the wire harness side
ECM 39P connector [1] and ground.
TOOL:
Test probe 07ZAJ-RDJA110
A19
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 4-77).

4-72
dummyhead

PGM-FI SYSTEM
IMU
REMOVAL/INSTALLATION
Remove the BCU tray (page 22-51).
[3]
Remove the shock absorber (page 18-9).
Remove the following:
– Nuts [1] [4]
– Washers [2]
– IMU mounting bolt/washers [3]
– IMU [4] [5] [2]

Remove the grommets [5] from the ABS modulator box

[6].
[6]

• Do not drop the IMU.

• Never use the dropped IMU.
• Do not use an impact wrench while removing or
installing the IMU.
• Do not have an impact on the IMU while removing or
installing it. [1]
Installation is in the reverse order of removal.
TORQUE:
IMU mounting bolt/washer:
6.0 N·m (0.6 kgf·m, 4.4 lbf·ft)

A/F SENSOR
REMOVAL/INSTALLATION

• Handle the A/F sensor with care.

• Do not get grease, oil, or other materials in the A/F
sensor air hole.
• Be careful not to damage the sensor wire.
• Do not use an impact wrench while removing or
installing the A/F sensor.
LEFT SIDE
Remove the left middle cowl (page 2-7).
[1]
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]. [2]

[3] [4]

4-73
 dummyhead

PGM-FI SYSTEM
Remove the left A/F sensor [1] using the special tool.
[2]
TOOL:
Sensor socket wrench [2] FRXM17 (Snap on) [1]
or equivalent
Installation is in the reverse order of removal.
TORQUE: 24.5 N·m (2.5 kgf·m, 18 lbf·ft)

• Route the hose and wire properly (page 1-32).

RIGHT SIDE
Remove the right middle cowl (page 2-7).
Front [3]
Open the clamp [1] and release the right A/F sensor
wire [2]. Right
Disconnect the right A/F sensor 4P connector [3].
[1]
• When disconnecting the linear solenoid 4P (Black)
connector [4] and right A/F sensor 4P connector at
the same time, mark the main wire harness side
[2]
connectors to prevent the miss connection.

Release the wire clip [5].

[4] [3] [5]

Remove the exhaust pipe (page 2-45).

Remove the right A/F sensor [1] using the special tool.
TOOL:
Sensor socket wrench [2] FRXM17 (Snap on)
or equivalent [1]

Installation is in the reverse order of removal.

TORQUE: 24.5 N·m (2.5 kgf·m, 18 lbf·ft)
[2]

• Route the hose and wire properly (page 1-32).

MAP SENSOR
REMOVAL/INSTALLATION
Remove the fuel tank (page 7-7).
[2] [1]
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].
Installation is in the reverse order of removal.
[3]

[4]

4-74
dummyhead

PGM-FI SYSTEM
IAT SENSOR
REMOVAL/INSTALLATION
Remove the air cleaner housing (page 7-14).
[2]
Remove the screws [1].
Remove the IAT sensor [2] and O-ring [3].
[3]
Installation is in the reverse order of removal.
TORQUE: 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)

• Check the O-ring and replace if necessary as a IAT

sensor assembly.

[1]

ECT SENSOR
REMOVAL/INSTALLATION
Remove the thermostat (page 8-6).
[1] [2] [3]
Disconnect the ECT sensor 2P (Black) connector [1].
Remove the ECT sensor [2] and O-ring [3].
Installation is in the reverse order of removal.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

• Do not apply oil to the O-ring.

• Check the O-ring and replace if necessary as a ECT
sensor assembly.

INSPECTION
Remove the ECT sensor (page 4-75).
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]
Temperature 40°C (104°F) 100°C (212°F)
Resistance 1.0 – 1.3 kΩ 0.14 – 0.18 kΩ

Replace the ECT sensor if it is out of specification.

4-75
 dummyhead

PGM-FI SYSTEM
EGCA
REMOVAL/INSTALLATION
Remove the mud guard (page 2-38).
Disconnect the EGCA cables from the valve cable
guide of the muffler (page 2-47).
Disconnect the EGCA 6P connector [1].
Remove the rear master cylinder reservoir mounting
bolt [2] and release the rear master cylinder reservoir
[3].

• 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]

[1]

[6]
[4]

[7]

[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]

[3]/[4]

[2]

4-76
dummyhead

PGM-FI SYSTEM
Turn the EGCA pulley [1] and disconnect the EGCA
[2] [1]
cables [2] from the EGCA pulley.
Installation is in the reverse order of removal.
TORQUE:
Rear master cylinder reservoir mounting bolt:
10 N·m (1.0 kgf·m, 7 lbf·ft)

• Route the cables properly (page 1-32).

• 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
operating inspection of the EGCA cable (page 3-17).

ECM
REMOVAL/ INSTALLATION
ECM
Remove the fuel tank (page 7-7).
[2]
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 ECM
stay guide [5].
Open the ECM tray lid by releasing its slot [6] from the
tab [7]. [1]
[6]/[7]

[3] [4]/[5]

Disconnect the following:

[4]
– ECM 39P (Black) connector [1]
– ECM 33P (Black) connector [2]
– ECM 33P (Gray) connector [3]
Remove the ECM [4]. [2]

Installation is in the reverse order of removal.

• Route the hose and wires properly (page 1-32).

• If the ECM is replaced, perform the following
procedure: [3]
– Crank pulse initialize learning procedure (page 4-
84) (ED, KO only)
[1]
– Key Registration Procedure (page 23-5)
ECM TRAY
Remove the ECM (page 4-77).
[1]
Remove the tool box (page 2-26).
Remove the trim clip [1].

4-77
 dummyhead

PGM-FI SYSTEM
Remove the trim clips [1].
[2]
Release the tab [2] and remove the ECM tray [3].
Installation is in the reverse order of removal.

[3]

[1]

POWER/GROUND LINE INSPECTION

POWER INPUT LINE
Disconnect the ECM 39P connector (page 4-77).
[1]
Measure the voltage between the wire harness side
ECM 39P connector [1] and ground.
TOOL:
Test probe 07ZAJ-RDJA110 A11
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 FI relay and ECM
– FI relay and related circuit

GROUND LINE
Disconnect the ECM 39P and 33P (Black) connectors [1]
(page 4-77).
G
Check for continuity between the following connector G (A10) (A9)
terminals and ground:
– ECM 39P connector [1]
– ECM 33P (Black) connector [2]
G (A24) G (A22)
TOOL:
Test probe 07ZAJ-RDJA110 G (A23)

CONNECTION: Green (A9) – Ground

Green (A10) – Ground
Green (A22) – Ground
Green (A23) – Ground
Green (A24) – Ground
Green/blue (B12) – 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.
G/Bu
(B12)

4-78
dummyhead

PGM-FI SYSTEM
VS SENSOR
REMOVAL/INSTALLATION
Remove the battery box (page 21-6).
DCT model shown:
Disconnect the VS sensor 3P (Black) connector [1].
Remove the bolt [2], VS sensor [3], and O-ring [4]. [2]
Installation is in the reverse order of removal.
[4]

• Replace the O-ring with a new one.

• Apply engine oil to a new O-ring. [3]

[1]

GP SENSOR (MT model)

REMOVAL/INSTALLATION
Remove the left rear cover (page 2-26).
Disconnect the GP sensor 3P (Black) connector [1].

[1]

Remove the following:

[4] [1]
– GP sensor mounting bolt [1]
– Sensor cover [2]
– GP sensor [3]
– O-ring [4]
Installation is in the reverse order of removal.
TORQUE:
GP sensor mounting bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
[3]

• Always replace the O-ring with a new one.

• Apply engine oil to a new O-ring. [2] Align [4]
• Align the flat surfaces of the GP sensor and shift
drum end.
• Route the wire properly (page 1-32).

4-79
 dummyhead

PGM-FI SYSTEM
SHIFT SPINDLE SWITCH (MT model)
REMOVAL/INSTALLATION
Remove the shock absorber (page 18-9).
[1]
Release the rubber cap [1].
Remove the nut [2] and disconnect the shift spindle
switch terminal [3]. [2]/[3]
Remove the shift spindle switch [4] and sealing washer
[5].
Installation is in the reverse order of removal.
[4]
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) [5]

• Apply engine oil to the shift spindle switch threads

and seating surface.
• Replace the sealing washer with a new one.

GRIP APS
GRIP APS INSPECTION

• Before starting the inspection, check for loose or

poor contact on the grip APS 8P connector and ECM
39P (Black) connector, then recheck the DTC.
1. APS 1 and 2 Input Voltage Inspection
Turn the ignition switch OFF.
[1]
Disconnect the grip APS 8P connector [1] (page 22-
33).
Turn the ignition switch ON. Br
Measure the voltage at the harness side.
CONNECTION: Brown (+) [VCC 1] – Ground (–)
White (+) [VCC 2] – Ground (–) W

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
4-77).
2. APS 1 and 2 System Inspection
Erase the DTC (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.

4-80
dummyhead

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. W/Bl Gr Y/Bl Bu/W
CONNECTION:
APS 1: Blue/white (+) – Yellow/black (–)
APS 2: Gray (+) – White/black (–) W/R W/Bl Y/R Y/Bl

Calculate the 5 V / input voltage x output voltage.

STANDARD (at throttle opened):
APS 1: 4.588 – 4.612 V
APS 2: 2.288 – 2.312 V 5V 5V
STANDARD (at throttle closed): BATTERY BATTERY
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 4-77).
NO – Replace the right handlebar switch with a
known good one and recheck (page 22-
33).

REMOVAL/INSTALLATION
Refer to the right handlebar switch servicing (page 22-
33).

FI RELAY
REMOVAL/INSTALLATION
Remove the ECM tray (page 4-77).
[2]
Release the FI relay [1] from the stay.
Disconnect the relay connector [2] and remove the FI
relay.
Installation is in the reverse order of removal.

[1]

4-81
 dummyhead

PGM-FI SYSTEM
RELAY INSPECTION
Remove the FI relay (page 4-81).
[1]
Connect an ohmmeter to the FI relay [1] terminals as
shown.
Connect a 12 V battery to the FI 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 FI relay.
Install the FI relay (page 4-81).

TBW RELAY
REMOVAL/INSTALLATION
Remove the main seat (page 2-5).
Remove the power box cover and TBW relay [1].
Installation is in the reverse order of removal.

[1]

RELAY INSPECTION
Remove the TBW relay (page 4-82).
[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 4-82).

4-82
dummyhead

PGM-FI SYSTEM
SUB VB RELAY
REMOVAL/INSTALLATION
Remove the main seat (page 2-5). [1]
Remove the power box cover and sub VB relay [1].
Installation is in the reverse order of removal.
– For relay inspection (page 4-82)

CKP SENSOR
REMOVAL/INSTALLATION
Remove the skid plate (page 2-25).
[2]
Disconnect the CKP sensor 3P (Gray) connector [1].
[3]
Remove the CKP sensor bolt [2], CKP sensor [3], and
O-ring [4].
Installation is in the reverse order of removal. [1]
TORQUE:
CKP sensor bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

[4]
• Replace the O-ring with a new one.
• Apply engine oil to a new O-ring.
• After installing, perform the crank pulse initialize
learning procedure (page 4-83) (ED, KO only).

CRANK PULSE LEARNING (ED, KO

only)

• If you done the following works, perform the crank

pulse learning reset procedure and crank pulse
initialize learning procedure.
Perform the crank pulse learning reset procedure
first, and then the crank pulse initialize learning
procedure.
– CKP sensor removing
– Alternator cover removing
– Flywheel removing
– Stator removing
– Crankcase separation
– Crankshaft removing
– Main journal bearings removing
• If you replace the ECM, perform the crank pulse
initialize learning procedure.

4-83
 dummyhead

PGM-FI SYSTEM
CRANK PULSE LEARNING RESET PROCEDURE
1. Connect the SCS short connector to the DLC (page
4-6).
2. Turn the ignition switch ON.
Open the throttle grip fully within 5 seconds.
Close the throttle grip completely within 3 seconds.
Wait for more than 10 seconds.
3. Turn the ignition switch OFF.
Disconnect the SCS short connector from the DLC.
4. Turn the ignition switch ON.
Check the MIL.
If the MIL blinks, crank pulse learning reset
procedure is successful.
Turn the ignition switch OFF.

• If the crank pulse learning reset procedure is

unsuccessful, perform the reset procedure from step
1 again.

CRANK PULSE INITIALIZE LEARNING

PROCEDURE
1. Connect the SCS short connector to the DLC.
2. Turn the ignition switch ON.
Open the throttle grip fully within 5 seconds.
Close the throttle grip completely within 3 seconds.
Start the engine within 5 seconds.
3. Warm up the engine.
Snap the throttle 5 times keeping the engine
revolution at more than 4200 r/min.
4. Turn the ignition switch OFF.
Disconnect the SCS short connector from the DLC.
5. Turn the ignition switch ON.
Check the MIL.
If the MIL stays on for a few seconds then go off,
crank pulse learning procedure is successful.
Turn the ignition switch OFF.

• If the crank pulse learning procedure is

unsuccessful, perform the learning procedure from
step 1 again.

4-84
dummytext

5. IGNITION SYSTEM

SERVICE INFORMATION ·····························5-2 IGNITION SYSTEM INSPECTION ················ 5-7

TROUBLESHOOTING···································5-3 IGNITION COIL ············································· 5-9

SYSTEM LOCATION·····································5-4 IGNITION TIMING ······································· 5-13

SYSTEM DIAGRAM ······································5-5

5-1
 dummyhead

IGNITION SYSTEM
SERVICE INFORMATION
IGNITION SYSTEM

GENERAL

• 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 while 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.
• If the CKP sensor is removed, perform the crank pulse initialize learning procedure (page 4-83) (ED, KO only).
• Refer to following components informations:
– ECM (page 4-77)
– TCM (DCT model) (page 13-66)
– IMU (page 4-73)
– FI relay (page 4-81)
– Neutral switch (DCT model) (page 13-66)
– Neutral switch (MT model) (page 22-44)
– Engine stop switch (right handlebar switch) (page 22-33)
– CKP sensor (page 4-83)
– Sidestand switch (page 22-44)
• 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 O = Orange P = Pink R = Red V = Violet
W = White Y = Yellow

5-2
dummyhead

IGNITION SYSTEM
TROUBLESHOOTING
• Inspect the following before diagnosing the system.
– Faulty spark plug
– Loose spark plug cap and spark plug connection
– 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 FI relay or its related circuits
primary electrical components are 3. An open circuit between the FI 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
4. Faulty ECM (in case when above No. 1 through 3 are normal)
Initial voltage is normal, but 1. The multimeter impedance is too low; below 10 MΩ/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)
4. Faulty ECM (in case when above No. 1 through 3 are normal)
Initial and peak voltages are 1. Faulty spark plug or leaking ignition coil secondary current ampere
normal, but no spark jumps at 2. Faulty ignition coil
plug.

5-3
 dummyhead

IGNITION SYSTEM
SYSTEM LOCATION
No.1-1 IGNITION COIL

IGNITION SWITCH
ENGINE STOP SWITCH

No.1-2 IGNITION COIL

No.2-2 SPARK PLUG

FI 15 A

ECM IMU

No.2-1 IGNITION
COIL

No.2-2 IGNITION
COIL

POWER BOX
– ST-MAG 10 A

No.1-2 SPARK PLUG

No.1-1 SPARK PLUG

BATTERY TCM (DCT model)

CKP SENSOR FI RELAY

SIDESTAND SWITCH STARTER RELAY SWITCH
– MAIN FUSE 30 A
No.2-1 SPARK PLUG
NEUTRAL SWITCH

5-4
dummyhead

IGNITION SYSTEM
SYSTEM DIAGRAM
MT model:

Bl/Gr Bl
ECM
BATTERY

Gr W Y Y Bl G Bl R W Y
Lg
W Bl/R
G/Bl
W/Bu
NEUTRAL
SWITCH IMU
ENGINE
STOP
SWITCH CKP
SENSOR
MAIN
IGNITION
FUSE ST-MAG
SWITCH
30 A 10 A FI RELAY
R R/Bl Bl G
SIDESTAND
W R/Bu SWITCH
FI 15 A
G G/W

Br/Bl

Br
Br/Bl

Br
Br Br Br/Bl Br/Bl
Bl: Black Bu/Bl Bu/R Bu/W Bu/Y
Y: Yellow
Bu: Blue
No.1-1

No.2-1

No.1-2

No.2-2
G: Green IGNITION
R: Red COILS
W: White
Br: Brown
Lg: Light green
Gr: Gray

5-5
 dummyhead

IGNITION SYSTEM
DCT model:

Bl/Gr Bl
TCM ECM
BATTERY

Gr W Y Y Bl G Bl R W Y
Lg Bl
W Bl/R
Bl/R G/Bl
W/Bu
NEUTRAL
SWITCH IMU
ENGINE
STOP
SWITCH CKP
SENSOR
MAIN
IGNITION
FUSE ST-MAG
SWITCH
30 A 10 A FI RELAY
R R/Bl Bl G
SIDESTAND
W R/Bu SWITCH
FI 15 A
G G/W

Br/Bl

Br
Br/Bl

Br
Br Br Br/Bl Br/Bl
Bl: Black Bu/Bl Bu/R Bu/W Bu/Y
Y: Yellow
Bu: Blue
No.1-1

No.2-1

No.1-2

G: Green IGNITION No.2-2

R: Red COILS
W: White
Br: Brown
Lg: Light green
Gr: Gray

5-6
dummyhead

IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
• 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 MΩ/DCV minimum.
• The display value differs depending upon the
internal impedance of the multimeter.
• If using the imrie diagnostic tester (MODEL 625),
follow the manufacturer’s instructions.
Connect the peak voltage adaptor to the digital
[2]
multimeter, or use the peak voltage tester.

TOOLS:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor [1] 07HGJ-0020100
with commercially available digital multimeter [2]
(impedance 10 MΩ/DCV minimum)

[1]

IGNITION COIL PRIMARY PEAK

VOLTAGE

• 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 5-9).
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.

[1]

5-7
 dummyhead

IGNITION SYSTEM
With the ignition coil primary wire connected, connect
[3] [1]
the peak voltage adaptor or Imrie tester 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:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)
[4] [2]
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.
Check the initial voltage at this time.
The battery voltage should be measured.
If the initial voltage cannot be measured, follow the
checks described in the troubleshooting table
(page 5-3).
Shift the transmission into neutral.
Crank the engine with the starter motor and measure
the ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum
If the peak voltage is abnormal, follow the checks
described in the troubleshooting table (page 5-3).
Install the ignition coil tray (page 5-9).

CKP SENSOR CIRCUIT INSPECTION

Remove the skid plate (page 2-25).
[1]
Disconnect the CKP sensor 3P (Gray) connector [1].

5-8
dummyhead

IGNITION SYSTEM
POWER INPUT/GROUND LINE INSPECTION
Turn the ignition switch ON.
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
W Y
If standard voltage does not appear, the Yellow and/or
White wires have an open circuit.

SIGNAL LINE INSPECTION

Turn the ignition switch OFF.
[1] [2]
Disconnect the ECM 33P (Black) connector (page 4-
77).
Check for continuity between the wire harness side
CKP sensor 3P (Gray) connector [1] and ECM 33P
(Black) connector [2] terminals.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Yellow – B16 Y B16

If there is no continuity, check for open circuit in the

Yellow wire.

Check for continuity between the wire harness side

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.

IGNITION COIL
IGNITION COIL TRAY REMOVAL/
INSTALLATION
Remove the PAIR control solenoid valve stay (page 7-
[1]
20).
Disconnect the No.1-2 spark plug cap [1].

5-9
 dummyhead

IGNITION SYSTEM
Disconnect the No.2-2 spark plug cap [1].
[2]
Release the spark plug wire clip [2] from the right
radiator shroud.

[1]

Release the immobilizer receiver 4P (Black) connector

[1]
[1].
Disconnect the ignition sub harness 6P connector [2].

[2]

5-10
dummyhead

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.
Installation is in the reverse order of removal.

• Route the wires properly (page 1-32).

[1]

[3]

[2]

[4] [5]

5-11
 dummyhead

IGNITION SYSTEM
IGNITION COIL TRAY DISASSEMBLY/
ASSEMBLY
Remove the ignition coil tray assembly (page 5-9).
Release the wire clip [1].
Remove the bolts [2].
Disconnect the following:
– No.1-1 ignition coil connectors [3]
– No.1-2 ignition coil connectors [4]
– No.2-1 ignition coil connectors [5]
– No.2-2 ignition coil connectors [6]
Remove the following parts from the ignition tray [7]:
– No.1-1 ignition coil [8]
– No.1-2 ignition coil [9]
– No.2-1 ignition coil [10]
– No.2-2 ignition coil [11]
– Ignition sub harness [12]
Installation is in the reverse order of removal.

• Route the wire harness properly (page 1-32).

[2] [2]

[10]
[8]

[2]

[2]

[11]

[7]

[5]
[4]
[9]

[6] [3]

[4]
[1] [12]

5-12
dummyhead

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.

• Read the instructions for timing light operation. [2] [3]

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. [1]

Apply engine oil to a new O-ring [1] and install it to the

[1]
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 lbf·ft)

[2]

5-13
dummyhead

MEMO
dummytext

6. ELECTRIC STARTER

SERVICE INFORMATION ·····························6-2 STARTER MOTOR ······································· 6-7

TROUBLESHOOTING···································6-3 STARTER RELAY SWITCH ························· 6-9

SYSTEM LOCATION·····································6-4 STARTER RELAY······································· 6-11

SYSTEM DIAGRAM ······································6-5

6-1
 dummyhead

ELECTRIC STARTER
SERVICE INFORMATION
ELECTRIC STARTER

GENERAL

If the 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 (DCT model) (page 13-66)
– Neutral switch (MT model) (page 22-44)
– Ignition switch (page 22-25)
– Starter switch (right handlebar switch) (page 22-33)
– Engine stop switch (right handlebar switch) (page 22-33)
– Clutch switch (MT model) (page 22-43)
– Sidestand switch (page 22-44)
– 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 O = Orange P = Pink R = Red V = Violet
W = White Y = Yellow

6-2
dummyhead

ELECTRIC STARTER
TROUBLESHOOTING
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
sidestand retracted 4. Faulty starter relay switch
and clutch lever 5. Faulty starter relay or its related circuits
pulled in 6. Faulty clutch switch or its related circuits
7. Faulty clutch cruise cancel switch or its related circuits
8. Faulty sidestand switch or its related circuits
9. Faulty starter motor or its related circuits
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
sidestand lowered 4. Faulty starter relay switch
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
8. Faulty starter motor 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
 dummyhead

ELECTRIC STARTER
SYSTEM LOCATION
FRONT BRAKE SWITCH ENGINE STOP SWITCH

IGNITION SWITCH
STARTER SWITCH

CLUTCH SWITCH
(MT model) STARTER RELAY

STARTER RELAY SWITCH

– MAIN FUSE 30 A
ECM
POWER BOX
– ST-MAG 10 A

BATTERY

STARTER MOTOR

MT model: GP SENSOR
DCT model: TP SENSOR

SIDESTAND SWITCH
TCM (DCT model)
NEUTRAL SWITCH
REAR BRAKE SWITCH

6-4
dummyhead

ELECTRIC STARTER
SYSTEM DIAGRAM
MT model:

from FI RELAY
CLUTCH CRUISE
CANCEL SWITCH
Br Bl

Bl/Gr Bl G Bl/R ECM

CLUTCH
BATTERY SWITCH
Lg

Bl Y Gr G Gr Gr W
Bl/R W Y/W

NEUTRAL
SWITCH GP
IMU
SENSOR
IGNITION
SWITCH

R R/Bl

ST-MAG
10 A
Bl
Bl

G/R G
Bl SIDESTAND
STARTER SWITCH
RELAY
G G/W
MAIN
FUSE G G/Bl
30 A STARTER
RELAY
SWITCH STARTER
SWITCH

Bl G/Bl Bl

STARTER G/Bl W/Bu

MOTOR

Bl: Black ENGINE STOP

Y: Yellow SWITCH
G: Green
R: Red
W: White
Lg: Light green
Gr: Gray

6-5
 dummyhead

ELECTRIC STARTER
DCT model:

Bl/Gr Bl
TCM ECM
BATTERY

Bl G G Gr Gr W
Y W Gr Bl
Bl/R Y/W
Lg
Bl/R
NEUTRAL
TR IMU
SWITCH
SENSOR
FRONT BRAKE
SWITCH

IGNITION Bl/R Bl/G G/Y

HORN/STOP
SWITCH
10 A
R/Bl Bl/R REAR BRAKE
SWITCH
R/Bl
ST-MAG 10 A
Bl Bl/G G

Bl
R

Bl

G/R G
SIDESTAND
STARTER SWITCH
RELAY
G G/W
MAIN
FUSE G G/Bl
30 A STARTER
RELAY
SWITCH STARTER
SWITCH

Bl G/Bl Bl

STARTER G/Bl W/Bu

MOTOR
Bl: Black
Y: Yellow
G: Green ENGINE STOP
R: Red SWITCH
W: White
Lg: Light green
Gr: Gray

6-6
dummyhead

ELECTRIC STARTER
STARTER MOTOR
REMOVAL/INSTALLATION
Remove the battery box (page 21-6).
[2]/[3] [1] [4]
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].

[5]

[6]

Remove the O-ring [1].

[1]
Installation is in the reverse order of removal.
TORQUE:
Starter motor cable terminal nut/washer:
10 N·m (1.0 kgf·m, 7 lbf·ft)

• Replace the O-ring with a new one.

• Apply engine oil to the new O-ring.

DISASSEMBLY/ASSEMBLY

The coil may be damaged if the magnet pulls the armature against the motor case.

STARTER MOTOR SETTING BOLTS

4.9 N·m (0.5 kgf·m, 3.6 lbf·ft)
FRONT COVER
O-RINGS

SEAL RING

TERMINAL BOLT MOTOR CASE

POSITIVE BRUSH SEAL RING

NEGATIVE BRUSH STOPPER
SCREW/WASHER ARMATURE
3.7 N·m (0.4 kgf·m, TERMINAL
2.7 lbf·ft) STOPPER
INSULATOR
NEGATIVE BRUSH
WASHER
SPRINGS

BRUSH HOLDER

REAR COVER NUT/WASHER

O-RING

6-7
 dummyhead

ELECTRIC STARTER
When installing the front cover [1] and rear cover [2]
Align [2]
onto the motor case [3], align the lines as shown.

[1]

[3]

INSPECTION
FRONT COVER
Check the oil seal [1] in the front cover for deterioration,
[1]
wear, or damage.
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
[3] [1]
rear cover [1] as below:
– Between the positive brush [2] and cable terminal
[3]: should be continuity.
– Between the cable terminal and the rear cover:
should be no continuity. [2]
– Between the positive brush and rear cover: should
be no continuity.
– Between positive brush and negative brush [4]:
should be no continuity.

[4]

ARMATURE
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.
– Between each commutator bar and the armature
shaft [2]: should be no continuity.
Replace the starter motor as an assembly if necessary.

[2]

6-8
dummyhead

ELECTRIC STARTER
STARTER RELAY SWITCH
REMOVAL/INSTALLATION
Remove the socket bolts [1].
[1]
Remove the battery box cover [2].

[2]

Release the starter relay switch [1] from the battery box.
[2]
Remove the starter relay switch cover [2].

[1]

Disconnect the starter relay switch 4P (Black)

[1]
connector [1].
Remove the bolts [2].
Disconnect the starter motor cable [3] and battery
positive (+) cable [4]. [2]
Installation is in the reverse order of removal.
[4]

[3]

INSPECTION
Remove the battery box cover (page 6-9).
[1]
Shift the transmission into neutral.
Turn the ignition switch ON and engine stop switch " ".
Push the starter switch.
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:

6-9
 dummyhead

ELECTRIC STARTER
STARTER RELAY SWITCH INPUT VOLTAGE LINE
INSPECTION
Disconnect the starter relay switch 4P (Black)
[1]
connector (page 6-9).
Turn the ignition switch ON.
Check for continuity between the wire harness side
starter relay switch 4P (Black) connector [1] terminals.
CONNECTION: Red – Black
R Bl
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

Check for continuity between the wire harness side

[1]
starter relay switch 4P (Black) connector [1] terminal
and ground.
CONNECTION: Green/red – Ground
If there is no continuity, check the following: G/R
– 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
dummyhead

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.

STARTER RELAY
REMOVAL/INSTALLATION
Remove the ECM tray (page 4-77).
[2]
Release the starter relay [1] from the stay.
Disconnect the relay connector [2] and remove the
starter relay.
Installation is in the reverse order of removal.
– For relay inspection (page 4-81)

[1]

6-11
dummyhead

MEMO
dummytext

7. FUEL SYSTEM

SERVICE INFORMATION ·····························7-2 FUEL RELAY ·············································· 7-14 7

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
 dummyhead

FUEL SYSTEM
SERVICE INFORMATION
FUEL SYSTEM

GENERAL
• 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 22-24).

7-2
dummyhead

FUEL SYSTEM
COMPONENT LOCATION

7-3
 dummyhead

FUEL SYSTEM
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING

• Before disconnecting the fuel hose, relieve pressure

from the system as follows. [1]

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.
5. Turn the ignition switch OFF.

QUICK CONNECT FITTING REMOVAL/

INSTALLATION

• Clean around the quick connect fitting before

[1]
disconnecting the fuel feed hose, and be sure that
no dirt is allowed to enter into the fuel system.
• Do not bend or twist the fuel feed hose.
Relieve the fuel pressure (page 7-4).
Disconnect the battery negative (–) cable (page 21-6).
Push the retainer tab [1] forward. [2]
Press down the retainer and disconnect the connector
[2] from the fuel pump joint/fuel rail.

• To prevent damage and keep foreign matter out,

cover the disconnected connector and pipe end with
the plastic bags [3].
Press the connector onto the fuel pump joint/fuel rail
until the retainer locks with a “CLICK”.

• If it is hard to connect, put a small amount of engine

oil on the pipe end.
Make sure the connection is secure; check visually and
by pulling the connector.
Increase the fuel pressure (page 7-5).

[3]

7-4
dummyhead

FUEL SYSTEM
FUEL PRESSURE NORMALIZATION
1. Connect the fuel pump unit 3P (Black) connector [1].
[1]
Connect the battery negative (–) cable (page 21-6).
2. Turn the ignition switch ON.
The fuel pump will run for about 2 seconds and fuel
pressure will rise.

• Do not start the engine.

3. Turn the ignition switch OFF.
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: [2]
Fuel pressure gauge [1] 07406-0040004 [3]
Pressure gauge attachment set [2] 070MJ-K260100
Hose attachment, 6 mm/9 mm [3] 07ZAJ-S5A0130
Hose attachment, 8 mm/9 mm [4] 07ZAJ-S7C0100
Attachment joint, 8 mm/9 mm [5] 07ZAJ-S7C0200
Attachment joint, 6 mm/9 mm [6] 07ZAJ-S5A0150 [6]

Temporarily connect the battery negative (–) cable and

fuel pump unit 3P (Black) connector.
Start the engine and let it idle.
Read the fuel pressure. [5]
STANDARD:
324 – 367 kPa (3.3 – 3.7 kgf/cm2, 47 – 53 psi) Fuel feed
hose side
If the fuel pressure is higher than specified, replace the Fuel pump
fuel pump unit. side
If the fuel pressure is lower than specified, inspect the
following: [4]
– 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
 dummyhead

FUEL SYSTEM
FUEL FLOW INSPECTION
Disconnect the quick connect fitting from the fuel rail
[1]
(page 7-4).
Place the end of the fuel feed hose [1] into an approved
fuel container.

• Clean up any spilled fuel.

Temporarily connect the battery negative (–) cable and
fuel pump unit 3P (Black) connector.
Turn the ignition switch ON.
Measure the amount of fuel flow.

• 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 cm3 (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
dummyhead

FUEL SYSTEM
FUEL TANK
REMOVAL/INSTALLATION
Disconnect the quick connect fitting (fuel pump side)
(page 7-4).
Disconnect the following:
– 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
cap bolts, if necessary.

CRF1100D4 shown: [6] [4]

9.0 mm
(0.35 in)
[5]

[2] [1]
[4] [3]

Installation is in the reverse order of removal.

TORQUE:
Fuel filler cap bolt:
1.8 N·m (0.2 kgf·m, 1.3 lbf·ft)

• 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]
1-32).
Connect the quick connect fitting (fuel pump side) (page
7-4).

7-7
 dummyhead

FUEL SYSTEM
FRONT CROSS PLATE
REMOVAL/INSTALLATION
Remove the following:
[1] [2]
– Rear seat under cover (page 2-34)
– Fuel tank (page 7-7)
Remove the front cross plate bolts [1] and front cross
plate [2].
Installation is in the reverse order of removal.
TORQUE:
Front cross plate bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
[1]

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:
Turn the ignition switch OFF.
[1]
Disconnect the fuel pump unit 3P (Black) connector
(page 7-4).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 3P (Black)
connector [1]. Y/R G
CONNECTION: Yellow/red (+) – Green (–)
There should be battery voltage for a few seconds.
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 4-77)

REMOVAL
Remove the fuel tank (page 7-7).
[4]
Clean around the fuel pump unit.
Loosen the fuel pump unit mounting nuts [1] in a
crisscross pattern in 2 or 3 steps.
[3]
Remove the fuel pump unit mounting nuts and fuel
pump guard [2].
Remove the fuel pump unit [3] and packing [4].

[1] [2]

7-8
dummyhead

FUEL SYSTEM
DISASSEMBLY/INSPECTION
CRF1100A/AL/D/DL
Remove the screws [1], Black wire terminals [2], and
[3] [1]
stoppers [3].
Disconnect the White wire connector [4] and Blue wire [2]
connector [5].

[2] [3]

[4] [5]

Remove the fuel filter assembly [1] and O-ring [2] from
the fuel pump stay [3].

[1]

[3] [2]

Remove the chamber [1] by releasing the tabs [2].

[1]

[2]

Remove the fuel pump [1] and O-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. [3]
[5]
Remove the pressure regulator [4] and O-ring [5] from
the fuel filter [6].

[2] [1] [6]

7-9
 dummyhead

FUEL SYSTEM
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4
Remove the screws [1], Black wire terminals [2], and
[3] [3]
stoppers [3].
Disconnect the White wire connector [4] and Blue wire
connector [5]. [2]

[2]

[1]

[4] [5] [1]

Remove the fuel filter assembly [1] and O-ring [2] from
[1]
the fuel pump stay [3].

[3] [2]

Remove the chamber [1] by releasing the tabs [2].

[1]

[2]

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

[5] [4]
Visually inspect the suction filter [3] for dirt, debris, or
any clogging. [3]
Replace fuel pump unit as an assembly if the suction
filter is abnormal.
Remove the pressure regulator [4] and O-ring [5] from
the fuel filter [6].

[2] [1] [6]

7-10
dummyhead

FUEL SYSTEM
ASSEMBLY
CRF1100A/AL/D/DL
Replace the fuel filter [1] with a new one.
[2] [3]
Apply engine oil to a new O-ring.
Install the O-ring [2] to new pressure regulator [3].
Install the pressure regulator.

[1]

Apply engine oil to a new O-ring.

[6]
Install the O-ring [1] to the fuel pump [2].
Install the fuel pump.
[7]

• Align the Blue wire [3] with the fuel filter groove [4]. [2]
• Lead the Black wire [5] through the hole [6] of the
fuel filter as shown. [5]
[3]
Insert the suction filter [7] edge between the fuel pump
and pressure regulator.

[4] [1] [5]

Set the Blue wire [1] through the groove [2] of the fuel
[4]
filter [3] as shown.
Install the chamber [4]. [2]

[1]
[3]

Apply engine oil to a new O-ring.

[3]
Install the O-ring [1] to the fuel pump stay [2].
Install the fuel filter assembly [3] by aligning the groove
with the fuel pump stay tab.
Align

[2] [1]

7-11
 dummyhead

FUEL SYSTEM
Install the stoppers [1], Black wire terminals [2], and fuel
[1] [3]
pump/reserve sensor terminal screws [3].
Tighten the fuel pump/reserve sensor terminal screws [2]
to the specified torque.
TORQUE: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
Connect the White wire connector [4] and Blue wire
connector [5]. [1]
[2]

[4] [5]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4
Replace the fuel filter [1] with a new one.
[2] [3]
Apply engine oil to a new O-ring.
Install the O-ring [2] to new pressure regulator [3].
Install the pressure regulator.
[1]

Apply engine oil to a new O-ring.

[2] [3] [7]
Install the O-ring [1] to the fuel pump [2].
Install the fuel pump.
[5]

• 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.
[6]
Insert the suction filter [7] edge between the fuel pump
and pressure regulator.
[1]

[4] [5]

Set the Blue wire [1] through the groove [2] of the fuel
[4]
filter [3] as shown.
Install the chamber [4].
[2]

[1]
[3]

7-12
dummyhead

FUEL SYSTEM
Apply engine oil to a new O-ring.
[3]
Install the O-ring [1] to the fuel pump stay [2].
Install the fuel filter assembly [3] by aligning the groove
with the fuel pump stay tab.

Align

[2] [1]

Install the stoppers [1], Black wire terminals [2], and fuel
[1] [1]
pump/reserve sensor terminal screws [3].
Tighten the fuel pump/reserve sensor terminal screws
to the specified torque. [2]

TORQUE: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) [2]

Connect the White wire connector [4] and Blue wire
connector [5].
[3]

[4] [5] [3]

INSTALLATION
Install a new packing [1] onto the fuel pump unit [2].
[2] [1]

• 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.
4
Install the fuel pump guard [2] and fuel pump unit
mounting nuts [3].
Tighten the fuel pump unit mounting nuts to the
2 [1]
specified torque in the sequence as shown. 6
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the fuel tank (page 7-7). 5
1

3
[3] [2]

7-13
 dummyhead

FUEL SYSTEM
FUEL RELAY
REMOVAL/INSTALLATION
Remove the main seat (page 2-5).
[1]
Remove the power box cover and fuel relay [1].
Installation is in the reverse order of removal.
– For relay inspection (page 4-82)

AIR CLEANER HOUSING

REMOVAL/INSTALLATION
Remove the following:
[5]
– Horn (page 22-46)
– 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]. [2]
Remove the wire band [5]. [2]

[3] [3]

[4] [1] [4]

Remove the bolts [1].

[1]

Open the clamp A [1].

DCT model: Open the clamp B [2].
Release the air cleaner housing drain hose [3]. [2]
Remove the hose clip [4] and drain plug [5].
[1]

[3]

[4] [5]

7-14
dummyhead

FUEL SYSTEM
Release the left and right air cleaner duct tabs [1] from
Right side shown:
the inner covers.
[1]

Release the ignition switch 2P connector [1] from the

[3] [2] [4] [1]
stay.
Release the ignition switch wire [2] from the guide [3]. [5]

Disconnect the air suction hose [4].

Loosen the connecting hose band screws [5].

[5]

Remove the following:

[3] [6] [1]
– Bolts [1]
– Collars A [2]
– Bolt/washer [3]
Disconnect the air cleaner housing connecting hoses
[4].
[5] [2]
Pull the air cleaner housing [5] upward.
Disconnect the crankcase breather hose [6] from the
cylinder head cover. [9]

Disconnect the IAT sensor 2P (Blue) connector [7]. [11]

Remove the air cleaner housing. [4]
Remove the collars B [8]. [10]
Remove the following from the air cleaner housing: [8]
– Grommets A [9]
– Collar C [10]
– Grommet B [11]

[7]

7-15
 dummyhead

FUEL SYSTEM
Installation is in the reverse order of removal.

• Route the wires and hoses properly (page 1-32).

• Align the hose band holes with the connecting hose
bosses.
• Tighten the connecting hose band screws [1] until
the collars [2] are fully seated. Align

[1]
[2]

THROTTLE BODY
REMOVAL/INSTALLATION
Remove the following:
– Tool box (page 2-26)
– Air cleaner housing (page 7-14)
Loosen the insulator band screws [1].

[1]

Disconnect the following: [9]

– 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- [2]
throttle body hose [5] from the EVAP purge control [1]
solenoid valve [6].
[3]
Release the fuel feed hose [7] from the clamp [8].
Remove the throttle body [9].
[7]

[8]

[6]

[4] [5]

7-16
dummyhead

FUEL SYSTEM

• Do not loosen or tighten the white painted screws

[1]
[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]

[2]

[3] [1]

[1]

[3]

Installation is in the reverse order of removal.

Align
• Route the wires and hoses properly (page 1-32).
• 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
Remove the fuel tank (page 7-7).
[1] [4]
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].

[3]
[2]

7-17
 dummyhead

FUEL SYSTEM
Clean around the fuel injector base with compressed
air.
Disconnect the fuel injector 2P (Gray) connectors [1].
[2]
Remove the fuel injector assembly mounting bolts [2] [1]
and fuel injector assembly [3].
Disconnect the quick connect fitting from the fuel rail
(page 7-4).

• Be sure that no debris is allowed to enter the

combustion chamber.

[3] [1]

Remove the fuel injectors [1] from the fuel injector joints
[6] [5]
[2].
Remove the seal rings [3] and O-rings [4] from the fuel [2]
injectors.
Remove the fuel injector joints and O-rings [5] from the
fuel rail [6].

[4]

[3] [1]

INSTALLATION
Apply engine oil to new O-rings.
[3] [1]
Install the O-rings [1] and fuel injector joints [2] to the
fuel rail [3].
[2]
Apply engine oil to new seal rings and new O-rings.
Install the seal rings [4] and O-rings [5] to the fuel
injectors [6].
Install the fuel injectors to the fuel injector joints.

[7] [6] [7]

• Align the fuel injector connectors with the fuel joint
tabs [7] as shown. [5]

[4] [6]

Connect the quick connect fitting to the fuel rail (page 7-

4).
Install the fuel injector assembly [1].
[2]
[3]
• 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.
TORQUE: 5.1 N·m (0.5 kgf·m, 3.8 lbf·ft)
Connect the fuel injector 2P connectors [3].
[1] [3]

7-18
dummyhead

FUEL SYSTEM
Install the MAP sensor [1] to the MAP sensor stay.
[5] [2]
Install and tighten the MAP sensor screw/washer [2] to
the specified torque. [1]

TORQUE: 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft)

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). [4]
[3]

SECONDARY AIR SUPPLY SYSTEM

SYSTEM INSPECTION
Start the engine and warm it up to normal operating
temperature.
Stop the engine.
Remove the fuel tank (page 7-7).
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).

[1] [2]

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 [3]
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 7-22).

[2]

FRESH AIR
EXHAUST GAS

7-19
 dummyhead

FUEL SYSTEM
PAIR CONTROL SOLENOID VALVE
REMOVAL/INSTALLATION
Remove the air cleaner housing (page 7-14).
[3] [5] [4]
Disconnect the air suction hose [1] and air supply hose
[2].
Release the suspension rubber [3] from the PAIR [6]
control solenoid valve stay.
Release the grommet [4] from the boss.
Disconnect the PAIR control solenoid valve 2P (Black)
connector [5]. [2]
Remove the PAIR control solenoid valve [6].
Remove the suspension rubber and grommet from the
PAIR control solenoid valve.
[1]

Remove the screws [1] and PAIR control solenoid valve

[2]
stay [2].
Installation is in the reverse order of removal.

[1] [1]

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)

Replace the solenoid valve if it does not operate

properly.
Install the PAIR control solenoid valve (page 7-20). (B)

PAIR REED VALVE

REMOVAL/INSTALLATION
Remove the cylinder head cover (page 10-4).
[1]
Remove the PAIR reed valve cover bolts [1].

7-20
dummyhead

FUEL SYSTEM
Remove the PAIR reed valve cover [1].
[1]

• When installing the PAIR reed valve cover, align the

boss of the PAIR reed valve cover with the hole of
the PAIR reed valve.

Align

Remove the PAIR reed valves [1] and port plates [2].
[1]
Installation is in the reverse order of removal.
TORQUE:
PAIR reed valve cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

• Install the PAIR reed valves and port plates as

shown.

[2]

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]

7-21
 dummyhead

FUEL SYSTEM
EVAP PURGE CONTROL SOLENOID
VALVE/CANISTER
EVAP PURGE CONTROL SOLENOID
VALVE
REMOVAL/INSTALLATION
Remove the fuel tank (page 7-7).
[2]
Disconnect the following:
– 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]
[3]
Remove the screws [4] and EVAP purge control
solenoid valve [5].
[1]
Installation is in the reverse order of removal.
[4] [5]

INSPECTION
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. (B) (A)
Replace the solenoid valve if it does not operate
properly.
Install the EVAP purge control solenoid valve (page 7- [3]
22).

[2]

7-22
dummyhead

FUEL SYSTEM
EVAP CANISTER
REMOVAL/INSTALLATION
Remove the BCU tray (page 22-51).
[3]
Release the EVAP canister mounting rubber [1] from
the rear fender B stay.
Release the grommet [2] from the boss.
[2]
Pull the EVAP canister [3] up.

[1]

Disconnect the following:

Left side: Right side:
– EVAP canister drain hose [1]
– EVAP canister-to-purge control solenoid valve hose [4]
[2] [2]
– Fuel tank breather hose [3]
Remove the grommet [4] and EVAP canister mounting [5]
rubber [5] from the EVAP canister [6].
Installation is in the reverse order of removal.

• Route the hoses properly (page 1-32).

[1] [6] [3]

7-23
dummyhead

MEMO
dummytext

8. COOLING SYSTEM

SERVICE INFORMATION ·····························8-2 THERMOSTAT ·············································· 8-6

8
TROUBLESHOOTING···································8-2 RADIATOR/COOLING FAN·························· 8-7

SYSTEM FLOW PATTERN···························8-3 RADIATOR RESERVE TANK····················· 8-11

SYSTEM TESTING········································8-4 WATER PUMP ············································ 8-11

COOLANT REPLACEMENT ·························8-5 FAN RELAY ················································ 8-12

8-1
 dummyhead

COOLING SYSTEM
SERVICE INFORMATION
COOLING SYSTEM

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.

• 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. (Except IN/MA/TH)
• Use only Honda genuine PRE-MIX COOLANT containing corrosion inhibitors, specifically recommended for aluminum engines
when adding or replacing the coolant. Honda genuine PRE-MIX COOLANT is excellent at preventing corrosion and overheating.
The effects last for up to 3 years. (IN/MA/TH)
• 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 4-75).

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 O-rings
• Faulty radiator cap
• Damaged or deteriorated cylinder head gasket
• Loose hose connection or clamp
• Damaged or deteriorated hose
• Damaged radiator

8-2
dummyhead

COOLING SYSTEM
SYSTEM FLOW PATTERN
LEFT
RADIATOR

RADIATOR CAP

THERMOSTAT

RIGHT
RADIATOR

SIPHON HOSE
RADIATOR
RESERVE TANK

WATER PUMP

8-3
 dummyhead

COOLING SYSTEM
SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the right middle cowl (page 2-7).
Remove the radiator cap [1].

• Remove the radiator cap while the engine is cold.

[1]

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.

Excessive pressure can damage the cooling system

components. Do not exceed 137 kPa (1.4 kgf/cm2,
20 psi).
Repair or replace components if the system will not hold
specified pressure for at least 6 seconds.

8-4
dummyhead

COOLING SYSTEM
COOLANT REPLACEMENT
REPLACEMENT/AIR BLEEDING

• 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.
Remove the following:
MT model: DCT model:
– Clutch EOP sensor cover (DCT 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.
TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft)
Remove the radiator reserve tank (page 8-11).
Empty the coolant and rinse the inside of the reserve [1]/[2] [1]/[2]
tank with water.
Install the radiator reserve tank (page 8-11).
Fill the system with the recommended coolant through
[1] [2]
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).

• 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.
Install the following:
– Radiator cap (page 8-4)
– Clutch EOP sensor cover (DCT model) (page 2-27)

8-5
 dummyhead

COOLING SYSTEM
THERMOSTAT
REMOVAL/INSTALLATION
Drain the coolant (page 8-5).
Remove the thermostat cover bolts [1] and open the
thermostat cover [2].

[1]

[2]

Remove the thermostat [1] from the cylinder head.

[2] [1]
Installation is in the reverse order of removal.
TORQUE:
Thermostat cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

• 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

[2]
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]

• 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
dummyhead

COOLING SYSTEM
RADIATOR/COOLING FAN
REMOVAL/INSTALLATION
Drain the coolant (page 8-5).
[1]
Remove the Inner covers (page 2-9).
Remove the horn (page 22-46).
Release the following from the right radiator shroud:
– Right handlebar switch 4P connector [1]
– Connector stay [2]
– Clamp [3]
– Wire clip [4]
[2]

[4] [3]

Release the following from the right radiator shroud: [1]

[2]
– Right grip heater 2P connector [1]
– Right fan motor 2P connector [2]
– Siphon hose [3]
– Wire clip [4]
Disconnect the right fan motor 2P connector.

[4] [3]

Disconnect the siphon hose [1]. [3] [1]

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

[2]

Loosen the hose band screw [1].

[2]
Disconnect the radiator hose B [2].
Loosen the hose band screw [3]. [4]
Disconnect the lower radiator hose [4].

[3] [1]

8-7
 dummyhead

COOLING SYSTEM
Remove the bolts [1].
[2]
Release the wire clip [2].
Remove the right radiator.

[1]

Release the following from the left radiator shroud:

[1]
– Clamp [1]
– Wire clip [2]
– Left A/F sensor 4P connector [3]

[3] [2]

Loosen the hose band screw [1].

[2]
Disconnect the upper radiator hose [2].

[1]

Disconnect left fan motor 2P (Black) connector [1].

[1]

8-8
dummyhead

COOLING SYSTEM
Loosen the hose band screw [1].
Disconnect the lower radiator hose [2].

[1] [2]

Remove the bolts [1].

Remove the left radiator.

[1]

Installation is in the reverse order of removal.

• Tighten the water hose band screws to the specified

range as shown.
• Route the hoses and wires properly (page 1-32).
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-5).

0 – 0.5 mm (0 – 0.02 in)

8-9
 dummyhead

COOLING SYSTEM
DISASSEMBLY/ASSEMBLY

Right side shown: FAN MOTOR SHROUD

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
SHROUD

RADIATOR GRILL

GROMMETS

COLLARS

FAN MOTOR
WIRE

RADIATOR
RADIATOR
SHROUD

• Align the cooling fan and fan motor shaft flat

surfaces.
• Apply locking agent to the cooling fan mounting nut
threads.

8-10
dummyhead

COOLING SYSTEM
RADIATOR RESERVE TANK
REMOVAL/INSTALLATION
Remove the shock absorber (page 18-9).
[2] [5]
Remove the radiator reserve tank mounting bolt [1].
[1]
Remove the radiator reserve tank [2] by releasing the
boss [3] from the frame.
Disconnect the siphon hose [4] and drain the coolant.
Installation is in the reverse order of removal.

• Route the radiator reserve tank drain hose [5]

properly (page 1-32).

[3] [4]

WATER PUMP
MECHANICAL SEAL INSPECTION
Remove the skid plate (page 2-25).
[1]
Check the water pump bleed pipe [1] for signs of
coolant leakage.

• 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:
MT model shown: [3]
– MT model: (page 12-4)
– DCT model: (page 13-41)
Remove the coolant drain bolt [1] and sealing washer
[2].
Remove the water pump cover bolts [3] and water
pump body [4].

[1]/[2] [4]

8-11
 dummyhead

COOLING SYSTEM
INSTALLATION
Install a new O-ring [1] into the groove in the water
MT model shown: [1]
pump body [2].
Install the dowel pins [3] and water pump body.

[2]

[3]

Apply locking agent to the water pump cover bolts

MT model shown: [1]
threads (page 1-27).
Install and tighten the water pump cover bolts [1] to the
specified torque.
TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft)
Install the coolant drain bolt [2] and a new sealing
washer [3].
Tighten the coolant drain bolt to the specified torque.
TORQUE: 13 N·m (1.3 kgf·m, 10 lbf·ft)
Install the right crankcase cover:
– MT model: (page 12-6) [2]/[3]
– DCT model: (page 13-44)

FAN RELAY
REMOVAL/INSTALLATION
Remove the main seat (page 2-5). [1]
Remove the power box cover and fan relay [1].
Installation is in the reverse order of removal.
– For relay inspection (page 4-82)

8-12
dummytext

9. LUBRICATION SYSTEM

SERVICE INFORMATION ·····························9-2 OIL PUMP ····················································· 9-5

TROUBLESHOOTING···································9-2 OIL PUMP DRIVEN GEAR ··························· 9-8

9
LUBRICATION SYSTEM DIAGRAM ············9-3 OIL STRAINER ············································· 9-9

OIL PRESSURE INSPECTION ·····················9-5

9-1
 dummyhead

LUBRICATION SYSTEM
SERVICE INFORMATION
LUBRICATION SYSTEM

GENERAL

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.

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

9-2
dummyhead

LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
MT model:

CAMSHAFT
ROCKER ARM SHAFT

PISTON

CRANKSHAFT
PISTON OIL
JETS

ALTERNATOR

MAINSHAFT

EOP SWITCH

ENGINE OIL
FILTER

CLUTCH

COUNTERSHAFT

REAR BALANCER
SHAFT
SCAVENGE PUMP

OIL FILTER SCREEN

OIL PAN

ENGINE OIL PRESSURE

RELIEF VALVE ENGINE OIL
OIL FEED PUMP
STRAINER

9-3
 dummyhead

LUBRICATION SYSTEM
DCT model:

CAMSHAFT
ROCKER ARM SHAFT

No.1
LINEAR
SOLENOID
PISTON VALVE
No.2
No.1
LINEAR
CLUTCH
SOLENOID
EOP No.2 VALVE
SENSOR CLUTCH
EOP
SENSOR
CRANKSHAFT

PISTON
OIL JETS
ALTERNATOR

EOP SENSOR

MAINSHAFT

ENGINE OIL
FILTER
No.1 CLUTCH

No.2
COUNTERSHAFT DCT OIL PUMP CLUTCH CLUTCH LINE
EOP SENSOR
ENGINE OIL FEED PUMP

SCAVENGE PUMP DCT OIL FILTER

REAR BALANCER
SHAFT
OIL FILTER SCREEN

ENGINE OIL PRESSURE DCT OIL PRESSURE

RELIEF VALVE RELIEF VALVE

OIL
OIL PAN
STRAINER

9-4
dummyhead

LUBRICATION SYSTEM
OIL PRESSURE INSPECTION
Remove the engine oil filter cartridge (page 3-12).
[2]
Apply engine oil to the O-ring and install the oil pressure
attachment [1] onto the oil filter boss.
TOOL:
Oil pressure gauge attachment 070MJ-0010101 [3]

Apply engine oil to the O-ring and engine oil filter

cartridge threads. [1]
Install the engine oil filter cartridge [2] onto the oil
pressure attachment.
TOOL: [4]
Oil filter wrench 07HAA-PJ70101

TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft)

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.
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
REMOVAL/INSTALLATION
Remove the oil strainer (page 9-9).
MT model shown:
Remove the oil pump mounting bolts [1] and oil pump
[2].
Installation is in the reverse order of removal.
[1]
TORQUE:
Oil pump mounting bolt:
16 N·m (1.6 kgf·m, 12 lbf·ft)

• Align the oil pump driven shaft end with the oil pump
drive shaft groove.

[2] Align

9-5
 dummyhead

LUBRICATION SYSTEM
DISASSEMBLY/ASSEMBLY

• 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

FLANGE BOLT (6 x 35 mm)

12 N·m (1.2 kgf·m, 9 lbf·ft)

ENGINE OIL FEED OIL PUMP SHAFT

PUMP OUTER
ROTOR
DRIVE PIN

SEALING BOLT (22 mm)

30 N·m (3.1 kgf·m, 22 lbf·ft)

ENGINE OIL FEED

PUMP INNER ROTOR ENGINE OIL
PRESSURE
RELIEF VALVE
DOWEL PINS
OIL PUMP BODY C

O-RING

DOWEL PINS
FLANGE BOLT (6 x 20 mm)
12 N·m (1.2 kgf·m, 9 lbf·ft)
DRIVE PIN
OIL PUMP BODY B
SCAVENGE PUMP
INNER ROTOR

SCAVENGE PUMP
OUTER ROTOR
FLANGE BOLT (6 x 40 mm)
12 N·m (1.2 kgf·m, 9 lbf·ft)

9-6
dummyhead

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)

OIL PUMP BODY
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) O-RING OUTER ROTOR

DCT OIL PUMP

INNER ROTOR
ENGINE OIL FEED
PUMP OUTER ROTOR DRIVE PIN

DOWEL PINS

OIL PUMP BODY A

ENGINE OIL
OIL PUMP SHAFT
FEED PUMP
INNER ROTOR

DRIVE PIN

DOWEL PINS

DOWEL PINS O-RING ENGINE OIL

PRESSURE
RELIEF VALVE

SEALING BOLT (22 mm)

DRIVE PIN
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
FLANGE BOLT (6 x 40 mm)
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 1-10).
If any of the measurement is out of the service limit,
replace the oil pump as an assembly.

9-7
 dummyhead

LUBRICATION SYSTEM
PRESSURE RELIEF VALVE
Remove the pressure relief valve (page 9-6).
[1] [1]
Check the operation of the valve by pushing on the
piston [1].
– Engine oil pressure relief valve [2]
– DCT oil pressure relief valve (DCT model) [3]

[3] [2]

OIL PUMP DRIVEN GEAR

REMOVAL
Remove the rear balancer (page 14-8).
[1] [2]
Remove the following:
– Oil pump driven gear set plate bolt [1]
– Set plate [2]
– Oil pump driven gear [3] [4]
– Washer [4]

[3]

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].
Align
Install the oil pump driven gear to the crankcase.
[2]
• Align the oil pump driven gear shaft groove with the
oil pump shaft end.

[1]

Apply locking agent to the oil pump driven gear set

[2] [1]
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.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the rear balancer (page 14-9).

9-8
dummyhead

LUBRICATION SYSTEM
BEARING REPLACEMENT
Remove the oil pump driven gear (page 9-8).
[1] [2]
Remove the needle bearing (12 x 18 x 14 mm) [1] using
the special tools.
TOOLS:
Bearing remover shaft set,
12 mm 07936-1660101
Remover weight 07741-0010201
Remover handle 07936-3710100
Remove the needle bearing (12 x 16 x 10 mm) [2] using
the same special tools.
Apply engine oil to new needle bearing rolling areas
and contact surfaces.
Drive in the needle bearing (12 x 16 x 10 mm) using the
special tools until it is in position as shown. [1] [2]
TOOLS:
Pilot, 16 mm 07746-0041300
Driver 07749-0010000

• Drive in a new needle bearing with its marked side

facing out.
Drive in the needle bearing (12 x 18 x 14 mm) using the 0 – 0.5 mm
special tools until it is in position as shown. (0 – 0.02 in)
TOOLS:
19.5 – 20.0 mm
Pilot, 17 mm 07746-0040400
(0.77 – 0.79 in)
Driver 07749-0010000

• Drive in a new needle bearing with its seal side

facing out.
Install the oil pump driven gear (page 9-8).

OIL STRAINER
REMOVAL
Drain the engine oil (page 3-12).
[2]
Loosen the bolts [1] in a crisscross pattern in 2 or 3
steps.
Remove the bolts and oil pan [2].

[1]

9-9
 dummyhead

LUBRICATION SYSTEM
Remove the oil strainer [1] and seal ring [2].
[1]
Clean the oil strainer and check for damage, replace it if
necessary.

[2]

Remove the gasket [1] and O-rings [2] from the oil pan.
DCT model shown:
DCT model: Remove the oil joints [3] from the oil pan.
[3]/[4]/[5]
Remove the O-rings [4] and back up rings [5] from the
oil joints.

[1]

[2]

Remove the oil filter screen [1] from the oil pan.
[1]
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
[1]
direction as shown.

9-10
dummyhead

LUBRICATION SYSTEM
Apply engine oil to a new O-rings. [5]
DCT model shown:
Install the new gasket [1] and O-rings [2] to the oil pan.
[4]
[3]/[4]/[5]
DCT model: Apply engine oil to a new O-rings.
Install the new back up rings [3] and O-rings [4] to the
oil joints [5]. [3]
Install the oil joints to the oil pan.

• Install the back up rings and O-rings to the oil joints

as shown.

[1]

[2]

Apply engine oil to a new seal ring.

[2]
Install the seal ring [1] to the oil pump.
Install the oil strainer [2].

[1]
• Align the oil strainer boss with the oil pump groove.

Align

Install the oil pan [1].

[1]
Install and tighten the bolts [2] in a crisscross pattern in
2 or 3 steps.
Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-12).

[2]

9-11
dummyhead

MEMO
dummytext

10. CYLINDER HEAD/VALVE/CAMSHAFT

SERVICE INFORMATION ···························10-2 ROCKER ARM ············································ 10-8

TROUBLESHOOTING·································10-2 CAM CHAIN TENSIONER LIFTER··········· 10-11

COMPONENT LOCATION ··························10-3 CAMSHAFT··············································· 10-12

10
CYLINDER COMPRESSION·······················10-4 CYLINDER HEAD/CAM CHAIN
TENSIONER·············································· 10-18
CYLINDER HEAD COVER··························10-4
INSULATOR ·············································· 10-26

10-1
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
SERVICE INFORMATION
CYLINDER HEAD/VALVE/CAMSHAFT

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.

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

10-2
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
COMPONENT LOCATION
10 N·m (1.0 kgf·m, 7 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

20 N·m (2.0 kgf·m, 15 lbf·ft)

83 N·m (8.5 kgf·m, 61 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

18 N·m (1.8 kgf·m, 13 lbf·ft)

23 N·m (2.3 kgf·m, 17 lbf·ft)

10-3
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
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 " ".
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.
COMPRESSION PRESSURE:
1.4 MPa (14.3 kgf/cm2, 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 ignition coil tray (page 5-9).
Remove the horn (page 22-46).
Remove the bolts [1].

[1]

Release the following from the left radiator shroud: [1]

– Clamp [1]
– Wire clip [2]
– Left A/F sensor 4P connector [3]

[3] [2]

10-4
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Remove the bolts [1].

[1]

MT model: Release the clutch cable [1] to the clutch cable stay [2].
MT model: [3] [2]
Remove the bolt [3] and clutch cable guide.

[1]

Disconnect the secondary air supply hose [1].

[1]
Remove the cylinder head cover bolts [2] and mounting
rubbers [3].

[2]/[3]

Remove the cylinder head cover [1] to the right side as

shown.

[1]

10-5
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Remove the plug pipe seals [1] and cylinder head cover
packing [2] from the cylinder head cover.

[1] [2]

INSTALLATION
Install new plug pipe seals [1] to the cylinder head
[2]
cover.

• 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]

[1]

Clean the cylinder head [1] mating surface thoroughly.

[2]
Apply liquid sealant (TB5211C manufactured by
ThreeBond, KE45T manufactured by Shin-Etsu Silicone
or an equivalent) to the cylinder head cover packing [2]
[1]
as shown.

• Do not apply more liquid sealant than necessary.

Insert the cylinder head cover [1] from the right side as
shown.

[1]

10-6
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Install the cylinder head cover [1] on the cylinder head.
[6]

• Be sure to be installed the dowel pins [2] of the

cylinder head cover to the cylinder head holes
securely.
[2]
Check that the mounting rubbers [3] are in good
condition, and replace them if necessary.
Install the mounting rubbers.
[1]

• Install the mounting rubbers with their "UP" marks

[4] facing up.
Install and tighten the cylinder head cover bolts [5] to [3]/[5]
the specified torque.
[4]
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Connect the secondary air supply hose [6].

[3]

MT model: Install the clutch cable stay [1] and bolt [2].
MT model: Align [2]

• Align the clutch cable stay tab with the frame hole.
[1]
Tighten the bolt securely.
Hook the clutch cable [3] to the clutch cable stay.

[3]

Install and tighten the bolts [1] securely.

[1]

10-7
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Install the following to the left radiator shroud: [1]
– Clamp [1]
– Wire clip [2]
– Left A/F sensor 4P connector [3]

[3] [2]

Install and tighten the bolts [1] securely.

Install the ignition coil tray (page 5-9).
Install the horn (page 22-46).

[1]

ROCKER ARM
REMOVAL
Remove the following:
[1] [2]
– Cylinder head cover (page 10-4)
– Crankshaft hole cap (page 3-7)
– Timing hole cap (page 3-7)
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.

[4]

[3]

10-8
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Remove the rocker arm shaft stopper bolt [1], sealing
washer [2], and rocker arm shaft bolts [3].

[3] [1]/[2]

Temporarily install the suitable 6 mm bolt [1] to the

[4]
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].

[3] [2] [1]

INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning.
– Rocker arm A
– Rocker arm B
– Rocker arm shaft
Measure each part according to CYLINDER HEAD/
VALVE/CAMSHAFT SPECIFICATIONS (page 1-10).
Replace any part if it is out of the service limit.

10-9
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
INSTALLATION
Turn the crankshaft counterclockwise and align the "T1"
[1] [2]
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.

[4]

[3]

The rocker arms have the following identification marks:

– "SAA" mark [1]: rocker arm A
– "SAB" mark [2]: rocker arm B

[1] [2]

10-10
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Apply molybdenum oil solution to the rocker arm sliding
[4]
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.

• Install the rocker arm shaft by aligning its grooves [1]

with the rocker arm shaft bolt holes of the cylinder
head. [3] [2]
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.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
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.
TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft) [5] [6]/[7]

Install the following:

– Cylinder head cover (page 10-6)
– Crankshaft hole cap (page 3-7)
– Timing hole cap (page 3-7)

CAM CHAIN TENSIONER LIFTER

REMOVAL
Remove the cam chain tensioner lifter plug [1] and
[3] [4]
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
Remove the bolts [4], cam chain tensioner lifter [5] and
gasket [6].

[1]/[2] [5] [6]

10-11
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
INSTALLATION
Install the cam chain tensioner lifter [1] and a new
[4] [3]
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.

[1] [2] [5]/[6]

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 [2]
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.

[1]

CAMSHAFT
REMOVAL
Remove the rocker arms (page 10-8).
[1] [2]
Turn the crankshaft counterclockwise and align the "T2"
mark [1] on the flywheel with the index mark [2] of the
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.

• Do not remove the cam sprocket bolts yet.

[4]

[3]

10-12
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
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

[1]/[2] [3]

Loosen the camshaft holder bolts [1].

[1]

• Loosen the camshaft holder bolts in a crisscross

pattern in 2 or 3 steps.
Remove the camshaft holder bolts and camshaft
holders [2].

• Be careful not to let the camshaft holder bolts fall

into the crankcase.
• Do not forcibly remove the dowel pins from the
camshaft holders.
[2]

Remove the camshaft [1] by releasing the cam chain

[2] [1]
[2].
[4]
• 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.

[3]

Remove the valve lifters [1] and shims [2].

[1]

• 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
magnet.

[2]

10-13
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning, or clogs in oil passages.
– Cam sprocket
– Camshaft
– Camshaft holder
– Valve lifter
Measure each part according to CYLINDER HEAD/
VALVE/CAMSHAFT SPECIFICATIONS (page 1-10).
Replace any part if it is out of the service limit.

CAMSHAFT OIL CLEARANCE

• Do not rotate the camshaft during inspection.

Wipe any oil from the journals of the cylinder head,
[1]
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

[2]
(page 10-15).

• 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.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

• Tighten the camshaft holder bolts in a crisscross [1]

pattern in 2 or 3 steps.
Loosen the camshaft holder bolts.

• Loosen the camshaft holder bolts in a crisscross

pattern in 2 or 3 steps.
Remove the camshaft holder bolts and camshaft
holders.

10-14
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
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
Turn the crankshaft counterclockwise and align the "T2"
[1] [2]
mark [1] on the flywheel with the index mark [2] of the
alternator cover.

• Be careful not to jam the cam chain and timing

sprocket of the crankshaft when rotating the
crankshaft.

Install the shims [1] and valve lifters [2].

[2]

• Do not allow the shims to fall into the crankcase.

• Install all valve lifters and shims in their original
locations.

[1]

10-15
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
If the cam sprockets bolts are removed, apply locking
[4] [3]
agent to the cam sprocket bolts threads.
Loosely install the cam sprocket [1] and cam sprocket
bolts [2] to the camshaft [3]. [1]

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.

• Make sure that the punch mark [5] on the cam

sprocket aligns with the upper surface of the cylinder
[2]
head as shown.
• Make sure that the camshaft end groove [6] is in
position as shown.

[5] [6]

Apply molybdenum oil solution to the camshaft holder B

[1]
inside.
Install the camshaft holder B [1].

• Align the groove of the camshaft holder B with the

guide of the camshaft.
Align

10-16
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Apply molybdenum oil solution to the left camshaft
[5]
holder A and right camshaft holder A insides.
Install the left camshaft holder A [1] and right camshaft
holder A [2].

• 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 [1]
[2]
specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) [2] [1]

• Tighten the camshaft holder bolts in a crisscross

pattern in 2 or 3 steps.

[4] [3]

Remove the special tool [1].

[1]
Install the cam chain tensioner lifter plug [2] and a new
sealing washer [3].
Tighten the plug securely.

[2]/[3]

If the cam sprocket bolts are removed, tighten the cam

[1]
sprocket bolts [1] to the specified torque.

TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

Install the rocker arms (page 10-10).

10-17
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
CYLINDER HEAD/CAM CHAIN
TENSIONER
REMOVAL
Remove the following:
[3] [1]
– Battery box cover (page 6-9)
– Exhaust pipe (page 2-45)
– Throttle body (page 7-16)
– Thermostat (page 8-6)
– Right crankcase cover (MT model) (page 12-4)
– Primary drive gear (DCT model) (page 13-54)
– Camshaft (page 10-12)
Remove the following:
– Front head engine hanger bolts (left side) [1]
– Front head engine hanger bolt (right side) [2]
– Front head engine hanger plate [3]
[2] [3]

Remove the 6 mm bolts [1].

[2]
Loosen the cylinder head bolt/washers [2].

• Loosen the cylinder head bolt/washers in a

crisscross pattern in 2 or 3 steps.

[1]

Remove the cam chain tensioner bolt [1], cam chain

MT model shown:
tensioner [2], and washer [3].
[1]/[3]

[2]

Lift up the cylinder head [1] and gasket [2] to get the
clearance for cam chain guide [3] removal.

• 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.

[3] [1]/[2]

10-18
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Remove the gasket [1] and dowel pins [2].
[2] [1]

[2]

DISASSEMBLY
Remove the following:
– Insulator (page 10-26)
– Cam chain tensioner lifter (page 10-11)
– Spark plugs (page 3-6) TOP VIEW
5 mm 5 mm
– ECT sensor (page 4-75)
Install the tappet hole protector into the valve lifter bore.
A tool can easily be made from a plastic 35 mm film
31 mm
container or equivalent as shown.
15 mm

Remove the valve cotters [1] using the special tool as

[2]
shown.

TOOL:
Valve spring compressor [2] 07757-0010000

• To prevent loss of tension, do not compress the

valve springs more than necessary.
Remove the tappet hole protector.
[1]

Remove the following:

– Spring retainers [1]
– Intake valve springs [2]
– Exhaust valve springs [3]
– Intake valves [4]
– Exhaust valves [5]
– Intake stem seals [6]
– Exhaust stem seals [7]
– Spring seats [8]

• Mark all the parts so they can be placed back in their

original location.
[1] [3] [5] [7] [8] [6] [4] [2] [1]

10-19
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Remove carbon deposits from the combustion chamber
[1]
[1].

INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning or clogs in oil passages.
– Cylinder head
– Valve springs
– Valves
– Valve guides
– Cam chain tensioner
– Cam chain guide
Measure each part according to CYLINDER HEAD/
VALVE/CAMSHAFT SPECIFICATIONS (page 1-10).
Replace any part if it is out of service limit.

• Ream the valve guide using the valve guide reamer

to remove any carbon build up before measuring the
guide (page 10-20).
• Refer to valve seat inspection (page 10-21).

VALVE GUIDE REPLACEMENT

Disassemble the cylinder head (page 10-19).
[1]
Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
Do not use a torch Heat the cylinder head to 100 – 150°C (212 – 302°F)
to heat the cylinder with a hot plate or oven.
head; it may cause To avoid burns, wear heavy gloves when handling the
warping. heated cylinder head.
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

Adjust the valve guide driver [1] to the specified depth.

While the cylinder head is still heated, drive in new
valve guides [2] from the camshaft side until the
exposed depth is the specified value.
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 07743-0020000
[2]
Let the cylinder head cool to room temperature.
[1]

10-20
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Use cutting oil on Ream new valve guides after installation.
[1]
the reamer during Insert the reamer [1] from the combustion chamber side
this operation. of the cylinder head and always rotate the reamer
clockwise.
TOOL:
Valve guide reamer, 5.5 mm 07984-2000001

• Take care not to tilt or lean the reamer in the guide

while reaming.
Clean the cylinder head thoroughly to remove any
metal particles.
Inspect the valve seat (page 10-21).

VALVE SEAT INSPECTION

Disassemble the cylinder head (page 10-19).
[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
HEAD/VALVE/CAMSHAFT SPECIFICATIONS (page
1-10).

Reface the valve seat (page 10-22) 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

• 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 1-10).
If the valve stem-to-valve guide clearance are normal,
replace the valve guide (page 10-20).

10-21
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
VALVE SEAT REFACING
Inspect the valve seat (page 10-21).
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
Interior cutter, 34 mm (60° EX) 07780-0014700

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: Old seat width
IN: 1.5 mm (0.06 in)
EX: 1.9 mm (0.07 in)
32°

• Follow the refacer manufacturer’s operating

instructions.
• Be careful not to grind the seat more than Old seat width
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. 60°
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
width.
[1]
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.

• 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 10-23).

10-22
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
ASSEMBLY

VALVE COTTERS EXHAUST VALVE SPRINGS

SPRING RETAINERS

EXHAUST STEM SEALS

INTAKE VALVE SPRINGS

INTAKE STEM SEALS

SPRING SEATS

VALVE GUIDES

INTAKE EXHAUST
STEM SEAL STEM SEAL

INTAKE VALVES
EXHAUST VALVES
Blow through the oil passage in the cylinder head with
compressed air.
Install the spring seats [1]. [5] [4]
Apply engine oil to the inside of new stem seals.
Install new intake stem seals [2] and exhaust stem
seals [3]. [7] [6]

Apply molybdenum oil solution to the valve stem sliding

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 [8] [3] [1] [2] [8]
combustion chamber.

• 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]

COMBUSTION CHAMBER SIDE

10-23
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Install the tappet hole protector into the valve lifter bore
[2]
(page 10-19).
Install the valve cotters [1] using the special tool as
shown.
TOOL:
Valve spring compressor [2] 07757-0010000

• 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.

• Support the cylinder head above the work bench

surface to prevent valve damage.
Install the following:
– Cam chain tensioner lifter (page 10-12)
– Spark plugs (page 3-6)
– ECT sensor (page 4-75)
– Insulator (page 10-26)

INSTALLATION
Install the dowel pins [1] and a new gasket [2].
[2]

• Route the cam chain [3] through the gasket.

[3]

[1]

Install the cylinder head [1] from the right side.

[1]

• 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.

[3]

[2]

10-24
dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
Install the cam chain guide [1].
[1]

• 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.

Align [4]/[5] [2]/[3]

Apply locking agent to the cam chain tensioner pivot

MT model shown:
bolt threads.
Install the washer [1], cam chain tensioner [2], and cam
chain tensioner pivot bolt [3].
[1]/[3]
Tighten the bolt to the specified torque.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft) [1]

[2]

[2] [3]

Apply molybdenum oil solution to the cylinder head bolt

[2] [1]
threads and seating surface of cylinder head bolt/
washers.
Apply engine oil to the washer of cylinder head bolt/
washers.
Install and tighten the cylinder head bolt/washers [1] to
the specified torque.
TORQUE: 83 N·m (8.5 kgf·m, 61 lbf·ft)

• Tighten the cylinder head bolt/washers in a [2]

crisscross pattern in 2 or 3 steps.
Install and tighten the 6 mm bolts [2] securely.
Install the following:
[1] [3]
– Front head engine hanger plate [1]
– 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
the specified torque.
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)
Tighten the front head engine hanger bolts (left side) to
the specified torque.
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)
Install the following: [2] [1]
– Camshaft (page 10-15)
– Primary drive gear (DCT model) (page 13-54)
– Right crankcase cover (MT model) (page 12-6)
– Thermostat (page 8-6)
– Throttle body (page 7-16)
– Exhaust pipe (page 2-51)
– Battery box cover (page 6-9)

10-25
 dummyhead

CYLINDER HEAD/VALVE/CAMSHAFT
INSULATOR
REMOVAL/INSTALLATION
Remove the throttle body (page 7-16).
[1]
Remove the insulator mounting bolts [1] and insulator
[2].
Remove the O-rings [3] from the insulator.
Installation is in the reverse order of removal.
TORQUE:
Insulator mounting bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

• Replace O-rings with new ones.

• Apply engine oil to new O-rings.
[2]

[3]

10-26
dummytext

11. ALTERNATOR/STARTER CLUTCH

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 11

11-1
 dummyhead

ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
ALTERNATOR/STARTER CLUTCH

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)
• If the following parts are removed, perform the crank pulse initialize learning procedure (page 4-83) (ED, KO only).
– Alternator cover
– Stator
– Flywheel
– Crank pulser plate

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
dummyhead

ALTERNATOR/STARTER CLUTCH
COMPONENT LOCATION

137 N·m
(14.0 kgf·m, 101 lbf·ft)

12 N·m
(1.2 kgf·m, 9 lbf·ft)

11-3
 dummyhead

ALTERNATOR/STARTER CLUTCH
ALTERNATOR COVER
REMOVAL/INSTALLATION
Drain the engine oil (page 3-12).
[1]
Remove the left rear cover (page 2-26).
Disconnect the alternator 3P (Gray) connector (page
21-9).
MT model: Remove the gearshift spindle cover (page 12-18). [2]
DCT model: Remove the shift control motor cover (page 13-55).
Remove the wire band [1].
Release the wire clip [2].

MT model: Remove the clamp [1].

MT model:

[1]

Release the alternator wire from the frame.

DCT model shown:
Disconnect the CKP sensor 3P (Gray) connector [1].
Release the wire clips [2].
DCT model: Remove the wire band [3].
[1]

[3] [2]

Remove the following:

[1] [6]
– Dipstick [1]
– Alternator cover bolt (long) [2]
– Alternator cover bolts (short) [3]
– Skid plate stay [4]
– Stay [5] [3]

• Loosen the bolts in a crisscross pattern in 2 or 3

steps.
Remove the alternator cover [6].
[5]
• The alternator cover (stator) is magnetically [4] [2]
attracted to the flywheel, be careful during removal
and installation.

11-4
dummyhead

ALTERNATOR/STARTER CLUTCH
Remove the dowel pins [1] and oil orifice [2].
[1]
Clean off any sealant from the alternator cover mating
surfaces.
[2]

Installation is in the reverse order of removal.

TORQUE:
Alternator cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

• Apply liquid sealant (TB1207B manufactured by

Three bond or equivalent) to the alternator cover
mating surface as shown.
• Do not apply more liquid sealant than necessary.
• Install the oil orifice with the narrow hole side facing
out.
• Route the wires properly (page 1-32).
• Perform the crank pulse initialize learning procedure
(page 4-83) (ED, KO only).
Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-12).

STATOR
REMOVAL/INSTALLATION
Remove the alternator cover (page 11-4).
[2]
Release the wire grommet [1] from the alternator cover
groove. [1]

Remove the alternator wire clamper bolt [2] and

alternator wire clamper [3].
Remove the stator bolt [4] and stator [5]. [5]
Installation is in the reverse order of removal.
TORQUE: [3]
Stator bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

[4]
• Apply locking agent to the stator bolt threads.
• Apply liquid sealant (TB1207B manufactured by
Three Bond or equivalent) to the alternator wire
grommet mating surface of the alternator cover as
shown.
• Route the wires properly (page 1-32).

11-5
 dummyhead

ALTERNATOR/STARTER CLUTCH
FLYWHEEL
REMOVAL
Remove the alternator cover (page 11-4).

• Be careful not to damage the crank pulser plate [1] [3]

when the flywheel servicing.
Remove the starter reduction gear shaft [2] and starter
reduction gear B [3]. [4]

Remove the starter reduction gear shaft [4] and starter

reduction gear A [5].
[2]

[5]
[1]

Hold the flywheel [1] using the special tool and loosen
[2]/[4]
the flywheel mounting bolt [2].
TOOL:
Flywheel holder [3] 07725-0040001
Remove the flywheel mounting bolt and washer [4].

[1] [3]

Remove the flywheel [1] using the special tool.

[1]
TOOL:
Rotor puller [2] 07733-0020001

[2]

Remove the needle bearing [1].

Remove the woodruff key [2].

[1]
• Be careful not to damage the key groove and
crankshaft.

[2]

11-6
dummyhead

ALTERNATOR/STARTER CLUTCH
DISASSEMBLY/ASSEMBLY
Remove the starter driven gear (page 11-8).
[4]
Hold the flywheel [1] using the special tool.
TOOL:
Flywheel holder [2] 07725-0040001
[3] [2]
Remove the crank pulser plate bolts [3] and crank
pulser plate [4].
Assembly is in the reverse order of disassembly.
Align

• Be careful not to damage the crank pulser plate.

• Align the crank pulser plate tab with the flywheel
groove.
[1]
• Apply locking agent to the crank pulser plate bolt
threads (page 1-27).

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
Replace if necessary.

INSTALLATION
Install the woodruff key [1].

• Be careful not to damage the key groove and

crankshaft. [2]
Apply engine oil to the needle bearing rotating area.
Install the needle bearing [2].

[1]

Clean any oil from the crankshaft and flywheel tapered

[2] [3]/[4]
areas thoroughly.
Install the flywheel [1] to the crankshaft.

• 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
and seating surface. Align
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.
[5] [1]
TOOL:
Flywheel holder [5] 07725-0040001

TORQUE: 137 N·m (14.0 kgf·m, 101 lbf·ft)

11-7
 dummyhead

ALTERNATOR/STARTER CLUTCH
Apply molybdenum oil solution to the starter reduction
gear shafts outer surfaces.
Install the starter reduction gear A [1] and shaft [2]. [3]
Install the starter reduction gear B [3] and shaft [4].
Install the alternator cover (page 11-4). [2]

[4]

[1]

STARTER CLUTCH
REMOVAL

• 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.

Hold the flywheel [1] using the special tool.

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

[1]

Remove the starter clutch assembly [1].

[2]
Remove the starter one-way clutch [2] from the starter
clutch outer [3].

[1]

[3]

11-8
dummyhead

ALTERNATOR/STARTER CLUTCH
INSPECTION
Inspect the following parts for scratches, damage,
abnormal wear, or deformation.
– Starter driven gear
– Starter clutch outer
– Starter one-way clutch
Measure each part according to ALTERNATOR/
STARTER CLUTCH SPECIFICATIONS (page 1-10).
Replace any part if it is out of service limit.

INSTALLATION

• Be careful not to damage the crank pulser plate

when the starter clutch servicing.
Apply engine oil to the starter one-way clutch sliding
[1]
surface.
Install the starter one-way clutch [1] to the starter clutch
outer [2].
[3]
Install the starter clutch assembly [3].

[2]

Hold the flywheel [1] using the special tool.

[3]
TOOL:
Flywheel holder [2] 07725-0040001
Apply locking agent to the starter clutch torx bolt [2]
threads (page 1-27).
Install and tighten the starter clutch torx bolts [3] to the
specified torque.
[1]
TORQUE: 29 N·m (3.0 kgf·m, 21 lbf·ft)

Install the starter driven gear [1] into the starter clutch
outer while turning the starter driven gear
counterclockwise.
[1]
Recheck the one-way clutch operation (page 11-8).
Install the flywheel (page 11-7).

11-9
dummyhead

MEMO
dummytext

12. CLUTCH/GEARSHIFT LINKAGE (MT model)

SERVICE INFORMATION ···························12-2 PRIMARY DRIVE GEAR ··························· 12-16

TROUBLESHOOTING·································12-2 GEARSHIFT LINKAGE ····························· 12-18

COMPONENT LOCATION ··························12-3 GEARSHIFT ARM/GEARSHIFT

PEDAL······················································· 12-21
RIGHT CRANKCASE COVER ····················12-4
CLUTCH LEVER ······································· 12-23
CLUTCH ······················································12-8 12

12-1
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

SERVICE INFORMATION
CLUTCH/GEARSHIFT LINKAGE (MT model)

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.

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 14-13)
• Bent shift fork shaft (page 14-13)
• Bent shift fork claw (page 14-13)
• Loose shift drum center bolt
• Damaged shift drum center
• Damaged shift drum guide grooves (page 14-13)
• 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 14-13)
• Damaged or bent shift forks (page 14-13)
• Worn gear engagement dogs or slots
– Mainshaft (page 14-14)
– Countershaft (page 14-13)
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Damaged or bent gearshift spindle

12-2
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

COMPONENT LOCATION

23 N·m (2.3 kgf·m, 17 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

128 N·m (13.1 kgf·m, 94 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12-3
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

RIGHT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-12).
[3]
Drain the coolant (page 8-5).
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].

[2]

[4] [1]

Cut off and remove the hose clamp [1].

[1] [2]
Disconnect the bypass hose [2].
Loosen the hose band screw [3].
Disconnect the radiator hose B [4].

[4] [3]

Remove the right crankcase cover bolts [1].

[2] [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].

• Be careful not to drop the return spring [4].

[4]

[3]

[4]

12-4
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Remove the dowel pins [1] and gasket [2].
[1]

[1] [2]

Remove the O-ring [1].

[1]

CLUTCH LIFTER LEVER

REMOVAL/INSTALLATION
Remove the right crankcase cover (page 12-4).
[1]
Remove the clutch lifter lever [1] and return spring [2].
Installation is in the reverse order or removal.

• Align the return spring end with the clutch lifter lever Hook
groove.
• Hook the return spring end to the right crankcase
cover groove.

[2]
Align

OIL SEAL/BEARING REPLACEMENT

Remove the clutch lifter lever (page 12-5).
6.5 – 7.5 mm
Remove the oil seal [1]. (0.26 – 0.30 in)
Remove the needle bearings. 0.3 – 0.8 mm
(0.01 – 0.03 in)
Apply engine oil to new needle bearings. [2]
Install the needle bearings to the specified depth as
shown.
Install a new oil seal to the specified depth as shown.
Apply grease to the oil seal lips.
Install the clutch lifter lever (page 12-5).

69.4 – 70.4 mm
[1] (2.73 – 2.77 in)

12-5
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

INSPECTION
Inspect the following parts for scratches, damage,
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 O-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.

[1]

Align

Align the following by rotating the crankshaft:

[1]/[2]
– Primary drive gear index line [1]
– Crankcase " " mark [2]
Make sure that the front balancer shaft end [3] is in
position as shown.

[3]

12-6
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Install the dowel pins [1] and a new gasket [2].
[1]

[1] [2]

Turn the clutch lifter lever [1] clockwise so that the lever
[1]
slit [2] is in position as shown.

[2]

Install the right crankcase cover [1] by holding the

[2] [3]
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)

[1]

Connect the radiator hose B [1].

Tighten the hose band screw [2] to the specified range
(page 8-7).

[1] [2]

12-7
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Install a new hose clamp [1] onto the bypass hose [2].
[1] [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

[3]

[2] [3]
1.0 mm
(0.04 in)
[1]

[1]

[4]

Connect the clutch cable [1] to the clutch lifter lever [2].
[1]
Install the right rear engine cover (page 2-27).
Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-12).
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-5).
Adjust the clutch cable freeplay (page 3-25).

[2]

CLUTCH
REMOVAL
Remove the right crankcase cover (page 12-4).
[1]/[3]
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].

[2]

12-8
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Remove the following:
[8] [9]
– Clutch pressure plate [1]
– Clutch lifter pin [2]
– 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]
– Judder spring [8]
– Judder spring seat [9] [3]
Remove the clutch spring seats [10] from the clutch
pressure plate.
[7]
• When removing the clutch friction discs and clutch
plates, note the number of them.
[5] [6]
[4]

[10] [1] [2] [3]

Unstake the clutch center lock nut [1].

• Be careful not to damage the mainshaft threads. Unstake

[1]

Install special tool.

[2]
TOOL:
Clutch center holder 07724-0050002
P.D. 48 – 135 [1]
Loosen the clutch center lock nut [2] while holding the
clutch center with the special tool.
Remove the lock nut.

[1]

Remove the spring washer [1], thrust washer [2], and

[1] [2]
clutch center [3].

[3]

12-9
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Remove the washer [1] and clutch outer [2].
[1]

[2]

Remove the washer [1] and clutch outer guide [2].

[1]

[2]

INSPECTION
Check the following for scratches, damage, abnormal
wear and deformation:
– Clutch pressure plate cam areas [1]
[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.

[4]
[2]

[3] [5]

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] [3] [4]

12-10
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Check the following of the for scratches, damage,
[2] [1] [4]
abnormal wear and deformation:
– Clutch outer grooves [1]
– Clutch outer needle bearing [2]
– Primary driven gear [3]
Replace the clutch outer [4] if necessary.

[3]

Inspect the following parts for scratches, damage,

abnormal wear and deformation. Replace if necessary.
– 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 1-11).
Replace any part if it is out of service limit.

• Replace the clutch springs as a set.

• Replace the clutch friction discs and plates as a set.

12-11
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

INSTALLATION

CLUTCH CENTER CLUTCH OUTER

WASHER
THRUST WASHER
JUDDER SPRING SEAT

SPRING WASHER JUDDER

SPRING

CLUTCH CENTER
LOCK NUT
128 N·m
(13.1 kgf·m, 94 lbf·ft)

CLUTCH
FRICTION
DISC C

CLUTCH
PLATE B

CLUTCH PLATES
(5 pcs) CLUTCH PLATE C

CLUTCH FRICTION
DISCS B (6 pcs)
CLUTCH FRICTION DISC C

CLUTCH CLUTCH
FRICTION FRICTION CLUTCH LIFTER PIN
DISCS B DISCS C CLUTCH SPRING SEATS

CLUTCH PRESSURE PLATE

Apply molybdenum oil solution to the clutch outer guide

[2]
entire surface.
Install the clutch outer guide [1] and washer [2].

[1]

12-12
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

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].

[1]

[2]

Install the clutch center [1], thrust washer [2], and spring
[3] [4] [2]
washer [3].

• Install the spring washer with its "OUT" mark [4]

facing out.

[1]

Apply engine oil to a new clutch center lock nut threads

[1]
and seating surface.
Install the clutch center lock nut [1] onto the mainshaft.
Install special tool.
TOOL:
Clutch center holder
P.D. 48 – 135 [2] 07724-0050002
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)
[2]

Stake the clutch center lock nut [1].

• Be careful not to damage the mainshaft threads. Stake

[1]

12-13
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

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]
onto the clutch center [3] as shown. [2] [1] [1] [2] [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.

• The clutch friction disc C lining width is smaller than [7]

the clutch friction disc B.
• Clutch plate surface treatment is difference from [6]
clutch plate B.
[4]

[5]

Install the spring seats [1] onto the clutch pressure plate
[2]
[2] grooves.

• Make sure that the spring seats are fully seated in

the pressure plate grooves.

[1] [1]

Install the clutch lifter pin [1].

[1]

12-14
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Apply engine oil to the entire surface of clutch friction [2] [1] [3]
disc C.
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.

• Align the clutch plate C grooves with the clutch [2]

pressure plate lugs.

[3]
Align
[1]

Install the clutch pressure plate assembly [1] by rotating

[1]
counterclockwise.

• Install the clutch disc C tabs [2] into the shallow slots
[3] of the clutch outer.

[2]

[3]

Install the clutch springs [1], clutch set plate [2] and
[1]/[3]
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 lbf·ft)
Install the right crankcase cover (page 12-6).

[2]

12-15
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

PRIMARY DRIVE GEAR
REMOVAL
Remove the cylinder head (page 10-18).
[3]
Remove the cam chain guide plate bolts [1], cam chain
guide plate [2], and cam chain [3].

[2]

[1]

Install the special tool between the primary drive and

[1]
driven gears.
TOOL:
Gear holder, 2.5 [1] 07724-0010100
Remove the primary drive gear bolt [2] and washer [3].
[3]
Remove the special tool.

[2]

Remove the timing sprocket [1] and primary drive gear

[1]
[2].

[2]

INSPECTION
Inspect the following parts for scratches, damage,
abnormal wear and deformation. Replace if necessary.
– Primary drive gear
– Timing sprocket

12-16
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

INSTALLATION
Apply engine oil to the primary drive gear teeth.
Install the primary drive gear [1].
Align
• Align the primary drive gear wide tooth with the
crankshaft wide tooth. Align
• Make sure that the primary drive gear index line is
positioned between the rear balancer driven gear
index lines.

[1]

Apply engine oil to the timing sprocket teeth.

Install the timing sprocket [1].
[1]
[2]
• Install the timing sprocket with its punch mark [2]
facing out.
• Align the timing sprocket wide tooth with the
crankshaft wide tooth.

Align

Apply engine oil to the primary drive gear bolt threads

[1]
and seating surface.
Install the washer [1] and primary drive gear bolt [2].
Install the special tool between the primary drive and
driven gears.
TOOL:
Gear holder, 2.5 [3] 07724-0010100
Tighten the primary drive gear bolt to the specified [2]
torque.
TORQUE: 103 N·m (10.5 kgf·m, 76 lbf·ft)
Remove the special tool. [3]

Coat the cam chain with the engine oil.

[1]
Install the cam chain [1].
Apply locking agent to the cam chain guide plate bolts
threads (page 1-27).
Install the cam chain guide plate [2] and cam chain [2]
guide plate bolts [3].
Tighten the cam chain guide plate bolts securely.
Install the cylinder head (page 10-24).

[3]

12-17
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

GEARSHIFT LINKAGE
REMOVAL
Remove the following:
[3] [2]
– Clutch (page 12-8)
– Gearshift arm (page 12-21)
Remove the gearshift spindle cover bolts [1].
Release the wire clip [2]. [1]
Remove gearshift spindle cover [3]. [1]
Clean off any dirt from the gearshift spindle serration
[4].

[4]

Remove the gearshift spindle set plate bolt [1] and set
[1]
plate [2].

[2]

Remove the gearshift spindle assembly [1] and thrust

[1] [2]
washer [2].

Remove the shift drum center bolt [1].

[1]

12-18
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Remove the shift drum center [1] while holding the shift
[2]
drum stopper arm [2] using a screwdriver as shown.

[1]

Remove the following:

[1]
– Dowel pin [1]
– Shift drum stopper arm pivot bolt [2]
– Shift drum stopper arm [3]
– Shift drum return spring [4] [4]
– Washer [5]

[2]/[5]

[3]

Remove the oil seal [1].

[1]

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

12-19
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

INSTALLATION
Install a new oil seal [1] until it is fully seated.
[1]
Apply grease to the oil seal lips.

Apply locking agent to the shift drum stopper arm pivot [3] [2] [1]
[5]
bolt threads (page 1-27).
Install the following: [4]
– Shift drum return spring [1] [1]
– Washer [2]
– Shift drum stopper arm [3]
– 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)
[2]/[4]
Check the shift drum stopper arm for proper operation.
[3]
Install the dowel pin [5].
Hold the shift drum stopper arm [1] using a screwdriver.
[1]
Install the shift drum center [2].

Align
• Align the shift drum center groove with the dowel
pin.

[2]

Apply locking agent to the shift drum center bolt threads

[1]
(page 1-27).
Install and tighten the shift drum center bolt [1] to the
specified torque.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)

12-20
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Install the thrust washer [1] onto the gearshift spindle
[2] [1]
[2].
Install the gearshift spindle into the crankcase.

• Align the gearshift spindle return spring ends with

the spring pin.

Align

Apply locking agent to the gearshift spindle set plate

[2] [3]
bolt threads (page 1-27).
Install the set plate [1] and gearshift spindle set plate
bolt [2].

• Install the set plate with its punch mark [3] facing
out.
Tighten the gearshift spindle set plate bolt to the
specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[1]

Install the gearshift spindle cover [1] and gearshift

[1] [3]
spindle cover bolts [2].
Tighten the gearshift spindle cover bolts to the specified
torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) [2]
Install the wire clip [3] to the gearshift spindle cover. [2]

• Route the wire harness properly (page 1-32).

Install the following:
– Clutch (page 12-12)
– Gearshift arm (page 12-21)

GEARSHIFT ARM/GEARSHIFT PEDAL

REMOVAL/INSTALLATION
Remove the pinch bolt [1] and gearshift arm [2] from the
[1]
gearshift spindle [3].

[3]
Align

[2]

12-21
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

Remove the gearshift pedal pivot bolt [1].
[3] [4]
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.
Installation is in the reverse order of removal.
TORQUE:
Gearshift pedal pivot bolt:
27 N·m (2.8 kgf·m, 20 lbf·ft)

• 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].

• 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)

12-22
dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

CLUTCH LEVER
REMOVAL/INSTALLATION
Remove the left rearview mirror [1].
[1]
Remove the screw [2].

[2]

Disconnect the following:

– Clutch switch connectors (upper side) [1]
– Cruise cancel switch connectors (lower side) [2]

[2] [1]

Loosen the lock nut [1] and disconnect the clutch cable
[1] [2]
by turning the adjuster bolt [2].
Remove the bolts [3], holder [4], and clutch lever
assembly [5].
Installation is in the reverse order of removal.

• 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).

[3]

[5]
[6]

Align

[4]
[3]

12-23
 dummyhead

CLUTCH/GEARSHIFT LINKAGE (MT model)

DISASSEMBLY/ASSEMBLY

CLUTCH CRUISE
CANCEL SWITCH

CLUTCH
CLUTCH SWITCH SWITCH
LOCK NUT
ADJUSTER BOLT

CLUTCH LEVER
BRACKET

CLUTCH SWITCH
MOUNTING SCREW
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

CLUTCH LEVER PIVOT BOLT

1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)

WELL NUT

PLASTIC WASHER

KNUCKLE GUARD
HOLDER

COLLAR CLUTCH CRUISE

CLUTCH LEVER
CANCEL SWITCH
CLUTCH LEVER PIVOT NUT
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)

12-24
dummytext

13. DUAL CLUTCH TRANSMISSION (DCT model)

SERVICE INFORMATION ···························13-2 SHIFT CONTROL MOTOR/REDUCTION

GEARS ······················································ 13-55
DCT SYMPTOM TROUBLESHOOTING ·····13-3
GEARSHIFT LINKAGE ····························· 13-58
COMPONENT LOCATION ··························13-4
MAINSHAFT SENSOR ····························· 13-62
SYSTEM LOCATION···································13-5
TR SENSOR·············································· 13-63
SYSTEM DIAGRAM ····································13-6
SHIFT SPINDLE ANGLE SENSOR ·········· 13-64
13
DCT TROUBLESHOOTING
INFORMATION············································13-7 CLUTCH EOP SENSOR ··························· 13-64

DCT DTC INDEX ·······································13-10 EOT SENSOR ··········································· 13-65

DCT DTC TROUBLESHOOTING··············13-12 EOP SENSOR ··········································· 13-65

CLUTCH OIL FEED PIPE··························13-39 NEUTRAL SWITCH ·································· 13-66

RIGHT CRANKCASE COVER ··················13-41 TCM ··························································· 13-66

LINEAR SOLENOID VALVE ·····················13-47 DCT RELAY ·············································· 13-68

DUAL CLUTCH/PRIMARY DRIVEN CLUTCH INITIALIZE LEARNING

GEAR·························································13-51 (TCM)························································· 13-68

PRIMARY DRIVE GEAR ···························13-54

13-1
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

SERVICE INFORMATION
DUAL CLUTCH TRANSMISSION (DCT model)

GENERAL
• This section covers service of the electrical and mechanical systems of the Dual Clutch Transmission (DCT).
• A faulty DCT system is often related to poorly connected or corroded connectors. Check those connections before proceeding.
• Read the "DCT Troubleshooting Information" carefully, and inspect and troubleshoot the DCT system according to the DTC.
Perform each step of the procedures one by one. Note the DTC 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 13-68).
• The drive mode AT or MT are changed electrically with the A/M switch.
• 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 22-26)
• For right handlebar switch service (page 22-33)
• For VS sensor service (page 4-79)
• For oil pump service (page 9-5)
• 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 O = Orange P = Pink R = Red V = Violet
W = White Y = Yellow

For DCT System Troubleshooting

• The DCT system is controlled by the TCM. Therefore, some detection items are shared in the PGM-FI and DCT 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 DTC for the PGM-FI system appeared (page 4-5).
– Shift indicator blinks or DTC for the DCT system appeared (page 13-7)
– Symptom of the DCT system operation (page 13-3)
• The gearshift mechanism includes the following items. If the gearshift mechanism is faulty, refer to each component service.
– Shift control motor/reduction gears (page 13-55)
– Gearshift linkage (page 13-58)
– Shift drum/shift fork (page 14-13)

Shift Control Motor Function Procedures

• If the system has a DTC, 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
– Shift spindle angle sensor
Connect the MCS (page 4-6), and perform the shift control motor function test.

Linear Solenoid Valve Function Procedures

• If the system has a DTC, 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
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DCT SYMPTOM TROUBLESHOOTING
Check the shift indicator "–" blinking of the meter (page 13-7).
If the shift indicator "–" is blinking, refer to the DTC 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 13-52).

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.

13-3
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

COMPONENT LOCATION

31 N·m (3.2 kgf·m, 23 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

118 N·m (12.0 kgf·m, 87 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m
(1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)

13-4
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

SYSTEM LOCATION

FUSE BOX
– FI 15 A
N-D SWITCH – MAIN2 30 A
– DCT-M 30 A
MID A/M SWITCH

ECM FI RELAY

METER
IMU

TCM

SHIFT UP
SWITCH (+) DLC

SHIFT DOWN DCT RELAY

SWITCH (–)

FRONT WHEEL
SPEED SENSOR

No.1 CLUTCH
EOP SENSOR
POWER BOX
SHIFT – SUB VB 10 A
CONTROL – ST-MAG 10 A
MOTOR – SUB VB RELAY

CKP SENSOR

REAR WHEEL
SPEED SENSOR
VS SENSOR
TR SENSOR
SHIFT SPINDLE
EOP SENSOR
No.2 CLUTCH ANGLE SENSOR
OUTER MAINSHAFT EOP SENSOR
SENSOR STARTER RELAY SWITCH
INNER MAINSHAFT – MAIN FUSE 30 A
SENSOR
LINEAR SOLENOID VALVE

NEUTRAL SWITCH CLUTCH LINE EOP SENSOR

EOT SENSOR

13-5
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

SYSTEM DIAGRAM
MAIN IGNITION FI
FUSE SWITCH ST-MAG RELAY
Bl/Gr Bl 30A R R/Bl 10A Bl G

W FI 15A R/Bu Br/Bl Br

DCT
RELAY
G Y

BATTERY DCT-M R/W W

W 30A SUB VB
RELAY
G

V
MAIN2 SUB VB Br
30A 10A R/W A7 IGP
W R W
A3 PVB
W
A14 PVB
V V Bu
A8 SUBVB LSOLHN A19
P Bl
B25 NM2P PT_CANL A21 ECM
Gr Bl/R
PT_CANH A33
Bl
FRM_CANL B2
G/Bl Gr Bl/R
OUTER FRM_CANH B13
MAINSHAFT V Bl/W P
A18 NM1P
SENSOR
INNER
MAINSHAFT METER
SENSOR

Bl/Bu Bl
B32 HSFT
ABS
SHIFT UP SWITCH (+) MODULATOR

SHIFT DOWN SWITCH (-)

G/W
BCU
Bl/Bu V
B31 RANGE
N SWITCH
CRF1100D4/DL4

D SWITCH SCU
TCM

A/M SWITCH G/W

Gr IMU
A22 SG
CLUTCH R
B18 PLINE
LINE EOP Y/R Y/R
SENSOR A4 VCC

P/Bu
SFTMOP A1
No.1 CLUTCH Y/G P/Bu Bu
B19 PC1 SFTMOP A12 SHIFT CONTROL
EOP SENSOR Y/R Y/Bu Y
SFTMOM A2 MOTOR
Y/Bu
SFTMOM A13
No.2 CLUTCH Bl
B8 PC2 Y
EOP SENSOR Y/R LSOL1P A5
W W/R No.1 LINEAR
LSOL1M A9 SOLENOID
Bu Gr
VALVE
W Bu
B20 SPDL LSOL2P A6 No.2 LINEAR
SHIFT SPINDLE Bl Y Gr
ANGLE SENSOR LSOL2M A10 SOLENOID
VALVE
G Gr
W W
B7 DRUMANG K-LINE B3
Y/R Y
TR SENSOR

DUMMY Y Br
SHIFT PEDAL Gr Y
ANGLE SENSOR Y Y
B10 SFTPANG
G/Bu

EOT SENSOR Bu G/Bu

B21 TOIL LG A11
G DLC
PG A23 Bl : Black
Lg G
A32 NEUTRAL PG A24 Br : Brown
Bu : Blue
G : Green
NEUTRAL
SWITCH Gr : Gray
Lg : Light green
P : Pink
R : Red
W : White
Y : Yellow
V : Violet
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 23 24 25 26 27 28 29 30 31 32 33

TCM 33P (Black) TCM 33P (Gray)

CONNECTOR A CONNECTOR B
(TCM SIDE) (TCM SIDE)

13-6
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

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 13-8).
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 13-3).

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 DTC/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-
8).
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 13-8).
• 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.
• 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.

2 sec. 1.2 sec. 2 sec. 1.2 sec.

ON

OFF

2.5 sec. 2.5 sec. 0.4 sec. 2.5 sec. 0.4 sec. 2.5 sec. 2.5 sec. 0.4 sec.

DTC 14 DTC 8 DTC 14

One long blink = 10 blinks, Eight short blinks
plus four short blinks

Pattern repeated
1 cycle

13-7
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

GST (Generic Scan Tool) INFORMATION
Refer to the PGM-FI system (page 4-6).

MCS INFORMATION
Refer to the PGM-FI system (page 4-6).

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

• If there is any problem in the PGM-FI system, troubleshoot it first. Then recheck the DCT system after erasing the PGM-FI DTC.
Read the DTC and stored data with the MCS or GST, and follow the troubleshooting index (page 13-10).
To read the DTC without the MCS or GST, use the following procedure.
Reading DTC with the shift indicator "–"
1. Connect the SCS short connector to the DLC (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).

• If the TCM has no DTC in its memory, the shift indicator "–" will start
blinking (page 13-9).
3. Release the shift up switch (+).

13-8
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

ERASING DTC
Connect the MCS to the DLC (page 4-6) or connect the GST to the DLC (page 4-6).
Erase the DTC with the MCS or GST while the engine is stopped.
To erase the DTC without MCS or GST, refer to the following procedure.
How to erase the DTC without MCS or GST
1. Erase the DTC (page 4-8).
2. The DTC is erased if the shift indicator "–" goes off and starts blinking as shown.

2 sec. 2 sec. 2 sec.

ON

OFF

3 sec. 3 sec. 3 sec.

Pattern repeated
1 cycle

Note that the DTC cannot be erased if the ignition switch is turned to "OFF" before the shift indicator "–" starts blinking.
3. Turn the ignition switch OFF.
4. Remove the special tool from the DLC.

13-9
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DCT DTC INDEX
• If GST or MCS is not used, perform all of the inspection of on the corresponding main code (digits in front of hyphen) of the DTC.
• About Diagnostic Trouble Codes other than in this DTC INDEX, refer to PGM-FI SYSTEM DTC INDEX (page 4-10).
• Follow the prior diagnosis notes before performing the troubleshooting, refer to the PRIOR DIAGNOSIS (page 13-12).
DTC Detected D/C Refer to
DTC DTC name
(Honda code) (Driving Cycle) page
EOT Sensor Circuit Low
P0197 44-1 –
(EOT Sensor Low Voltage)
13-13
EOT Sensor Circuit High
P0198 44-2 –
(EOT Sensor High Voltage)
VSP Sensor 1 Malfunction
P0500 67-1 1 4-42
(Front Wheel Speed Sensor Malfunction)
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 4-44
(Sub VB Relay Malfunction)
Control Module Processor
P0606 – 1 4-48
(CPU in the ECM Malfunction)
ECM/PCM Power Relay Control Circuit Low
P0686 37-1 1
(Ignition Hold Relay Stuck OFF)
4-44
ECM/PCM Power Relay Control Circuit High
P0687 37-1 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
(VS Sensor Circuit No Signal)
OS Sensor Circuit No Signal
P0722 11-1 1 4-50
(VS Sensor Circuit No Signal)
Pressure Control Solenoid Malfunction
55-1 1
(No.1 Linear Solenoid Valve Current Failure)
P0745 13-17
Pressure Control Solenoid Malfunction
55-2 1
(No.1 Linear Solenoid Valve Driver in the TCM Failure)
Pressure Control Solenoid 2 Malfunction
56-1 1
(No.2 Linear Solenoid Valve Current Failure)
P0775 13-18
Pressure Control Solenoid 2 Malfunction
56-2 1
(No.2 Linear Solenoid Valve Driver in the TCM Failure)
Park/Neutral Switch Input Circuit Low
P0851 52-1 –
(Neutral Switch Stuck OFF)
13-19
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
P170B 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 4-58
(CPU in the TCM Malfunction)

13-10
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC Detected D/C Refer to
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
Gearshift Mechanism))
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
(No.1 Clutch Operation Malfunction (Clutch Slips))
Clutch (2) Being Dysversion
P171A 69-1 1 13-30
(No.2 Clutch Operation Malfunction (Clutch Slips))
Clutch Bite Crowded (Clutch 1 No Opening)
P171B 58-1 –
(No.1 Clutch Does Not Disengage (When Shifting Gear))
13-30
Clutch Bite Crowded (Clutch 2 No Opening)
P171C 59-1 –
(No.2 Clutch Does Not Disengage (When Shifting Gear))
Clutch Bite Crowded (1) Pressure No Opening
P171D 61-4 –
(No.1 Clutch Oil Pressure Canceling Malfunction)
Clutch (1) Hydraulic Pressure Malfunction
P171E 61-1 1 (No.1 Clutch Oil Pressure Malfunction (at Clutch Initial
Diagnosis))
Clutch (1) No Pressure
P171F 61-2 1
(No.1 Clutch No Oil Pressure)
Clutch (1) Hydraulic Pressure Low
P1720 61-3 1
(No.1 Clutch Oil Pressure Degradation)
Clutch (1) Hydraulic Pressure Rise
P1721 62-1 –
(No.1 Clutch Oil Pressure High)
13-31
Clutch Bite Crowded (2) Pressure No Opening
P1722 63-4 –
(No.2 Clutch Oil Pressure Canceling Malfunction)
Clutch (2) Hydraulic Pressure Malfunction
P1723 63-1 1 (No.2 Clutch Oil Pressure Malfunction (at Clutch Initial
Diagnosis))
Clutch (2) No Pressure
P1724 63-2 1
(No.2 Clutch No Oil Pressure)
Clutch (2) Hydraulic Pressure Low
P1725 63-3 1
(No.2 Clutch Oil Pressure Degradation)
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 –
(Shift Pedal Angle Sensor (Option) Malfunction)
13-31
Shift Angle Sensor High Voltage
P172B 1-1 –
(Shift Pedal Angle Sensor (Option) Malfunction)
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
Gearshift Mechanism))
VSP Sensor 2 Malfunction
P2158 66-1 1 4-64
(Rear Wheel Speed Sensor Malfunction)
Input Speed Sensor 2 Circuit
P2765 54-1 1 13-37
(Outer Mainshaft Speed Low)
CAN Communication Malfunction (PTCAN)
U019E 112-1 1 4-70
(Power train CAN Communication Malfunction)

13-11
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DCT DTC TROUBLESHOOTING
PRIOR DIAGNOSIS
Before processing the DTC troubleshooting, check as
follows:
• Check for loose or poor contact on the DTC related
connectors (each sensor, solenoid, unit etc.), then
recheck the DTC.
• Erase the DTC (page 13-9) and recheck it.
• Refer to probable cause of each detected DTC and
check the listed items first. If possible, correct the
abnormally.

• Always turn the ignition switch OFF when checking

the continuity of the circuit and before disconnecting
the connectors.
• Some DTCs have a recheck function, so that the
priority DTC is detected when the ignition switch is
switched from OFF to ON. Wait for 10 seconds and
check the DTC again.

COMMON TROUBLESHOOTING
INFORMATION

• Always use the test probe when inspecting at the

ECM, TCM, ABS modulator, BCU, and SCU
connectors.
TOOL:
Test probe 07ZAJ-RDJA110
• If the ECM is replaced, perform the following:
– CKP sensor initialize learning procedure (page 4-
84)
– Key Registration Procedure (page 23-5)
• If the TCM is replaced, perform the Clutch Initialize
Learning Procedure (page 13-68).
• 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.

13-12
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P0197/DTC P0198
Probable cause:
• Faulty EOT sensor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function works normally
1. EOT Sensor Input Line Open Circuit Inspection
Disconnect the TCM 33P (Gray) connector (page
13-66).
Disconnect the EOT sensor connector (page 13-
65).
Check for continuity between the wire harness side
EOT sensor connector [1] and TCM 33P (Gray) B21
connector [2].
Bu
CONNECTION: Blue – B21
Is there continuity?
YES – GO TO STEP 2.
NO – Open circuit in the Blue wire
[1] [2]

2. EOT Sensor Ground Line Open Circuit

Inspection
Disconnect the TCM 33P (Black) connector (page
13-66).
Check for continuity between the wire harness side
EOT sensor connector [1] and TCM 33P (Black)
connector [2].
CONNECTION: Gray – A22 A22
Is there continuity? Gr

YES – GO TO STEP 3.
NO – Open circuit in the Gray wire

[1] [2]

3. EOT Sensor Input Line Short Circuit Inspection

Check the continuity between the wire harness side
[1]
EOT sensor connector [1] and ground.
CONNECTION: Blue – Ground
Is there continuity? Bu
YES – Short circuit in the Blue wire
NO – GO TO STEP 4.

13-13
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

4. EOT Sensor Inspection
Replace the EOT sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original EOT sensor

DTC P0501
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 DTC
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates normally
• Cruise control does not operate
Refer to DTC P0500 troubleshooting (page 4-42).

DTC P0522/DTC P0523

Probable cause:
• Faulty EOP sensor or its related circuit
• Faulty ECM
Symptom/Fail-safe function:
• Engine operates at idle speed
1. EOP Sensor Input Line Open Circuit Inspection
Disconnect the EOP sensor connector (page 13-
65).
Measure the voltage at the wire harness side EOP
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 Gr Y
• If the wire is OK, replace the ECM with
a new one, and recheck.

[1]

13-14
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

2. EOP Sensor Output Line Open Circuit
Inspection
Disconnect the ECM 33P (Gray) connector (page 4-
[1] [2]
77).
Check for continuity between the wire harness side
EOP sensor connector [1] and ECM 33P (Gray)
connector [2].
CONNECTION: White – C20
Is there continuity?
YES – GO TO STEP 3. W
C20
NO – Open circuit in the White wire

3. EOP Sensor Output Line Short Circuit

Inspection
Check for continuity between the wire harness side
[1]
EOP sensor connector [1] and ground.
CONNECTION: White – Ground
Is there continuity?
YES – Short circuit in the White wire
NO – GO TO STEP 4. W

4. EOP Sensor Inspection

Replace the EOP sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original EOP sensor

13-15
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P0715
Probable cause:
• Electromagnetic interference
• Faulty inner mainshaft sensor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Inner Mainshaft Sensor Input Voltage Inspection
Disconnect the inner mainshaft sensor connector
[1]
(page 13-62).
Turn the ignition switch ON.
Measure the voltage at the wire harness side inner
mainshaft sensor connector [1].
CONNECTION: Violet (+) – Gray (–)
V Gr
Is there about battery voltage?
YES – GO TO STEP 2.
NO – • Open or short circuit in the Violet wire
• Open circuit in the Gray wire
• If the wire is OK, replace the TCM with
a new one, and recheck.

2. Inner Mainshaft Sensor Output Line Open

Circuit Inspection
Check for continuity between the wire harness side
inner mainshaft sensor connector [1] and TCM 33P
(Black) connector [2].
CONNECTION: Pink – A18
Is there continuity?
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
Check for continuity between the wire harness side
[1]
inner mainshaft sensor connector [1] and ground.
CONNECTION: Pink – Ground
Is there continuity?
YES – Short circuit in the Pink wire
P
NO – GO TO STEP 4.

13-16
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

4. Inner Mainshaft Sensor Inspection
Replace the inner mainshaft sensor with a new one.
Erase the DTC.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original inner mainshaft sensor

DTC P0721
Probable cause:
• Faulty rear wheel pulser ring or its related parts
• ABS modulator has DTC
• Faulty ECM
Symptom/Fail-safe function:
• Cruise control does not work

• When other DTC is displayed, together with P0721,

troubleshoot it first.
1. Rear Wheel Pulser Ring Inspection
Replace the rear wheel pulser ring with a new one.
Erase the DTC.
Perform the test ride (page 4-17).
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original rear wheel pulser ring

DTC P0745
Probable cause:
• Faulty No.1 linear solenoid valve or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. No.1 Linear Solenoid Valve Line Open Circuit
Inspection
Disconnect the TCM 33P (Black) connector (page
[1] [2]
13-66).
Disconnect the liner solenoid valve connector (page
13-47).
Check for continuity between the wire harness side A5
linear solenoid valve connector [1] and TCM 33P
(Black) connector [2]. Y
CONNECTION:
Yellow – A5
W
White – A9 A9
Is there continuity?
YES – GO TO STEP 2.
NO – • Open circuit in the Yellow wire
• Open circuit in the White wire

13-17
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

2. No.1 Linear Solenoid Valve Line Short Circuit
Inspection
Check for continuity between the wire harness side
[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.

3. No.1 Linear Solenoid Valve Inspection

Replace the linear solenoid valve with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Start the engine and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
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
Symptom/Fail-safe function:
• Gearshift function does not work
1. No.2 Linear Solenoid Valve Line Open Circuit
Inspection
Disconnect the TCM 33P (Black) connector (page
[1] [2]
13-66).
Disconnect the liner solenoid valve connector (page
13-47).
Check for continuity between the wire harness side A6
linear solenoid valve connector [1] and TCM 33P
Bu
(Black) connector [2].
CONNECTION:
Blue – A6 Gr
Gray – A10 A10
Is there continuity?
YES – GO TO STEP 2.
NO – • Open circuit in the Blue wire
• Open circuit in the Gray wire

13-18
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

2. No.2 Linear Solenoid Valve Line Short Circuit
Inspection
Check for continuity between the wire harness side
[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.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Start the engine and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original No.2 linear solenoid valve

DTC P0851/DTC P0852

Probable cause:
• Faulty neutral switch or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Neutral Switch Line Open Circuit Inspection
Disconnect the TCM 33P (Black) connector (page
[1] [2]
13-66).
Remove the neutral switch terminal (page 13-66).
Check for continuity between the wire harness side
TCM 33P (Black) connector [1] and neutral switch
terminal [2].
CONNECTION: A32 – Light green
Lg
Is there continuity?
A32
YES – GO TO STEP 2.
NO – Open circuit in the Light green wire

2. Neutral Switch Line Short Circuit Inspection

Check for continuity between the neutral switch
terminal and ground.
CONNECTION: Light green – Ground
Is there continuity?
YES – Short circuit in the Light green wire
NO – GO TO STEP 3.

13-19
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

3. Neutral Switch Inspection
Replace the neutral switch with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON with gearshift "N"
position.
Shift the gearshift 1st position and wait for 10
seconds.
Recheck the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
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
Symptom/Fail-safe function:
• Gearshift function does not work

• When other DTC is displayed, together with P1700/

P1701 first.
1. TCM Inspection
Replace the TCM with a new one.
Erase the DTC.
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.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the main wire harness with a new
one, and recheck.
NO – Faulty original TCM

13-20
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P1702/DTC P1703
Probable cause:
• Faulty TR sensor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Engine operates normally
• Gearshift function does not work
1. TR Sensor Input Voltage Inspection
Disconnect the TR sensor connector (page 13-63).
[1]
Turn the ignition switch ON.
Measure the voltage at the wire harness side TR
sensor connector [1].
CONNECTION: Yellow (+) – Gray (–)
Is the voltage within 4.75 – 5.25 V? Y Gr

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 TCM with
a new one, and recheck.

2. TR Sensor Signal Line Open Circuit Inspection

Disconnect the TCM 33P (Gray) connector (page
[1] [2]
13-66).
Check for continuity between the wire harness side
TR sensor connector [1] and TCM 33P (Gray)
connector [2].
CONNECTION: White – B7
Is there continuity?
W B7
YES – GO TO STEP 3.
NO – Open circuit in the White wire

3. TR Sensor Output Line Short Circuit Inspection

Check for continuity between the wire harness side
[1]
TR sensor connector [1] and ground.
CONNECTION: White – Ground
Is there continuity?
YES – Short circuit in the White wire W

NO – GO TO STEP 4.

13-21
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

4. TR Sensor Inspection
Replace the TR sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original TR sensor

DTC P1704/DTC P1705/DTC P1706/

DTC P1707
Probable cause:
• Faulty No.1/2 clutch EOP sensor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Clutch EOP Sensor Input Voltage Inspection
Disconnect the following connectors:
– No.1 clutch EOP sensor connector (page 13-64)
– No.2 clutch EOP sensor connector (page 13-64)
Measure the voltage at the wire harness side clutch
EOP sensor connector [1].
CONNECTION: Yellow/red (+) – Gray (–)
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 2. Gr Y/R
NO – • Open or short circuit in the Yellow/red
wire
• Open circuit in the Gray wire
• If the wire is OK, replace the TCM with [1]
a new one, and recheck.
2. Clutch EOP Sensor Output Line Open Circuit
Inspection
Disconnect the TCM 33P (Gray) connector (page
[1] [2]
13-66).
Check for continuity between the wire harness side
clutch EOP sensor connector [1] and TCM 33P
(Gray) connector [2]. B8
CONNECTION: No.2:
No.1 clutch EOP sensor: Bl
Yellow/green – B19
No.2 clutch EOP sensor: No.1:
Black – B8 Y/G B19
Is there continuity?
YES – GO TO STEP 3.
NO – • Open circuit in the Yellow/green wire
• Open circuit in the Black wire

13-22
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

3. Clutch EOP Sensor Output Line Short Circuit
Inspection
Check for continuity between the wire harness side
[1]
clutch EOP sensor connector [1] and ground.
CONNECTION:
No.1 clutch EOP sensor:
Yellow/green – Ground
No.2 clutch EOP sensor: No.1: Y/G
Black – Ground No.2: Bl
Is there continuity?
YES – • Short circuit in the Yellow/green wire
• Short circuit in the Black wire
NO – GO TO STEP 4.

4. Clutch EOP Sensor Inspection

Replace the clutch EOP sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original clutch EOP sensor

DTC P1708/DTC P1709

Probable cause:
• Faulty shift spindle angle sensor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Shift Spindle Angle Sensor Input Voltage
Inspection
Disconnect the shift spindle angle sensor connector
[1]
(page 13-64).
Turn the ignition switch ON.
Measure the voltage at the wire harness side shift
spindle angle sensor connector [1].
CONNECTION: Yellow (+) – Gray (–) Y Gr
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 TCM with
a new one, and recheck.

13-23
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

2. Shift Spindle Angle Sensor Signal Line Open
Circuit Inspection
Turn the ignition switch OFF.
[1] [2]
Disconnect the TCM 33P (Gray) connector (page
13-66).
Check for continuity between the wire harness side
shift spindle angle sensor connector [1] and TCM
33P (Gray) connector [2].
CONNECTION: White – B20
Is there continuity? W
YES – GO TO STEP 3. B20

NO – Open circuit in the White wire

3. Shift Spindle Angle Sensor Output Line Short

Circuit Inspection
Check for continuity between the wire harness side
[1]
shift spindle angle sensor connector [1] and ground.
CONNECTION: White – Ground
Is there continuity?
W
YES – Short circuit in the White wire
NO – GO TO STEP 4.

4. Shift Spindle Angle Sensor Inspection

Replace the shift spindle angle sensor with a new
one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original shift spindle angle sensor

13-24
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P170A/DTC P170B
Probable cause:
• Faulty shift control motor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Shift Control Motor Line Open Circuit Inspection
Disconnect the following:
[2]
– TCM 33P (Black) connector (page 13-66)
– Shift control motor connector (page 13-55)
Check for continuity between the wire harness side Y A2
shift control motor connector [1] and TCM 33P A13
(Black) connector [2]. Y
CONNECTION: A1
Blue – A1
Blue – A12
Yellow – A2 Bu A12
Yellow – A13
Bu
Is there continuity?
YES – GO TO STEP 2.
[1]
NO – • Open circuit in the Blue or Pink/blue
wire
• Open circuit in the Yellow or Yellow/
blue wire
2. Shift Control Motor Line Short Circuit Inspection
Check for continuity between the wire harness side
shift control motor connector [1] and ground.
CONNECTION:
Blue – Ground
Yellow – Ground
Bu Y
Is there continuity?
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.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original shift control motor

13-25
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P170F
Probable cause:
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift system stops
1. TCM Inspection
Replace the TCM with a new one.
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the main wire harness with a new
one, and recheck.
NO – Faulty original TCM

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
Symptom/Fail-safe function:
• Gearshift function does not work
1. Shift Spindle Angle Sensor Inspection
Replace the shift spindle angle sensor with a new
one.
Erase the DTC.
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 DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original shift spindle angle sensor

13-26
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P1714
Probable cause:
• Faulty TR sensor
• Faulty gearshift mechanism (reduction gears)
• Faulty shift control motor
• Faulty TR sensor installation status
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. TR Sensor Inspection
Replace the TR sensor with a new one.
Erase the DTC.
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 DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original TR sensor

DTC P1716/DTC P1717

Probable cause:
• Faulty clutch line EOP sensor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Clutch Line EOP Sensor Input Voltage
Inspection
Disconnect the clutch line EOP sensor connector
(page 13-64).
Measure the voltage at the wire harness side clutch
line EOP sensor connector [1].
CONNECTION: Yellow/red (+) – Gray (–)
Is the voltage within 4.75 – 5.25 V?
YES – GO TO STEP 2.
NO – • Open or short circuit in the Yellow/red
wire Gr Y/R
• Open circuit in the Gray wire
• If the wire is OK, replace the TCM with
a new one, and recheck.
[1]

13-27
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

2. Clutch Line EOP Sensor Output Line Open
Circuit Inspection
Disconnect the TCM 33P (Gray) connector (page
[1] [2]
13-66).
Check for continuity between the wire harness side
clutch line EOP sensor connector [1] and TCM 33P
(Gray) connector [2].
CONNECTION: Red – B18
Is there continuity?
YES – GO TO STEP 3. R
B18
NO – Open circuit in the Red wire

3. Clutch Line EOP Sensor Output Line Short

Circuit Inspection
Check for continuity between the wire harness side
[1]
clutch line EOP sensor [1] and ground.
CONNECTION: Red – Ground
Is there continuity?
YES – Short circuit in the Red wire
R
NO – GO TO STEP 4.

4. Clutch Line EOP Sensor Inspection

Replace the clutch line EOP sensor with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original clutch line EOP sensor

13-28
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

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
Symptom/Fail-safe function:
• Gearshift function does not work
1. Clutch Line EOP Sensor Inspection
Replace the clutch line EOP sensor with a new one.
Erase the DTC.
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 DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original clutch line EOP sensor

DTC P1719
Probable cause:
• Faulty No.1 clutch
• Faulty VS sensor
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
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.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original No.1 clutch assembly

13-29
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P171A
Probable cause:
• Faulty No.2 clutch
• Faulty VS sensor
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. No.2 Clutch Inspection
Replace the No.2 clutch assembly with a new one.
Erase the DTC.
Drive the motorcycle in 2nd, 4th and 6th gear for a
minute in each gear.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original No.2 clutch assembly

DTC P171B/DTC P171C

Probable cause:
• DTC P171B: Faulty No.1 clutch sticking
• DTC P171C: Faulty No.2 clutch sticking
• Faulty clutch oil circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Clutch Inspection
Replace the clutch assembly with a new one.
– DTC P171B: No.1 clutch assembly
– DTC P171C: No.2 clutch assembly
Erase the DTC.
Drive the motorcycle using following gears for a
minute in each gear.
– DTC P171B: 1st, 3rd, 5th
– DTC P171C: 2nd, 4th, 6th
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original clutch assembly

13-30
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P171D/DTC P171E/DTC P171F/
DTC P1720/DTC P1721/DTC P1722/
DTC P1723/DTC P1724/DTC P1725/
DTC P1726
Probable cause:
• Engine oil level is low
• Faulty oil pump
• Faulty clutch oil circuit
• Faulty clutch EOP sensor
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Clutch EOP Sensor Inspection
Replace the clutch EOP sensor with a new one.
Erase the DTC.
Drive the motorcycle using all gears for a minute in
each gear.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original clutch EOP sensor

DTC P1728/DTC P1729

Probable cause:
• Faulty gearshift mechanism
• Faulty TR sensor
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
Refer to DTC P1714 (page 13-27).

DTC P172A/DTC P172B

Probable cause:
• Faulty DCT shift pedal (option) mechanism
• Faulty shift pedal angle sensor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• DCT shift pedal (option) function does not work
1. Shift Pedal Angle Sensor Input Voltage
Inspection
Disconnect the shift pedal angle sensor connector
[1]
(page 13-64).
Turn the ignition switch ON.
Measure the voltage at the wire harness side shift
pedal angle sensor connector [1].
CONNECTION: Yellow (+) – Gray (–)
Y Gr
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 TCM with
a new one, and recheck.

13-31
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

2. Shift Pedal Angle Sensor Output Line Open
Circuit Inspection
Disconnect the TCM 33P (Gray) connector (page
13-66).
Check for continuity between the wire harness side
shift pedal angle sensor connector [1] and TCM 33P
(Gray) connector [2].
CONNECTION: Yellow – B10
B10
Is there continuity? Y
YES – GO TO STEP 3.
NO – Open circuit in the Yellow wire

[1] [2]

3. Shift Pedal Angle Sensor Output Line Short

Circuit Inspection
Check for continuity between the wire harness side
[1]
shift pedal angle sensor connector [1] and ground.
CONNECTION: Yellow – Ground
Is there continuity?
YES – Short circuit in the Yellow wire. Y
NO – GO TO STEP 4.

4. Shift Pedal Angle Sensor Inspection

Replace the shift pedal angle sensor with a new
one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original shift pedal angle sensor

13-32
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P172C
Probable cause:
• Faulty N-D switch or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• N-D switch does not work
1. N-D Switch Signal Line Open Circuit Inspection
Disconnect the TCM 33P (Gray) connector (page
[1] [2]
13-66).
Disconnect the right handlebar switch 12P
connector (page 22-33).
Check for continuity between the wire harness side
right handlebar switch 12P connector [1] and TCM
33P (Gray) connector [2].
CONNECTION: Violet – B31
V
Is there continuity?
B31
YES – GO TO STEP 2.
NO – Open circuit in the Violet wire

2. N-D Switch Signal Line Short Circuit Inspection

Check for continuity between the wire harness side
[1]
right handlebar switch 12P connector [1] and
ground.
CONNECTION: Violet – Ground
Is there continuity?
YES – Short circuit in the Violet wire V

NO – GO TO STEP 3.

3. N-D Switch Ground Line Open Circuit Inspection

Disconnect the TCM 33P (Black) connector (page
[1] [2]
13-66).
Check for continuity between the wire harness side
right handlebar switch 12P connector [1] and 33P
(Black) connector [2].
CONNECTION: Gray – A22
Is there continuity?
YES – GO TO STEP 4. Gr
A22
NO – Open circuit in the Gray wire

13-33
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

4. N-D Switch Inspection
Replace the right handlebar switch with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original N-D switch

DTC P172D
Probable cause:
• Faulty shift switch or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Shift switch does not work
1. Shift Switch Signal Line Open Circuit Inspection
Disconnect the TCM 33P (Gray) connector (page
[1] [2]
13-66).
Disconnect the left handlebar switch 12P connector
(page 22-26).
Check for continuity between the wire harness side
left handlebar switch 12P connector [1] and TCM
33P (Gray) connector [2].
CONNECTION: Black – B32 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

Check for continuity between the wire harness side
[1]
left handlebar switch 12P connector [1] and ground.
CONNECTION: Black – Ground
Is there continuity?
YES – Short circuit in the Black wire
Bl
NO – GO TO STEP 3.

13-34
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

3. Shift Switch Ground Line Open Circuit
Inspection
Disconnect the TCM 33P (Black) connector (page
[1] [2]
13-66).
Check for continuity between the wire harness side
left handlebar switch 12P connector [1] and TCM
33P (Black) connector [2].
CONNECTION: Gray – A22
Is there continuity?
Gr
YES – GO TO STEP 4. A22
NO – Open circuit in the Gray wire

4. Shift Switch Inspection

Replace the left handlebar switch with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original shift switch

DTC P172E
Probable cause:
• Faulty DCT relay or its related circuit
• Blown DCT-M 30 A fuse
• Faulty TCM
Symptom/Fail-safe function:
• DCT relay does not work
1. DCT Relay Input Voltage Inspection
Remove the DCT relay (page 13-68).
Turn the ignition switch ON.
Measure the voltage at the relay connector [1].
CONNECTION: Red/white (+) – Green (–)
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open circuit in the Red/white wire R/W G
• Open circuit in the Green wire

[1]

13-35
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

2. DCT Relay Output Line Open Circuit Inspection
Disconnect the TCM 33P (Black) connector (page
[1] [2]
13-66).
Check for continuity between the wire harness side
relay connector [1] and TCM 33P (Black) connector
[2].
CONNECTION: A3
White – A3 W
White – A14
W
Is there continuity?
A14
YES – GO TO STEP 3.
NO – Open circuit in the White wire

3. DCT Relay Coil Input Line Open Circuit

Inspection
Disconnect the ECM 33P (Gray) connector (page 4-
[1] [2]
77).
Check for continuity between the wire harness side
relay connector [1] and ECM 33P (Gray) connector
[2].
CONNECTION: Yellow – Yellow (C9)
Is there continuity?
YES – GO TO STEP 4. Y
Y (C9)
NO – Open circuit in the Yellow wire

4. DCT Relay Inspection

Replace the DCT relay with a new one.
Connect the disconnected connector(s).
Erase the DTC.
Turn the ignition switch ON and wait for 10 seconds.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the ECM with a new one, and
recheck.
NO – Faulty original DCT relay

DTC P172F
Probable cause:
• Faulty shift spindle angle sensor
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
Refer to DTC P1713 (page 13-26).

13-36
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DTC P2765
Probable cause:
• Electromagnetic interference
• Faulty outer mainshaft sensor or its related circuit
• Faulty TCM
Symptom/Fail-safe function:
• Gearshift function does not work
1. Outer Mainshaft Sensor Input Voltage
Inspection
Disconnect the outer mainshaft sensor connector
[1]
(page 13-63).
Temporarily install the removed electrical parts in
the reverse order of removal.
Turn the ignition switch ON.
Measure the voltage at the wire harness side outer
mainshaft sensor connector [1]. V Gr
CONNECTION: Violet (+) – Gray (–)
Is there about battery voltage?
YES – GO TO STEP 2.
NO – • Open or short circuit in the Violet wire
• Open circuit in the Gray wire
• If the wire is OK, replace the TCM with
a new one, and recheck.
2. Outer Mainshaft Sensor Output Line Open
Circuit Inspection
Disconnect the TCM 33P (Gray) connector (page
[1] [2]
13-66).
Check for continuity between the wire harness side
outer mainshaft sensor connector [1] and TCM 33P
(Gray) connector [2].
CONNECTION: Pink – B25
Is there continuity? P
B25
YES – GO TO STEP 3.
NO – Open circuit in the Pink wire

3. Outer Mainshaft Sensor Output Line Short

Circuit Inspection
Check for continuity between the wire harness side
[1]
outer mainshaft sensor connector [1] and ground.
CONNECTION: Pink – Ground
Is there continuity?
YES – Short circuit in the Pink wire P
NO – GO TO STEP 4.

13-37
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

4. Outer Mainshaft Sensor Inspection
Replace the outer mainshaft sensor with a new one.
Erase the DTC.
Drive the motorcycle in 2nd, 4th and 6th gear for a
minute in each gear.
Check the DTC with GST or MCS.
Is same DTC indicated?
YES – Replace the TCM with a new one, and
recheck.
NO – Faulty original outer mainshaft sensor

13-38
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

CLUTCH OIL FEED PIPE
REMOVAL
Remove the following:
[1]/[2]
– Feed pipe cover bolts [1]
– Sealing washers [2]
– Feed pipe cover [3]
– O-ring [4]

[4]

[3]

Remove the inner clutch oil feed pipe [1].

• Be careful not to bend or damage the inner clutch oil

feed pipe.

[1]

Remove the following:

[2] [3]
– Feed pipe guide plate bolts [1]
– Feed pipe guide plate [2]
– O-rings [3]

[3]

[1]

Remove the following:

[1]/[2]
– Outer clutch oil feed pipe [1]
– O-ring [2]

• Be careful not to bend or damage the outer clutch oil

feed pipe.

13-39
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

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 (DCT model)
(page 1-11).
Replace any part if it is out of the service limit.

INSTALLATION
Apply engine oil to a new O-ring.
[2] [1]
Install the O-ring [1] to the outer clutch oil feed pipe [2].
Install the outer clutch oil feed pipe into the right
crankcase cover.

• Align the feed pipe tabs with the right crankcase

cover lugs.

Align

Apply engine oil to new O-rings.

[2] [1]
Install the O-rings [1] to the feed pipe guide plate [2]
grooves.
Install the feed pipe guide plate.

• Align the feed pipe guide plate pin with the right
crankcase cover hole.

Align

Install and tighten the feed pipe guide plate bolts [1] to
the specified torque.

TORQUE: 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)

[1]

13-40
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Install the inner clutch oil feed pipe [1] to the feed pipe
[1] [2]
guide plate.

• Align the feed pipe tabs with the guide plate lugs.
Apply engine oil to a new O-ring.
Install the O-ring [2] to the feed pipe cover [3] groove.
Install the feed pipe cover.

Align [3]

Install the following:

[1]/[2]
– New sealing washers [1]
– Feed pipe cover bolts [2]
Tighten the feed pipe cover bolts to the specified
torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

RIGHT CRANKCASE COVER

REMOVAL
Drain the engine oil (page 3-12).
[3]
Drain the coolant (page 8-5).
Remove the clutch EOP sensor cover (page 2-27).
Remove right rear engine cover (page 2-27).
Remove the clutch oil feed pipe (page 13-39).
Remove the shift spindle angle sensor bolt [1], shift [2]
spindle angle sensor [2], and O-ring [3].

[1]

Disconnect the following:

[4]
– 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 [5]
stay [5].

[2]

[1] [3]

13-41
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Open the clamps [1].
[4]
Release the linear solenoid valve wire [2] and main wire
harness [3] from the clamps.
Disconnect the linear solenoid valve 4P (Black)
connector [4].

[1]
• When disconnecting the right A/F sensor 4P
connector and linear solenoid valve 4P (Black)
connector at the same time, mark the main wire [2]
harness side connectors to prevent the [1]
misconnection. [1]

[3]

Loosen the hose band screw [1].

Disconnect the radiator hose B [2].

[2] [1]

Remove the water pipe bolts [1].

[2]
Disconnect the water pipe [2] from the right crankcase
cover.
[1]
Remove the O-ring [3] from the water pipe.

[1]

[3]

Remove the right crankcase cover bolts [1].

Remove the right crankcase cover [2].

[2] [1]

13-42
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Remove the gasket [1], dowel pins [2], and oil joint [3].
[2]
Remove the O-rings [4] and back up rings [5] from the
oil joint.

[2]

[3]/[4]/[5] [1]

Remove the O-ring [1].

[1]

Check the bearings [1] and replace if necessary (page

[1]
13-43).

[1]

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
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 [1]
Attachment, 52 x 55 mm 07746-0010400
Pilot, 40 mm 07746-0040900

• Drive in the bearing (40 x 52 x 7 mm) with the

marking side facing up.

13-43
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Remove the bearing (6304) [1] using special tools.
[1]
TOOLS:
Remover weight 07741-0010201
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

• Drive in the bearing (6304) with the marking side

facing up.

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 O-rings [1] and new back up

[2]
rings [2] and install them onto the oil joint [3] as shown.
Install the oil joint into the crankcase hole.

[3]

[2] [1]

[1]

Coat a new O-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.

[1]

Align

13-44
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Align the following by rotating the crankshaft:
[1]/[2]
– Primary drive gear index line [1]
– Crankcase " " mark [2]
Make sure that the front balancer shaft end [3] is in
position as shown.

[3]

Install the dowel pins [1] and new gasket [2].

[1]

[1]

[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 lbf·ft)

[1] [2]

Coat a new O-ring with engine oil.

[2]
Install the O-ring [1] onto the water pipe [2].

[1]

13-45
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Connect the water pipe [1] to the right crankcase cover.
[1]
Install and tighten the water pipe bolts [2] to the
specified torque.
[2]
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[2]

Connect the radiator hose B [1].

Tighten the hose band screw [2] to the specified range
(page 8-7).

[1] [2]

Connect the linear solenoid valve 4P (Black) connector

Front [1]
[1].
Clamp the linear solenoid valve wire [2] and main wire Right
harness [3] with the clamps [4].
[4]
• Route the wire properly (page 1-32).
[2]

[4]
[4]

[1] [3]

Install the stay [1] and clutch EOP sensor wire stay bolt
[2]
[2].
Tighten the wire stay bolt to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[1]
Connect the following:
– Clutch line EOP sensor 3P (Gray) connector [3]
– No.1 clutch EOP sensor 3P (Gray) connector [4]
– No.2 clutch EOP sensor 3P (Black) connector [5] [4]

[3] [5]

13-46
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Apply engine oil to a new O-ring.
Install the O-ring [1] onto the shift spindle angle sensor
[2]. [1]
Install the shift spindle angle sensor.

• Align the flat surfaces of the shift spindle angle

sensor and gearshift spindle end.

Align [2]

Install and tighten the shift spindle angle sensor bolt [1]
to the specified torque.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

• Route the hoses and wires properly (page 1-32).

Install the clutch oil feed pipe (page 13-40).
Install right rear engine cover (page 2-27).
Install the clutch EOP sensor cover (page 2-27).
Fill the engine with the recommended engine oil and
check that there are no oil leaks (page 3-12).
Fill the recommended coolant mixture to the filler neck
and bleed the air (page 8-5). [1]

LINEAR SOLENOID VALVE

REMOVAL

• Keep dust and dirt away from all the parts.

• Be careful not to damage the mating surfaces of the
valve body components.
Drain the engine oil (page 3-12).
[3]
Remove the right middle cowl (page 2-7).
Remove the clutch EOP sensor cover (page 2-27).
Open the clamps [1] and release the linear solenoid
valve wire [2] from the clamps.
Disconnect the linear solenoid valve 4P (Black)
connector [3]. [1]

[2]
• When disconnecting the right A/F sensor 4P
connector and linear solenoid valve 4P (Black) [1]
connector at the same time, mark the main wire [1]
harness side connectors to prevent the
misconnection.

13-47
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Remove the linear solenoid valve body mounting bolts
[1]
[1] and linear solenoid valve body [2].

[2]

Remove the following:

[1] [4]
– Separator plate [1]
– Dowel pins [2]
– O-rings [3]
– Spool valve filter/packing [4]
Remove the packing from the spool valve filter.
Check the spool valve filter and replace if necessary.

[3]

[2] [3]

13-48
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DISASSEMBLY/ASSEMBLY

LINEAR SOLENOID
VALVE BODY

VALVE BODY COVER

GASKET

LINEAR SOLENOID VALVE

BODY COVER BOLTS
12 N·m (1.2 kgf·m, 9 lbf·ft)

STOPPER PLATE

LINEAR SOLENOID VALVE

STOPPER PLATE BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft)

LINEAR SOLENOID VALVES

• 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 1-27).
• Apply liquid sealant (TB1207B manufactured by
Three Bond or equivalent) to the grommet mating
surface of the valve body as shown.

INSTALLATION
Coat a new O-ring with engine oil.
[1]
Install the following to the linear solenoid valve body.
– O-ring [1]
– Dowel pins [2]
– Separator plate [3]

[2] [3]

13-49
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Coat a new packing [1] with engine oil.
[1]/[2]
Install the packing to the spool valve filter [2].
Install the spool valve filter/packing onto the right
crankcase cover as shown.
Coat a new O-ring with engine oil.
Install the O-ring [3].
Install the linear solenoid valve body [4].

[3]

[4]

[1]

OUTSIDE

INSIDE
[2]

Install and tighten the linear solenoid valve body

[1]
mounting bolts [1] to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Connect the linear solenoid valve 4P (Black) connector

Front [1]
[1].
Clamp the linear solenoid valve wire [2] and main wire Right
harness [3] with the clamps [4].
[4]
• Route the wire properly (page 1-32).
Install the clutch EOP sensor cover (page 2-27). [2]
Install the right middle cowl (page 2-7).
Fill the engine with the recommended engine oil and [4]
check that there are no oil leaks (page 3-12). [4]

[1] [3]

13-50
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DUAL CLUTCH/PRIMARY DRIVEN
GEAR
REMOVAL
Remove the primary drive gear (page 13-54).
[1]
Remove the dual clutch assembly [1] from the
mainshaft.

Remove the seal rings [1] from the mainshaft grooves.

[1]

DISASSEMBLY
Remove the following from the clutches.
[1] [2]
– Clutch 1 guide [1]
– Clutch 2 guide [2]
– Washers [3]
[3] [3]

Remove the following from the primary driven gear:

[1] [3]
– No.1 Clutch assembly [1]
– No.2 Clutch assembly [2]
– O-rings [3]

• Do not disassemble the clutch assembly.

• The No.1 clutch assembly and No.2 clutch assembly
are the same parts.

[2]

[3]

13-51
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

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.
SERVICE LIMIT: 1.3 mm (0.05 in)
If the measured valve exceeds the service limit, replace 120° 120°
the clutch assembly.
120°

[1]

ASSEMBLY
Coat new O-rings with engine oil.
[3] [1]
Install the O-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]

[2] [1]

The clutch guides are different shapes as shown.

CLUTCH 1 GUIDE CLUTCH 2 GUIDE

Small Large

13-52
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

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]. [6]
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] [3]/[4] [2]

[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]. [4]
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.

[1]/[2]

[3] [4]

[2]

13-53
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

INSTALLATION
Apply engine oil to new seal rings.
[1]
Install the new seal rings [1] into the mainshaft grooves.
Push in the seal rings to seat them into the grooves as
shown.

Install the dual clutch assembly [1] onto the mainshaft.

• The dual clutch assembly should be installed with

the index line [2] facing the outside of the engine. [2]
• Be careful not to damage the seal rings.
Install the primary drive gear (page 13-54).

[1]

PRIMARY DRIVE GEAR

REMOVAL
Remove the right crankcase cover (page 13-41).
[2]/[3]
Install the special tool between the primary drive and
driven gears.
TOOL:
Gear holder, 2.5 [1] 07724-0010100
Loosen the primary drive gear nut [2].

• 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, [1] [4]
abnormal wear and deformation. Replace if necessary.
INSTALLATION
Apply engine oil to the primary drive gear tooth.
Align
Install the primary drive gear [1] to the crankshaft.

• Align primary drive gear wide tooth with the

crankshaft wide tooth.

[1]

13-54
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Apply engine oil to the primary drive gear nut threads
[3]
and seating surface.
Install the washer [1] and primary drive gear nut [2].
Install the special tool between the primary drive and
driven gears.
TOOL:
Gear holder, 2.5 [3] 07724-0010100
Tighten the primary drive gear nut to the specified
torque.
TORQUE: 118 N·m (12.0 kgf·m, 87 lbf·ft) [1]/[2]

• The primary drive gear nut has left-hand thread.

Install the right crankcase cover (page 13-44).

SHIFT CONTROL MOTOR/REDUCTION

GEARS
REMOVAL
Remove the shift control motor cover bolts [1] and shift
[1]
control motor cover [2].

[2]

Disconnect the shift control motor 2P (Black) connector

[4]
[1].
Remove the following:
– Shift control motor mounting torx bolts [2]
– Shift control motor [3]
– O-ring [4]

[1]

[3] [2]

13-55
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Remove the reduction gear cover torx bolts [1] and
[2]
reduction gear cover [2].

[1]

Remove the dowel pins [1] and gasket [2].

[1]
Remove the reduction gears [3].
[2]

[3]

BEARING REPLACEMENT
Heat the reduction gear cover to 80°C (176°F) evenly
using a heat gun. [3]

[1]
• Do not use a torch to heat the reduction gear cover;
it may cause warping.
Tap the reduction gear cover lightly and remove the
bearings.
– Radial ball bearing (699ZZ) [1]
– Radial ball bearing (607ZZ) [2]
– Radial ball bearing (696ZZ) [3]
Apply engine oil to new bearings.
Drive in new bearings squarely until they are fully [2]
seated.

• Drive in new bearings with the marking side facing

up.
For crankcase side bearings replacement (page 14-21)

13-56
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

INSTALLATION
Apply 2 – 4 g (0.07 – 0.14 oz) of specified grease to the
[1]
reduction gear bearing journals [1].

SPECIFIED GREASE:
UNIREX N3 manufactured by ExxonMobil or
equivalent

[1]

Apply 2 – 4 g (0.07 – 0.14 oz) of specified grease to the

[1] Align
reduction gear teeth.

SPECIFIED GREASE: Align

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

• Align the reduction gear B ends with the ribs of the

crankcase.
Install the reduction gear C [2].

[3] [2]
• Align each clinched tooth of the reduction gear C
and gearshift spindle.
• Make sure that the punch mark of the reduction gear
C is positioned between the reduction gear B tooth.
Install reduction gear A [3].
Install the dowel pins [1] and gasket [2].
[1]

[2]

Install the reduction gear cover [1] and reduction gear

[1]
cover torx bolts [2].
Tighten the reduction gear cover torx bolts to the
specified torque. [2]
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)

13-57
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Coat a new O-ring with engine oil.
[1]
Install the O-ring [1] into the groove in the shift control
motor [2].
Install the shift control motor.

[2]

Install the shift control motor mounting torx bolts [1].

Tighten the shift control motor mounting torx bolts to the
specified torque.
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)
Connect the shift control motor 2P (Black) connector
[2].

[2]

[1]

Install the shift control motor cover [1] and shift control
[2]
motor cover bolts [2].
Tighten the shift control motor cover bolts to the
specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

• Route the wire properly (page 1-32).

[1]

GEARSHIFT LINKAGE
REMOVAL
Remove the following:
[1] [2]
– Shift control motor/reduction gears (page 13-55)
– Dual clutch (page 13-51)
Remove the following:
– Gearshift spindle [1]
– Washer [2]
– Drum shifter collar [3]

[3]

13-58
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Remove the drum shifter guide plate/drum shifter
[2]
assembly mounting bolts [1].
Remove the drum shifter guide plate/drum shifter
assembly [2].

[1]

Remove the following:

[4] [1]
– Guide plate distance collar [1]
– Dowel pin [2] (if necessary)
– Stopper arm side collar [3]
– Shift drum center bolt [4]

[3] [2]

Remove the shift drum center [1] while holding the shift
[2]
drum stopper arm [2] using a screwdriver as shown.

[1]

Remove the following:

[4]
– Shift drum stopper arm [1]
– Stopper arm collar [2]
– Stopper arm return spring [3]
– Shift drum center dowel pin [4]
– Dowel pin [5] (if necessary) [1]

[5] [2] [3]

13-59
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Remove the oil seal [1].

[1]

INSPECTION
Inspect the following parts for scratches, damage,
abnormal wear, or deformation.
– Gearshift spindle, spindle arm, return spring
– Drum shifter guide plate
– Drum shifter
– Ratchet pawls
– Plungers
– Plunger springs
Replace if necessary.

INSTALLATION
Install the oil seal [1] until it is in position as shown.
Apply grease to the oil seal lips.

[1]

11.9 – 12.4 mm [1]

(0.47 – 0.49 in)

13-60
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Install the following: [3] [4] [5] [1]
– Shift drum center dowel pin [1]
– Dowel pin [2] (if you removed) [2]
– Shift drum stopper arm [3]
– Stopper arm collar [4]
– Stopper arm return spring [5]

[3]

[2] [4] [5]

Hold the shift drum stopper arm [1] with a screwdriver.

[1]
Install the shift drum center [2].

Align
• Aligning the shift drum center groove with the dowel
pin.

[2]

Apply locking agent to the shift drum center bolt threads

[1] [2]
(page 1-27).
Install and tighten the shift drum center bolt [1] to the
specified torque.
TORQUE: 31 N·m (3.2 kgf·m, 23 lbf·ft)
Install the following:
– Dowel pin [2] (if you removed)
– Guide plate distance collar [3]
– Stopper arm side collar [4]

[4] [3]

Install the following in the drum shifter [1]:

[4]
– Plunger springs [2]
– Plungers [3]
– Ratchet pawls [4]
[3]
Set the drum shifter assembly in the drum shifter guide
plate [5]. [2]

[1]

[5]

13-61
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

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 1-27).
Install and tighten the drum shifter guide plate/drum [1]
shifter assembly mounting bolts.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[2]

Install the drum shifter collar [1] onto the drum shifter.
[3] [2]
Install the thrust washer [2] onto the gearshift spindle
[3].
Install the gearshift spindle into the crankcase.

• Align the gearshift spindle return spring ends with

the spring pin.
• Align the gearshift spindle arm hole with the drum Align
shifter collar.
Install the following:
– Dual clutch (page 13-54)
– Reduction gears/shift control motor (page 13-57) Align [1]

MAINSHAFT SENSOR
REMOVAL/INSTALLATION
INNER MAINSHAFT SENSOR
Disconnect the inner mainshaft sensor 3P (Black)
connector [1].

[1]

Remove the bolts [1], inner mainshaft sensor [2], and

[1] [3]
O-ring [3].
Installation is in the reverse order of removal.

• Replace the O-ring with a new one.

• Apply engine oil to a new O-ring.

[2]

13-62
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

OUTER MAINSHAFT SENSOR
Remove the battery box (page 21-6).
[2]
Disconnect the outer mainshaft sensor 3P (Black)
connector [1].
Remove the bolt [2], outer mainshaft sensor [3], and O-
ring [4].
Installation is in the reverse order of removal.
[3]

• Replace the O-ring with a new one.

• Apply engine oil to a new O-ring.
[4]

[1]

TR SENSOR
REMOVAL/INSTALLATION
Remove the left rear cover (page 2-26).
Remove the shift control motor cover (page 13-55).
Disconnect the TR sensor 3P (Black) connector [1].

[1]

Remove the following:

[3] [1]
– Bolt [1]
– Sensor cover [2] [4]
– TR sensor [3]
– O-ring [4]
Installation is in the reverse order of removal.
TORQUE:
TR sensor mounting bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

• Always replace the O-ring with a new one.

• Apply engine oil to a new O-ring. [2] Align
• Align the flat surfaces of the TR sensor and shift
drum end.
• Route the wires properly (page 1-32).

13-63
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

SHIFT SPINDLE ANGLE SENSOR
REMOVAL/INSTALLATION
Remove right rear engine cover (page 2-27).
[2]
Remove the shock absorber (page 18-9).
Disconnect the shift spindle angle sensor 3P (Blue)
connector [1].
Release the wire clip [2].

[1]

Remove the shift spindle angle sensor bolt [1], shift

[3]
spindle angle sensor [2], and O-ring [3].

[2]

[1]

Installation is in the reverse order of removal.

TORQUE:
Shift spindle angle sensor bolt: [1]
12 N·m (1.2 kgf·m, 9 lbf·ft)

• Always replace the O-ring [1] with a new one.

• Apply engine oil to a new O-ring.
• Align the flat surfaces of the shift spindle angle
sensor and gearshift spindle end.
• Route the hoses and wires properly (page 1-32).

Align

CLUTCH EOP SENSOR

REMOVAL/INSTALLATION
Drain the engine oil (page 3-12).
[6] [5]
Remove the clutch EOP sensor cover (page 2-27).
Disconnect the following:
– Clutch line EOP sensor 3P (Gray) connector [1] [4]
– No.1 clutch EOP sensor 3P (Gray) connector [2]
– No.2 clutch EOP sensor 3P (Black) connector [3]
Remove the following:
[2]
– Clutch line EOP sensor [4]
– No.1 clutch EOP sensor [5]
– No.2 clutch EOP sensor [6]

[1] [3]
• These three clutch EOP sensors are the same parts.

13-64
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Installation is in the reverse order of removal.
[1]
TORQUE:
No.1/No.2 clutch EOP sensor:
20 N·m (2.0 kgf·m, 15 lbf·ft)
Clutch line EOP sensor:
20 N·m (2.0 kgf·m, 15 lbf·ft)

• Replace the O-ring [1] with a new one.

• Coat a new O-ring with engine oil.
• Route the wire properly (page 1-32).

EOT SENSOR
REMOVAL/INSTALLATION
Drain the engine oil (page 3-12).
[2]
Disconnect the EOT sensor 2P (Black) connector [1].
Remove the EOT sensor [2] and sealing washer [3].
Installation is in the reverse order of removal.
TORQUE:
EOT sensor:
15 N·m (1.5 kgf·m, 11 lbf·ft)

• Apply engine oil to the EOT sensor threads and

seating surface.
• Replace the sealing washer with a new one.
[1] [3]
Fill the engine oil with the recommended engine oil
(page 3-12).

EOP SENSOR
REMOVAL/INSTALLATION
Drain the engine oil (page 3-12).
Remove the wire band [1].
Disconnect the EOP sensor 3P (Black) connector [2].
Remove the EOP sensor [3].

[2] [1] [3]

13-65
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

Installation is in the reverse order of removal.

TORQUE:
EOP sensor:
22 N·m (2.2 kgf·m, 16 lbf·ft)

• Replace the O-ring [1] with a new one.

• Apply engine oil to the O-ring.
• Route the wire properly (page 1-32). [1]
Fill the engine oil with the recommended engine oil
(page 3-12).

NEUTRAL SWITCH
REMOVAL/INSTALLATION
Release the rubber cap [1].
[4]
Remove the nut [2] and disconnect the neutral switch
terminal [3].
[3]
Remove the neutral switch [4] and sealing washer [5].
Installation is in the reverse order of removal.
TORQUE:
Neutral switch:
[1] [2]
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)

[5]
• Apply engine oil to the neutral switch threads and
seating surface.
• Replace the sealing washer with a new one.

TCM
REMOVAL/INSTALLATION
Remove the BCU (page 22-51).
[4] [2]
Open the TCM holder [1].
Disconnect the TCM 33P (Black) connector [2] and
TCM 33P (Gray) connector [3].
Remove the TCM [4].
Installation is in the reverse order of removal.

• If the TCM is replaced, perform the clutch initialize

learning procedure (page 13-68).

[1] [3]

13-66
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

POWER/GROUND LINE INSPECTION
POWER INPUT LINE
Disconnect the TCM 33P (Black) connector (page 13-
[1]
66).
Turn the ignition switch ON.
Measure the voltage between the 33P (Black)
connector [1] and ground.
TOOL:
A7
Test probe 07ZAJ-RDJA110

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 FI relay
– Faulty FI relay or its circuits
POWER GROUND LINE
Disconnect the TCM 33P (Black) connector (page 13-
[1]
66).
Check for continuity between the wire harness side 33P
(Black) connector [1] and ground.
TOOL:
Test probe 07ZAJ-RDJA110
A24 A23
CONNECTION: A23 – Ground
A24 – Ground
There should be continuity at all times.
If there is no continuity, check for an open circuit in the
Green wires.

LOGIC GROUND LINE

Disconnect the TCM 33P (Black) connector (page 13-
[1]
66).
Check for continuity between the wire harness side 33P
(Black) connector [1] and ground.
TOOL:
Test probe 07ZAJ-RDJA110
A11
CONNECTION: A11 – Ground
There should be continuity at all times.
If there is no continuity, check for an open circuit in the
Green/blue wire.

13-67
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

DCT RELAY
REMOVAL/INSTALLATION
Remove the main seat (page 2-5).
[1]
Release the DCT relay [1] from the stay.
Disconnect the relay connector [2] and remove the DCT
relay.
Installation is in the reverse order of removal.
– For relay inspection (page 4-81)

[2]

CLUTCH INITIALIZE LEARNING (TCM)

• If the TCM and/or clutch assembly are replaced,
perform this procedure.
• Before starting this procedure, check the following:
– PGM-FI system and DCT system have no DTC.
– 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. [1]

• If the TCM is replaced with a new one, the shift

indicator [1] and S mode level indicator [2] will [2]
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:
necessary.
• When the shift indicator displays as shown, the
engine must be warmed before proceeding:
– Large "L": extremely low oil temperature indicator
– Small "L": low oil temperature indicator

[1]

Low oil temperature:

[1]

13-68
dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

2. Turn the ignition switch ON while pushing the D-S
side of the N-D switch [1].
The MIL [2] will come on.
Release the N-D 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):

3. Push the N-D switch [1] in the sequence as follows:

[1]
– Push the D-S side of the N-D switch
– Push the D-S side of the N-D switch
– Push the N side of the N-D switch
– Push the D-S side of the N-D switch
– Push the N side of the N-D switch
The TCM is ready to Clutch Initialize Learning when
the shift indicator [2] and S mode level indicator [3]
light as shown.

• 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 [2]
indicator goes off.
Stop the engine and perform steps 2 and 3 again.

[3]

Extremely low oil temperature:

Low oil temperature:

13-69
 dummyhead

DUAL CLUTCH TRANSMISSION (DCT model)

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.

• If the Clutch Initialize Learning is unsuccessful,

perform the initialize learning procedure from step 2
again.
5. Stop the engine.

13-70
dummytext

14. CRANKCASE/TRANSMISSION/BALANCER

SERVICE INFORMATION ···························14-2 CRANKCASE SEPARATION ··················· 14-11

TROUBLESHOOTING·································14-3 TRANSMISSION ······································· 14-13

COMPONENT LOCATION ··························14-4 CRANKCASE ASSEMBLY ······················· 14-26

BALANCER ·················································14-6

14

14-1
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
SERVICE INFORMATION
CRANKCASE/TRANSMISSION/BALANCER

GENERAL
• 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 thoroughly.
MT MODEL
• The crankcase must be separated to service the following:
– Transmission
– Crankshaft (page 15-4)
– Piston/cylinder (page 15-12)
• The following components must be removed before separating the crankcase:
– Engine (page 16-4)
– Clutch (page 12-8)
– Gearshift linkage (page 12-18)
– Primary drive gear (page 12-16)
– Balancer (page 14-6)
– Flywheel (page 11-6)
– Oil pump (page 9-5)
– Starter motor (page 6-7)
– VS sensor (page 4-79)
– GP sensor (page 4-79)
– Shift spindle switch (page 4-80)
– Neutral switch (page 22-44)

DCT MODEL
• The crankcase must be separated to service the following:
– Transmission
– Crankshaft (page 15-4)
– Piston/cylinder (page 15-12)
• The following components must be removed before separating the crankcase:
– Engine (page 16-4)
– Dual clutch (page 13-51)
– Gearshift linkage (page 13-58)
– Balancer (page 14-6)
– Flywheel (page 11-6)
– Cylinder head (page 10-18)
– Oil pump (page 9-5)
– Starter motor (page 6-7)
– Shift control motor/reduction gears (page 13-55)
– Mainshaft sensors (page 13-62)
– ECT sensor (page 4-75)
– VS sensor (page 4-79)
– Neutral switch (page 13-66)

14-2
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
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 12-18)
– DCT model (page 13-58)
Transmission jumps out of gear
• Worn gear dogs
• Worn gear shifter groove
• Bent shift fork shaft
• Worn or bent shift forks
• Broken shift drum stopper arm
– MT model (page 12-18)
– DCT model (page 13-58)
• Broken shift drum stopper arm return spring
– MT model (page 12-18)
– DCT model (page 13-58)
• Broken gearshift spindle return spring
– MT model (page 12-18)
– DCT model (page 13-58)
Excessive engine noise
• Worn or damaged transmission gear
• Worn or damaged transmission bearings
• Worn or damaged balancer

14-3
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
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)

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 lbf·ft)

29 N·m (3.0 kgf·m, 21 lbf·ft)

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)

14-4
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
DCT model:

39 N·m (4.0 kgf·m, 29 lbf·ft)

43 N·m (4.4 kgf·m, 32 lbf·ft)

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 lbf·ft)

24 N·m (2.4 kgf·m, 18 lbf·ft)

29 N·m (3.0 kgf·m, 21 lbf·ft)

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
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
BALANCER
FRONT BALANCER
REMOVAL
Remove the flywheel (page 11-6).
[3] [2]
Remove the right crankcase cover:
[4]
– MT model (page 12-4)
– DCT model (page 13-41)
Install the special tool between the front balancer drive
and driven gears.
TOOL:
Gear holder, 2.5 [1] 07724-0010100
Remove the front balancer shaft bolt [2], washer [3],
and front balancer driven gear [4].

[1]

Remove the left front balancer weight [1].

[1]

Remove the front balancer bearing set plate bolts [1]

[2]
and set plate [2].
Remove the front balancer shaft [3].
Check for damage of the front balancer shaft, and
replace it if necessary.

[1]

[1]

[3]

Remove the left front balancer bearing [1].

[1]
Check the left front balancer bearing should turn
smoothly and quietly, and replace it if necessary.

14-6
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
INSTALLATION
Apply engine oil to the left front balancer bearing rolling
[1]
area and contact surface.
Install the left front balancer bearing [1].

• Install the left front balancer bearing with the marked

side facing out.

Install the front balancer shaft [1].

[2]
Apply locking agent to the front balancer bearing set
plate bolts threads (page 1-27).
Install the set plate [2] and front balancer bearing set [4]
plate bolts [3].

[3]
• Install the set plate with its "OUTSIDE" mark [4]
facing out.
[3]
Tighten the front balancer bearing set plate bolts to the
specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[1]

Install the left front balancer weight [1].

Align

• Align the left front balancer weight wide tooth with

the front balancer shaft clinched tooth.

[1]

Apply engine oil to the front balancer driven gear teeth.

Align [1]
Install the front balancer driven gear [1].

• 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].

[2]/[3]

14-7
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
Install the special tool between the front balancer drive
[3] [2] [1]
gear and driven gear.

TOOL:
Gear holder, 2.5 [1] 07724-0010100
Apply engine oil to the front balancer shaft bolt threads
and seating surface.
Install the washer [2] and front balancer shaft bolt [3].
Tighten the front balancer shaft bolt to the specified
torque.
TORQUE: 103 N·m (10.5 kgf·m, 76 lbf·ft)
Install the right crankcase cover:
– MT model (page 12-6)
– DCT model (page 13-44)
Install the flywheel (page 11-7).

REAR BALANCER
REMOVAL
Remove the right crankcase cover:
– MT model (page 12-4)
– DCT model (page 13-41)
Remove the rear balancer shaft holder bolts [1] and
rear balancer shaft holder [2].

[1] [2] [1]

Remove the following:

[4]
– Collar [1]
– Thrust spring [2]
– Washers [3]
– Thrust bearing [4]

[1]

[2] [3]

14-8
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
Remove the following:
[1] [2]
– 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

[2]
balancer washer [2].
Check for damage of the rear balancer gear shaft, and
replace it if necessary.

[1]

INSTALLATION
Apply molybdenum oil solution to the rear balancer
[2]
washer seating surface.
Install the rear balancer gear shaft [1] and rear balancer
washer [2].

[1]

14-9
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
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 O.D.:
91015-MJP-G51 (Blue mark): Thickest
[1]
91016-MJP-G51 (White mark):
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
[1]
teeth with engine oil.
Install the following:
– Needle bearing [1]
– Rear balancer driven gear [2]
[5]/[6]
• 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 [2]
index lines [6].

[4] [3]

[2]

Outside

14-10
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
Coat the thrust bearing with engine oil.
[2]
Apply molybdenum oil solution to the thrust spring Outside
sliding surface.
Install the following:
– Washers [1]
– Thrust bearing [2]
– Thrust spring [3]
– Collar [4] [4]

• Install the thrust spring as shown.

[3] [1]

Install the rear balancer shaft holder [1].

• Align the dowel pins of the rear balancer shaft holder

with the crankcase holes.
Align

Align

[1]

Install and tighten the rear balancer shaft holder bolts

[1] to the specified torque.

TORQUE: 29 N·m (3.0 kgf·m, 21 lbf·ft)

Install the right crankcase cover:
– MT model (page 12-6)
– DCT model (page 13-44)

[1] [1]

CRANKCASE SEPARATION
Remove the engine (page 16-4).
[1]
Remove the bolts [1], water hose flange [2], and O-ring
[3].
Remove the necessary parts for separating the
crankcase by referring to Service Information (page 14-
2).

[3] [2]

14-11
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
DCT model: Remove the following:
DCT model: [3]
– Cam chain guide plate bolts [1]
– Cam chain guide plate [2]
– Cam chain [3] [2]
– Timing sprocket [4]
[4]

[1]

Place the engine upside down.

[1] [3]
Loosen the following:
– Crankcase 6 mm bolts (short) [1]
– Crankcase 6 mm bolt (long) [2] [2]
[5]
• Loosen the crankcase 6 mm bolts alternately from [4]
outside to inside in 2 or 3 steps.
[4] [6]
Loosen the following:
– Crankcase 8 mm bolts (short) [3] [4]
– Crankcase 8 mm bolts (middle) [4]
– Crankcase 8 mm bolt (long) [5] [1] [3]
– Crankcase 10 mm bolt [6] [3]

• Loosen the crankcase 8 mm and 10 mm bolts in a

crisscross pattern in 2 or 3 steps.
Remove the following:
[1] [4]
– Crankcase 6 mm bolts (short) [1]
– Crankcase 6 mm bolt (long) [2]
– 6 mm sealing washers [3]
– Crankcase 8 mm bolts (short) [4] [2]/[3]
– Crankcase 8 mm bolts (middle) [5]
[6]/[7]
– Crankcase 8 mm bolt (long) [6] [5]
– 8 mm sealing washers [7]
– Crankcase 10 mm bolt [8] [8]
[5]/[7]
[5]
[1]/[3]
[4]
[4]

Loosen the following:

[1] [2]
– Crankcase main journal bolts (short) [1]
– Crankcase main journal bolt (middle) [2]
– Crankcase main journal bolts (long) [3]

• Loosen the crankcase main journal bolts in a

crisscross pattern in 2 or 3 steps.
Remove the crankcase main journal bolts.
Separate the lower crankcase from the upper
crankcase. [3]

• Do not pry the crankcase halves with a screwdriver.

14-12
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
Remove the dowel pins [1], oil orifice A [2], and oil
[1] [1]
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. [3]
[2]

[1]

TRANSMISSION
REMOVAL
COUNTERSHAFT
Separate the crankcase halves (page 14-11).
MT model shown:
Remove the countershaft assembly [1].
Remove the dowel pin [2].

[1]

[2]

SHIFT FORK/SHIFT DRUM

Remove the countershaft (page 14-13).
MT model: DCT model:
Remove the shift drum bearing setting bolt/washer [1].
[1] [1]

MT model: Remove the following:

MT model: [2]
– Shift fork shaft [1]
– Countershaft shift forks [2]
– Mainshaft shift fork [3]

[3]

[1]

14-13
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
DCT model: Remove the following:
DCT model: [2]
– Countershaft shift fork shaft [1]
– Countershaft shift forks [2] [3]
– Mainshaft shift fork shaft [3]
– Mainshaft shift forks [4]

[1]

[4]

Remove the shift drum bearing setting bolt/washer [1].

MT model shown:

[1]

Remove the shift drum bearing [1] and shift drum [2].
MT model shown: [2]

[1]

MAINSHAFT
Remove the shift forks/shift drum (page 14-13).
MT model shown: [1]
Remove the mainshaft bearing set plate bolts [1] and
set plate [2].

[1] [2]

14-14
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
Remove the right mainshaft bearing [1] by moving the
MT model shown:
mainshaft assembly [2].
Remove the mainshaft assembly. [2]

[1]
DCT model:
• When removing the mainshaft assembly, position
the crankshaft [3] as shown.

DCT model shown:

[3]

[2]

14-15
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
DISASSEMBLY/ASSEMBLY
(MT model)
Clean all disassembled parts in solvent thoroughly.

• 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)

SPLINE WASHER M2 GEAR (18T)

M6 GEAR SPLINE BUSHING
LOCK WASHER WASHER
SPLINE WASHER

SNAP RING

M3/M4 GEAR (25/26T)

SNAP RING

SPLINE WASHER
M5 GEAR (31T)

M5 GEAR BUSHING

THRUST WASHER

MAINSHAFT/M1 GEAR (15T)

: Gear teeth, rotating surfaces

: Bushing surfaces, needle bearing surfaces,

and shifter gear grooves/spline area

14-16
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
COUNTERSHAFT
THRUST WASHER

C1 GEAR (43T)
NEEDLE BEARING
C1 GEAR BUSHING

THRUST WASHER

C5 GEAR (33T)

C4 GEAR (32T) COLLAR

C3 GEAR (37T)
C4 GEAR BUSHING LOCK WASHER

C3 GEAR BUSHING C6 GEAR (35T) SPLINE WASHER

SNAP RING

SPLINE WASHER SPLINE WASHER

SNAP RING
C2 GEAR BUSHING

COUNTERSHAFT

SNAP RING
COUNTERSHAFT BEARING SET RING
SPLINE WASHER
OIL SEAL
C2 GEAR (34T)

: Gear teeth, rotating surfaces

: Bushing/collar surfaces, needle bearing surfaces,

and shifter gear grooves/spline area

• 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]

14-17
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
DISASSEMBLY/ASSEMBLY
(DCT model)
Clean all disassembled parts in solvent thoroughly.

• 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)

NEEDLE BEARING
NEEDLE BEARING

THRUST WASHER

M6 GEAR BUSHING

M6 GEAR (34T)

SPLINE WASHER SPECIAL WASHER

SNAP RING
M3 GEAR (24T)
M4 GEAR (30T)

SNAP RING
M5 GEAR
BUSHING SPLINE WASHER

THRUST WASHER

M5 GEAR (37T)

INNER MAINSHAFT/M1 GEAR (16T)

: Gear teeth, rotating surfaces

: Bushing surfaces, needle bearing surfaces,

and shifter gear grooves/spline area

14-18
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
COUNTERSHAFT
C2 GEAR (37T)

THRUST WASHER
C2 GEAR BUSHING
NEEDLE BEARING
SNAP RING
THRUST WASHER
C3 GEAR (33T)

C6 GEAR (30T)
SPLINE WASHER

C4 GEAR (34T)

C4 GEAR BUSHING
SPLINE WASHER
C1 GEAR (41T) LOCK WASHER

SPLINE WASHER

C1 GEAR BUSHING C3 GEAR SPLINE BUSHING

SNAP RING

C5 GEAR (36T) COUNTERSHAFT

SNAP RING
BEARING SET RING
SPLINE WASHER

OIL SEAL

: Gear teeth, rotating surfaces

: Bushing surfaces, needle bearing surfaces,

and shifter gear grooves/spline area

• 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]

14-19
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
INSPECTION
Inspect the following parts for scratches, damage,
abnormal wear, or deformation.
– Transmission gears
– Transmission bushings
– Transmission bearings
– Shift drum/bearing
– Shift forks
– Shift fork shafts
Measure each part according to CRANKCASE/
TRANSMISSION SPECIFICATIONS (page 1-11).
Replace any part if it is out of service limit.

UPPER CRANKCASE BEARING

REPLACEMENT (MT model)
Before replacing the bearing, remove the following:
– Transmission (page 14-13)
– Crankshaft (page 15-4)
– Piston (page 15-12)
LEFT MAINSHAFT BEARING
Remove the left mainshaft bearing [1] using the special
[1]
tools.

TOOLS:
Bearing remover shaft set,
25 mm 07936-ZV10100
Remover weight 07741-0010201
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

• Drive in a new bearing squarely with the marked

side facing in.
Install the removed parts in the reverse order of
removal.

14-20
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
UPPER CRANKCASE BEARING
REPLACEMENT (DCT model)
Before replacing the bearings, remove the following:
– Transmission (page 14-13)
– Crankshaft (page 15-4)
– Piston (page 15-12)
LEFT MAINSHAFT BEARING
Remove the left mainshaft bearing [1] using the special
[1]
tools.
TOOLS:
Bearing remover shaft set,
25 mm 07936-ZV10100
Remover weight 07741-0010201
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

• Drive in a new bearing squarely with the marked

side facing in.
Install the removed parts in the reverse order of
removal.

SHIFT DRUM NEEDLE BEARING

Drive out the shift drum needle bearing [1].
[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

• Drive in a new needle bearing squarely with the

marked side facing out.
Install the removed parts in the reverse order of
removal.

[1]

115.1 – 116.1 mm
(4.53 – 4.57 in)

14-21
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
SHIFT CONTROL MOTOR REDUCTION GEAR
BEARING
Heat the upper crankcase to 80°C (176°F) evenly using
[1]
a heat gun.

• Do not use a torch to heat the upper crankcase; it

may cause warping.
Tap the upper crankcase lightly and remove the
bearings.
– Radial ball bearing (607ZZ) [1]
– Radial ball bearing (696ZZ) [2]
Apply engine oil to new bearings.
Drive in the bearings squarely until they are fully
seated. [2]

• Drive in the bearings with the marked side facing

toward the outside of the crankcase.
Install the removed parts in the reverse order of
removal.

GEARSHIFT SPINDLE NEEDLE BEARING

Heat the upper crankcase to 80°C (176°F) evenly using
a heat gun.

• 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 [1]

• 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)

[1]

14-22
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
INSTALLATION
MAINSHAFT
Install the mainshaft assembly [1] into the upper
DCT model shown:
crankcase.

[2]
DCT model:
• When install the mainshaft assembly, position the
[3]
crankshaft [2] as shown.
[1]
Insert the mainshaft end to the left mainshaft bearing
[3].

Apply engine oil to the right mainshaft bearing.

MT model shown:
Install the right mainshaft bearing [1] into the upper
crankcase.

• Install the bearing into the crankcase with the [1]

marked side facing out.

Apply locking agent to the mainshaft bearing set plate

MT model shown:
bolts threads (page 1-27).
Install the mainshaft bearing set plate [1]. [2]
Install and tighten the mainshaft bearing set plate bolts
[2] to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[2] [1]

SHIFT DRUM/SHIFT FORK

Apply engine oil to the shift drum bearing.
MT model shown: [2]
Install the shift drum [1] and shift drum bearing [2] into
the upper crankcase.

[1]

14-23
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
Apply locking agent to the shift drum bearing setting
MT model shown:
bolt/washer threads (page 1-27).
Install and tighten the shift drum bearing setting bolt/
washer [1] to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[1]

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
– DCT model:
– "L" mark [3]: left mainshaft shift fork
– "R" mark [4]: right mainshaft shift fork
– "C" mark [5]: countershaft shift fork
[2] [2]

[1]

DCT model:

[3] [4]

[5] [5]

MT model: Apply molybdenum oil solution to the shift fork shaft

MT model: [2]
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 [1]
identification marks facing toward the right side of the
engine.
Insert the shift fork shaft [3].
[3]

• Make sure that each shift fork guide pin is positioned

in the correct guide grooves of the shift drum.

14-24
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
DCT model: Install the following with the identification marks facing
DCT model: [4]
toward the right side of the engine:
– Left mainshaft shift fork [1] into the M3 gear [3]
– Right mainshaft shift fork [2] into the M4 gear
Apply molybdenum oil solution to the shift fork shafts
outer surface. [1]

Insert the mainshaft shift fork shaft [3]. [5]

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].
[2]
• Make sure that each shift fork guide pin is positioned
in the correct guide grooves of the shift drum.
Apply locking agent to the shift drum bearing setting
MT model: DCT model:
bolt/washer threads (page 1-27).
Install and tighten the shift drum bearing setting bolt/
washer [1] to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[1] [1]

COUNTERSHAFT
Install the dowel pin [1] onto the upper crankcase hole.
MT model shown:
Install the countershaft assembly [2].

• Align the needle bearing cap hole [3] with the dowel
pin. [2]
• Align the set ring with the upper crankcase groove.
• Align the oil seal flange with the upper crankcase
groove.
Assemble the crankcase halves (page 14-26).
[3]
Align

[1] Align

14-25
 dummyhead

CRANKCASE/TRANSMISSION/BALANCER
CRANKCASE ASSEMBLY
Apply liquid sealant (TB1207B manufactured by Three
Bond or equivalent) to the crankcase mating surface as
shown.

• Do not apply more liquid sealant than necessary.

• Do not apply liquid sealant to the crankcase main
journal bolts area and the oil passage area.

Install the dowel pins [1], oil orifice A [2], and oil orifice
[1] [1]
B [3] onto the upper crankcase.

• Install the oil orifice A with its narrow hole side facing
the upper crankcase.

[3]
[2]

[1]

Apply molybdenum oil solution to the main journal

[3] [2]
bearing sliding surfaces on the lower crankcase.
Install the lower crankcase onto the upper crankcase.

• 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 bolts (long) [1]
– Crankcase main journal bolt (middle) [2]
– Crankcase main journal bolts (short) [3]
TORQUE: 43 N·m (4.4 kgf·m, 32 lbf·ft)

• Tighten the crankcase main journal bolts in a

crisscross pattern in 2 or 3 steps.

14-26
dummyhead

CRANKCASE/TRANSMISSION/BALANCER
Install the following:
[8] [5]
– Crankcase 10 mm bolt [1]
– New 8 mm sealing washers [2]
– Crankcase 8 mm bolt (long) [3]
– Crankcase 8 mm bolts (middle) [4] [6]/[7]
– 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]
[5]

Tighten the following bolts to the specified torque:

[6] [4]
– 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]
[3]
Crankcase 10 mm bolt:
39 N·m (4.0 kgf·m, 29 lbf·ft)
[3] [1]
Crankcase 8 mm bolt (long/middle/short):
24 N·m (2.4 kgf·m, 18 lbf·ft) [3]

[6] [4]
• Tighten the crankcase 10 mm and 8 mm bolts in a [4]
crisscross pattern in 2 or 3 steps.
Tighten the crankcase 6 mm bolt (long) [5] and 6 mm
bolt (short) [6] securely.

• Tighten the crankcase 6 mm bolts alternately from

inside to outside in 2 or 3 steps.
DCT model: Install the timing sprocket [1].
DCT model: [3]
Align
• Install the timing sprocket with its punch mark [2]
facing outside as shown.
• Align the timing sprocket wide teeth with the [1]
crankshaft wide teeth. [4]

Coat the cam chain with the engine oil.

Install the cam chain [3]. [2]

Apply locking agent to the cam chain guide plate bolts

threads (page 1-27).
[5]
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
[1] [3]
Service Information (page 14-2).
Coat a new O-ring with engine oil.
Install the O-ring [1] into the groove in the water hose
flange [2].
Install and tighten the bolts [3] securely.
Install the engine (page 16-12).

[2]

14-27
dummyhead

MEMO
dummytext

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

15-1
 dummyhead

CRANKSHAFT/PISTON/CYLINDER
SERVICE INFORMATION
CRANKSHAFT/PISTON/CYLINDER

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
dummyhead

CRANKSHAFT/PISTON/CYLINDER
COMPONENT LOCATION
22 N·m (2.2 kgf·m, 16 lbf·ft) + 120°
MT model shown:

15-3
 dummyhead

CRANKSHAFT/PISTON/CYLINDER
CRANKSHAFT
Separate the crankcase halves (page 14-11).
SIDE CLEARANCE INSPECTION
Measure the connecting rod side clearance.

SERVICE LIMIT: 0.35 mm (0.014 in)

If the clearance exceeds the service limit, replace the
connecting rod.
Recheck and if still out of limit, replace the crankshaft.

REMOVAL

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
[1] [2]
bearing caps [2].
Remove the crankshaft [3].

[3]

[2]

INSPECTION
Support the crankshaft [1] on both end journals.
[1]
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
dummyhead

CRANKSHAFT/PISTON/CYLINDER
INSTALLATION
Apply molybdenum oil solution to the main journal
[1]
bearing [1] sliding surfaces on the upper crankcase.
Apply molybdenum oil solution to the crankpin bearing
[2] sliding surfaces on the connecting rods.

[2]

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.
[2]

• 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]. Align

Install the crankpin bearing caps.

[1]

• Align the I.D. code number on the crankpin bearing

caps and connecting rods.

Apply engine oil to new crankpin bearing cap bolt

threads and seating surfaces.
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 14-26).

[1]

15-5
 dummyhead

CRANKSHAFT/PISTON/CYLINDER
MAIN JOURNAL BEARING

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
severe engine damage.
Remove the crankshaft (page 15-4).
BEARING INSPECTION
Inspect the main journal bearings [1] on the upper and
Upper crankcase side [1]
lower crankcase halves for unusual wear or peeling.
shown:
Check the main journal bearing tabs for damage.

OIL CLEARANCE INSPECTION

• Do not rotate the crankshaft during inspection.

Clean off any oil from the main journal bearings and
[2]
main journals.
Install the crankshaft [1] onto the upper crankcase. [1]
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
dummyhead

CRANKSHAFT/PISTON/CYLINDER
Install the lower crankcase onto the upper crankcase.
[3] [2]

• 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:
– Crankcase main journal bolts (long) [1]
– Crankcase main journal bolt (middle) [2] [1]
– Crankcase main journal bolts (short) [3]
TORQUE: 43 N·m (4.4 kgf·m, 32 lbf·ft)

• Tighten the crankcase main journal bolts in a

crisscross pattern in 2 or 3 steps.
Loosen the following:
[1] [2]
– Crankcase main journal bolts (short) [1]
– Crankcase main journal bolt (middle) [2]
– Crankcase main journal bolts (long) [3]

• Loosen the crankcase main journal bolts in a

crisscross pattern in 2 or 3 steps.
Remove the crankcase main journal bolts.
Separate the lower crankcase from the upper
crankcase. [3]

Measure the compressed plastigauge at its widest point

on each main journal to determine the oil clearance.

SERVICE LIMIT: 0.05 mm (0.002 in)

If the oil clearance exceeds the service limit, select the
replacement bearing (page 15-8).

15-7
 dummyhead

CRANKSHAFT/PISTON/CYLINDER
MAIN JOURNAL BEARING
SELECTION
Record the crankcase bearing support I.D. code letters
[1] from left side of the upper crankcase as shown.

• Letters (A, B or C) on the left side of upper

crankcase are bearing support I.D. codes from left to
right.

[1]

If you are replacing the crankshaft, record the

corresponding main journal O.D. code numbers [1] from
the crank weight.

• 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.

[1]

Determine the replacement bearing color code [1] with

[1]
the main journal O.D. code number or the measured
main journal O.D., and the crankcase bearing support
I.D. code.
Refer to the main journal bearing selection table below
for bearing selection.
MAIN JOURNAL BEARING THICKNESS:
A: Blue: Thickest
B: Black:
C: Brown:
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)
O.D. 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)

After selecting new bearings, recheck the clearance

with a plastigauge. Incorrect clearance can cause
severe engine damage.

15-8
dummyhead

CRANKSHAFT/PISTON/CYLINDER
BEARING INSTALLATION
Clean the main journal bearing outer surfaces and
Upper crankcase side Align
crankcase bearing inserts.
shown:
Install the main journal bearings [1].

• Install the main journal bearing by aligning each tab

with each groove.

[1]

CRANKPIN BEARING

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
severe engine damage.
Remove the crankshaft (page 15-4).
BEARING INSPECTION
Check the crankpin bearings [1] for unusual wear or
Connecting rod side
peeling.
shown:
Check the crankpin bearing tabs for damage.

[1]

[1]

OIL CLEARANCE INSPECTION

• Do not rotate the crankshaft during inspection.

Clean off any oil from the crankpin bearings and
[2] [1]
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.

15-9
 dummyhead

CRANKSHAFT/PISTON/CYLINDER
Install the crankpin bearing caps [1].

• Align the I.D. code number on the crankpin bearing

caps and connecting rods. [1]

Align

Apply engine oil to the crankpin bearing cap bolt (reuse)

threads and seating surfaces.
[2]
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 lbf·ft) + 90°
Remove the crankpin bearing cap bolts and crankpin
bearing caps [2].

[1]

Measure the compressed plastigauge at its widest point

on each crankpin to determine the oil clearance.
SERVICE LIMIT: 0.065 mm (0.0026 in)
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.

• 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.

15-10
dummyhead

CRANKSHAFT/PISTON/CYLINDER
If you are replacing the crankshaft, record the
corresponding crankpin O.D. code letter [1].

• 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.

[1]

Determine the replacement bearing color code [1] with

[1]
the connecting rod I.D. code number or the measured
connecting rod I.D., and the crankpin O.D. code letter or
measured crankpin O.D.
Refer to the crankpin bearing selection table below for
bearing selection.
CRANKPIN BEARING THICKNESS:
A: Blue: Thickest
B: Black:
C: Brown:
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)
O.D. 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)

After selecting new bearings, recheck the clearance

with a plastigauge. Incorrect clearance can cause
severe engine damage.

BEARING INSTALLATION
Clean the crankpin bearing outer surfaces, crankpin
[1]
bearing cap and connecting rod.
Install the crankpin bearings [1] onto the crankpin
bearing cap and connecting rod.

• Install the crankpin bearings by aligning each tab

with each groove.

Align

15-11
 dummyhead

CRANKSHAFT/PISTON/CYLINDER
PISTON/CYLINDER
PISTON/CONNECTING ROD
REMOVAL

• Before piston removal, place a clean shop towel

around the connecting rod to prevent damaging the
cylinder inner surface.
• Do not try to remove the piston/connecting rod
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
in severe engine damage.
Remove the following:
[1]
– Transmission (page 14-13)
– Crankshaft (page 15-4)
Remove the piston/connecting rod assembly [1] from
the top of the cylinder.

PISTON REMOVAL
Remove the piston pin clips [1].
[3]
Push the piston pin [2] out of the piston [3] and [2]
connecting rod [4].
Remove the piston. [1]

[4]

PISTON RING REMOVAL

Spread each piston ring ends and remove them by
lifting up at a point opposite the gap.

• 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.

• Never use a wire brush; it will scratch the groove.

15-12
dummyhead

CRANKSHAFT/PISTON/CYLINDER
INSPECTION
Inspect the following parts for scratches, damage,
abnormal wear, or deformation.
– Cylinder
– Piston
– Piston rings
– Piston pin
– Connecting rod small end
Measure each part and calculate the clearance
according to CRANKSHAFT/PISTON/CYLINDER
SPECIFICATIONS (page 1-12).
Replace any part if it is out of service limit.

PISTON RING INSTALLATION

Clean the piston ring grooves thoroughly.
[1] [3]
Install the piston rings.

• Apply engine oil to the piston ring entire surfaces

and piston ring grooves.
• Avoid piston and piston ring damage during [2]
installation. 120°
• Install the top ring [1] and second ring [2] with their [3] 120° [1]
marks [3] facing up.
120°
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 [4]
ring groove.
Stagger the piston ring end gaps 120° apart from each [5]
other.
Stagger the side rail end gaps as shown.
20 mm (0.8 in)
[6] OR MORE

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]

[3]

15-13
 dummyhead

CRANKSHAFT/PISTON/CYLINDER
Apply molybdenum oil solution to the piston pin outer
surface.
Install the piston pin [1]. [1]
Secure the piston pin using new piston pin clips [2].
[2]

• Make sure that the piston pin clips are seated

securely.
• Do not align the piston pin clip end gap with the
piston cut-out [3] as shown.

[2] [3]

PISTON/CONNECTING ROD
INSTALLATION
Apply engine oil to the piston and cylinder inner surface.
[3]
Install the piston/connecting rod assemblies [1] into the
cylinders using a commercially available piston ring
compressor tool [2].

• While installing the piston, be careful not to damage

the top surface of the cylinder, especially around the
cylinder bore.
• Be careful not to damage the cylinder inner surface [2]
with the connecting rod.

• When reusing the connecting rods, they must be [1]

installed in their original locations.
• Install the piston/connecting rod assembly with the
"IN" mark [3] facing the intake side.
• 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.
Install the following:
– Crankshaft (page 15-5)
– Transmission (page 14-23)

PISTON OIL JET REMOVAL/

INSTALLATION
Separate the crankcase halves (page 14-11).
[1]
Remove the piston oil jets [1] and O-rings [2].
Installation is in the reverse order of removal.

• Replace the O-rings with new ones. [1]

• Apply engine oil to new O-rings. [2]
• Install the piston oil jets into the holes of upper
crankcase as shown.

[2]

15-14
dummytext

16. ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION ···························16-2 ENGINE REMOVAL ···································· 16-4

COMPONENT LOCATION ··························16-3 ENGINE INSTALLATION·························· 16-12

16

16-1
 dummyhead

ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
ENGINE REMOVAL/INSTALLATION

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.
• 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
sequence.
• MT model:
The following components can be serviced with the engine installed in the frame.
– Starter motor (page 6-7)
– Throttle body (page 7-16)
– Water pump (page 8-11)
– Oil pump (page 9-5)
– Rocker arm (page 10-8)
– Camshaft (page 10-12)
– Cylinder head/valves (page 10-18)
– Flywheel (page 11-6)
– Stator (page 11-5)
– Clutch (page 12-8)
– Primary drive gear (page 12-16)
– Gearshift linkage (page 12-18)
– Balancer (page 14-6)
• DCT model:
The following components can be serviced with the engine installed in the frame.
– Starter motor (page 6-7)
– Throttle body (page 7-16)
– Water pump (page 8-11)
– Oil pump (page 9-5)
– Rocker arm (page 10-8)
– Camshaft (page 10-12)
– Cylinder head/valves (page 10-18)
– Flywheel (page 11-6)
– Stator (page 11-5)
– Balancer (page 14-6)
– Shift control motor/reduction gears (page 13-55)
– Primary drive gear (page 13-54)
– Dual clutch (page 13-51)
– Gearshift linkage (page 13-58)
• The following components require engine removal for service.
– Transmission (page 14-13)
– Crankshaft (page 15-4)
– Piston/cylinder (page 15-12)

16-2
dummyhead

ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION
MT model shown:

12 N·m
(1.2 kgf·m, 9 lbf·ft)

32 N·m
(3.3 kgf·m, 24 lbf·ft)

80 N·m 44 N·m
(8.2 kgf·m, 59 lbf·ft) (4.5 kgf·m, 32 lbf·ft)

44 N·m 32 N·m
(4.5 kgf·m, 32 lbf·ft) (3.3 kgf·m, 24 lbf·ft)

32 N·m
(3.3 kgf·m, 24 lbf·ft)

54 N·m
(5.5 kgf·m, 40 lbf·ft)

32 N·m
(3.3 kgf·m, 24 lbf·ft) 32 N·m
(3.3 kgf·m, 24 lbf·ft)
44 N·m
(4.5 kgf·m, 32 lbf·ft)

16-3
 dummyhead

ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Support the motorcycle using a safety stand or hoist.
Remove the following:
• 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 5-9)
– 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 12-18)
– Shift pedal (page 12-21)
– CKP sensor (page 4-83)
• DCT 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)
– EOT sensor (page 13-65)
– Ignition coil tray (page 5-9)
– 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)
– Shift control motor cover (page 13-55)
– Clutch EOP sensor cover (page 2-27)
– CKP sensor (page 4-83)
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.

[4] [3] [1] [2]

Disconnect the alternator 3P (Gray) connector (page

[3] [1]
21-9).
Remove the wire band [1].
Release the wire clip [2].
[2]
Release the alternator wire [3] from the frame.

16-4
dummyhead

ENGINE REMOVAL/INSTALLATION
MT model: Remove the wire clamps [1].
MT model:

[1]

MT model: Release the alternator wire clip [1].

MT model: [5] [4] [2]
Remove the alternator cover bolt [2] and stay [3].
Disconnect the EOP switch terminal [4].
Remove the EOP switch [5].

[3]

[1]

DCT model: Release the alternator wire clip [1].

DCT model: [2] [3]
Remove the alternator cover bolt [2] and stay [3].
Remove the wire band [4].
Disconnect the EOP sensor 3P (Black) connector [5].
Remove the EOP sensor [6].

[5] [4] [6] [1]

Remove the alternator cover bolts [1] and skid plate

stay [2].

[1]

[2]

16-5
 dummyhead

ENGINE REMOVAL/INSTALLATION
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].

[2]

[1] [3] [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] [1]
Release the wire clip [6].

[3]

[6]

[4] [2] [5]

DCT model: Disconnect the following:

DCT model:
– Sidestand switch 2P (Black) connector [1]
– TR sensor 3P (Black) connector [2]
– Inner mainshaft sensor 3P (Black) connector [3] [5]
– Shift spindle angle sensor 3P (Blue) connector [4]
– Gear change switch (option) 3P (Black) connector [1]
[5]
– Neutral switch terminal [6]
Release the wire clips [7].

[6]
[7]
[2] [3] [4]

Remove the bolts [1] and harness clip stay [2].

[1] [2]

16-6
dummyhead

ENGINE REMOVAL/INSTALLATION
MT model: Disconnect the starter motor cable terminal [1] and VS
MT model: [1]
sensor 3P (Black) connector [2].

[2]

DCT model: Disconnect the following:

DCT model: [1]
– Starter motor cable terminal [1]
– VS sensor 3P (Black) connector [2]
– Outer mainshaft sensor 3P (Black) connector [3]

[2]

[3]

Disconnect the ECT sensor 2P (Black) connector [1].

[1]

DCT model: Disconnect the shift control motor 2P (Black) connector

DCT model:
[1].

[1]

16-7
 dummyhead

ENGINE REMOVAL/INSTALLATION
MT model: Remove the bolt [1] and clutch cable holder [2].
MT model: [1]
Disconnect the clutch cable [3] from the clutch lifter
lever [4]. [4]

[3] [2]

MT model: Remove the bolt [1] and clutch cable guide [2].
MT model:

[1]

[2]

Remove the bolt [1] and battery box stay [2].

[2] [1]

DCT model: Disconnect linear solenoid 4P (Black) connector [1].

DCT model:

[1]

16-8
dummyhead

ENGINE REMOVAL/INSTALLATION
DCT model: Remove the wire clamp [1].
DCT model: [5]
Disconnect the following:
– Clutch line EOP sensor 3P (Gray) connector [2]
– No.1 clutch EOP sensor 3P (Gray) connector [3]
– No.2 clutch EOP sensor 3P (Black) connector [4] [1]
[6]
Remove the clutch EOP sensor wire stay bolt [5] and
stay [6].

[3]

[2] [4]

Conventional Remove the bolt [1].

Conventional [2]
suspension model:
Release the brake hose guide [2]. suspension model:

[1]

Remove the bolt [1] and radiator reserve tank stay [2].
DCT model shown:
DCT model: Release the EOT sensor wire clip [3] from the radiator
reserve tank stay.
[1]

[2] [3]

Fully slacken the drive chain (page 3-18).

[1] [2]
Remove the drive sprocket bolt [1] and washer [2].
Remove the drive sprocket [3] from the countershaft
and drive chain.

[3]

16-9
 dummyhead

ENGINE REMOVAL/INSTALLATION
DCT model: Release the parking brake cable clip [1].
DCT model: [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.

[1]/[2]

Remove the following:

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

[1] [2]

[3]

Remove the following:

[3] [1]
– Front head engine hanger bolts (left side) [1]
– Front head engine hanger bolt (right side) [2]
– Front head engine hanger plate [3]

[2] [3]

16-10
dummyhead

ENGINE REMOVAL/INSTALLATION
Remove the following:
[3]
– Front engine hanger nut (10 mm) [1]
– 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]

[1]/[2]
[7]

[6] [4]/[5]

Remove the following:

[1]/[2]
– Front lower nut [1]
– Front lower bolt [2] [5]
– Right front lower engine hanger bolt (long) [3]
– Right front lower engine hanger bolt (short) [4]
– Right front lower engine hanger plate [5]

[4]

[3]

Remove the following:

[3]
– Rear lower nut [1]
– Rear lower bolt [2]
– Collars [3]
Carefully maneuver the engine and remove it out of the
frame to the right.

• 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. [1]/[2]

16-11
 dummyhead

ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
Place the jack or other adjustable support under the
engine.

• 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]
– Rear engine upper hanger plate [20] and bolts [21]
– Rear upper bolt [22], collars [23] and nut [24]

• The jack height must be continually adjusted to

relieve stress for ease of bolt installation.
Route the hoses, wires, and cables properly (page 1-
32).

MT model shown:
[21] [23] [22]
[1]
[20] [19]

[18]

[24] [17]

[11]
[15]
[12]
[4]

[13] [14]

[2]

[10]
[3]
[5] [14]
[16]

[9] [6] [8] [7]

16-12
dummyhead

ENGINE REMOVAL/INSTALLATION
Tighten the right front lower engine hanger bolt (short)
[1] to the specified torque.
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)
Tighten the right front lower engine hanger bolt (long)
[2] to the specified torque.
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)

[1]

[2]

Tighten the rear engine upper hanger bolts [1] to the

[1]
specified torque.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Tighten the swingarm pivot nut [1] to the specified

torque.

TORQUE: 80 N·m (8.2 kgf·m, 59 lbf·ft)

[1]

Tighten the rear lower nut [1] to the specified torque.

[1]
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

16-13
 dummyhead

ENGINE REMOVAL/INSTALLATION
Tighten the front lower nut [1] to the specified torque.
[1]
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

Tighten the front engine hanger nuts (8 mm) [1] to the

[2]
specified torque.

TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)

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

TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

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

TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)

Tighten the front head engine hanger bolts (left side) [2]
to the specified torque.
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)

[1]

Tighten the rear upper nut [1] to the specified torque.

[1]
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft)

16-14
dummyhead

ENGINE REMOVAL/INSTALLATION
DCT model: Install the parking brake cable clip [1].
DCT model: [1]

Install the drive sprocket [1] in the drive chain.

[4] [3]

• 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.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)
[2]

[1]

Install the radiator reserve tank stay [1] and bolt [2].
DCT model shown:
Tighten the bolt securely.
DCT model: Install the EOT sensor wire clip [3] to the radiator
reserve tank stay. [2]

[1] [3]

Conventional Install the brake hose guide [1] and bolt [2].
Conventional [1]
suspension model: Tighten the bolt securely.
suspension model:

[2]

16-15
 dummyhead

ENGINE REMOVAL/INSTALLATION
DCT model: Connect the following:
DCT model: [5]
– 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]
Install the stay [4] and clutch EOP sensor wire stay bolt [6]
[4]
[5].
Tighten the bolt to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the wire clamp [6]. [2]

[1] [3]

DCT model: Connect linear solenoid 4P (Black) connector [1].

DCT model:

[1]

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

Tighten the bolt securely.

[1] [2]

MT model: Install the clutch cable guide [1] and bolt [2].
MT model: Align

• Align the clutch cable guide tab with the frame hole.
Tighten the bolt securely.
[2]

[1]

16-16
dummyhead

ENGINE REMOVAL/INSTALLATION
MT model: Connect the clutch cable [1] to the clutch lifter arm [2].
MT model: Align [4]
Install the clutch cable holder [3] and bolt [4].
[2]

• Align the clutch cable holder slit with the frame tab.
Tighten the bolt securely.

[1] [3]

DCT model: Connect the shift control motor 2P (Black) connector

DCT model:
[1].

[1]

Connect the ECT sensor 2P (Black) connector [1].

[1]

MT model: Connect the starter motor cable terminal [1] and VS

MT model: [1]
sensor 3P (Black) connector [2].

[2]

16-17
 dummyhead

ENGINE REMOVAL/INSTALLATION
DCT model: Connect the following:
DCT model: [1]
– Starter motor cable terminal [1]
– VS sensor 3P (Black) connector [2]
– Outer mainshaft sensor 3P (Black) connector [3]

[2]

[3]

Install the harness clip stay [1] and bolts [2].

Tighten the bolts securely.

[2] [1]

MT model: Connect the following:

MT model:
– 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]
[3]
Install the wire clip [6].
TORQUE:
Neutral switch terminal nut: [5]
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
Shift spindle switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)

[1] [4] [2] [6]

DCT model: Connect the following:

DCT model:
– Neutral switch terminal [1]
– Sidestand switch 2P (Black) connector [2]
– TR sensor 3P (Black) connector [3] [6]
– Inner mainshaft sensor 3P (Black) connector [4]
– Shift spindle angle sensor 3P (Blue) connector [5] [2]
– Gear change switch (option) 3P (Black) connector
[6]
Install the wire clips [7].
TORQUE:
Neutral switch terminal nut:
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)
[1]
[7]
[3] [4] [5]

16-18
dummyhead

ENGINE REMOVAL/INSTALLATION
Install the connector cover [1].

• 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.
[4]

[3] [1] [2]

Install the skid plate stay [1] and alternator cover bolts
[2].
Tighten the alternator cover bolts to the specified
torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[2]

[1]

MT model: Install the EOP switch [1] (page 22-24).

MT model: [1] [2] [4]
Connect the EOP switch terminal [2].
Install the stay [3] and alternator cover bolt [4].
Tighten the alternator cover bolt to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the alternator wire clip [5].
[3]

[5]

DCT model: Install the EOP sensor [1] (page 13-65).

DCT model: [5] [4]
Connect the EOP sensor 3P (Black) connector [2].
Install the wire band [3].
Install the stay [4] and alternator cover bolt [5].
Tighten the alternator cover bolt to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the alternator wire clip [6].

[2] [3] [1] [6]

16-19
 dummyhead

ENGINE REMOVAL/INSTALLATION
MT model: Install the wire clamps [1].
MT model:

[1]

Install the alternator wire [1] onto the frame.

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

Install the skid plate bracket [1] and bolts [2].

Tighten the bolt securely.
Install the fuel tank drain hose [3] and EVAP canister
drain hose [4] to the skid plate bracket.

[2] [1] [3] [4]

16-20
dummyhead

ENGINE REMOVAL/INSTALLATION
Support the motorcycle using a safety stand or hoist.
Install the following:
• MT model:
– Radiator reserve tank (page 8-11)
– Engine oil filter (page 3-12)
– Battery box (page 21-6)
– Ignition coil tray (page 5-9)
– Main step bracket (page 2-27)
– Rear brake pedal (page 19-16)
– Muffler/exhaust pipe (page 2-45)
– Radiator (page 8-7)
– CKP sensor (page 4-83)
– Gearshift spindle cover (page 12-20)
– Shift pedal (page 12-21)
– Right rear engine cover (page 2-27)
– Heel guards (page 2-26)
• DCT model:
– Radiator reserve tank (page 8-11)
– Engine oil filter (page 3-12)
– EOT sensor (page 13-65)
– Battery box (page 21-6)
– Ignition coil tray (page 5-9)
– Main step bracket (page 2-27)
– Rear brake pedal (page 19-16)
– Muffler/exhaust pipe (page 2-45)
– Radiator (page 8-7)
– CKP sensor (page 4-83)
– Shift control motor cover (page 13-57)
– Clutch EOP sensor cover (page 2-27)
– Right rear engine cover (page 2-27)
– Heel guards (page 2-26)
Adjust the drive chain slack (page 3-18).

16-21
dummyhead

MEMO
dummytext

17. FRONT WHEEL/SUSPENSION/STEERING

SERVICE INFORMATION ···························17-2 FRONT WHEEL ········································ 17-13

TROUBLESHOOTING·································17-2 FORK························································· 17-20

COMPONENT LOCATION ··························17-3 STEERING STEM ····································· 17-45

HANDLEBAR ··············································17-4

17

17-1
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION
FRONT WHEEL/SUSPENSION/STEERING

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)

TROUBLESHOOTING
Hard steering
• 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
• Insufficient tire pressure
• 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
• Insufficient tire pressure
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

17-2
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION
ED model shown:
32 N·m
(3.3 kgf·m, 24 lbf·ft)

22 N·m
(2.2 kgf·m, 16 lbf·ft)

25 N·m
(2.5 kgf·m, 18 lbf·ft)

39 N·m
(4.0 kgf·m, 29 lbf·ft)

45 N·m
(4.6 kgf·m, 33 lbf·ft)

22 N·m
(2.2 kgf·m, 16 lbf·ft) 65 N·m
(6.6 kgf·m, 48 lbf·ft)

17-3
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR
REMOVAL
Remove the knuckle guards (page 2-22).
[1]
Remove the rearview mirrors [1].

MT model: Remove the wire clamps [1].

MT model: [1]
Disconnect the following:
– Clutch switch connectors (upper side) [2]
– Cruise cancel switch connectors (lower side) [3]

[2]

[3]

DCT model: Remove the wire clamps [1].

DCT model: [1]
Disconnect the parking brake switch connectors [2].

[2]

MT model: Remove the bolts [1], holder [2], and clutch lever
MT model: [1]
assembly [3].

[3]

[2]

17-4
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
DCT model: Remove the bolts [1], holder [2], and parking brake
DCT model: [1]
lever assembly [3].

[3]

[2]

Remove the left handlebar switch screws [1].

Separate the left handlebar switch housing [2].

[1]

[2]

Remove the screw [1].

[2] [4]
Remove the left handlebar switch front housing [2] by
opening the setting plate [3].
CRF1100A/AL/D/ Remove the left handlebar grip [4] if necessary.
DL:

CRF1100A2/AL2/ Remove the left grip heater if necessary (page 22-47).

A4/AL4/D2/DL2/D4/
DL4:
[3]

[1]

Remove the wire clamp [1].

[2] [1]
Disconnect the following:
– Front brake switch connectors (upper side) [2]
– Cruise cancel switch connectors (lower side) [3]

[3]

17-5
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the bolts [1], holder [2], and front master
cylinder [3].

• Keep the front master cylinder upright to prevent air

from entering the hydraulic system. [1]

[3]

[2]

Remove the right handlebar switch screws [1].

[2] [1]
Separate the right handlebar switch housing [2].
CRF1100A2/AL2/ Release the wire clip [3].
A4/AL4/D2/DL2/D4/
DL4:

[3]

Remove the screw [1] and right handlebar switch

[2] [3]
housing [2].
Remove the throttle grip pipe [3].

[1]

Remove the following:

[1] [2] [2]
– Handlebar upper holder bolts [1]
– Handlebar upper holders [2]
– Handlebar [3]

[3]

17-6
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
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 [2]
handlebar is damaged, replace with a new one.

[3]

[1]

INSTALLATION

• 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
1-32).
• CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:
If the grip heater is removed, refer to grip heater
installation (page 22-47).
CRF1100A/AL/D/ If the left handlebar grip are removed, clean the inside
CRF1100A/AL/D/DL:
DL: surface of the handlebar grip [1].
Apply Honda Bond A or an equivalent to the inside
surface of the grip and outside surface of the handlebar
[2]. [1]
Wait 3 – 5 minutes and install the grip.
Rotate the grip for even application of the adhesive.

• Allow the adhesive to dry for 1 hour before using.

[2]

Install the grip APS [1] to the handlebar [2].

[2]
Set the setting plate [3].

• Align the setting plate tab with the handlebar hole.

[3]
Install and tighten the screw [4] securely.

Align
[1]

[4]

17-7
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Place the handlebar [1] on the lower holders [2].
[5] [5] [1] [5] [4] [3]

• Align the paint mark on the handlebar with the edge

of the lower holder.
[3]
Install the handlebar upper holders [3].

• Install the handlebar upper holder with the punch [5]

marks [4] facing front.
[4]
Install the handlebar upper holder bolts [5].
Tighten the front bolts first, then the rear bolts to the
specified torque.
TORQUE: 32 N·m (3.3 kgf·m, 24 lbf·ft) Align [2]

Apply grease to the throttle grip pipe [1] and APS [2] 3 mm [1]
contact area as shown. 5 mm (0.1 in)
(0.2 in)
3 mm (0.1 in)

5 mm
(0.2 in) 5 mm (0.2 in)

3 mm
(0.1 in) 5 mm
3 mm (0.2 in)
(0.1 in)

5 mm
[2] (0.2 in) 3 mm
(0.1 in)
5 mm
(0.2 in)

3 mm
3 mm
(0.1 in)
(0.1 in)

3 mm 5 mm (0.2 in)
(0.1 in) 5 mm
(0.2 in)

Install the throttle grip pipe [1] as shown.

[1]

• Align the throttle grip pipe tabs [2] with the grip APS
grooves [3].

[2]
[3]

17-8
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the right handlebar switch rear housing [1].
Align [1]

• Align the rear housing tabs with the holes.

Install and tighten the screw [2] securely.

[2] Align

Install the right handlebar switch front housing [1].

[1]

• Align the front housing boss with the hole.

Install and tighten the right handlebar switch screws [2]
to the specified torque.
Align
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)
[2]
CRF1100A2/AL2/ Install the wire clip [3].
A4/AL4/D2/DL2/D4/
DL4:

[3]

Install the front master cylinder [1] by aligning its end

[4]
with the paint mark on the handlebar.
Align
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 lbf·ft) [1]

[3]

[2]
[5]

Connect the following:

[1] [3]
– Front brake switch connectors (upper side) [1]
– Cruise cancel switch connectors (lower side) [2]
Install the wire clamp [3].

[2]

17-9
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the left handlebar switch front housing [1].
[1]
Set the setting plate [2].

• Align the setting plate tab with the handlebar hole.

Install and tighten the screw [3] securely.

[2]
Align

[3]

Install the left handlebar switch rear housing [1].

Install and tighten the left handlebar switch screws [2] to
the specified torque.
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)

[2]

[1]

MT model: Install the clutch lever assembly [1] by aligning its end
MT model: [4]
with the paint mark on the handlebar.
Install the holder [2] with its punch mark [3] facing up.
Install the bolts, and tighten the upper bolt [4] first, then [1]
the lower bolt [5]. [3]

Align

[2]
[5]

DCT model: Install the parking brake lever assembly [1] by aligning
DCT model: [4]
its end with the paint mark on the handlebar.
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].

[3]
[1]

Align

[2] [5]

17-10
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
MT model: Connect the following:
MT model: [3]
– Clutch switch connectors (upper side) [1]
– Cruise cancel switch connectors (lower side) [2]
Install the wire clamps [3].

[1]

[2]

DCT model: Connect the parking brake switch connectors [1].

DCT model: [2]
Install the wire clamps [2].

[1]

Install the rearview mirrors [1].

[1]
Install the knuckle guards (page 2-22).

17-11
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR WEIGHT REMOVAL/
INSTALLATION
Remove the following:
[6] [7]
– Handlebar weight bolt [1]
– Rubber [2]
– Handlebar weight A [3]
– Snap ring [4]
– Handlebar weight B [5] [5]
– Handlebar weight rubbers [6]
– O-ring [7]
Installation is in the reverse order of removal.
TORQUE:
Handlebar weight bolt:
55 N·m (5.6 kgf·m, 41 lbf·ft) [4]

• Always replace the handlebar weight bolt, O-ring,

snap ring, and handlebar weight rubbers with new [1] [2] [3]
ones.
• Apply engine oil to a new O-ring.
• Install the handlebar weight rubbers as shown.

HANDLEBAR LOWER HOLDER

REMOVAL/INSTALLATION
Loosen the handlebar lower holder nuts [1].
[3]
Remove the following:
– Handlebar upper holder bolts [2]
– Handlebar upper holders [3]
– Handlebar [4]

[2]

[2]

[4]

[1]

17-12
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the following:
[3] [3]
– Handlebar lower holder nuts [1]
– Washers [2]
– Handlebar lower holders [3]
– Damper rubbers [4]

[2]/[4]

[2]/[4] [1]/[2]

Installation is in the reverse order of removal.

[4] [2]
TORQUE:
Handlebar upper holder bolt:
32 N·m (3.3 kgf·m, 24 lbf·ft)
Handlebar lower holder nut:
39 N·m (4.0 kgf·m, 29 lbf·ft) [3]

• 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. Align
• When tightening the handlebar upper holder bolts,
[5] [1]
tighten the front bolts [4] first then the rear bolts [5].

FRONT WHEEL
REMOVAL
Remove the front brake caliper mounting bolts [1] and
Right side shown:
front brake calipers [2].

• 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. [1]

[2]

Remove the axle cap [1] (Except IN/KO/MA/TH).

Right side: Left side:
Remove the front axle nut [2].
Loosen the left front axle holder pinch bolts [3].
Loosen the right front axle holder pinch bolts [4].
Support the motorcycle using a safety stand or hoist,
raise the front wheel off the ground.
Remove the front axle [5] and front wheel.

[5] [4] [3] [2] [1]

17-13
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the side collars [1].
Left side: Right side:

[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.
Inspect the following parts for damage, abnormal wear,
deformation, or bend.
– Front axle
– Front wheel
Measure each part according to FRONT WHEEL/
SUSPENSION/STEERING SPECIFICATIONS (page 1-
13).
Replace any part if it is out of service limit.
WHEEL BALANCE

• Carefully check balance before installing the wheel.

• The wheel balance must be checked when the tire is
remounted.
Note the rotating direction mark [1] on the tire, and upon
[1] [2]
tire installation, always fit the tire so that the mark faces
in the normal rotating direction.

• For optimum balance, the tire balance mark [2] (light

mass point: a paint dot on the side wall) must be
located next to the valve stem [3]. Remount the tire if
necessary.

[3]

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.

[1]

17-14
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
DISASSEMBLY/ASSEMBLY
CRF1100A/AL/D/DL

FRONT BRAKE DISC BOLTS

20 N·m (2.0 kgf·m, 15 lbf·ft)

RIGHT FRONT BRAKE DISC

BEARING
(6004UU)

DISTANCE
COLLAR
DUST SEAL

PULSER RING

BEARING
(6004UU) DUST SEAL
PULSER RING BOLTS
7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
LEFT FRONT BRAKE DISC

FRONT BRAKE DISC BOLTS

20 N·m (2.0 kgf·m, 15 lbf·ft)

• Install the dust seals until they are flush with the
wheel hub surface.
• Apply grease to the dust seal lips.
• 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,
[1]
assemble them as follows:
28.5 – 30.5 mm
Place the rim on a work bench. (1.12 – 1.20 in)
Place the hub in the center of the rim, and begin the
lacing with new spokes.
[2]
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 or three steps.
TORQUE: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)

17-15
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4

FRONT BRAKE DISC BOLTS

20 N·m (2.0 kgf·m, 15 lbf·ft)

RIGHT FRONT BRAKE DISC

BEARING
(6004UU)

DISTANCE
DUST SEAL COLLAR

PULSER RING

BEARING
(6004UU)

DUST SEAL
PULSER RING BOLTS
7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
LEFT FRONT BRAKE DISC

FRONT BRAKE DISC BOLTS

20 N·m (2.0 kgf·m, 15 lbf·ft)

• Install the dust seals until they are flush with the
wheel hub surface.
• Apply grease to the dust seal lips.
• Install the brake discs by aligning their arrow marks
with the wheel hub arrow mark.

17-16
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
If the rim [1], hub [2], and spokes are disassembled,
B
assemble them as follows:
Measure the width of the rim to obtain the dimension B. 58 mm
(2.3 in)

• When measurement, except 80 mm (3.1 in) from

welded area of the rim.
Perform the following calculation to obtain the
dimension A. A

58 mm (2.3 in) – B/2 = A [1]

Place the rim on a work bench.
Place the hub in the center of the rim, and begin the
lacing with new spokes.
[2]

• 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.
Tighten the spokes to the specified torque in a
crisscross pattern in two or three steps.
TORQUE: 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)

• Tighten the spokes with a ball point wrench.

TIRE VALVE REMOVAL/INSTALLATION

(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)
Remove the tire.
[1]
Remove the nut [1], tire valve [2] and O-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 O-ring onto the tire valve.

• Do not apply grease to the O-ring.

Gradually screw in the tire valve and position it with the [3]
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.

90°

17-17
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
WHEEL BEARING REPLACEMENT
Install the bearing remover head [1] into the bearing [2].
[3]
From the opposite side, install the bearing remover
shaft [3] and drive the bearing out of the wheel hub. [2]
TOOLS:
Bearing remover head, 20 mm 07746-0050600
Bearing remover shaft 07746-0050100
Remove the distance collar and drive out the other
bearing.

• Replace the wheel bearings in pairs.

• Do not reuse old bearings.
[1]

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.
[3] [2]
TOOLS:
Driver [2] 07749-0010000
Attachment, 42 x 47 mm [3] 07746-0010300
Pilot, 20 mm [4] 07746-0040500

[1] [4]

INSTALLATION
Install the side collars [1] to the front wheel.
Left side: Right side:

[1]

Apply a thin coat of grease to the front axle sliding

surface.
Install the front wheel between the forks.

• Be careful not to damage the pulser ring.

Install the front axle [1] from the right side.

[1]

17-18
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install and tighten the front axle nut [1] to the specified
torque.

TORQUE: 65 N·m (6.6 kgf·m, 48 lbf·ft)

Tighten the left front axle holder pinch bolts [2] to the
specified torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)

[2] [1]

Install the front brake calipers [1] and new front brake
Right side shown:
caliper mounting bolts [2].
Tighten the front brake caliper mounting bolts to the
specified torque.
TORQUE: 45 N·m (4.6 kgf·m, 33 lbf·ft)
With the front brake applied, pump the forks up and [2]
down several times to seat the axle and check brake
operation.

[1]

Tighten the right front axle holder pinch bolts [1] to the
Right side: Left side:
specified torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)
Install the axle cap [2] (Except IN/KO/MA/TH).
Check the clearance gap between the front wheel
speed sensor bracket and pulser ring (page 20-26).

[1] [2]

17-19
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
FORK
REMOVAL
Remove the following:
[1]
– Front fender (page 2-23)
– Front wheel (page 17-13)
Remove the bolt [1] and front wheel speed sensor [2].
[2]

Electronic Remove the wire clamps [1].

Electronic suspension model:
suspension model:
Disconnect the following:
Left side: Right side:
– Front suspension solenoid 2P connector [2]
– Front suspension stroke sensor connector [3]

[2]
[1] [3]

Conventional Loosen the top bridge pinch bolts [1].

Conventional suspension model: [1]
suspension model:
If you plan to disassemble the fork, loosen the fork bolts
[2] at this point. But do not remove yet.

• Be careful not to damage the fork bolt.

[2]

Electronic Loosen the top bridge pinch bolts [1].

Electronic suspension model: [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

• Be careful not to damage the fork bolt. [2]

[3] [4]

17-20
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Loosen the fork bottom bridge pinch bolts [1] while
holding the forks [2].
Remove the forks.

[1] [2]

DISASSEMBLY
(CONVENTIONAL SUSPENSION
MODEL)
Turn the following adjusters counterclockwise to the
softest position.
– Rebound damping adjuster [1] [1]
– Pre-load adjuster [2]
– Compression damping adjuster [3]

• Be sure to record the number of turns from the

starting position. [2]

[3]

Remove the fork bolt [1].

[1]

• Be careful not to damage the fork bolt.

Remove the O-ring [2] from the fork bolt.

[2]

[1]

Push the outer pipe [1] slowly down, and gently seat the
[1]
dust seal [2] onto the axle holder [3].

[2]
[3]

17-21
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Attach the special tool to the spring collar holes [1].
[6]
TOOL:
Spring collar holder [2] 070MF-MBZC110
Compress the spring collar [3] with the spring collar
holder.
[4]
Insert the special tool between the fork damper lock nut
[4] and spring seat stopper [5].
[5]
TOOL:
Stopper plate [6] 070MF-MBZC130

[2] [3] [1]

Loosen the fork bolt [1] while holding the fork damper
[1]
lock nut [2].

• Be careful not to damage the fork bolt.

[2]

Remove the following:

[2]
– Fork bolt [1]
– Stopper plate [2] [1]
– Spring collar holder [3]
– Spring seat stopper [4]
– Spring collar [5]

[4]

[5] [3]

Pour out the fork fluid by pumping the outer pipe [1]
[2]
several times.
Pour out the fork fluid from the fork damper by pumping
the damper rod [2] several times.
Remove the fork spring [3].
[3]
[1]

17-22
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Hold the axle holder in a vise with soft jaws or a shop
towel.
Remove the fork center bolt [1] and sealing washer [2].

[1]/[2]

Remove the fork damper [1] and centering plate [2].

[2]

[1]

Remove the dust seal [1].

Remove the oil seal stopper ring [2].

• Do not scratch the slide pipe surface.

[2]

[1]

Pull the slide pipe [1] out until you feel resistance from
[1]
the slider bushing. 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. [2]

17-23
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the following:
[3] [2]
– Slider bushing [1]
– Guide bushing [2]
– Back-up ring [3] [1]
– Oil seal [4]
– Stopper ring [5]
– Dust seal [6]

• Do not remove the slider bushing unless it is [6]

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
Fork bolt wrench [3] 070MA-MKS0100
Lock nut wrench, 50 mm [4] 07WMA-KZ30100
[2]
• Be careful not to damage the fork bolt.
[1]

[3] [4]

Remove the O-ring [1].

[1]

Remove the following from the outer collar [1]:

[2] [5]
– Plug bolt [2]
– Collar [3]
– Solenoid valve [4] [6]
Remove the O-ring [5] and grommet [6] from the plug
bolt.
[3]

[4] [1]

17-24
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the fork bolt [1] using the special tools.
[1] [1]
TOOLS:
Fork bolt wrench [2] 070MA-MKS0100
Lock nut wrench, 50 mm [3] 07WMA-KZ30100

• Be careful not to damage the fork bolt.

Remove the O-ring [4] from the fork bolt. [2] [4]

[3]

Push the outer pipe [1] slowly down, and gently seat the
[1]
dust seal [2] onto the axle holder [3].

[2]
[3]

Attach the special tool to the spring collar holes [1].

[6]
TOOL:
Spring collar holder [2] 070MF-MBZC110
Compress the spring collar [3] with the spring collar
holder.
Insert the special tool between the fork damper lock nut [4]
[4] and spring seat stopper [5].
TOOL: [5]
Stopper plate [6] 070MF-MBZC130

[1] [3] [2]

Loosen the fork bolt [1] using special tools while holding
[3]
the fork damper lock nut [2].

TOOLS:
Fork bolt wrench [3] 070MA-MKS0100
Lock nut wrench, 50 mm [4] 07WMA-KZ30100
[4]

• Be careful not to damage the fork bolt.

[1]

[2]

17-25
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the following:
[1]
– Fork bolt [1] [2]
– O-ring [2]
– Stopper plate [3]
– Spring collar holder [4]

[3]

[4]

Remove the following:

[1]
– Spring seat stopper [1]
– Spring collar [2]

[2]

Pour out the fork fluid by pumping the outer pipe [1]
[2]
several times.
Pour out the fork fluid from the fork damper by pumping
the damper rod [2] several times.
Remove the fork spring [3].
[3]

[1]

Hold the axle holder in a vise with soft jaws or a shop

towel.
Remove the fork center bolt [1] and sealing washer [2].

[1]/[2]

17-26
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the dust seal [1].
Remove the oil seal stopper ring [2].

• Do not scratch the slide pipe surface.

[2]

[1]

Pull the slide pipe [1] out until you feel resistance from
[1]
the slider bushing. 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.
[2]

Remove the following:

[3] [2]
– Slider bushing [1]
– Guide bushing [2]
– Back-up ring [3] [1]
– Oil seal [4]
– Stopper ring [5]
– Dust seal [6]

• Do not remove the slider bushing unless it is [6]

necessary to replace with a new one.

[5] [4]

RIGHT (Stroke sensor side)

Remove the fork bolt [1] using the special tools.

TOOLS:
Fork bolt wrench [2] 070MA-MKS0100 [1] [1]
Lock nut wrench, 50 mm [3] 07WMA-KZ30100

• Be careful not to damage the fork bolt.

Remove the O-ring [4] from the fork bolt.

[3] [4]

[2]

17-27
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Push the outer pipe [1] slowly down, and gently seat the
[1]
dust seal [2] onto the axle holder [3].

[2]

[3]

Attach the special tool to the inner fork bolt [1].

[3]
TOOL:
Rod guide wrench [2] 070MB-MKS0100
Remove the inner fork bolt while compressing the fork
bolt [3].
Remove the fork bolt.

[2]

[1]

Remove the inner rod [1] and fork spring [2].

[1]

[2]

Pour out the fork fluid.

17-28
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Remove the dust seal [1].
Remove the oil seal stopper ring [2].

• Do not scratch the slide pipe surface.

[2]

[1]

Pull the slide pipe [1] out until you feel resistance from
[1]
the slider bushing. 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.
[2]

Remove the following:

[3] [2]
– Slider bushing [1]
– Guide bushing [2]
– Back-up ring [3] [1]
– Oil seal [4]
– Stopper ring [5]
– Dust seal [6]

• Do not remove the slider bushing unless it is [6]

necessary to replace with a new one.

[5] [4]

17-29
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Inspect the following parts for damage, abnormal wear,
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
– Slider bushing
– Back-up ring
• Electronic suspension model (stroke sensor side):
– Fork bolt (stroke sensor)
– Inner fork bolt
– Outer pipe
– Slide pipe
– Inner rod
– Fork spring
– Guide bushing
– Slider bushing
– Back-up ring
Measure each part according to FRONT WHEEL/
SUSPENSION/STEERING SPECIFICATIONS
(page 1-13).
Replace any part if it is out of service limit.

17-30
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
ASSEMBLY
(CONVENTIONAL SUSPENSION
MODEL)

• Before assembly, wash all parts with a high flash

point or non-flammable solvent and blow them dry.

FORK DAMPER LOCK NUT SPRING SEAT

FORK DAMPER
20 N·m (2.0 kgf·m, 15 lbf·ft) STOPPER

SLIDE PIPE
SLIDER
BUSHING

GUIDE O-RING
BUSHING

BACK-UP
RING

OIL SEAL
FORK BOLT
35 N·m
(3.6 kgf·m, 26 lbf·ft)
SEALING
WASHER
STOPPER
RING

DUST SEAL FORK SPRING

OUTER PIPE SPRING COLLAR
FORK CENTER BOLT
34 N·m (3.5 kgf·m, 25 lbf·ft) CENTERING PLATE

Wrap the edge and groove of the slide pipe [1] with tape
[1] [2]
[2].
Apply fork fluid to new dust seal lips.
Install the dust seal [3] onto the slide pipe.

[3]

17-31
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
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].

• Install the oil seal with its marked side facing toward
the axle holder.
Remove the tape from the slide pipe.
[1]
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]
removed.
[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
[4] [5]
back-up ring [3] into the outer pipe until the stopper ring
groove [4] is visible using the special tools.
TOOL: [1]
Fork seal driver, 45.2 mm [5] 07KMD-KZ30100

[3]

[2]

Install the stopper ring [1] into the groove securely.

[1] [2]
• Do not scratch the slide pipe surface.
Install the dust seal [2].

Install the centering plate [1] to the fork damper [2].

[1]
Install the fork damper/centering plate into the slide
pipe/outer pipe assembly [3].
[2]

[3]

17-32
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the fork center bolt [1] with a new sealing washer
[2].
Hold the axle holder in a vise with soft jaws or a shop
towel.
Tighten the fork center bolt to the specified torque.
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)

[1]/[2]

Pour the specified amount of recommended fork fluid.

RECOMMENDED FORK FLUID:
Fork Fluid (viscosity: 10W)
FORK FLUID CAPACITY:
CRF1100A/A2/D/D2:
708 ± 2.5 cm3 (23.9 ± 0.1 US oz, 24.9 ± 0.1 Imp oz)
CRF1100AL/AL2/DL/DL2:
698 ± 2.5 cm3 (23.6 ± 0.1 US oz, 24.6 ± 0.1 Imp oz)

Tighten the fork damper lock nut [1] fully.

[1]

Bleed the air from the fork as follows:

[3]
1. Extend the fork, cover the top of the outer pipe [1]
with your hand and compress the fork slowly. [1]

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: [2]
Damper rod holder [3] 070MF-MBZC120
Pump the fork damper rod slowly 8 – 10 times.

[1]

17-33
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Slowly push the outer pipe [1], and gently seat the dust
[1]
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: [2]
CRF1100A/A2/D/D2:
93 mm (3.7 in)
CRF1100AL/AL2/DL/DL2:
104 mm (4.1 in) [3]

• Be sure the oil level is the same in both forks.

Install the fork spring [1] into the slide pipe with its
Up [1] [3]
tapered side facing up.
Install the spring collar [2] and spring seat stopper [3].

[2]

[1]

Attach the special tool to the spring collar holes [1].

[7] [3]
TOOL:
Spring collar holder [2] 070MF-MBZC110
While pulling the damper rod holder [3] up, compress
the spring collar [4] with the special tool.
Insert the special tool between the fork damper lock nut [5]
[5] and spring seat stopper [6].
TOOL: [6]
Stopper plate [7] 070MF-MBZC130
Remove the damper rod holder.
[2] [4] [1]

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. [2]
[3]

[1]

17-34
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Tighten the fork damper lock nut [1] to the specified
[2]
torque.

TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

• 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.

[1]

Compress the spring collar [1] with the spring collar

[3]
holder [2].
Remove the stopper plate [3].
Remove the spring collar holder.

[2] [1]

Apply fork fluid to a new O-ring.

[2]
Install the O-ring [1] to the fork bolt [2].
Install the fork bolt.

• Be careful not to damage the fork bolt.

• Tighten the fork bolt after installing the fork into the
steering stem. [1]

[2]

Return the following adjusters to their original positions

as noted during disassembly.
– Rebound damping adjuster [1] [1]
– Pre-load adjuster [2]
– Compression damping adjuster [3]

[2]

[3]

17-35
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
ASSEMBLY
(ELECTRONIC SUSPENSION MODEL)
LEFT (Solenoid side)

• Before assembly, wash all parts with a high flash

point or non-flammable solvent and blow them dry.

SUSPENSION SOLENOID
15 N·m (1.5 kgf·m, 11 lbf·ft)

FORK DAMPER LOCK NUT

20 N·m (2.0 kgf·m, 15 lbf·ft)
O-RING

FORK DAMPER
PLUG BOLT
SLIDE PIPE

O-RING
SLIDER
BUSHING

O-RING
GUIDE
BUSHING

BACK-UP
RING O-RING FORK BOLT
35 N·m
(3.6 kgf·m, 26 lbf·ft)

OIL SEAL
SPRING SEAT
STOPPER

STOPPER
RING

SPRING COLLAR
SEALING DUST SEAL OUTER PIPE
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
[1] [2]
[2].
Apply fork fluid to new dust seal lips.
Install the dust seal [3] onto the slide pipe.

[3]

17-36
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
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].

• Install the oil seal with its marked side facing toward
the axle holder. [7]
[1]
Remove the tape from the slide pipe.
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.
[3]

• 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
[4] [5]
back-up ring [3] into the outer pipe until the stopper ring
groove [4] is visible using the special tools.
TOOL: [1]
Fork seal driver, 45.2 mm [5] 07KMD-KZ30100

[3]

[2]

Install the stopper ring [1] into the groove securely.

[1] [2]
• Do not scratch the slide pipe surface.
Install the dust seal [2].

Apply locking agent to the fork center bolt threads.

[1]
Install the fork center bolt [1] with a new sealing washer
[2].
Hold the axle holder in a vise with soft jaws or a shop
towel.
Tighten the fork center bolt to the specified torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

[2]

17-37
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Pour the specified amount of recommended fork fluid.

RECOMMENDED FORK FLUID:

Fork Fluid (viscosity: 10W)
FORK FLUID CAPACITY:
CRF1100A4/D4:
664 ± 2.5 cm3 (22.5 ± 0.1 US oz, 23.4 ± 0.1 Imp oz)
CRF1100AL4/DL4:
663 ± 2.5 cm3 (22.4 ± 0.1 US oz, 23.3 ± 0.1 Imp oz)

Tighten the fork damper lock nut [1] fully.

[1]

Bleed the air from the fork as follows:

[3]
1. Extend the fork, cover the top of the outer pipe [1] [1]
with your hand and compress the fork slowly.
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].
[2]
TOOL:
Damper rod holder [3] 070MF-MBZC120
Pump the fork damper rod slowly 8 – 10 times.

[1]

Slowly push the outer pipe [1], and gently seat the dust
[1]
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:
CRF1100A4/D4: [2]
69 mm (2.7 in)
CRF1100AL4/DL4:
59 mm (2.3 in) [3]

17-38
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the fork spring [1] into the slide pipe with its
Up [1]
tapered side facing up.
Install the spring collar [2] and spring seat stopper [3].

[3]

[1]

[2]

Attach the special tool to the spring collar holes [1].

TOOL:
Spring collar holder [2] 070MF-MBZC110 [3] [7]

While pulling the damper rod holder [3] up, compress

the spring collar [4] with the special tool.
Insert the special tool between the fork damper lock nut
[5] and spring seat stopper [6]. [5]
TOOL:
Stopper plate [7] 070MF-MBZC130 [6]

Remove the damper rod holder.

[1] [4] [2]

Recheck the fork damper lock nut [1] is tightened fully.

[3]
Apply fork fluid to a new O-ring [2] and install it to the
fork bolt [3]. [2]
Install the fork bolt to the fork damper [4] until it is fully
seated. [4]

[1]

Tighten the fork damper lock nut [1] using special tools
[2]
to the specified torque.
TOOLS: [3]
Fork bolt wrench [2] 070MA-MKS0100
Lock nut wrench, 50 mm [3] 07WMA-KZ30100

TORQUE:
Actual: 20 N·m (2.0 kgf·m, 15 lbf·ft) [4]
Indicated: 18 N·m (1.8 kgf·m, 13 lbf·ft)

• Tighten the fork damper lock nut with the specified

torque by tightening the fork bolt [4] while holding
[1]
the fork damper lock nut.
• Be careful not to damage the fork bolt.

17-39
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Compress the spring collar [1] with the spring collar
holder [2]. [4]
Remove the stopper plate [3].
[3]

• Be sure to insert the fork bolt [4] to the spring seat

stopper [5].
Remove the spring collar holder.

[5]

[1] [2]

Apply fork fluid to a new O-ring.

[2] [2]
Install the O-ring [1] to the fork bolt [2].
Install the fork bolt using the special tools.
TOOLS:
Fork bolt wrench [3] 070MA-MKS0100
Lock nut wrench, 50 mm [4] 07WMA-KZ30100
[1]
[4]
• Be careful not to damage the fork bolt.
• Tighten the fork bolt after installing the fork into the
steering stem.

[3]

Clean the suspension solenoid whole surface.

[1]

• Do not wipe with a cloth after cleaning. Let it

naturally dry. [2]
Apply fork fluid to a new O-ring. [2]
Install the O-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].
[5]

• Align the solenoid valve tabs with the plug bolt and [6] Align
collar grooves.
Install the solenoid valve assembly to the outer collar
[6].
Apply fork fluid to a new O-ring.
[2]
Install the O-ring [1] and suspension solenoid [2].

[1]

17-40
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Tighten the suspension solenoid [1] using the special
tools to the specified torque.

TOOLS: [2]
Pin type wrench [2] 070MA-MKS0200
Fork bolt wrench [3] 070MA-MKS0100
Lock nut wrench, 50 mm [4] 07WMA-KZ30100

TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft) [1]

• Be careful not to damage the fork bolt.

[3] [4]

Pump the fork [1] several times to bleed the air.

[1]

RIGHT (Stroke sensor side)

• Before assembly, wash all parts with a high flash

point or non-flammable solvent and blow them dry.

OUTER PIPE

SLIDE PIPE O-RING

SLIDER
BUSHING

GUIDE
BUSHING

BACK-UP
RING

FORK BOLT
35 N·m
OIL SEAL (3.6 kgf·m, 26 lbf·ft)

STOPPER INNER FORK BOLT

RING 90 N·m
(9.2 kgf·m, 66 lbf·ft)

DUST SEAL INNER ROD

FORK SPRING

17-41
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Wrap the edge and groove of the slide pipe [1] with tape
[1] [2]
[2].
Apply fork fluid to new dust seal lips.
Install the dust seal [3] onto the slide pipe.

[3]

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].

• Install the oil seal with its marked side facing toward
the axle holder. [7]
[1]
Remove the tape from the slide pipe.
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.
[3]

• 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
[4] [5]
back-up ring [3] into the outer pipe until the stopper ring
groove [4] is visible using the special tools.

TOOL: [1]
Fork seal driver, 45.2 mm [5] 07KMD-KZ30100

[3]

[2]

Install the stopper ring [1] into the groove securely.

[1] [2]
• Do not scratch the slide pipe surface.
Install the dust seal [2].

17-42
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Pour the specified amount of recommended fork fluid.
RECOMMENDED FORK FLUID:
Fork Fluid (viscosity: 10W)
FORK FLUID CAPACITY:
CRF1100A4/D4:
637 ± 2.5 cm3 (21.5 ± 0.1 US oz, 22.4 ± 0.1 Imp oz)
CRF1100AL4/DL4:
630 ± 2.5 cm3 (21.3 ± 0.1 US oz, 22.2 ± 0.1 Imp oz)

Slowly push the outer pipe [1], and gently seat the dust
[1]
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. [2]

FORK FLUID LEVEL:

CRF1100A4/D4:
139 mm (5.5 in)
CRF1100AL4/DL4:
130 mm (5.1 in) [3]

Install the inner rod [1].

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

[2]

Install the fork bolt [1].

[1]
Tighten the inner fork bolt [2] using the special tool to
the specified torque.
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)

[2] [3]

17-43
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Apply fork fluid to a new O-ring.
Install the O-ring [1] to the fork bolt [2].
Install the fork bolt using the special tools. [2] [2]

TOOLS:
Fork bolt wrench [3] 070MA-MKS0100
Lock nut wrench, 50 mm [4] 07WMA-KZ30100

• Be careful not to damage the fork bolt.

• Tighten the fork bolt after installing the fork into the
steering stem. [1] [4]

[3]

INSTALLATION
Install the forks [1] through the bottom bridge and top
bridge.

• Align the end of the outer pipe with the top bridge
upper surface.
Tighten the bottom bridge pinch bolts [2] to the
specified torque.
TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft)

[2] [1]

Conventional If the fork bolt [1] is loosened, tighten it to the specified

Conventional suspension model: [2]
suspension model: torque.

TORQUE: 35 N·m (3.6 kgf·m, 26 lbf·ft)

• Be careful not to damage the fork bolt.

Tighten the top bridge pinch bolts [2] to the specified
torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)

[1]

Electronic If the fork bolt [1] is loosened, tighten it using the special
Electronic suspension model: [4]
suspension model: tools to the specified torque.
TOOLS:
Fork bolt wrench [2] 070MA-MKS0100
Lock nut wrench, 50 mm [3] 07WMA-KZ30100

TORQUE:
Actual: 35 N·m (3.6 kgf·m, 26 lbf·ft)
Indicated: 32 N·m (3.3 kgf·m, 24 lbf·ft)
[1]

• Be careful not to damage the fork bolt.

Tighten the top bridge pinch bolts [4] to the specified [2] [3]
torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)

17-44
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Electronic Connect the following:
Electronic suspension model:
suspension model:
– Front suspension solenoid 2P connector [1]
– Front suspension stroke sensor connector [2] Left side: Right side:

Install the wire clamps [3].

[1]
[3] [2]

Install the front wheel speed sensor [1] and a new bolt
[2]
[2].
Tighten the bolt securely.
Install the following:
– Front wheel (page 17-18) [1]
– Front fender (page 2-23)

STEERING STEM
REMOVAL
Remove the air cleaner housing (page 7-14).
Remove the handlebar lower holder (page 17-12).
Electronic Disconnect the following connectors (page 17-20): [2]
suspension model:
– Front suspension solenoid 2P connector
– Front suspension stroke sensor connector
Disconnect the immobilizer receiver 4P (Black)
connector [1] and ignition switch 2P (Brown) connector
[2].

[1]

Remove the wire band [1].

Remove the socket bolt [2] and stay [3].
Release the immobilizer receiver wire clip [4] and
ignition switch wire clip [5] from the stay.

[3]

[4]

[5] [2] [1]

17-45
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Release the left handlebar switch wire clip [1].
CRF1100D4 shown:
Release the left grip heater 2P connector [2] from the
stay.
[2]
Conventional Remove the wire clamp [3].
suspension model:

[1] [3]

Release the right handlebar switch wire clip [1].

MT model: Release the clutch cable [2] from the cable guide.
DCT model: Release the parking brake cable [2] from the cable
guide. [2]

[1]

Remove the steering stem nut [1] and washer [2].

[3]
Remove the forks (page 17-20).
Remove the top bridge [3].

[1]/[2]

Remove the bolt [1] and brake hose clamp [2].

[1]

[2]

17-46
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Loosen and remove the steering stem adjusting nut [1]
[2]
using the special tool.

TOOL:
Steering stem socket [2] 07916-KA50100

[1]

Remove the following:

[1] [5]
– Upper dust seal [1]
– Upper inner race [2]
– Upper bearing [3]
– Steering stem [4]
– Lower bearing [5]

[2]

[3] [4]

BEARING REPLACEMENT

• Replace the bearing, outer race, and inner race as a

set.
Remove the upper outer race using a special tools.
[3]
TOOLS:
Adjustable bearing puller, 07JAC-PH80100 [2]
20 – 40 mm [1]
Bearing remover shaft [2] 07JAC-PH80200
Remover weight [3] 07741-0010201

[1]

Remove the lower outer race using the special tool and
suitable shaft.

TOOL:
Bearing remover [1] 07946-3710500

[1]

17-47
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Temporarily install the steering stem nut [1] onto the
[2]
steering stem [2] to prevent the threads from being
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].
[1]

[3] [4]

Apply specified grease to a new lower dust seal lips

[4]
(page 1-29).
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: [3]
Inner driver, 30 x 36 x 300 L [4] 07946-MB00000
[2]
[1]

Drive in a new upper outer race [1] using the special

[2]
tools.
TOOLS:
Driver [2] 07749-0010000
Attachment, 42 x 47 mm [3] 07746-0010300
[3]

[1]

Drive in a new lower outer race [1] using the special

[1]
tools.
TOOLS:
Driver [2] 07749-0010000
Attachment, 52 x 55 mm [3] 07746-0010400
[3]

[2]

17-48
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION

: BEARINGS, BEARING RACES, DUST SEALS

STEERING STEM NUT

WASHER

LOWER OUTER RACE

STEERING STEM
ADJUSTING NUT
LOWER BEARING
UPPER DUST
SEAL
LOWER INNER RACE UPPER INNER
RACE
LOWER DUST SEAL
UPPER BEARING

UPPER OUTER RACE

BRAKE HOSE CLAMP

STEERING STEM

Apply specified grease (page 1-29) to the upper and

[1] [5]
lower bearings and bearing races.
Install the following:
– Lower bearing [1]
– Steering stem [2]
– Upper bearing [3]
– Upper inner race [4]
– Upper dust seal [5]

[4]

[2] [3]

Apply 0.10 – 0.30 g (0.004 – 0.011 oz) of urea based

[2]
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:
Steering stem socket [2] 07916-KA50100

TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft)

[1]

17-49
 dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Move the steering stem [1] right and left, lock-to-lock,
five times to seat the bearings.

[1]

Retighten the steering stem adjusting nut [1] to the

[2]
specified torque using a special tool.

TOOL:
Steering stem socket [2] 07916-KA50100

TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft)

Recheck that the steering stem moves smoothly without
play or binding.

[1]

Install the brake hose clamp [1] and bolt [2] and tighten
[2]
the bolt securely.

[1]

Install the top bridge [1].

[4] [1]
Install the washer [2] and steering stem nut [3], but do
not tighten it yet.
Temporarily install the forks [4].
[4]
Tighten the steering stem nut to the specified torque.
TORQUE: 100 N·m (10.2 kgf·m, 74 lbf·ft)
Turn the steering stem left and right, lock-to-lock
several times to make sure the steering stem moves
smoothly without play or binding.

[2]/[3]

17-50
dummyhead

FRONT WHEEL/SUSPENSION/STEERING
Install the right handlebar switch wire clip [1]
MT model: Install the clutch cable [2] into the cable guide.
DCT model: Install the parking brake cable [2] into the cable guide.
[2]

[1]

Install the left handlebar switch wire clip [1].

CRF1100D4 shown:
Install the left grip heater 2P connector [2].
Conventional Install the wire clamp [3]. [2]
suspension model:

[1] [3]

Install the immobilizer receiver wire clip [1] and ignition

switch wire clip [2] to the stay [3].
Install the stay and socket bolt [4]. [3]

• Align the stay tab with the frame hole. Align

Tighten the socket bolt securely.
Install the wire band [5].

[1]

[2] [4] [5]

Connect the immobilizer receiver 4P (Black) connector

[1] and ignition switch 2P (Brown) connector [2].
Electronic Connect the following connectors (page 17-44): [2]
suspension model:
– Front suspension solenoid 2P connector
– Front suspension stroke sensor connector
Install the following:
– Forks (page 17-44)
– Air cleaner housing (page 7-14)
– Handlebar lower holder (page 17-12)
[1]

17-51
dummyhead

MEMO
dummytext

18. REAR WHEEL/SUSPENSION

SERVICE INFORMATION ···························18-2 SHOCK ABSORBER ·································· 18-9

TROUBLESHOOTING·································18-2 CUSHION LINKAGE ································· 18-17

COMPONENT LOCATION ··························18-3 SWINGARM ·············································· 18-21

REAR WHEEL ·············································18-4

18

18-1
 dummyhead

REAR WHEEL/SUSPENSION
SERVICE INFORMATION
REAR WHEEL/SUSPENSION

GENERAL
• When servicing the rear wheel and suspension, support the motorcycle using a safety stand or hoist.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
• 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 17-14)
• For driven sprocket inspection (page 3-19)
• For electronic suspension troubleshooting (page 22-84)

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
• Insufficient tire pressure
• 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

18-2
dummyhead

REAR WHEEL/SUSPENSION
COMPONENT LOCATION
CRF1100D4 shown:

80 N·m (8.2 kgf·m, 59 lbf·ft)

54 N·m (5.5 kgf·m, 40 lbf·ft)

44 N·m (4.5 kgf·m, 32 lbf·ft) 1.2 N·m (0.1 kgf·m, 0.9 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)

74 N·m (7.5 kgf·m, 55 lbf·ft)

54 N·m (5.5 kgf·m, 40 lbf·ft)

18-3
 dummyhead

REAR WHEEL/SUSPENSION
REAR WHEEL
REMOVAL
Fully slacken the drive chain (page 3-18).
[3] [2]
Support the motorcycle using a safety stand or hoist,
and raise the rear wheel off the ground.
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.

• Do not suspend the rear brake caliper assembly

[4]
from the brake hose. Do not twist the brake hose.
• Do not operate the brake pedal after removing the
rear wheel.

DCT model: • Do not operate the parking brake lever after

removing the rear wheel.

[5] [6] [1]

Remove the side collars [1].

Left side: Right side:

[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.
Inspect the following parts for damage, abnormal wear,
deformation or bends.
– Rear axle
– Rear wheel
Measure each part according to REAR WHEEL/
SUSPENSION SPECIFICATIONS (page 1-14).
Replace any part if it is out of service limit.
Refer to the wheel balance service (page 17-14).

18-4
dummyhead

REAR WHEEL/SUSPENSION
DISASSEMBLY/ASSEMBLY
CRF1100A/AL/D/DL

DAMPER RUBBERS
DRIVEN FLANGE
DUST SEAL
DRIVEN FLANGE
BEARING 63/22

DRIVEN PULSER RING BOLTS

SPROCKET 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

REAR WHEEL
DISTANCE COLLAR B
DRIVEN SPROCKET NUTS
100 N·m (10.2 kgf·m, 74 lbf·ft)
PULSER RING

BRAKE DISC BOLTS

42 N·m (4.3 kgf·m, 31 lbf·ft)
O-RING
REAR BRAKE DISC

DUST SEAL

LEFT WHEEL
RIGHT WHEEL
BEARING 6204 (UU) DISTANCE COLLAR
BEARING 6204 (UU)

• 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.
• Apply grease to the dust seal lips.
• Align the arrow mark on the rear brake disc with the
rotating direction of the rear wheel.
If the rim [1], hub [2], and spokes are disassembled,
assemble them as follows: 5.2 – 7.2 mm
(0.20 – 0.28 in)
Place the rim on a work bench.
Place the hub in the center of the rim, and begin the
lacing with new spokes.
[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 or three steps.
TORQUE: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)

18-5
 dummyhead

REAR WHEEL/SUSPENSION
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4

REAR WHEEL
DISTANCE COLLAR B

DRIVEN FLANGE DAMPER RUBBERS

DRIVEN FLANGE
BEARING 63/22

DRIVEN SPROCKET PULSER RING BOLTS

7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

DUST SEAL

PULSER
RING
DRIVEN SPROCKET NUTS
100 N·m (10.2 kgf·m, 74 lbf·ft)
BRAKE DISC BOLTS
42 N·m
(4.3 kgf·m, 31 lbf·ft)

REAR BRAKE DISC

DUST SEAL

O-RING
LEFT WHEEL
BEARING 6204 (UU) RIGHT WHEEL
BEARING 6204 (UU)
DISTANCE COLLAR

• For tire valve service (page 17-17)

• 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.
• Apply grease to the dust seal lips.
• Align the arrow mark on the rear brake disc with the
rotating direction of the rear wheel.

18-6
dummyhead

REAR WHEEL/SUSPENSION
If the rim [1], hub [2], and spokes are disassembled,
B 75.5 mm
assemble them as follows:
(2.97 in)
Measure the width of the rim to obtain the dimension B.

• When measurement, except 80 mm (3.1 in) from

welded area of the rim.
Perform the following calculation to obtain the
dimension A. [1] A

75.5 mm (2.97 in) – B/2 = A

Place the rim on a work bench. [2]
Place the hub in the center of the rim, and begin the
lacing with new spokes.

• 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.
Tighten the spokes to the specified torque in a
crisscross pattern in two or three steps.
TORQUE: 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)

• 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
Pilot, 20 mm [4] 07746-0040500
[5]
Drive the driven flange bearing [5] out. [3]

[4] [1]

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

[1]

18-7
 dummyhead

REAR WHEEL/SUSPENSION
Drive in a new right wheel bearing [1] squarely until it is
fully seated.

TOOLS: [2]
Driver [2] 07749-0010000
Attachment, 42 x 47 mm [3] 07746-0010300
Pilot, 20 mm [4] 07746-0040500
[3]

• Replace the driven flange and wheel bearings as a

set.
• Do not reuse old bearings.
Install the distance collar.
Drive in a new left wheel bearing squarely until it is [1] [4]
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]
[1]
• Replace the driven flange and wheel bearings as a
set.
• Do not reuse old bearing.

[2] [5]

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

[1] [4]

INSTALLATION
Install the rear brake caliper assembly [1] to the
[1]
swingarm.

• Align the caliper bracket groove with swingarm

guide.

Align

18-8
dummyhead

REAR WHEEL/SUSPENSION
Install the side collars [1].
Left side: Right side:

[1]

Apply a thin coat of grease to the rear axle outer

surface.
Install the rear wheel in the swingarm.

• 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].
[3] [2] [1]
Adjust the drive chain slack (page 3-18).
Check the clearance gap between the rear wheel speed [5] [6]
sensor bracket and pulser ring (page 20-26).

[4]

SHOCK ABSORBER
CONVENTIONAL SUSPENSION
MODEL
REMOVAL/INSTALLATION
Support the motorcycle using a safety stand or hoist,
[1]/[2]
and raise the rear wheel off the ground.
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].

[3]/[4]

18-9
 dummyhead

REAR WHEEL/SUSPENSION
Remove the shock absorber upper nut [1] and shock
[1]/[2]
absorber upper bolt [2].

Remove the shock absorber [1] downward.

• Lift the swingarm [2] and remove the shock absorber

while turning it.
Installation is in the reverse order of removal.
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) [1] [2]

• Install the bolts from the left side.

INSPECTION
Visually inspect the shock absorber for wear or
[4] [2] [1]
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.

18-10
dummyhead

REAR WHEEL/SUSPENSION
ELECTRONIC SUSPENSION MODEL
REMOVAL
Remove the following:
DCT model shown: [6] [7]
– Right heel guard (page 2-26)
– Front cross plate (page 7-8) [1]
Support the motorcycle using a safety stand or hoist,
and raise the rear wheel off the ground. [3]
Disconnect the following:
– Rear brake switch 4P (Black) connector [1]
– Rear wheel speed sensor 2P (Black) connector [2] [4]
Release the rear brake switch wire [3] and rear wheel
speed sensor wire [4] from the guide [5].
Release the power box [6].
[5] [2]
DCT model: Remove the DCT relay [7].
Disconnect the rear suspension pre-load motor 2P
[1]
connector [1].
Disconnect the rear suspension position sensor 3P
(Gray) connector [2].

[2]

Disconnect the rear suspension solenoid 2P connector

[1].
Release the rear suspension solenoid wire clip [2].

[1] [2]

Remove the brake hose clamp screw [1] and brake

[3] [5]
hose clamp [2].
Remove the brake hose guide screws [3] and brake
hose guide [4].
Remove the bolt [5] and brake hose clamp [6]. [2]

[1] [4] [6]

18-11
 dummyhead

REAR WHEEL/SUSPENSION
Remove the bolts [1] and washers [2].
[4]
Remove the rear suspension level adjuster [3] by
releasing its boss [4] from the grommet of the rear [1]/[2]
suspension level adjuster bracket.

[3]

Release the rear suspension level adjuster hose [1]

[2] [1]
from the hose guide [2].
Remove the bolt [3] and brake hose guide [4].
Remove the following: [4]
– Rear master cylinder reservoir mounting bolts [5]
– Rear master cylinder mounting bolts [6] [7]

• Keep the rear master cylinder reservoir [7] and rear

master cylinder [8] upright to prevent air from
entering the hydraulic system.
[5]
Remove the rear brake switch spring [9] from the
middle arm [10]. [3]

[8]

[9]

[6]
[10]

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].

[1]/[2] [3]/[4]

18-12
dummyhead

REAR WHEEL/SUSPENSION
Remove the shock absorber upper nut [1] and shock
[1]/[2]
absorber upper bolt [2].
Remove the shock absorber.

REAR SUSPENSION LEVEL ADJUSTER BRACKET

REMOVAL/INSTALLATION
Remove the shock absorber (page 18-11).
[3] [4]
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]
Installation is in the reverse order of removal.

[1] [5] [2]

INSPECTION
Visually inspect the shock absorber for wear or
[6] [4] [7] [2]
damage.
Check the following: [3]
– Damper rod [1] for bends or damage [7]
– 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 [5]
Replace the shock absorber assembly if necessary. [1]

18-13
 dummyhead

REAR WHEEL/SUSPENSION
SUSPENSION SOLENOID REPLACEMENT
Remove the shock absorber (page 18-11).
[1] [4]
Remove the suspension solenoid [1] from the shock
absorber [2] using special tools.
TOOLS:
Pin type wrench 070MA-MKS0200 [3]

Remove the O-ring [3] from the plug bolt [4].

[1]
Apply engine oil to a new O-ring.
Install the O-ring to the plug bolt. [2]
Install the suspension solenoid to the shock absorber
using special tools.
Tighten the suspension solenoid to the special torque.
TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft)
Install the shock absorber (page 18-14).

INSTALLATION
Install the shock absorber.
[1]/[2]

• Route the hose, wire, and cable properly (page 1-

32).
Install the shock absorber upper bolt [1] from the left
side.
Install and tighten the shock absorber upper nut [2] to
the specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)
Install the shock absorber lower bolt [3] from the left
side.
Install and tighten the shock absorber lower nut [4] to
the specified torque.
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)
Install the rear cushion connecting rod bolt [5] from the
left side.
Install and tighten the rear cushion connecting rod nut
[6] to the specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)

[5]/[6] [3]/[4]

18-14
dummyhead

REAR WHEEL/SUSPENSION
Install the rear brake switch spring [1] to the middle arm
[10] [9]
[2].
Install the rear master cylinder [3] and rear master
cylinder mounting bolts [4]. [7]
Tighten the rear master cylinder mounting bolts to the
specified torque.
[5]
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)
Install the rear master cylinder reservoir [5] and rear
master cylinder reservoir mounting bolt [6].
Tighten the rear master cylinder reservoir mounting bolt
to the specified torque. [6]
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
[8]
Install the brake hose guide [7] and bolt [8].
Tighten the bolt securely.
Install the rear suspension level adjuster hose [9] to the
hose guide [10].

[3]

[1]

[4]
[2]

Install the rear suspension level adjuster [1] to the rear

[2]
suspension level adjuster bracket.
[3]/[4]
• 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.

[1]

Install the brake hose clamp [1] and bolt [2].

[4] [2]
Tighten the bolt securely.
Install the brake hose guide [3] and new brake hose
guide screws [4].
Tighten the brake hose guide screws to the specified
torque. [5]
TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
Install the brake hose clamp [5] and new brake hose
clamp screw [6].
Tighten the brake hose clamp screw to the specified
torque.
TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) [6] [3] [1]

• Route the hose, wire, and cable properly (page 1-

32).

18-15
 dummyhead

REAR WHEEL/SUSPENSION
Install the rear suspension solenoid wire clip [1].
Connect the rear suspension solenoid 2P connector [2].

[2] [1]

Connect the rear suspension pre-load motor 2P

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

[2]

Connect the following:

DCT model shown: [6] [7]
– Rear brake switch 4P (Black) connector [1]
– Rear wheel speed sensor 2P (Black) connector [2]
[1]
Install the rear brake switch wire [3] and rear wheel
speed sensor wire [4] to the guide [5]. [3]
Install the power box [6].
DCT model: Install the DCT relay [7].
Install the following: [4]

– Front cross plate (page 7-8)

– Right heel guard (page 2-26)
[5] [2]

18-16
dummyhead

REAR WHEEL/SUSPENSION
DISPOSAL

• 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. 35 mm
• The shock absorber contains nitrogen gas and (1.4 in)
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
Support the motorcycle using a safety stand or hoist,
[6]
and raise the rear wheel off the ground.
Remove the left main step bracket (page 2-27).
If you plan to disassemble cushion linkage, loosen the
rear cushion connecting rod nut [1]. [7]
Remove the following:
– Front cushion connecting rod bolt [2]
– Front cushion connecting rod nut [3]
[1]
– Shock absorber lower bolt [4]
– Shock absorber lower nut [5]
– Cushion arm bolt [6]
– Cushion arm nut [7]
– Cushion arm/connecting rod assembly [8] [8] [4]/[5] [2]/[3]

DISASSEMBLY
Remove the rear cushion connecting rod nut [1] and
rear cushion connecting rod bolt [2]. [4]

Disassemble the cushion arm [3] and cushion

connecting rod [4].
[2]

[1]

[3]

18-17
 dummyhead

REAR WHEEL/SUSPENSION
Remove the collars [1] and dust seals [2] from the
[2] [3]
cushion arm [3].

[1] [2]

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

BEARING REPLACEMENT
CUSHION ARM
Remove the needle bearings (17 x 24 x 30 mm) [1]
[2] [4]
using the special tools.
TOOLS:
Remover weight [2] 07741-0010201
Remover handle [3] 07936-3710100
Bearing remover set, 17 mm [4] 07936-3710300
[5]
Remove the needle bearings (20 x 26 x 20 mm) [5]
using the special tools. [3]

TOOLS:
Remover weight 07741-0010201
Remover handle 07936-3710100
Bearing remover set, 20 mm 07936-3710600 [1]

18-18
dummyhead

REAR WHEEL/SUSPENSION
Remove the needle bearing (17 x 24 x 17 mm) [1] using
the special tools and hydraulic press.

TOOLS: [2]
Driver, 15 x 280L [2] 07949-3710001
Attachment, 22 x 24 mm [3] 07746-0010800

[3]

[1]

Apply molybdenum disulfide grease to new needle

bearing rotating areas.
[2] [6]
• Do not reuse old bearings.
Install the needle bearing (17 x 24 x 17 mm) [1] to the
specified range using the special tools and hydraulic
press as shown.
TOOLS: [3]/[4]
Driver, 15 x 280L [2] 07949-3710001
Attachment, 22 x 24 mm [3] 07746-0010800
Pilot, 17 mm [4] 07746-0040400
[1] [5]
• Install the needle bearing with the marked side
facing outside. Needle bearing Needle bearings
(17 x 24 x 17 mm): (20 x 26 x 20 mm):
Install the needle bearings (20 x 26 x 20 mm) [5] to the
specified range using the special tools and hydraulic
press as shown. 5.8 – 6.2 mm 5.3 – 5.7 mm
(0.23 – 0.24 in) (0.21 – 0.22 in)
TOOLS:
Driver, 15 x 280L 07949-3710001
Attachment, 22 x 24 mm 07746-0010800
Pilot, 20 mm 07746-0040500
[5]

• Install the needle bearing with the marked side

facing outside.
[1]
Install the needle bearings (17 x 24 x 30 mm) [6] until it
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

• Install the needle bearing with the marked side

facing outside.

18-19
 dummyhead

REAR WHEEL/SUSPENSION
CUSHION CONNECTING ROD
Remove the needle bearings (17 x 24 x 30 mm) [1]
[3] [2]
using the special tools.

TOOLS:
Bearing remover set, 17 mm [2] 07936-3710300
Remover weight [3] 07741-0010201
Remover handle [4] 07936-3710100

[1]
[4]

Apply molybdenum disulfide grease to new needle

bearing rotating areas.
[2]

• Do not reuse old bearings.

Install the needle bearings (17 x 24 x 30 mm) [1] until it
is flush with the cushion arm surface using the special [3]/[4]
tools and hydraulic press.
TOOLS:
Driver [2] 07749-0010000 [1]
Attachment, 32 x 35 mm [3] 07746-0010100
Pilot, 17 mm [4] 07746-0040400

• Install the needle bearing with the marked side

facing outside.

ASSEMBLY/INSTALLATION
Apply molybdenum disulfide grease to new dust seal
[1] [2]
lips.
Install the new dust seals [1] into the cushion arm [2]
until they are fully seated.
Install the collars [3].

[3] [1]

Install the collar [1] into the cushion connecting rod [2].

[2]

[1]

18-20
dummyhead

REAR WHEEL/SUSPENSION
Assemble the cushion arm [1] and cushion connecting
rod [2]. [2] [5]

Install the rear cushion connecting rod bolt [3] and rear
cushion connecting rod nut [4].
[3]
• Assemble the cushion arm and cushion connecting
rod with "UP" mark [5] of the cushion connecting rod
facing up.
[4]

[1]

Install the cushion arm/connecting rod assembly [1] and

[2]
cushion arm bolt [2].

• Install the cushion arm bolt from the right side.

Install and tighten the cushion arm nut [3] to the [3]
specified torque.
TORQUE: 74 N·m (7.5 kgf·m, 55 lbf·ft)
Install the shock absorber lower bolt [4] from the left [8]
side.
Install and tighten the shock absorber lower nut [5] to
the specified torque.
[1] [4]/[5] [6]/[7]
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)
Apply engine oil to the front cushion connecting rod nut
threads and seating surface.
Install the front cushion connecting rod bolt [6] from the
left side.
Install and tighten the front cushion connecting rod nut
[7] to the specified torque.
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)
If the cushion linkage is disassembled, tighten the rear
cushion connecting rod nut [8] to the specified torque.
TORQUE: 54 N·m (5.5 kgf·m, 40 lbf·ft)
Install the left main step bracket (page 2-27).

SWINGARM
REMOVAL
Remove the following:
[2]
– Heel guards (page 2-26)
– Mud guard (page 2-38)
– Rear wheel (page 18-4)
Remove the socket bolts [1] and drive chain case [2].

[1]

18-21
 dummyhead

REAR WHEEL/SUSPENSION
Remove the brake hose clamp screw [1] and brake
[3] [5]
hose clamp [2].
Remove the brake hose guide screws [3] and brake
hose guide [4].
Remove the bolt [5] and brake hose clamp [6]. [2]

[1] [4] [6]

Remove the cushion arm nut [1] and cushion arm bolt
[2].

[1]/[2]

Remove the swingarm pivot nut [1], swingarm pivot bolt

[2] and swingarm [3].

• Be careful not to damage the rear brake switch

spring.

[3] [1]/[2]

18-22
dummyhead

REAR WHEEL/SUSPENSION
DISASSEMBLY/ASSEMBLY

DUST SEAL
NEEDLE BEARING
PIVOT COLLAR A
(24 x 31 x 28 mm) SNAP RING

RIGHT PIVOT
DISTANCE COLLAR
BEARING 6003

DUST SEAL
SWINGARM
DUST SEAL

NEEDLE BEARING

LEFT PIVOT
DISTANCE COLLAR

DUST SEAL
DRIVE CHAIN
ADJUSTING BOLT

CHAIN SLIDER

DRIVE CHAIN
ADJUSTING BOLT
WASHERS A WASHERS B LOCK NUT

DRIVE CHAIN GUARD

CHAIN SLIDER RUBBER
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)

• Install the dust seals until they are flush with the
swingarm surface.
• Apply molybdenum disulfide grease to the dust seal
lips.

18-23
 dummyhead

REAR WHEEL/SUSPENSION
INSPECTION
Inspect the following parts for damage, abnormal wear,
or deformation and replace if necessary.
– Dust seals
– Pivot collars
– Swingarm
– Bearings
– Drive chain slider

PIVOT BEARING REPLACEMENT

Remove the snap ring [1] from the right pivot.
[1]

Remove the ball bearing 6003 [1] out of the right pivot
using the special tools and hydraulic press.

TOOLS:
[2]
Driver, 15 x 280L [2] 07949-3710001
Attachment, 22 x 24 mm [3] 07746-0010800
Pilot, 17 mm [4] 07746-0040400

[3]/[4]

[1]

Remove the needle bearing (24 x 31 x 28 mm) [1] out of

[2]
the right pivot using the special tools and hydraulic
press.
TOOLS: [3]
Driver [2] 07749-0010000
Attachment, 28 x 30 mm [3] 07946-1870100

[1]

18-24
dummyhead

REAR WHEEL/SUSPENSION
Remove the needle bearing [1] out of the left pivot using
[2]
the special tools and hydraulic press.

TOOLS:
Driver, 15 x 280L [2] 07949-3710001
Pilot, 32 mm [3] 07MAD-PR90200

[3]

[1]

Apply molybdenum disulfide grease to a new needle

[2]
bearing rotating area.
5.0 – 5.5 mm
Install the needle bearing [1] into the left pivot to the (0.20 – 0.22 in)
specified range using the special tools and hydraulic [3]
press as shown.
TOOLS:
Driver [2] 07749-0010000 [4]
Attachment, 32 x 35 mm [3] 07746-0010100
Pilot, 25 mm [4] 07746-0040600 [1] [1]

• Install the needle bearing with the marked side

facing up.

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)
and hydraulic press as shown. [2]
TOOLS:
Driver, 15 x 280L [2] 07949-3710001
Attachment, 28 x 30 mm [3] 07946-1870100
[3]
Pilot, 22 mm [4] 07746-0041000 [1] [1]

[4]
• Install the needle bearing with the marked side
facing up.

Apply grease to a new ball bearing 6003 rotating area.

[2]
Install the ball bearing 6003 [1] into the right pivot until it
is fully seated using the special tools and hydraulic
press. [3]

TOOLS:
Driver [2] 07749-0010000
[4]
Attachment, 32 x 35 mm [3] 07746-0010100
Pilot, 17 mm [4] 07746-0040400
[1]
• Install the ball bearing with the marked side facing
out.

18-25
 dummyhead

REAR WHEEL/SUSPENSION
Install the snap ring [1] into the right pivot groove
[1]
securely.

• Do not reuse the snap ring which could easily spin in

the groove.
• Make sure that the snap ring is firmly seated in the
groove.

INSTALLATION
Set the drive chain onto the swingarm.
[3]
Install the swingarm [1] to the frame.

• 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.
TORQUE: 80 N·m (8.2 kgf·m, 59 lbf·ft)
[1] [2]

Install the cushion arm bolt [1] from the right side.
Install and tighten the cushion arm nut [2] to the
specified torque.
TORQUE: 74 N·m (7.5 kgf·m, 55 lbf·ft)

[1]/[2]

Install the brake hose clamp [1] and bolt [2].

[4] [2]
Tighten the bolt securely.
Install the brake hose guide [3] and new brake hose
guide screws [4].
Tighten the brake hose guide screws to the specified
torque. [5]
TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
Install the brake hose clamp [5] and new brake hose
clamp screw [6].
Tighten the brake hose clamp screw to the specified
torque.
TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) [6] [3] [1]

• Route the hose, wire, and cable properly (page 1-

32).

18-26
dummyhead

REAR WHEEL/SUSPENSION
Install the drive chain case [1] and socket bolts [2].
[1]
Tighten the bolt securely.
Install the following:
– Heel guards (page 2-26)
– Mud guard (page 2-38)
– Rear wheel (page 18-8)

[2]

18-27
dummyhead

MEMO
dummytext

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 (DCT model) ············································· 19-23

FRONT MASTER CYLINDER ···················19-13 PARKING BRAKE CALIPER

(DCT model) ············································· 19-25

19

19-1
 dummyhead

HYDRAULIC BRAKE
SERVICE INFORMATION
HYDRAULIC BRAKE

GENERAL

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.

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
high quality brake degreasing agent.
• 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 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 brake hydraulic system
• Low brake fluid level
• Leaking brake 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 cylinder piston
• Contaminated master cylinder
• Bent brake lever/pedal
Brake lever/pedal hard
• Clogged/restricted brake hydraulic system
• Sticking/worn caliper piston
• Caliper not sliding properly
• Worn caliper piston seal
• Sticking/worn master cylinder piston
• Bent brake lever/pedal
Brake drag
• Contaminated brake pad/disc
• Misaligned wheel
• Warped/deformed brake disc
• Caliper not sliding properly
• Clogged/restricted brake hydraulic system
• Sticking/worn caliper piston
• Clogged master cylinder port

19-2
dummyhead

HYDRAULIC BRAKE
COMPONENT LOCATION
FRONT

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4 shown:

34 N·m
(3.5 kgf·m, 25 lbf·ft)

9.8 N·m
(1.0 kgf·m, 7.2 lbf·ft)

Right side shown:

45 N·m
(4.6 kgf·m, 33 lbf·ft)

34 N·m
(3.5 kgf·m, 25 lbf·ft)

45 N·m
(4.6 kgf·m, 33 lbf·ft)

19-3
 dummyhead

HYDRAULIC BRAKE
REAR

34 N·m
(3.5 kgf·m, 25 lbf·ft)

14 N·m
(1.4 kgf·m, 10 lbf·ft)

10 N·m
(1.0 kgf·m, 7 lbf·ft)

34 N·m
(3.5 kgf·m, 25 lbf·ft)

22 N·m
(2.2 kgf·m, 16 lbf·ft)

19-4
dummyhead

HYDRAULIC BRAKE
DCT model:

30 N·m
(3.1 kgf·m, 22 lbf·ft)

30 N·m
(3.1 kgf·m, 22 lbf·ft)
9.0 N·m
(0.9 kgf·m, 6.6 lbf·ft)

19-5
 dummyhead

HYDRAULIC BRAKE
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
Front brake: Turn the handlebar until the reservoir is parallel to the
[1]
ground.
Remove the following:
– Front master cylinder reservoir cap screws [1]
– Reservoir cap [2]
– Set plate [3]
– Diaphragm [4] [2]

[3]

[4]

Rear brake: Support the motorcycle in an upright position.

[3]
Remove the rear master cylinder reservoir mounting
bolt [1]. [4]
Release the rear master cylinder reservoir [2].
Remove the following: [5]

– Rear master cylinder reservoir cap screws [3]

– Reservoir cap [4]
– Set plate [5]
– Diaphragm [6] [6]
Temporarily install the rear master cylinder reservoir
and rear master cylinder reservoir mounting bolt.

[1] [2]

Connect a bleed hose to the bleed valve [1].

Front: Rear:
Loosen the bleed valve and pump the brake lever/pedal
until no more fluid flows out of the bleed valve. [1] [1]

Tighten the bleed valve.

19-6
dummyhead

HYDRAULIC BRAKE
BRAKE FLUID FILLING/AIR BLEEDING
Fill the reservoir with DOT 4 brake fluid to the upper
Front: Rear: [1]
level line [1] from a sealed container.
Connect a commercially available brake bleeder to the [1]
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.

• 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. Front: Rear:
[2] [2]
• 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.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
Fill the reservoir with DOT 4 brake fluid to the upper
level line from a sealed container.

If the brake bleeder is not available, perform the

Front: Rear: [1]
following procedure.
Fill the reservoir with DOT 4 brake fluid to the upper [1]
level line [1] from a sealed container.
Connect a bleed hose to the bleed valve [2].
Pump up the system pressure with the brake lever/
pedal until the lever/pedal resistance is felt.
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.

• Do not release the brake lever/pedal until the bleed

valve has been closed.
2. Release the brake lever/pedal slowly and wait Front: Rear:
several seconds after it reaches the end of its travel. [2] [2]
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.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
Fill the reservoir with DOT 4 brake fluid to the upper
level line from a sealed container.

19-7
 dummyhead

HYDRAULIC BRAKE
Front brake: Install the following:
[4]
– Diaphragm [1]
– Set plate [2]
– Reservoir cap [3]
– Front master cylinder reservoir cap screws [4]
Tighten the front master cylinder reservoir cap screws
to the specified torque. [3]
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

[2]

[1]

Rear brake: Remove the rear master cylinder reservoir mounting

[6]
bolt [1] and rear master cylinder reservoir [2].
Install the following: [5]
– Diaphragm [3]
– Set plate [4] [4]
– Reservoir cap [5]
– Rear master cylinder reservoir cap screws [6]
Tighten the rear master cylinder reservoir cap screws to
the specified torque.
[3]
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
Install the rear master cylinder reservoir and rear
master cylinder reservoir mounting bolt.
Tighten the rear master cylinder reservoir mounting bolt [1] [2]
to the specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

BRAKE PAD/DISC
• 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
Right side shown:
front brake calipers [2].

• Do not operate the brake lever after removing the

front brake calipers.

[1]

[2]

19-8
dummyhead

HYDRAULIC BRAKE
Remove the brake pads [1].
Right side shown: [5]
Check the pad spring [2] and replace if necessary.
[1]

• Install the pad spring with its arrow marks [3] facing
up.
Install new brake pads.

• Align the pad lugs [4] with the caliper grooves [5].
• Make sure that the brake pads seat against the pad
spring.

[4]

Right side shown:

[3]

[2]

Install the front brake calipers [1] and new front brake
Right side shown:
caliper mounting bolts [2].
Tighten the front brake caliper mounting bolts to the
specified torque.
TORQUE: 45 N·m (4.6 kgf·m, 33 lbf·ft)
Operate the brake lever to seat the caliper pistons [2]
against the pads.

[1]

REAR BRAKE PAD REPLACEMENT

Remove the brake pad pin [1] and rear brake caliper
[1]
mounting bolt [2].
Lift the rear brake caliper [3].
Remove the brake pads [4].

• Do not operate the brake pedal after removing the

brake pads.
[4]

[2] [3]

19-9
 dummyhead

HYDRAULIC BRAKE
Install new brake pads [1].
[1] [5]

• Make sure that the brake pad retainer [2] and pad
spring are installed to the rear brake caliper. [6]
• 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 [3]
condition, and replace it if necessary.
Apply silicone grease to the brake pad pin stopper ring. [2] [4]
Install the brake pad pin [6] by pushing the brake pads.

• Align the brake pad pin holes of the brake pads and
caliper body.
Tighten the rear brake caliper mounting bolt [1] to the
[2]
specified torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)
Tighten the brake pad pin [2] to the specified torque.
TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft)
Operate the brake pedal to seat the caliper piston
against the pads.

[1]

PARKING BRAKE PAD

REPLACEMENT (DCT model)
REMOVAL
Remove the parking brake caliper cover bolts [1] and
[1]
parking brake caliper cover [2].

[2]

19-10
dummyhead

HYDRAULIC BRAKE
Remove the drive chain guard bolts [1] and drive chain
[1]
guard [2].

[2]

Loosen the parking brake pad pins [1].

[1]

Remove the parking brake caliper mounting bolts [1]

[1]
and parking brake caliper [2].

[2]

Remove the parking brake pad pins [1] and parking

[1]
brake pads [2].

[2]

19-11
 dummyhead

HYDRAULIC BRAKE
INSTALLATION
Install new parking brake pads [1].
[2]

• Make sure the pad spring is installed in position.

Install new parking brake pad pins [2].

[1]

Install the parking brake caliper [1] and new parking

[2]
brake caliper mounting bolts [2].
Tighten the parking brake caliper mounting bolts to the
specified torque.
TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)

[1]

Tighten the parking brake pad pins [1] to the specified

torque.
TORQUE: 17.2 N·m (1.8 kgf·m, 13 lbf·ft)

[1]

Install the drive chain guard [1] and drive chain guard
[2]
bolts [2].
Tighten the drive chain guard bolts to the specified
torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

[1]

19-12
dummyhead

HYDRAULIC BRAKE
Install the parking brake caliper cover [1] and parking
[2]
brake caliper cover bolts [2].
Tighten the parking brake caliper cover bolts to the
specified torque.
TORQUE: 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
Check the parking brake lock operation (page 3-23).

[1]

BRAKE DISC INSPECTION

Visually inspect the brake discs for damage or cracks.
Measure the brake disc according to HYDRAULIC
BRAKE SPECIFICATIONS (page 1-14) and replace if
necessary.

FRONT MASTER CYLINDER

REMOVAL/INSTALLATION
Drain the brake fluid from the front brake hydraulic
system (page 19-6).
[1]
Remove the rearview mirror [1].
Remove the screw [2].

[2]

Disconnect the following:

[1] [4] [3]
– Front brake switch connectors (upper side) [1]
– Cruise cancel switch connectors (lower side) [2]
Remove the oil bolt [3], sealing washers [4] and brake
hose [5]. [5]
[2]
• When removing the oil bolt, cover the end of the
brake hose to prevent contamination.
• Avoid spilling fluid on painted, plastic, or rubber
parts.

19-13
 dummyhead

HYDRAULIC BRAKE
Remove the front master cylinder holder bolts [1],
[3]
holder [2], and front master cylinder [3].
Installation is in the reverse order of removal.
TORQUE: Align
Front master cylinder holder bolt:
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)

• Align the end of the master cylinder with the [2]

handlebar paint mark.
• Install the holder with the "UP" mark [4] facing up. [1] [4]
• 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).

19-14
dummyhead

HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY

SECONDARY CUP PRIMARY CUP

FRONT MASTER
MASTER PISTON SPRING CYLINDER

BOOT

SNAP RING

FRONT BRAKE LEVER FRONT BRAKE/

CRUISE CANCEL SWITCH

FRONT BRAKE SWITCH

FRONT BRAKE LEVER PIVOT BOLT MOUNTING SCREW
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)

PLASTIC WASHER
KNUCKLE GUARD HOLDER
WELL NUT

COLLAR FRONT BRAKE LEVER PIVOT NUT

5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

• Apply 0.10 g (0.004 oz) of silicone grease to the

following:
– 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
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 1-14).

19-15
 dummyhead

HYDRAULIC BRAKE
REAR BRAKE PEDAL
REMOVAL/INSTALLATION
Remove the right heel guard (page 2-26).

DUST SEALS

Right Left

COTTER PIN
DUST SEAL

BRAKE PEDAL

JOINT PIN

RETURN
RETURN
SPRING
SPRING
Align
BRAKE PEDAL
PINCH BOLT

MIDDLE ARM

DUST SEAL

• Align the brake pedal slit with the middle arm punch
mark.
• Apply grease to the dust seal lips.
• Apply grease to the middle arm pivot sliding surface.

19-16
dummyhead

HYDRAULIC BRAKE
REAR MASTER CYLINDER
REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic
[1]
system (page 19-6).
Remove the oil bolt [1], sealing washers [2] and brake [3]
hose [3].

• When removing the oil bolt, cover the end of the

brake hose to prevent contamination.
• Avoid spilling fluid on painted, plastic, or rubber
parts. [2]

Remove the cotter pin [1] and joint pin [2].

Remove the rear master cylinder mounting bolts [3] and
rear master cylinder [4].
Installation is in the reverse order of removal. [4]
TORQUE:
Rear master cylinder mounting bolt:
14 N·m (1.4 kgf·m, 10 lbf·ft)
Oil bolt:
[3]
34 N·m (3.5 kgf·m, 25 lbf·ft)
[1]

• Always replace the cotter pin and sealing washers

with new ones. [2]
• Install the brake hose eyelet joint against the master
cylinder stopper.
Fill and bleed the rear brake hydraulic system (page 19-
7).

19-17
 dummyhead

HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY

REAR MASTER CYLINDER

RESERVOIR

SPRING

HOSE

PRIMARY CUP

MASTER PISTON
CLAMPS

SECONDARY CUP
O-RING

SNAP RING
REAR MASTER CYLINDER
CONNECTOR SCREW BOOT
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

REAR MASTER CYLINDER PUSH ROD

CONNECTOR
PUSH ROD LOCK NUT
17.2 N·m (1.8 kgf·m, 13 lbf·ft)
REAR MASTER CYLINDER PUSH ROD JOINT

• 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.
• Apply locking agent to the rear master cylinder
connector screw threads.
If the push rod [1], push rod lock nut [2] and push rod
joint are disassembled, adjust the push rod length as [2]
shown.

• 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)

19-18
dummyhead

HYDRAULIC BRAKE
INSPECTION
Check the following parts for scoring, scratches,
deterioration, or damage.
– Rear master cylinder
– Master piston
– Piston cups
– Spring
– Boot
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-14).

FRONT BRAKE CALIPER

REMOVAL/INSTALLATION
Drain the brake fluid from the front brake hydraulic
Right side shown:
system (page 19-6).
Remove the oil bolt [1], sealing washers [2] and brake [4]
hose [3].

• When removing the oil bolt, cover the end of the

brake hose to prevent contamination. [3]
[5]
• Avoid spilling fluid on painted, plastic, or rubber
parts.
Remove the front brake caliper mounting bolts [4] and
front brake caliper [5]. [2]

Installation is in the reverse order of removal.

[1] [4]
TORQUE:
Front brake caliper mounting bolt:
45 N·m (4.6 kgf·m, 33 lbf·ft)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)

• 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.
Fill and bleed the rear brake hydraulic system (page 19-
7).

19-19
 dummyhead

HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY

DUST SEAL A FRONT BRAKE CALIPER

ASSEMBLY TORX BOLTS
27 N·m (2.8 kgf·m, 20 lbf·ft)
CALIPER
PISTONS A BLEED VALVE
(larger O.D.) PAD SPRING
5.4 N·m
PISTON SEAL A (0.6 kgf·m, 4.0 lbf·ft)

DUST SEAL A O-RING

CALIPER
PISTONS A
(larger O.D.)

PISTON SEAL B

DUST SEAL B

BRAKE PADS/
SHIMS PISTON SEAL A
CALIPER
PISTON B CALIPER BODIES
(smaller O.D.)
PISTON SEAL B
CALIPER
PISTON B
(smaller O.D.)

DUST SEAL B

• Be careful not to damage each piston.

• When removing the caliper pistons 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.
• 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.
– Piston B: smaller O.D.

19-20
dummyhead

HYDRAULIC BRAKE
INSPECTION
Check the following parts for scoring, scratches,
deterioration, or damage.
– Caliper cylinder of caliper bodies
– Caliper pistons
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS (page 1-14).

REAR BRAKE CALIPER

REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic
[2] [1]
system (page 19-6).
Remove the oil bolt [1], sealing washers [2] and brake [3]
hose [3].

• When removing the oil bolt, cover the end of the

brake hose to prevent contamination.
• 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.
[4]
Installation is in the reverse order of removal.
TORQUE:
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)

• Always replace the sealing washers with new ones.

• Install the brake hose eyelet joint against the brake
caliper stopper.
Fill and bleed the rear brake hydraulic system (page 19-
7).

19-21
 dummyhead

HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY

BRAKE PAD BLEED VALVE

CALIPER 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
RETAINER PIN BOOT
CALIPER BODY

BLEEDER CAP

REAR BRAKE CALIPER

PIN BOLT
27 N·m (2.8 kgf·m, 20 lbf·ft)

CALIPER
BRACKET

PAD SPRING
CALIPER CALIPER SLEEVE
PISTON

PISTON SEAL SLEEVE BOOT

PAD SPRING

DUST SEAL

• 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.
– Caliper cylinder of caliper body
– Caliper piston
Measure the parts according to HYDRAULIC BRAKE
SPECIFICATIONS and replace if necessary (page 1-
14).

19-22
dummyhead

HYDRAULIC BRAKE
PARKING BRAKE LEVER (DCT model)
REMOVAL/INSTALLATION
Remove the rearview mirror [1].
[1]
Remove the screw [2].

[2]

Disconnect the parking brake switch connectors [1].

[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].
Installation is in the reverse order of removal. [5]

[3]
• Install the parking brake lever assembly by aligning
its end with the paint mark on the handlebar. [4]
• Install the holder with its punch mark [6] facing up.
• Tighten the upper bolt first, then the lower bolt. Align

After installation, adjust the parking brake lock

operation (page 3-23).
[2] [6] [1]

19-23
 dummyhead

HYDRAULIC BRAKE
DISASSEMBLY/ASSEMBLY

PARKING BRAKE STOPPER STAY

HEX BOLT
2.3 N·m (0.2 kgf·m, 1.7 lbf·ft)

PARKING BRAKE STOPPER STAY

FLANGE BOLT
STOPPER STAY 11.9 N·m (1.2 kgf·m, 9 lbf·ft)

ADJUSTER BOLT
LOCK LEVER PIVOT BOLT
LOCK NUT
6.9 N·m (0.7 kgf·m, 5.1 lbf·ft)

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

PARKING BRAKE
LEVER
KNUCKLE GUARD
HOLDER
PARKING BRAKE LEVER
COLLAR BRACKET

PARKING BRAKE LEVER

PIVOT NUT PARKING BRAKE
5.9 N·m (0.6 kgf·m, 4.4 lbf·ft) SWITCH

PARKING BRAKE SWITCH

MOUNTING SCREW
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)

19-24
dummyhead

HYDRAULIC BRAKE
PARKING BRAKE CALIPER
(DCT model)
REMOVAL/INSTALLATION
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.
[2] [1] [3]
Disconnect the parking brake cable end from the brake
arm [4].
Installation is in the reverse order of removal.
After installing, check the parking brake lock operation
(page 3-23).

[4] [1] [3] [2]

DISASSEMBLY
Remove the parking brake caliper pin bolt [1].

[1]

Remove the following:

[2] [1]
– Parking brake bracket [1]
– Pad spring [2]
– Bracket pin boot [3]
– Caliper pin boots [4]
– Sleeve [5]

[3]

[5] [4]

Remove the adjuster lock nut [1] while holding the

[1]
brake arm [2].
Remove the brake arm. [3]
Remove the brake shaft boot [3].

[2]

19-25
 dummyhead

HYDRAULIC BRAKE
Remove the push rod [1] while holding the brake shaft
[1]
[2].
Remove the brake shaft and push rod/piston assembly.

[2]

Remove the dust seal [1].

Clean the caliper cylinder of caliper body and brake
shaft sliding surface.

[1]

INSPECTION
Inspect the following parts for scoring, scratches, or
damage.
– Caliper cylinder of caliper body
– Caliper piston
Replace if necessary.

19-26
dummyhead

HYDRAULIC BRAKE
ASSEMBLY

PAD SPRING PISTON

BRACKET PIN BOOT PUSH ROD

DUST SEAL

BRAKE SHAFT
PARKING BRAKE
BRACKET

BRAKE SHAFT BOOT

CALIPER PIN BOOT

BRAKE ARM
CALIPER BODY

SLEEVE

ADJUSTER LOCK NUT

17.2 N·m (1.8 kgf·m, 13 lbf·ft) CALIPER PIN BOOT

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.

[1]

Apply 0.4 g minimum of silicone grease to the parking

[1]
brake shaft threads.
Install the parking brake shaft [1] to the caliper body [2].
Screw the parking brake shaft in completely.
[4]

• Make sure that the punch mark [3] of the brake shaft [3]
is positioned opposite the index line [4].

[2]

19-27
 dummyhead

HYDRAULIC BRAKE
Apply 0.4 g minimum of silicone grease to the push rod
[4]
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.

[1]
[2]

[3]

Apply 0.4 g minimum of silicone grease to the brake

Align
shaft boot lips.
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].

[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.
Install the following:
– Bracket pin boot [1]
– Caliper pin boots [2]
– Sleeve [3]
– Pad spring [4]
– Parking brake bracket [5]
[1]

[3] [2]

19-28
dummyhead

HYDRAULIC BRAKE
Apply locking agent to the parking brake caliper pin bolt
threads.
Install and tighten the parking brake caliper pin bolt [1]
to the specified torque. [1]
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)

19-29
dummyhead

MEMO
dummytext

20. ANTI-LOCK BRAKE SYSTEM (ABS)

SERVICE INFORMATION ···························20-2 ABS INDICATOR CIRCUIT

TROUBLESHOOTING ······························ 20-11
SYSTEM LOCATION···································20-3
ABS DTC TROUBLESHOOTING ············· 20-13
SYSTEM DIAGRAM ····································20-4
WHEEL SPEED SENSOR ························ 20-24
ABS TROUBLESHOOTING
INFORMATION············································20-6 ABS MODULATOR ··································· 20-27

ABS DTC INDEX ·········································20-9

20

20-1
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

SERVICE INFORMATION
ANTI-LOCK BRAKE SYSTEM (ABS)

GENERAL

• 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 DTC 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 DTC 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
– Pulser ring and sensor tip for deformation or damage
• Be careful not to damage the pulser ring when removing and installing the wheel.
• For pulser ring service:
– Front: (page 17-15)
– Rear: (page 18-5)
• 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 O = Orange P = Pink R = Red V = Violet
W = White Y = Yellow

20-2
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

SYSTEM LOCATION

POWER BOX
– ABS MAIN 10 A
– HORN/STOP 10 A
BATTERY

ABS FSR+ 20 A
IMU

DLC

FRONT WHEEL
SPEED SENSOR

REAR WHEEL FUSE BOX

SPEED SENSOR – MAIN2 FUSE 30 A

STARTER RELAY SWITCH

– MAIN FUSE 30 A
– ABS-M 30 A

ABS MODULATOR

20-3
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

SYSTEM DIAGRAM
MT model:

Bl/Gr Bl

BATTERY

Bl/R Bl/G
IGNITION
MAIN FUSE SWITCH HORN/STOP FRONT BRAKE
30 A 10A SWITCH
W R R/Bl Bl/R G/Y G

Bl Bl/G G BRAKE/TAIL
LIGHT
REAR BRAKE
SWITCH

ABS MAIN
10A
R/G G/Y
7 IG BLS 4

METER
PUMP MOTOR
W/Bu ABS
IND 13 INDICATOR

ABS-M W/G REAR ABS

30 A MODE IND 16 OFF
R/Y INDICATOR Bl
9 MR +B
G Bl/R MID
1 MOTOR GND

CRF1100A4/AL4

MAIN2 FUSE ABS FSR +

30 A 20 A SCU
W R R R/G
18 FSR +B

IMU
SOLENOID VALVE

BCU

W
17 FVW S (-)
Bu Bl/R
8 FVW B (+) CAN-H 2
Bl
CAN-L 11
W Bu/Y ECM
15 RVW S (-) FPO 12
Bu Bu/Bl
6 RVW B (+) RPO 3

FRONT WHEEL REAR WHEEL

SPEED SENSOR SPEED SENSOR
W
DIAG 5
Y
SCS 14
G/Bu
G
GND 10 DLC

FRONT PULSER RING REAR PULSER RING

ABS MODULATOR

1 2 3 4 5 6 7 8 9
Bl : Black
Bu : Blue
G : Green
10 11 12 13 14 15 16 17 18 Gr : Gray
R : Red
W : White
ABS MODULATOR 18P (Black) CONNECTOR (MODULATOR SIDE) Y : Yellow

20-4
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

DCT model:

Bl/Gr Bl

BATTERY

Bl/R Bl/G
IGNITION
MAIN FUSE SWITCH HORN/STOP FRONT BRAKE
30 A 10A SWITCH
W R R/Bl Bl/R G/Y G

Bl Bl/G G BRAKE/TAIL
LIGHT
REAR BRAKE
SWITCH
ABS MAIN
10A
R/G G/Y
7 IG BLS 4

METER
PUMP MOTOR
W/Bu ABS
IND 13 INDICATOR

ABS-M W/G REAR ABS

30 A MODE IND 16 OFF
R/Y INDICATOR Bl
9 MR +B
G Bl/R MID
1 MOTOR GND

CRF1100D4/DL4

MAIN2 FUSE ABS FSR +

30 A 20 A SCU
W R R R/G
18 FSR +B

IMU

SOLENOID VALVE
BCU

TCM

W
17 FVW S (-)
Bu Bl/R
8 FVW B (+) CAN-H 2
Bl
CAN-L 11
W Bu/Y ECM
15 RVW S (-) FPO 12
Bu Bu/Bl
6 RVW B (+) RPO 3

FRONT WHEEL REAR WHEEL

SPEED SENSOR SPEED SENSOR
W
DIAG 5
Y
SCS 14
G/Bu
G
GND 10 DLC

FRONT PULSER RING REAR PULSER RING

ABS MODULATOR

1 2 3 4 5 6 7 8 9
Bl : Black
Bu : Blue
G : Green
10 11 12 13 14 15 16 17 18 Gr : Gray
R : Red
W : White
ABS MODULATOR 18P (Black) CONNECTOR (MODULATOR SIDE) Y : Yellow

20-5
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

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 (DTC).
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 DTC (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 Start
Stop

MOTORCYCLE 6 km/h (4 mph) or above

0
SPEED

PUMP ON
MOTOR OFF

ABS ON
INDICATOR OFF

2 sec. Pre-start serf-diagnosis is

REAR ON completed at 10 km/h (6 mph)
ABS OFF
INDICATOR OFF

CPU completion of
the initial settings

PRE-START SELF-DIAGNOSIS PROCEDURE (Daily check)

1. Turn the ignition switch ON and engine stop switch " ".
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.
4. Start the engine.
5. Ride the motorcycle and increase the motorcycle speed to approximately 10 km/h (6 mph).
6. The ABS is normal if the ABS indicator goes off.

MCS INFORMATION
Refer to the PGM-FI system (page 4-6).

20-6
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

DTC READOUT

• The DTC is not erased by turning the ignition switch to OFF while the DTC is being indicated. Note that turning the ignition
switch ON again does not indicate the DTC. To show the DTC again, repeat the DTC readout procedures from the beginning.
• Be sure to record the indicated DTC.
• After diagnostic troubleshooting, erase the DTC 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 DTC readout.
Connect the MCS to the DLC (page 4-6).
Read the DTC, stored data and follow the DTC index (page 20-9).
If the MCS is not available, perform the following.

Reading DTC with the ABS indicator

1. Connect the SCS short connector to the DLC (page 4-6).
2. Turn the ignition switch ON.
The ABS indicator should come on for 2 seconds (start signal), then goes off for 3.6 seconds and starts DTC indication.
The DTC is indicated by the number of the times of the ABS indicator blinking.
If the DTC is not stored, the ABS indicator stays on.
3. Turn the ignition switch OFF and disconnect the SCS short connector.
Install the removed parts in the reverse order of removal.

DTC INDICATION PATTERN

• The ABS indicator indicates the DTC 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 DTC is 1-2 (one long blink = 1 blink, plus two
short blinks = 2 blinks).
• 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. 1.3 sec. Pattern repeated
2 sec. 0.3 sec.

ABS ON 3.6 sec.

INDICATOR OFF
DTC start signal
0.4 sec. 3.6 sec. 0.5 sec.

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
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

ERASING STORED DTC

• The stored DTC can not be erased by simply disconnecting the battery negative (–) cable.
Connect the MCS to the DLC (page 4-6).
Erase the DTC with the MCS while the engine is stopped.
To erase the DTC without MCS, refer to the following procedure.
How to erase the DTC without MCS
1. Connect the SCS short 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 DTC 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 short connector.
Install the removed parts in the reverse order of removal.

CIRCUIT INSPECTION
INSPECTION AT ABS MODULATOR CONNECTOR
Remove the BCU tray (page 22-51).
Disconnect: Connect:
Turn the ignition switch OFF.
[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:
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.

[3]

• Always clean around and keep any foreign material away from the
[1]
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.
TOOL:
Test probe 07ZAJ-RDJA110

TERMINAL LAYOUT:

(Terminal side of the wire harness)

20-8
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

ABS DTC INDEX
• 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 DTC
(page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph) and check the DTC (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
(A) (B) to
ABS indicator malfunction • ABS indicator never comes
20-11
• ABS modulator voltage input line ON at all
• Indicator related wires • ABS indicator stays ON at all
–
• Meter
• ABS modulator 20-11
• Sub fuse ABS MAIN 10 A
Front wheel speed sensor circuit malfunction • Stops ABS operation
1-1
• Wheel speed sensor or related wires
Front wheel speed sensor malfunction • Stops ABS operation 20-13
• Wheel speed sensor, pulser ring or related
1-2
wires
• Electromagnetic interference
Rear wheel speed sensor circuit malfunction • Stops ABS operation
1-3
• Wheel speed sensor or related wires
Rear wheel speed sensor malfunction • Stops ABS operation 20-15
• Wheel speed sensor, pulser ring or related
1-4
wires
• Electromagnetic interference
Front pulser ring • Stops ABS operation
2-1 20-13
• Pulser ring or related wires
Rear pulser ring • Stops ABS operation
2-3 20-15
• Pulser ring or related wires
3-1 Solenoid valve malfunction (ABS modulator) • Stops ABS operation
3-2
20-17
3-3
3-4
Front wheel lock • Stops ABS operation
4-1
• Riding condition
20-13
Front wheel lock (Wheelie)
4-2
• Riding condition
Rear wheel lock • Stops ABS operation
4-3 20-15
• Riding condition
Pump motor lock • Stops ABS operation
5-1 • Pump motor (ABS modulator) or related wires
• ABS-M 30 A fuse
Motor stuck off • Stops ABS operation
20-17
5-2 • Pump motor (ABS modulator) or related wires
• ABS-M 30 A fuse
Motor stuck on • Stops ABS operation
5-3
• Pump motor (ABS modulator) or related wires
Fail-safe relay malfunction • Stops ABS operation
5-4 • Fail-safe relay (ABS modulator) or related wires 20-18
• Sub fuse ABS FSR+ 20 A
Power circuit under voltage • Stops ABS operation
6-1 • Input voltage (too low)
• Sub fuse ABS MAIN 10 A 20-19
Power circuit over voltage • Stops ABS operation
6-2
• Input voltage (too high)

20-9
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

Detection Refer
DTC Function failure Symptom/Fail-safe function
(A) (B) to
Tire malfunction • Stops ABS operation
7-1 20-20
• Tire size
ABS control unit malfunction • Stops ABS operation
8-1 20-20
• ABS modulator
Rear ABS off indicator • Rear ABS off mode function
8-2 20-20
• Rear ABS off indicator (meter) or related wire does not work
IMU malfunction • Stops ABS operation
8-3
• Acceleration sensor
20-22
• Gyro sensors • Stops ABS operation
8-4 • IMU installation status
IMU circuit malfunction • Stops ABS operation
8-5 20-23
• IMU or related wires
CAN communication malfunction (bus-off) • Stops ABS operation
8-6 20-23
• Faulty CAN communication line
CAN communication error (ECM or meter) • ABS level does not change
8-7 20-23
• Faulty CAN communication line (ECM or meter)

(A) Pre-start self-diagnosis (page 20-6)

(B) Ordinary self-diagnosis: diagnoses while the motorcycle is running (after pre-start self-diagnosis)

20-10
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INDICATOR CIRCUIT
TROUBLESHOOTING
ABS INDICATOR DOES NOT COME ON
(when the ignition switch turned ON)

• Before starting this inspection, check the initial

function of the meter (page 22-15).
1. Indicator Operation Inspection
Turn the ignition switch OFF.
Disconnect the ABS modulator 18P (Black)
connector (page 20-8).
Turn the ignition switch ON.
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
Turn the ignition switch OFF.
[1]
Check for continuity between the wire harness side
18P (Black) connector [1] and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: 13 – Ground
13
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
Turn the ignition switch OFF.
[1]
Disconnect the ABS modulator 18P (Black)
connector (page 20-8).
Check for continuity between the wire harness side
18P (Black) connector [1] and ground.
TOOL:
Test probe 07ZAJ-RDJA110
14
CONNECTION: 14 – Ground
Is there continuity?
YES – Short circuit in the Yellow wire
NO – GO TO STEP 2.

20-11
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

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:
Test probe 07ZAJ-RDJA110

CONNECTION: 13 – Ground
Turn the ignition switch ON. 13 [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
Turn the ignition switch OFF.
[1]
Remove the jumper wire.
Check for continuity between the wire harness side
18P (Black) connector [1] and ground.
CONNECTION: 10 – Ground
Is there continuity? 10
YES – GO TO STEP 4.
NO – Open circuit in the Green wire

4. Fuse Inspection
Open the power box cover.
[1]
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
[1]
for continuity between the wire harness side 18P
(Black) connector [1] and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: 7 – Ground
7
Is there continuity?
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
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

6. Power Input Line Open Circuit Inspection
Install the sub fuse ABS MAIN 10 A.
[1]
Turn the ignition switch ON.
Measure the voltage between the wire harness side
18P (Black) connector [1] and ground.
TOOL:
Test probe 07ZAJ-RDJA110
7
CONNECTION: 7 (+) – Ground (–)
Is there battery voltage?
YES – Faulty ABS modulator
NO – Open circuit in Red/green wire

ABS DTC TROUBLESHOOTING

• 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)

• 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
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

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
Turn the ignition switch OFF.
[1]
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. W Bu
CONNECTION: White – Ground
Blue – Ground
Is there continuity?
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]
connector (page 20-8).
Check for continuity between each terminal of the
wire harness side 2P (Black) connector [1] and
ground. Bu W
CONNECTION: Blue – Ground
White – Ground
Is there continuity?
YES – • Short circuit in the Blue wire
• Short circuit in the White wire
NO – GO TO STEP 5.

20-14
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

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]. 8
CONNECTION: 8 – 17
Check for continuity between the wire harness side
2P (Black) connector [3] terminals.
CONNECTION: Blue – White [3]
17
Is there continuity?
Bu W
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.
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 1-1, 1-2, 2-1, 4-1 or 4-2 indicated?
YES – Faulty ABS modulator
NO – Faulty original front wheel speed sensor

DTC 1-3/1-4/2-3/4-3 (Rear Wheel Speed

Sensor Circuit/Rear Wheel Speed
Sensor/Rear Pulser Ring/Rear Wheel
Lock)

• 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 4-3 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).
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
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

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
Turn the ignition switch OFF.
[1]
Disconnect the rear wheel speed sensor 2P (Black)
connector (page 20-25).
Check for continuity between each terminal of the
sensor side 2P (Black) connector [1] and ground. W Bu
CONNECTION: White – Ground
Blue – Ground
Is there continuity?
YES – Faulty rear wheel speed sensor
NO – GO TO STEP 4.

4. Rear Wheel Speed Sensor Line Short Circuit

Inspection
Disconnect the ABS modulator 18P (Black)
[1]
connector (page 20-8).
Check for continuity between each terminal of the
wire harness side 2P (Black) connector [1] and
ground. Bu W
CONNECTION: Blue – Ground
White – Ground
Is there continuity?
YES – • Short circuit in the Blue wire
• Short circuit in the White wire
NO – GO TO STEP 5.

20-16
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

5. Rear Wheel Speed Sensor Line Open Circuit
Inspection
Short the wire harness side 18P (Black) connector
[2] [1]
[1] terminals with a jumper wire [2]. 6
CONNECTION: 6 – 15
Check for continuity between the wire harness side
2P (Black) connector [3] terminals.
[3]
CONNECTION: Blue – White 15
Is there continuity?
Bu W
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.
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 1-3, 1-4, 2-3, or 4-3 indicated?
YES – Faulty ABS modulator
NO – Faulty original rear wheel speed sensor

DTC 3-1/3-2/3-3/3-4 (Solenoid Valve)

1. Failure Reproduction
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 3-1, 3-2, 3-3 or 3-4 indicated?
YES – Faulty ABS modulator
NO – Solenoid valve is normal (intermittent
failure).

DTC 5-1/5-2/5-3 (Pump Motor)

1. Fuse Inspection
Turn the ignition switch OFF.
[1]
Remove the starter relay switch cover (page 6-9)
and check for a blown ABS-M 30 A fuse [1].
Is the fuse blown?
YES – GO TO STEP 2.
NO – GO TO STEP 3.

20-17
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

2. Motor Power Input Line Short Circuit Inspection
Disconnect the ABS modulator 18P (Black)
[1]
connector (page 20-8).
With the ABS-M 30 A fuse removed, check for
continuity between the wire harness side 18P
(Black) connector [1] terminal and ground.
CONNECTION: 9 – Ground
Is there continuity? 9
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.
Disconnect the ABS modulator 18P (Black)
connector (page 20-8).
Measure the voltage between the wire harness side [1]
18P (Black) connector [1] terminals.
CONNECTION: 9 (+) – 1 (–)
Is there battery voltage? 9 1
YES – GO TO STEP 4.
NO – • Open circuit in the Black or Red/yellow
wire between the battery and 18P
(Black) connector
• Open circuit in the Green wire between
the 18P (Black) connector and ground
terminal
4. Failure Reproduction
Connect the 18P (Black) connector.
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 5-1, 5-2, or 5-3 indicated?
YES – Faulty ABS modulator
NO – Pump motor is normal (intermittent failure)

DTC 5-4 (Fail-safe Relay)

1. Fuse Inspection
Turn the ignition switch OFF.
[1]
Remove the main seat (page 2-5).
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
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

2. Solenoid Power Input Line Short Circuit
Inspection
Disconnect the ABS modulator 18P (Black)
[1]
connector (page 20-8).
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
Is there continuity? 18
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.
[1]
Disconnect the ABS modulator 18P (Black)
connector (page 20-8).
Measure the voltage between the wire harness side
18P (Black) connector [1] terminal and ground.
CONNECTION: 18 (+) – Ground (–)
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

4. Failure Reproduction
Connect the ABS modulator 18P (Black) connector.
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 5-4 indicated?
YES – Faulty ABS modulator
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
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

3. Failure Reproduction
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 6-1 or 6-2 indicated?
YES – Faulty ABS modulator
NO – Power circuit is normal (intermittent failure)

DTC 7-1 (Tire Size)

• 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
1. Failure Reproduction
If the above items are normal, recheck the DTC as
follows:
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 7-1 indicated?
YES – Faulty ABS modulator
NO – Tire size is normal (intermittent failure)

DTC 8-1 (ABS Control Unit)

1. Failure Reproduction
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 8-1 indicated?
YES – Faulty ABS modulator
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 OFF.
Disconnect the ABS modulator 18P (Black)
connector (page 20-8).
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
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

2. Rear ABS Off Indicator Line Short Circuit
Inspection
Turn the ignition switch OFF.
[1]
Disconnect the meter 20P connector (page 22-13).
Check tor continuity between the wire harness side
18P (Black) [1] connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110
16
CONNECTION: 16 – Ground
Is there continuity?
YES – Short circuit in the White/green wire
NO – Replace the meter with a new one and
recheck (page 22-13).

3. Rear ABS Off Indicator Inspection 2

Ground the wire harness side 18P (Black) connector
[1]
[1] with a jumper wire [2].
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: 16 – Ground
Turn the ignition switch ON. 16
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.

4. Failure Reproduction
Erase the DTC (page 20-8).
Recheck the DTC (page 20-7).
Is the DTC 8-2 indicated?
YES – Faulty ABS modulator
NO – ABS control unit is normal (intermittent
failure)
5. Rear ABS Off Indicator Line Open Circuit
Inspection
Turn the ignition switch OFF.
[1]
Disconnect the meter 20P connector (page 22-13).
Check tor continuity between the wire harness side
18P (Black) [1] and 20P [2] connectors.
TOOL:
Test probe 07ZAJ-RDJA110 16

CONNECTION: 16 – White/Green
Is there continuity?
W/G
YES – Replace the meter with a new one and
recheck (page 22-13).
NO – Open circuit in the White/green wire
[2]

20-21
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

DTC 8-3/8-4 (IMU)

• 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) and check that the ABS indicator operates
normally (page 20-6).
1. IMU System Inspection
Erase the DTC (page 20-8).
Recheck the DTC (page 20-7).
Is the DTC 8-3 or 8-4 indicated?
YES – GO TO STEP 2.
NO – GO TO STEP 3.
2. IMU Input Voltage Inspection
Turn the ignition switch OFF.
[1]
Disconnect the IMU 4P (Black) connector (page 22-
51).
Turn the ignition switch ON.
Measure the voltage between the 4P (Black)
connector [1] terminals.
CONNECTION: Black/red (+) – Green/blue (–)
G/Bu Bl/R
Does the battery voltage exist?
YES – Faulty IMU
NO – • Open circuit in Black/red wire
• Open circuit in Green/blue wire

3. Failure Reproduction
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 8-3 or 8-4 indicated?
YES – GO TO STEP 4.
NO – IMU is normal (intermittent failure)
4. IMU Installation Inspection
Check the correct IMU installation (page 4-73).
Is the IMU installed correctly?
YES – Faulty IMU
NO – Faulty IMU stay

20-22
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

DTC 8-5 (IMU CIRCUIT)
1. PGM-FI DTC Check
Check the PGM-FI DTC (page 4-6).
Does the ECM store the DTC U0125 (103-3)?
YES – Perform the DTC U0125 troubleshooting
(page 4-69).
NO – GO TO STEP 2.
2. ABS Control Unit CAN Line Open Circuit
Inspection
Disconnect the following:
[1]
– ABS modulator 18P (Black) connector (page 20-
8)
– IMU 4P (Black) connector (page 22-51)
Check for continuity between the 18P (Black) 2
connector [1] and 4P (Black) connector [2]. Bl/R
TOOL:
Test probe 07ZAJ-RDJA110 Bl
11
CONNECTION: 2 – Black/red
11 – Black
Is there continuity?
[2]
YES – GO TO STEP 3.
NO – • Open circuit in the Black/red wire
• Open circuit in the Black wire
3. IMU Inspection
Replace the IMU with a known good one (page 4-
73).
Erase the DTC (page 20-8).
Test-ride the motorcycle above 10 km/h (6 mph).
Recheck the DTC (page 20-7).
Is the DTC 8-5 indicated?
YES – Faulty ABS modulator
NO – Faulty original IMU

DTC 8-6 (CAN COMMUNICATION

MALFUNCTION (BUS-OFF))
Refer to PGM-FI troubleshooting:
– DTC U0001: (page 4-66)
– DTC U0121: (page 4-68)

DTC 8-7 (CAN COMMUNICATION

ERROR (ECM OR METER))
Refer to PGM-FI troubleshooting DTC U0155 (page 4-
70).

20-23
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

WHEEL SPEED SENSOR
• Refer to procedure for the pulser ring removal/
installation:
– Front: (page 17-15)
– Rear: (page 18-5)
FRONT WHEEL SPEED SENSOR
REMOVAL/INSTALLATION
Remove the front fender (page 2-23).
Remove the ignition coil tray (page 5-9).
Disconnect the front wheel speed sensor 2P (Black)
connector [1] from the clip and disconnect it.

[1]

Remove the bolts [1].

[1] [1]
Release the front wheel speed sensor wire [2] from the
clamps [3].
Remove the wire clips [4]. [2]

[2]

[3]

[3]

[2]

[4] [4]

Remove the wire clips [1].

[1]

20-24
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

Remove the bolt [1] and front wheel speed sensor [2].
[1]
Clean around the mounting area of the caliper bracket
thoroughly and be sure that no foreign material is
allowed to enter the mounting hole.
Installation is in the reverse order of removal.

• Route the hose and wire properly (page 1-32).

• Always replace the front wheel speed sensor bolt
with a new one.
• After installation, check the clearance gap (page 20- [2]
26).

REAR WHEEL SPEED SENSOR

REMOVAL/INSTALLATION
Drain the brake fluid from the brake hydraulic system
(page 19-6).
Remove the fuel tank (page 7-7).
Remove the rear wheel (page 18-4).
Disconnect the rear wheel speed sensor 2P (Black)
[3]
connector [1].
Release the rear wheel speed sensor wire [2] from the
guide [3].

[2] [1]

Remove the clip [1].

[4] [3]
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.

[2]

[1]

Remove the brake hose clamp screw [1] and brake

[3] [5]
hose clamp [2].
Remove the brake hose guide screws [3] and brake
hose guide [4].
Remove the bolt [5] and brake hose clamp [6]. [2]
Remove the clips [7].

[7]

[1] [4] [7] [6]

20-25
 dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

Remove the clip [1].
[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.
[3]
Installation is in the reverse order of removal.
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) [2]

• 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-
32).
• After installation, check the clearance gap (page 20-
26).

CLEARANCE GAP INSPECTION

Support the motorcycle securely using a hoist or
Front:
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.
Rear:

20-26
dummyhead

ANTI-LOCK BRAKE SYSTEM (ABS)

ABS MODULATOR

Spilled fluid can damage painted, plastic or rubber

parts. Place a rag over these parts whenever the
system is serviced.

• When removing the oil bolt, cover the end of the

brake hose to prevent contamination.
• Be careful not to bend or damage the brake pipes.

REMOVAL/INSTALLATION
Drain the brake fluid from the brake hydraulic system
[2] [1]
(page 19-6).
Remove the following:
– EVAP canister (page 7-23)
– Mud guard (page 2-38)
Disconnect the ABS modulator 18P (Black) connector
(page 20-8).
Remove the following:
– Bolt/washers [1] [2]
– Collars [2]

[1]

Remove the following:

[1] [1]
– Oil bolts [1]
– Sealing washers [2] [2]
– Rear brake hose A [3]
– Rear brake hose B [4] [2]
Open the clamp [5].
Release the front brake pipe B [6] and front brake pipe [3]
C [7].
[4]
Loosen the brake pipe joint nuts [8]. [6]
Remove the front brake pipes from the ABS modulator [2]
[7]
[9].
Remove the ABS modulator.
Installation is in the reverse order of removal.
[8] [2]
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)

• Apply brake fluid to the joint nut threads. [9]

• Replace the sealing washers with new ones.
Fill and bleed the rear brake hydraulic system (page 19- [5]
6).

20-27
dummyhead

MEMO
dummytext

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

21

21-1
 dummyhead

BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
BATTERY/CHARGING SYSTEM

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.

• 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 battery negative (–) 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).
• 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 O = 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.
• 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.
BATTERY CHARGING
• Turn power ON/OFF at the charger, not at the battery terminal.
• These models are equipped with the Lithium Ion (Li-Ion) battery. To charge the battery, use only the specified battery charger
(C-1401B manufactured by ELIIY Power Co., Ltd.). Follow the manufacturer’s instructions.
• Quick charging should only be done in an emergency; slow charging is preferred.
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.
Battery charger: C-1401B manufactured by ELIIY Power Co., Ltd.

21-2
dummyhead

BATTERY/CHARGING SYSTEM
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove the battery (page 21-6).
Check the battery condition using the recommended battery tester.
Battery charger:
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
NO – • Shorted wire harness
• Faulty ignition switch
4. ALTERNATOR CHARGING COIL INSPECTION
Check the alternator charging coil (page 21-10).
Is the alternator charging coil resistance within 0.1 – 1.0 Ω (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).
Start the engine.
Measure the charging voltage (page 21-8).
Compare the measurement to result of the following calculation.
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
NO – GO TO STEP 6.
6. REGULATOR/RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/rectifier connector (page 21-9).
Are the results of checked voltage and resistance correct?
YES – Faulty regulator/rectifier
NO – • Open circuit in related wire
• Shorted wire harness
• Loose or poor contacts of related terminal

21-3
 dummyhead

BATTERY/CHARGING SYSTEM
ELECTRICAL SYSTEM DOES NOT TURNED ON WHEN THE IGNITION SWITCH IS TURNED ON OR
STARTER MOTOR CANNOT BE TURNED
1. ELECTRICAL SYSTEM INSPECTION
Remove the battery (page 21-6).
Connect a fully charged 12 V battery and turn the ignition switch ON.
Is the electrical system turned ON?
YES – GO TO STEP 2.
NO – • Check the following:
– Main fuse 30 A
– MAIN2 fuse 30 A
– FI 15 A
– FI relay
– Sub fuses
– 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
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.
4. BATTERY VOLTAGE INSPECTION
Leave the battery for 30 minutes and check the battery voltage.
Is the voltage below 6 V or above 14.6 V?
YES – Replace the battery (page 21-6).
NO – GO TO STEP 5.
5. CHARGING CONDITION INSPECTION
Charge the battery using the specified battery charger (C-1401B manufactured by ELIIY Power Co., Ltd.).
Is the battery charged?
YES – Battery is normal.
NO – Replace the battery (page 21-6).

21-4
dummyhead

BATTERY/CHARGING SYSTEM
SYSTEM LOCATION

IGNITION SWITCH STARTER RELAY SWITCH

– MAIN FUSE 30 A

BATTERY

ALTERNATOR

REGULATOR/RECTIFIER

SYSTEM DIAGRAM
MAIN FUSE 30 A

Bl Bl/Gr
G R Y Y Y

BATTERY REGULATOR/RECTIFIER

Bl: Black ALTERNATOR

G: Green
R: Red
Y: Yellow
Gr: Gray

21-5
 dummyhead

BATTERY/CHARGING SYSTEM
BATTERY
BATTERY REMOVAL/INSTALLATION
Remove the tool box (page 2-26).
[3]/[4] [5]
Turn the ignition switch OFF.
Remove the bolt [1] and disconnect the battery negative
(–) cable [2] first.
[6]
Then remove the bolt [3] and disconnect the battery
positive (+) cable [4]. [1]/[2]
Remove the trim clip [5].
Open the battery holder [6].
Remove the battery [7].
Install the battery in the reverse order of removal.
[7]
• Connect the battery positive (+) cable first and then
the negative (–) cable.

BATTERY BOX REMOVAL/

INSTALLATION
Disconnect the battery negative (–) cable (page 21-6).
Remove the battery box cover (page 6-9).
Remove the ECM tray (page 4-77).
Release the following:
– Junction 1 24 P (White) connector [1]
– Junction 2 24 P (White) connector [2]
– FI relay [3]
– Starter relay [4]

[4]

[1] [2] [3]

Release the following from the battery box:

[1] [3]
– Starter relay switch [1]
– Fuse box [2]
– Fuse box 4P connector [3]

[2]

21-6
dummyhead

BATTERY/CHARGING SYSTEM
Remove the bolt [1] and disconnect the battery positive
[1]/[2] [3]
(+) cable [2].
Remove the battery [3].
Remove the socket bolt [4].

[4]

Release the battery box bosses [1] from the grommets

[2]
[2] of the frame.
Remove the battery box [3] to the left side.
Remove the battery box lid [4] from the battery box.
Installation is in the reverse order of removal.
[4]

• Route the battery positive (+) cable [5] and battery

negative (–) cable [6] as shown.
[1]

[6]

[3] [5]

VOLTAGE INSPECTION
Remove the tool box (page 2-26).
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
Remove the battery (page 21-6).
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery charger C-1401B manufactured
by ELIIY Power Co., Ltd.

21-7
 dummyhead

BATTERY/CHARGING SYSTEM
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE TEST
Turn the ignition switch OFF.
[2] [4]
Disconnect the battery negative (–) cable (page 21-6).
Connect the ammeter (+) probe [1] to the battery
negative (–) cable [2] and the ammeter (–) probe [3] to
the battery (–) terminal [4].
With the ignition switch OFF, check for current leakage.
[3]
• 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
[1]
switch ON. A sudden surge of current may blow the
fuse in the tester.
SPECIFIED CURRENT LEAKAGE:
0.4 mA max.
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

• Make sure the battery is in good condition before

performing this test.
Start the engine and warm it up to the operating
[1] [2]
temperature; then stop the engine.
Remove the tool box (page 2-26).
Connect the multimeter between the battery positive (+)
terminal [1] and negative (–) terminal [2].

• 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
dummyhead

BATTERY/CHARGING SYSTEM
REGULATOR/RECTIFIER
REMOVAL/INSTALLATION
Remove the mud guard (page 2-38).
Disconnect the alternator 3P (Gray) connector [1] and
regulator/rectifier 3P (Black) connector [2].
Remove the bolts [3] and regulator/rectifier [4].
Installation is in the reverse order of removal.
[4]

[3] [2] [1]

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
Turn the ignition switch OFF.
[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

Turn the ignition switch OFF.
[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.
CONNECTION: Green – Ground
There should be continuity at all times.

21-9
 dummyhead

BATTERY/CHARGING SYSTEM
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
Y Y
STANDARD: 0.1 – 1.0 Ω (20°C/68°F)
Y
[1]

Check for continuity between the alternator 3P (Gray)

[1]
connector [1] terminals at the stator side and ground.

CONNECTION: Yellow – Ground

STANDARD: No continuity
Replace the stator if the resistance is out of Y Y
specification, or if any wire has continuity to ground.
Y
For stator replacement (page 11-5)

21-10
dummytext

22. LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

SERVICE INFORMATION ···························22-2 HORN ························································ 22-46

SYSTEM LOCATION···································22-3 HSTC ························································· 22-46

Apple CarPlayTM TROUBLESHOOTING ····22-4 ACCESSORY SOCKET (CRF1100A2/AL2/A4/

AL4/D2/DL2/D4/DL4) ································ 22-47
HEADLIGHT ················································22-6
GRIP HEATER (CRF1100A2/AL2/A4/AL4/D2/
TURN SIGNAL LIGHT·······························22-11 DL2/D4/DL4) ············································· 22-47

LICENSE LIGHT········································22-12 BCU ··························································· 22-51

BRAKE/TAILLIGHT···································22-13 BODY CONTROL SYSTEM

TROUBLESHOOTING INFORMATION ···· 22-53
METER/MID ···············································22-13
BODY CONTROL SYSTEM DIAGRAM···· 22-54
OPEN AIR TEMPERATURE SENSOR ·····22-23
BODY CONTROL SYSTEM DTC
INDEX························································ 22-55
EOP SWITCH (MT model) ························22-24
BODY CONTROL SYSTEM DTC
FUEL LEVEL SENSOR ·····························22-24 TROUBLESHOOTING ······························ 22-56

IGNITION SWITCH ····································22-25 SCU ··························································· 22-83

LEFT HANDLEBAR SWITCH ···················22-26 ELECTRONIC SUSPENSION SYSTEM

TROUBLESHOOTING INFORMATION ···· 22-84
RIGHT HANDLEBAR SWITCH ·················22-33
ELECTRONIC SUSPENSION SYSTEM 22
BRAKE SWITCH ·······································22-40 SYMPTOM TROUBLESHOOTING ··········· 22-85

CLUTCH SWITCH (MT model) ·················22-43 ELECTRONIC SUSPENSION SYSTEM

DIAGRAM·················································· 22-86
PARKING BRAKE SWITCH
(DCT model)··············································22-43 ELECTRONIC SUSPENSION SYSTEM DTC
INDEX························································ 22-87
NEUTRAL SWITCH (MT model)···············22-44
ELECTRONIC SUSPENSION SYSTEM DTC
SIDESTAND SWITCH ·······························22-44 TROUBLESHOOTING ······························ 22-88

GPS ANTENNA········································· 22-99

22-1
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

SERVICE INFORMATION
LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

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.
• If the ECM is replaced, perform the following procedure.
– Crank pulse initialize learning procedure (page 4-84) (ED, KO only)
– Key Registration Procedure (page 23-5)
• 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 O = Orange P = Pink R = Red V = Violet
W = White Y = Yellow

• Only iPhone 5 or newer versions with iOS 10 or later are compatible with Apple CarPlayTM. For details on countries and regions
where Apple CarPlayTM is available, as well as information pertaining to function, refer to the Apple homepage.
• Apple CarPlayTM's features and services may be discontinued without notice due to operating system, hardware, software, Apple
CarPlayTM's specification change or newly defined regulation or regulatory amendment. Honda has no warranty as to the
mechanism and function of Apple CarPlayTM provided by Apple.
• If Apple CarPlayTM can not be used, check the following items.
– Is it an Apple CarPlayTM compatible model?
– Is iPhone version up to date?
– Is the Bluetooth® headset connected?
– Is Apple CarPlayTM 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 CarPlayTM permitted on the equipment use confirmation screen?
– Is the setting on the iPhone side allowed to use Apple CarPlayTM?
• 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
(For iPhone, mobile phone or Bluetooth® device) A2DP (Advanced Audio Distribution Profile) ver. 1.2
AVRCP (Audio/Video 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
• You cannot pair a Bluetooth® device and Bluetooth® headsets while the motorcycle is moving.
When pairing, park your motorcycle in a safe place.
• Bluetooth® connection cannot be established while launching Apple CarPlayTM.
• 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.

22-2
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

SYSTEM LOCATION
IGNITION SWITCH

MID USB CONNECTOR

OPEN AIR TEMPERATURE
METER SENSOR
FRONT BRAKE/CRUISE CANCEL SWITCH

GPS ANTENNA
RIGHT HANDLEBAR SWITCH

FUEL LEVEL SENSOR

– CLUTCH SWITCH SCU

(MT model)
– CLUTCH CRUISE BCU
CANCEL SWITCH
(MT model) DLC
– PARKING BRAKE
SWITCH
(DCT model)

ACCESSORY
SOCKET

LEFT
HANDLEBAR
SWITCH

HORN

BATTERY

REAR BRAKE
EOP SWITCH SWITCH
(MT model) NEUTRAL SWITCH

SIDESTAND SWITCH

22-3
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Apple CarPlayTM TROUBLESHOOTING

Apple CarPlayTM Does Not Start-up
Connect the following:
– Lightning cable to USB
– Lightning cable to iPhone
To start-up Apple CarPlayTM, refer to the motorcycle
Owner’s Manual.
Check the following:
1. Power
Check iPhone display.
Is your iPhone turned ON?
YES – GO TO STEP 2.
NO – Turn ON the power switch.
2. Charge status
Check iPhone display.
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 CarPlayTM only works through USB.
4. Operation message
Check iPhone display.
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 CarPlayTM?
YES – GO TO STEP 7.
NO – Set the mode to Apple CarPlayTM and
reconnect the Lightning cable.

22-4
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

7. iOS version
Check iOS version.
Does your device have the latest version of iOS?
YES – GO TO STEP 8.
NO – Apple CarPlayTM works only with iPhone 5
or later with iOS 10 or later.
8. iPhone configuration
Check configuration screen.
Is Apple CarPlayTM enabled in your iPhone’s
configuration screen?
YES – GO TO STEP 9.
NO – Set Apple CarPlayTM operational in your
iPhone’s configuration screen.
9. License agreement
Check license agreement.
Do you accept the agreement to use Apple
CarPlayTM?
YES – The MID unit or its related circuit is faulty.
NO – If you do not accept the agreement, you
cannot use Apple CarPlayTM.

22-5
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

HEADLIGHT
REMOVAL/INSTALLATION
Remove the front upper cover (page 2-21).
Disconnect the GPS connector [1].
Remove the wire band [2].
Remove the bolts [3].
Disconnect the headlight 6P connector [4].
CRF1100A2/AL2/ Disconnect the cornering light 6P connector [5].
A4/AL4/D2/DL2/D4/
DL4:
Remove the headlight unit [6].
Remove the collars [7] and grommets [8] from the
headlight unit.
Remove the GPS antenna if necessary (page 22-99).
Installation is in the reverse order of removal.

• Route the wires properly (page 1-32).

CRF1100D4 shown:

[1]

[2]

[4]
[3]

[7]

[8]

[5]
[6]

22-6
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

INSPECTION
Check the following before inspection:
– Battery condition
– Blown sub fuse HEAD LIGHT 15 A
– Blown sub fuse HORN/STOP 10 A
– DTC indicated
Check the following lighting condition:
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4 shown:
– Headlight [1]
– DRL [2] (Except CH/IN) [1]
– Position light [2] (CH/IN only)
– Cornering light [3] (CRF1100A2/AL2/A4/AL4/D2/
DL2/D4/DL4)

• If any LED in the headlight unit does not turn on,

replace the headlight unit as an assembly.
• When the headlight, DRL, or cornering light does not
light properly, check the following: [2] [2]
– No DTC in the ABS and IMU system
– Headlight power/ground line (page 22-9)
[3]
– Faulty circuit between the headlight unit and BCU
– Photosensor [4] (in the meter) for damage or
cover
• When the headlight dimmer/passing light control
switch is turned to DRL auto or off (low beam), the
headlights and DRL are switched automatically
according to the ambient brightness.
When it gets brighter, DRL lights up, and when it
gets dark, low beam lights up and DRL decreases to
the brightness of the position light.
• The cornering light lights up the direction of travel of
the motorcycle when cornering.
[4]

DRL/CORNERING LIGHT FORCIBLY ACTIVATE

To forcibly activate the DRLs or cornering light lights,
perform the procedure as follows:
1. Pull and hold the page switch [1] or touch the clock
area [2] of the MID. [1]

[2]

22-7
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

2. Select the "DRL Service Mode" [1] or "Cornering
"DRL Service Mode" or
Light Service Mode" [2] by using the sel up switch
[3], sel down switch [4], sel left/right switch [5], ENT "Cornering Light Service Mode":
[1]
switch [6] and back switch [7] or touch the MID. ED shown:

• Select the display in the following order to the "DRL

Service Mode" or "Cornering Light Service Mode" :
"Settings" > "Service" > "Service Mode" > "DRL
Service Mode" or "Cornering Light Service Mode"
3. Check the each lights are lighting.

• In the cornering light service mode, you can switch

[2]
left and right by operating the turn signal switch [8].

[6] [3] [5]

[4]

[8] [7]

22-8
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

POWER/GROUND LINE INSPECTION
HEADLIGHT DRIVER

HEADLIGHT 6P CONNECTOR

Bl/Y G

IGNITION
SWITCH

IGN 1 Bl/Y Y/Bu R/Bl

HEAD LIGHT 15 A

HEADLIGHT PO R/Bl
Bl/R Bl/R
DRIVER (CH only)
HORN/STOP 10 A

GND G G

1. Headlight Power Input Line Inspection

Disconnect the headlight 6P connector (page 22-6).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 6P
connector terminal and ground.
CONNECTION: Black/yellow (+) – Ground (–)
STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open circuit in the Black/yellow or
Yellow/blue wire
• Blown sub fuse HEAD LIGHT 15 A
2. Position Light Power Input Line Inspection (CH
only)
Measure the voltage at the wire harness side 6P
connector terminal and ground.
CONNECTION: Black/red (+) – Ground (–)
STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 3.
NO – • Open circuit in the Black/red wire
• Blown sub fuse HORN/STOP 10 A
3. Headlight Ground Line Open Circuit Inspection
Check the continuity between the wire harness side
6P connector terminal and ground.
CONNECTION: Green – Ground
Is there continuity?
YES – Faulty headlight unit
NO – Open circuit in the Green wire

22-9
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

CORNERING LIGHT DRIVER (CRF1100A2/AL2/A4/
AL4/D2/DL2/D4/DL4)

CORNERING LIGHT 6P CONNECTOR

Bl/W

G
IGNITION
SWITCH

IGN 2 Bl/W Y/W R/Bl

CORNER LIGHT/
ACC 10 A
CORNERING
LIGHT DRIVER

GND G G

1. Cornering light Power Input Line Inspection

Disconnect the cornering light 6P connector (page
22-6).
Turn the ignition switch ON.
Measure the voltage at the wire harness side 6P
connector terminal and ground.
CONNECTION: Black/white (+) – Ground (–)
STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open circuit in the Black/white or
Yellow/white wire
• Blown sub fuse CORNER LIGHT/ACC
10 A
2. Cornering light Ground Line Open Circuit
Inspection
Check the continuity between the wire harness side
6P connector terminal and ground.
CONNECTION: Green – Ground
Is there continuity?
YES – Faulty headlight unit
NO – Open circuit in the Green wire

22-10
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

TURN SIGNAL LIGHT
TURN SIGNAL LIGHT REMOVAL/
INSTALLATION
FRONT
Remove the front winker cover (page 2-15).
Remove the following from the front turn signal light [5]
cover [1]:
– Screw/washer [2]
– Collar [3]
– Turn signal light [4]
– Grommet [5] [4] [2]
Installation is in the reverse order of removal.

[1]

[3]

REAR
Disassemble the rear fender A (page 2-39).
[5]
Remove the following from the rear fender A [1]:
– Screw/washer [2]
– Collar [3]
– Turn signal light [4] [3]
– Grommet [5]
[4] [2]
Installation is in the reverse order of removal.

[1]

AUTO CANCEL TURN SIGNAL

SYSTEM INSPECTION
Check the following:
[1]
– DTC 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
one and recheck.

22-11
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

ESS SYSTEM INSPECTION
(Except CH)

• While the hazard system is operating, the ESS

system will not operate.
Check the following:
– DTC indicated
– Turn signal light
– Brake light switch and related circuit

• Even if any turn signal lights are abnormal, other

normal turn signal lights will work with the ESS
system.
• If the ESS system operates at all times, replace the
ABS modulator and/or BCU with a new one.
To forcibly activate the ESS system, perform the
procedure as follows:
1. Connect the SCS short connector to the DLC (page
4-6).
2. Turn the ignition switch ON.
3. Apply the front or rear brake and check the turn
signal lights operation.
The turn signal lights should be blinking with the
brake applied and turning OFF with the brake
released.

LICENSE LIGHT
REMOVAL/INSTALLATION
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]: [5]
– Screws [4]
– Washers [5] [7] [6]
– Stay [6]
– Grommets [7] [2]
Installation is in the reverse order of removal.
TORQUE:
License light bolt:
2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)

[1]

[3]

INSPECTION
Check that all LEDs in the license light unit illuminate
with the ignition switch turned ON.
If any LED does not turn on, replace the license light.

22-12
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

BRAKE/TAILLIGHT
REMOVAL/INSTALLATION
Remove the rear center cowl (page 2-35).
Disconnect the brake/taillight 3P (Black) connector [1]. [2]
Remove the following:
– Bolts [2]
– Washer [3] [3]
– Brake/taillight unit [4]
Remove the collars [5], grommets [6] from the brake/
taillight unit.
[4]
Installation is in the reverse order of removal.

[6]

[5]

[1]

INSPECTION
Turn the ignition switch ON.
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.

[1]

METER/MID
REMOVAL/INSTALLATION
Remove the front upper cover (page 2-21).
Disconnect the following: [3] [6]
– USB connector [1]
– GPS connector [2]
– MID 7P connector [3]
– Meter 20P connector [4] [1] [5]
Remove the bolts [5] and meter/MID assembly [6].

[2]

[4]

22-13
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Remove the following from the meter stay [1]:
– Meter/MID screws [2] and washers [3]
– MID [4]
– Meter [5]
– Grommets [6]
Installation is in the reverse order of removal.
TORQUE:
Meter/MID screw:
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)

METER/MID side [4]

[6]

[3]
[5]

[2]

[1]

PROTECTION FILM REPLACEMENT

Remove the protection film from the MID.
[3] [1] [4]

• Be careful not to damage the touchscreen.

Install a new protection film [1] in the following
procedure:
1. Wipe off dust and any oil on the MID touch screen
with a microfiber cloth.
2. Remove the film A [2] while slowly sticking the
protective film as shown.
3. Remove the film B [3].

[2]
• Be careful not to let air bubbles or dust get between
the touch screen and the protective film.
• Push out air bubbles using a spatula [4].
• Do not reuse the protective film once attached to the
entire surface of the touch screen.

22-14
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

SYSTEM INSPECTION

• 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 22-16).

METER:

22-15
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

POWER/GROUND LINE INSPECTION
METER

METER 20P CONNECTOR

R/W Bl/R G

IGNITION MAIN FUSE

SWITCH 30 A

METER

IGN Bl/R Bl/R R/Bl

METER 10 A

BATT R/W R/W R

CLOCK/TURN/
FOG/DRL 15 A
GND G

MID

1. Meter Power Input Line Inspection

Disconnect the meter 20P connector (page 22-13).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
20P connector terminal and ground.
CONNECTION: Black/red (+) – Ground (–)
STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open circuit in the Black/red wire
• Blown sub fuse METER 10 A
2. Meter Back-up Voltage Line Inspection
Turn the ignition switch OFF.
Measure the voltage between the wire harness side
20P connector terminal and ground.
CONNECTION: Red/white (+) – Ground (–)
STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 3.
NO – • Open circuit in the Red/white wire
• Blown sub fuse CLOCK/TURN/FOG/
DRL 15 A
3. Meter Ground Line Open Circuit Inspection
Check the continuity between the wire harness side
20P connector terminal and ground.
CONNECTION: Green – Ground
Is there continuity?
YES – Faulty meter
NO – Open circuit in the Green wire

22-16
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

MID

MID 7P CONNECTOR

Bl/R

R/W G
IGNITION MAIN FUSE
SWITCH 30 A

MID

IGN Bl/R Bl/R R/Bl

METER 10 A

BATT R/W R/W R

CLOCK/TURN/
FOG/DRL 15 A
GND G

METER

1. MID Power Input Line Inspection

Disconnect the MID 7P connector (page 22-13).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
7P connector terminal and ground.
CONNECTION: Black/red (+) – Ground (–)
STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open circuit in the Black/red wire
• Blown sub fuse METER 10 A
2. MID Back-up Voltage Line Inspection
Turn the ignition switch OFF.
Measure the voltage between the wire harness side
7P connector terminal and ground.
CONNECTION: Red/white (+) – Ground (–)
STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 3.
NO – • Open circuit in the Red/white wire
• Blown sub fuse CLOCK/TURN/FOG/
DRL 15 A
3. MID Ground Line Open Circuit Inspection
Check the continuity between the wire harness side
7P connector terminal and ground.
CONNECTION: Green – Ground
Is there continuity?
YES – Faulty MID
NO – Open circuit in the Green wire

22-17
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

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 DTC
• Check the meter
Indicator does not comes on when the • Check the ABS indicator circuit (page
ignition switch turned ON 20-11)
When the motorcycle is running but • Check the meter
indicator does not go off (No DTC) • Check the ABS modulator
ALARM INDICATOR Does not operate properly • Check the alarm (option) or its related
(ED only) 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
DRL INDICATOR Does not operate properly • Check the CAN communication line
(Except CH/IN) • Check the meter
FOG LIGHT INDICATOR Does not operate properly • Check the CAN communication line
• Check the meter
FUEL RESERVE Does not operate properly • Check the fuel reserve sensor (fuel
INDICATOR pump unit)
• Check the meter
SHIFT INDICATOR "–" blinks • Check the DTC
• Check the meter
HIGH BEAM INDICATOR Does not operate properly • Check the CAN communication line
• Check the meter
COOLANT TEMPERATURE Does not operate properly • Check the CAN communication line
INDICATOR • 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
LOW OIL PRESSURE MT model: Indicator does not come • Check for open circuit in the EOP switch
INDICATOR on with the ignition switch wire
turned ON • Check the EOP switch
• Check the meter
Indicator does not go off • Check the engine oil level
with the engine running • Check the engine oil pressure
• Check for short circuit in the EOP switch
wire
• Check the EOP switch
• Check the meter
DCT model: Indicator does not come • Check the CAN communication line
on with the ignition switch • Check the meter
turned ON
Indicator does not go off • Check the engine oil level
with the engine running • Check the engine oil pressure
• Check the DTC
• Check the meter
MIL MIL comes on or blinks • Check the DTC
• Check the meter
When the ignition switch ON, the MIL does • Check the CAN communication line
not come on • Check the meter
When the ignition switch ON, the MIL does • Check the CAN communication line
not go off within a few seconds (No DTC) • Check for short circuit in the Yellow wire
between the ECM and DLC
• Check the ECM
• Check the meter

22-18
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Meter function Symptoms Diagnosis procedure
NEUTRAL INDICATOR Does not operate properly • Check the CAN communication
• Check the neutral switch or its related
circuit
• Check the meter
PARKING BRAKE Indicator does not come on with the parking • Check for open circuit in the parking
INDICATOR (DCT model) brake lever applied brake switch wire
• Check the parking brake switch
• Check the meter
Indicator does not go off with the parking • Check for short circuit in the parking
brake lever released brake switch wire
• Check the parking brake switch
• Check the meter
REAR ABS INDICATOR Indicator does not come on in the rear ABS • Check for 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 • Check for short circuit in the rear ABS
ON mode indicator circuit
• Check the meter
• Check the ABS modulator
SUSPENSION INDICATOR Indicator lights or blinks while riding • Check the DTC
(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 "0 km/h" while riding • Check the VS sensor or its related circuit
• Check the meter
TORQUE CONTROL Indicator comes ON while riding • Check the CAN communication line
INDICATOR • Check the meter
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

22-19
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

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 • Check the CAN communication line
• 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 DTC
• Check the MID
• Check the meter
GRIP HEATER INDICATOR Blinks • Check the DTC
(CRF1100A2/AL2/A4/AL4/D2/ • Check the BCU
DL2/D4/DL4) • Check the MID
• Check the meter
FUEL GAUGE The fuel gauge flashes in all segments • Check the CAN communication line
brink (page 22-24) • Check the fuel level sensor or its related
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
• Check the MID
• Check the meter
TRIPMETER Display is not update
[TRIP A/B]
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.]
• Check the meter
TRIP TIME Display is not update
[ELAPSED]
AVAILABLE DRIVING DISTANCE Display is not update
[RANGE]
SUBTRACTION TRIP Display is not update
[-TRIP]
BATTERY VOLTAGE Display is not update
[VOLTAGE]
DATE Display is not update • Check the MID
[DATE]
INDICATORS ([P], [EB], [T], [G], Indicators ([P], [EB], [T], [G], • Check the CAN communication line
[ABS mode], [S]) [ABS mode], [S]) blink • Check the MID
• Check the meter

22-20
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

MID SOFTWARE UPDATE
PROCEDURE
1. Turn the ignition switch ON.
Connect the USB flash memory [1] to the USB
connector.

• Use the USB flash memory in which only the file to

be updated is stored.
[1]

2. The update starts automatically, so wait for it to

[1]
finish.

• 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]

• You can check the software version on "Software

Version" [1].
• Select the display in the following order to the
"Software Version":
"Settings" > "Service" > "System Information" >
"Software Version"
Turn the ignition switch OFF.
Disconnect the USB flash memory from the USB
connector.

22-21
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

TOUCHSCREEN CALIBRATION
1. Select the "Touchscreen Calibration" [1].
[1]

• Select the display in the following order to the

"Touchscreen Calibration":
"Settings" > "Service" > "Initialise" > "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.

[1] [1]

22-22
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

OPEN AIR TEMPERATURE SENSOR
REMOVAL/INSTALLATION
CRF1100A/AL/D/DL
Remove the right middle cowl (page 2-7).
[3]
Disconnect the open air temperature sensor 2P
connector [1].
Remove the open air temperature sensor screw [2].
Remove the open air temperature sensor [3].
[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)

[1]

CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4
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
Remove the open air temperature sensor 2P connector
(page 2-11).
Measure the resistance at the 2P connector [1] of the
sensor side.
STANDARD: 4.9 – 5.1 kΩ (25°C/77°F) [1]
Replace the open air temperature sensor if
measurement is out of specification.

22-23
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

EOP SWITCH (MT model)
REMOVAL/INSTALLATION
Drain the engine oil (page 3-12).
[2]/[3]
Release the rubber cap [1].
Remove the bolt/washer [2] and disconnect the EOP
switch terminal [3].
Remove the EOP switch [4]. [4]
Installation is in the reverse order of removal.
TORQUE:
EOP switch:
12 N·m (1.2 kgf·m, 9 lbf·ft)
EOP switch terminal bolt/washer:
2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)
[1]

• Apply sealant (TB1207B manufactured by 3 – 4 mm (0.1 – 0.2 in)

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.
• Route the wire properly (page 1-32).
Fill the engine oil with the recommended engine oil
(page 3-12).

[4]

FUEL LEVEL SENSOR

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 Gold/Bronze image shown:
blink as shown with the ignition switch turned ON.
Check the following:
– 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
If they are normal, inspect the fuel level sensor (page
22-25).
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

• Check the initial operation of the MID first (page 22-

15).
Inspect the fuel level sensor (page 22-25).
If the fuel level sensor is normal, replace the MID and
recheck.

22-24
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

FUEL LEVEL SENSOR REMOVAL/
INSTALLATION
Remove the fuel tank (page 7-7).
[1]
Remove the nuts [1].
Remove the fuel level sensor [2] and O-ring [3].
Installation is in the reverse order of removal.
[2]

• Replace the O-ring with a new one.

• Apply engine oil to a new O-ring.
• Align the sensor plate hole [4] with the tank boss.

[4] [3]

FUEL LEVEL SENSOR INSPECTION

Remove the fuel level sensor (page 22-25).
R/Bu G [2]
Connect the ohmmeter to the fuel level sensor 2P
(Black) connector [1].
CONNECTION: Red/blue – Green
FULL
Measure the resistance with the float [2] at the full and
empty positions.
CRF1100A/AL/D/DL:
FULL EMPTY
Resistance 6 – 10 Ω 434 – 446 Ω EMPTY
[1]
CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4:
FULL EMPTY
Resistance 6 – 10 Ω 328 – 338 Ω
If it is out of specification, replace the fuel level sensor
(page 22-25).

IGNITION SWITCH
REMOVAL/INSTALLATION
Remove the top bridge (page 17-45).
[1]
Remove the harness cover [1].

22-25
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Remove the ignition switch mounting bolts [1] and
[1]
ignition switch [2].

• Use a drill or an equivalent tool when removing the

ignition switch mounting bolts.
Installation is in the reverse order of removal.
TORQUE:
Ignition switch mounting bolt:
26 N·m (2.7 kgf·m, 19 lbf·ft)

• Replace the ignition switch mounting bolts with new [2]

ones.
INSPECTION
Remove the fuel tank (page 7-7).
[1]
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:
– MT model: (page 24-2)
– DCT model: (page 24-5)

[1]

R/Bl R

LEFT HANDLEBAR SWITCH

REMOVAL
Remove the following:
Electronic suspension model shown :
– Left knuckle guard (page 2-22)
– Left inner cover (page 2-9)
– Air cleaner housing (page 7-14)
Disconnect the following:
– Left handlebar switch 12P connector [1]
– Left handlebar switch 8P connector [2]
– Front suspension solenoid 2P connector [3]
(electronic suspension model only)

[3]

[2] [1]

22-26
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Remove the wire band [1].
Remove the socket bolt [2] and stay [3].
Release the left handlebar switch wire clip [4] from the
stay.

[3]

[4] [2] [1]

Remove the left rearview mirror [1].

[1]

Remove the wire clamp [1].

Electronic suspension model shown :
Release the wire clip [2] from the stay.
[3]
Disconnect the following:
[4]
– Left grip heater 2P connector [3]
– Front suspension solenoid 2P connector [4]
(electronic suspension model only)

[2]

[1]

MT model: Remove the wire clamps [1].

MT model: [1]
Disconnect the following:
– Clutch switch connectors (upper side) [2]
– Cruise cancel switch connectors (lower side) [3]

[2]

[3]

22-27
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DCT model: Remove the wire clamps [1].
DCT model: [1]
Disconnect the parking brake switch connectors [2].

[2]

MT model: Remove the bolts [1], holder [2], and clutch lever
MT model: [1]
assembly [3].

[3]

[2]

DCT model: Remove the bolts [1], holder [2], and parking brake
DCT model: [1]
lever assembly [3].

[3]

[2]

Remove the wire band [1].

Remove the left handlebar switch screws [2].
Separate the left handlebar switch housing [3].

[2]

[1] [3]

22-28
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Remove the screw [1].
[2]
Remove the left handlebar switch front housing [2] by
opening the setting plate [3].

[3]

[1]

INSTALLATION
Install the left handlebar switch front housing [1].
[1]
Set the setting plate [2].

• Align the setting plate tab with the handlebar hole.

[2]
Install and tighten the screw [3] securely.

Align
[3]

Install the left handlebar switch rear housing [1].

Install and tighten the left handlebar switch screws [2] to
the specified torque.
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)
Install a new wire band [3].

[2]

[3] [1]

MT model: Install the clutch lever assembly [1] by aligning its end
MT model: [4]
with the paint mark on the handlebar.
Install the holder [2] with its punch mark [3] facing up.
Install the bolts, and tighten the upper bolt [4] first, then [1]
the lower bolt [5]. [3]

Align

[2]
[5]

22-29
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DCT model: Install the parking brake lever assembly [1] by aligning
DCT model: [4]
its end with the paint mark on the handlebar.
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].

[3]
[1]

Align

[2] [5]

MT model: Connect the following:

MT model: [3]
– Clutch switch connectors (upper side) [1]
– Cruise cancel switch connectors (lower side) [2]
Install the wire clamps [3].

[1]

[2]

DCT model: Connect the parking brake switch connectors [1].

DCT model: [2]
Install the wire clamps [2].

[1]

Install the wire clip [1].

Electronic suspension model shown :
Install the wire clamp [2].
[3]
Connect the following:
[4]
– Left grip heater 2P connector [3]
– Front suspension solenoid 2P connector [4]
(electronic suspension model only)

[1]

[2]

22-30
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Install the left rearview mirror [1].
[1]

Install the left handlebar switch wire clip [1] to the stay.
Install the stay [2] and socket bolt [3].
[2]

• Align the stay tab with the frame hole.

Tighten the socket bolt securely. Align

Install the wire band [4].

[1] [3] [4]

Connect the following:

– Left handlebar switch 12P connector [1]
– Left handlebar switch 8P connector [2]
– Front suspension solenoid 2P connector [3]
(electronic suspension model only)
Install the following:
– Left knuckle guard (page 2-22)
– Left inner cover (page 2-9)
– Air cleaner housing (page 7-14)

[3]

[2] [1]

22-31
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

INSPECTION

• Before inspection, check that there is no DTCs.

Disconnect the left handlebar switch 12P (Black)
connector (page 22-26).
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 Ω
Passing light control switch: 338.9 – 374.7 Ω
White/black [4] – Green/blue [3] Page switch: 1609.6 – 1779.1 Ω
Voice control switch: 736.1 – 813.7 Ω
Function lever (up): 95.5 – 105.5 Ω
Function lever (down): 338.9 – 374.7 Ω
White/blue [5] – Green/blue [3] Sel left switch: 95.5 – 105.5 Ω
Back switch: 338.9 – 374.7 Ω
Sel up switch: 736.1 – 813.7 Ω
Sel down switch: 1609.6 – 1779.1 Ω
White/red [6] – Green/blue [3] Sel right switch: 95.5 – 105.5 Ω
ENT switch: 338.9 – 374.7 Ω
Skip switch: 736.1 – 813.7 Ω
Goes back switch: 1609.6 – 1779.1 Ω
White/green [7] – Green/blue [3] Horn switch: 95.5 – 105.5 Ω
Favorite switch: 338.9 – 374.7 Ω
White/yellow [8] – Green/blue [3] Turn signal left switch: 736.1 – 813.7 Ω
Turn signal right switch: 1609.6 – 1779.1 Ω
Turn signal cancel switch: 338.9 – 374.7 Ω
Hazard switch (except CH): 95.5 – 105.5 Ω
Lighting switch (CH):
DCT model only:
CONNECTION: STANDARD (at 25°C/77°F):
Black/blue [9] – Green/white [10] Shift up switch (+) : 406.9 – 449.8 Ω
Shift down switch (–) : 267.8 – 296.1 Ω
Replace the left handlebar switch if any switch
resistance are not standard value.

22-32
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

RIGHT HANDLEBAR SWITCH
REMOVAL
Remove the following:
DCT model shown: [4]
– Right knuckle guard (page 2-22)
– Right inner cover (page 2-9) [3]
– Air cleaner housing (page 7-14)
Disconnect the following:
– Right handlebar switch 12P connector [1] [2]
– Right handlebar switch 4P connector [2]
– Grip APS 8P connector [3]
– Right grip heater connector [4]

[1]

Remove the wire band A clip [1] and wire band B clip [2]
[1]
from the stays.

[2]

Remove the right rearview mirror [1].

[1]

Remove the wire clamp [1].

Electronic suspension model shown :
Electronic Disconnect the front suspension stroke sensor
suspension model connector [2].
only:

[2]

[1]

22-33
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Remove the wire clamp [1].
[2] [1]
Disconnect the following:
– Front brake switch connectors (upper side) [2]
– Cruise cancel switch connectors (lower side) [3]

[3]

Remove the bolts [1], holder [2], and front master

cylinder [3].

• Keep the front master cylinder upright to prevent air

from entering the hydraulic system. [1]

[3]

[2]

Remove the wire band [1].

[3] [2]
Remove the right handlebar switch screws [2].
Separate the right handlebar switch housing [3].
CRF1100A2/AL2/ Release the wire clip [4].
A4/AL4/D2/DL2/D4/
DL4: [1]

[4]

Remove the screw [1].

[2] [3]
Remove the right handlebar switch housing [2] and
throttle grip pipe [3].

[1]

22-34
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Remove the screw [1].
[2]
Remove the grip APS [2] by opening the setting plate
[3].

[3]

[1]

DISASSEMBLY
Remove the right handlebar switch (page 22-33).
[1] [4]
Remove the following:
– 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]

ASSEMBLY
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]
[2] [3]
– Right grip heater wire [4] (CRF1100A2/AL2/A4/AL4/
D2/DL2/D4/DL4)

• Install the wire band A so that its clip is in the

direction as shown.

[4]

[1]
[4]: 365 ± 10 mm
(14.4 ± 0.4 in)

22-35
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Secure the following wires with new wire band B [1] and
[4]: 230 ± 5 mm (9.1 ± 0.2 in)
wire protector [2] to specified range from the wire band
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] (CRF1100A2/AL2/A4/AL4/ [2] [4] [5]
D2/DL2/D4/DL4)

• 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:
[1] [6] [3]
– Grip APS
– Throttle grip pipe

INSTALLATION
Install the grip APS [1].
[1]
Set the setting plate [2].

• Align the setting plate tab with the handlebar hole.

Install and tighten the screw [3] securely.

[2]

Align

[3]

Apply grease to the throttle grip pipe [1] and APS [2] 3 mm [1]
contact area as shown. 5 mm (0.1 in)
(0.2 in)
3 mm (0.1 in)

5 mm
(0.2 in) 5 mm (0.2 in)

3 mm
(0.1 in) 5 mm
3 mm (0.2 in)
(0.1 in)

5 mm
[2] (0.2 in) 3 mm
(0.1 in)
5 mm
(0.2 in)

3 mm
3 mm
(0.1 in)
(0.1 in)

3 mm 5 mm (0.2 in)
(0.1 in) 5 mm
(0.2 in)

22-36
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Install the throttle grip pipe [1] as shown.
[1]

• Align the throttle grip pipe tabs [2] with the grip APS
grooves [3].

[2]
[3]

Install the right handlebar switch rear housing [1].

Align [1]

• Align the rear housing tabs with the holes.

Install and tighten the screw [2] securely.

[2] Align

Install the right handlebar switch front housing [1].

[1] [2]

• Align the front housing boss with the hole.

Install and tighten the right handlebar switch screws [2]
to the specified torque.
Align
TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) [3]

Install a new wire band [3].

CRF1100A2/AL2/ Install the wire clip [4].
A4/AL4/D2/DL2/D4/
DL4:
[4]

Install the front master cylinder [1] by aligning its end

[4]
with the paint mark on the handlebar.
Align
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.
TORQUE: 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft) [1]

[3]

[2]
[5]

22-37
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Connect the following:
[1] [3]
– Front brake switch connectors (upper side) [1]
– Cruise cancel switch connectors (lower side) [2]
Install the wire clamp [3].

[2]

Install the wire clamp [1].

Electronic suspension model shown :
Electronic Connect the front suspension stroke sensor connector
suspension model [2].
only:

[2]

[1]

Install the right rearview mirror [1].

[1]

Install wire band A clip [1] and wire band B clip [2] to the
[1]
stays.

[2]

22-38
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Connect the following:
DCT model shown: [4]
– Right handlebar switch 12P connector [1]
– Right handlebar switch 4P connector [2] [3]
– Grip APS 8P connector [3]
– Right grip heater connector [4]
Install the following: [2]
– Right knuckle guard (page 2-22)
– Right inner cover (page 2-9)
– Air cleaner housing (page 7-14)

• Route the hoses and wires properly (page 1-32).

[1]

INSPECTION

• Before inspection, check that there is no DTCs.

STARTER SWITCH INSPECTION
Disconnect the right handlebar switch 12P connector
[1]
(page 22-33).
Check the continuity between the switch side 12P
connector [1] terminals.
CONNECTION: Black – Green/black
Bl G/Bl
There should be continuity only when the starter switch
is pushed.
If the starter switch is OK, check the following:
– Open circuit in the Gray wire between the ECM 39P
(Black) connector and right handlebar switch 12P
(Black) connector
– Open circuit in the Gray wire between the right
handlebar switch 12P and ECM 33P (Black)
connectors
– Open circuit in the Gray wire between the ECM 33P
(Gray) and right handlebar switch 12P connectors
– Engine stop switch function (page 22-39)
If the wires are OK, replace the ECM with a known good
one and recheck.
ENGINE STOP SWITCH INSPECTION
Disconnect the right handlebar switch 12P connector
[1]
(page 22-33).
Check the continuity between the switch side 12P
connector [1] terminals.
CONNECTION: White/blue – Green/black
W/Bu G/Bl
There should be no continuity only when the engine
stop switch is OFF.
If the engine stop switch is OK, check the following:
– Open circuit in the White wire between the ECM 33P
(Gray) and right handlebar switch 12P connectors
– Open circuit in the Gray wire between the right
handlebar switch 12P and ECM 33P (Black)
connectors
– Short circuit in the White wire between the ECM 33P
(Gray) and right handlebar switch 12P connectors
If the wire is OK, replace the ECM with a known good
one and recheck.

22-39
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

OTHER SWITCHES INSPECTION
Disconnect the right handlebar switch 12P connector
(page 22-33).
Measure the resistance between the right handlebar
switch side 12P connector [1] terminals when each
switch is operated.

[1]

[2] [6] [7]

[3] [5] [4] [8]

CONNECTION: STANDARD (at 25°C/77°F):

Green/blue [2] – Blue [3] Function switch: 95.5 – 105.5 Ω
White/black [4] – Green/black [5] Cruise control main switch: 85.2 – 94.1 Ω
SET/– Cruise control lever: 187.2 – 207.0 Ω
White [6] – Green/black [5] RES/+ Cruise control lever: 87.8 – 97.0 Ω
DCT model only:
CONNECTION: STANDARD (at 25°C/77°F):
Black/blue [7] – Green/white [8] N switch: 85.2 – 94.1 Ω
D–S switch: 187.2 – 207.0 Ω
A/M switch: 372.4 – 411.7 Ω
Replace the right handlebar switch if any switch
resistance are not standard value.

BRAKE SWITCH
REMOVAL/INSTALLATION
FRONT
Refer to front master cylinder service (page 19-15).
REAR
Remove the front cross plate (page 7-8).
[1]
Disconnect the rear brake switch 4P connector [1].
Release the rear brake switch wire from the guide [2].

[2]

22-40
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

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]

• Route the wire properly (page 1-32). [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 [1]
released.

Disconnect the cruise cancel switch connectors (lower

side) [1].
Check for continuity between the front brake switch side
terminals.
There should be no continuity with the brake lever
applied, and there should be continuity with the brake
lever released.

[1]

22-41
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

REAR
Remove the front cross plate (page 7-8).
[1]
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/green
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: Brown – Brown/green
There should be no continuity with the brake pedal
applied, and there should be continuity with the brake
pedal released.
Bl Bl/G

[1]

Br Br/G

22-42
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

CLUTCH SWITCH (MT model)
REMOVAL/INSTALLATION
Refer to clutch lever service (page 12-24).
INSPECTION
Disconnect the clutch switch connectors (upper side)
[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.

[1]

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.

[1]

PARKING BRAKE SWITCH (DCT model)

REMOVAL/INSTALLATION
Refer to parking brake lever service (page 19-24).

INSPECTION
Disconnect the parking brake switch connectors [1] and
check for continuity between the terminals.
There should be continuity with the parking brake lever
applied, and there should be no continuity with the
parking brake lever released.

[1]

22-43
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

NEUTRAL SWITCH (MT model)
REMOVAL/INSTALLATION
Release the rubber cap [1].
[4]
Remove the nut [2] and disconnect the neutral switch
terminal [3].
Remove the neutral switch [4] and sealing washer [5].
Installation is in the reverse order of removal.
TORQUE:
[1]
Neutral switch:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Neutral switch terminal nut: [2]/[3]
1.7 N·m (0.2 kgf·m, 1.3 lbf·ft)

[5]
• Apply engine oil to the neutral switch threads and
seating surface.
• Replace the sealing washer with a new one.

SIDESTAND SWITCH
REMOVAL/INSTALLATION
Remove the battery box (page 21-6).
MT model shown:
MT model: Remove the shift spindle cover (page 12-18).
DCT model: Remove the following:
– Left rear cover (page 2-26)
– Shift control motor cover (page 13-55)
Disconnect the sidestand switch 2P (Black) connector
[1].

[1]

MT model: Remove the clamp [1].

MT model:

[1]

22-44
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Remove the sidestand switch bolt [1] and sidestand
switch [2].

[1] [2]

Remove the left main step bracket bolts [1] and left
[1]
main step bracket [2].

[1] [2]

Installation is in the reverse order of removal.

[2] [4] [5]
TORQUE:
Left main step bracket bolt:
35 N·m (3.6 kgf·m, 26 lbf·ft) [3]
Sidestand switch bolt:
10 N·m (1.0 kgf·m, 7 lbf·ft)

• Route the wires properly (page 1-32).

• Align the sidestand switch tab [1] with the sidestand
hole [2].
• Align the sidestand switch groove [3] with the return
spring holding pin [4].
[1]
• Replace the sidestand switch bolt [5] with a new
one.

INSPECTION
Disconnect the sidestand switch 2P (Black) connector
[1]
(page 22-44).
Check for continuity at the switch side 2P (Black)
connector [1] terminals.
CONNECTION: Green/white – Green
There should be continuity with the sidestand retracted G/W G
and no continuity with the sidestand lowered.

22-45
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

HORN
REMOVAL/INSTALLATION
Turn the ignition switch OFF.
[5] [3]
Disconnect the horn connectors [1] from the horn [2].
Remove the bolt [3] and horn. [4]
Installation is in the reverse order of removal.

• Rest the horn stay [4] against the stopper [5].

[1]

[2]

INSPECTION
Disconnect the horn connectors from the horn (page
22-46). [1]

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.

HSTC
• 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 DTC 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
" ".
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.

22-46
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

ACCESSORY SOCKET (CRF1100A2/
AL2/A4/AL4/D2/DL2/D4/DL4)
REMOVAL/INSTALLATION
Remove the inner panel cover (page 2-18).
[3] [5] [4]
Remove the ring nut [1].
Remove the accessory socket [2] from the inner panel
cover [3].
Installation is in the reverse order of removal.
[1]
• Align the accessory socket boss [4] with the inner
[2]
panel cover groove [5].

SYSTEM INSPECTION
Disconnect the accessory socket 2P connector (page 2-
[1]
18).
Measure the voltage at the wire harness side 2P
connector [1] terminals.
Y/W G
CONNECTION: Yellow/white (+) – Green (–)
STANDARD: Battery voltage
There should be battery voltage with the ignition switch
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 22-47).

GRIP HEATER (CRF1100A2/AL2/A4/

AL4/D2/DL2/D4/DL4)
REPLACEMENT
LEFT GRIP HEATER
Remove the left knuckle guard (page 2-22).
Electronic suspension model shown :
Release the wire clamp [1].
Disconnect the left grip heater 2P connector [2]. [2]

[1]

22-47
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

Separate the left handlebar switch (page 22-26).
[2]
Remove the wire band [1].
Remove the left grip heater [2].

[1]

Clean the outside surface of the left handlebar [1] and

Apply Honda Bond A or an equivalent.
inside surface of the new left grip heater [2].
Apply 1.0 g (0.04 oz) of Honda Bond A or an equivalent
to the outside surface of the left handlebar and inside
surface of the left grip heater.

[1]

Apply Honda Bond A or an equivalent.

[2]

22-48
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

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.

• 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.
• If the grip gets stuck halfway during installation,
apply isopropyl alcohol to the gap between the grip
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.

• Push the left grip heater in tight against the left

handlebar switch housing.
• Align the left grip heater wire end with the left
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. [2]
• Do not set the heater level higher than level 2 for the
first week after installation.
Install a new wire band [3].

[3]

Align

Install the left handlebar switch (page 22-29).

Electronic suspension model shown :
Install the wire clamp [1].
[2]
Connect the left grip heater 2P connector [2].

[1]

RIGHT GRIP HEATER

Refer to the right handlebar switch servicing (page 22-
33).

22-49
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

FAILURE SYMPTOM CHECK

• 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 DTC (page 22-53)
– Grip heater resistance (page 22-50)
The grip heaters and their circuits are OK, check the [1]
following:
– MID (page 22-15)
– BCU (page 22-52)

GRIP HEATER RESISTANCE

INSPECTION
Turn the ignition switch OFF.
[1]
Disconnect the following:
– Left grip heater 2P (Black) connector (page 22-26)
– Right grip heater 2P (Black) connector (page 22-33)
Measure the resistance between the grip heater
connector [1] terminals at the grip heater side. Bl Bl
CONNECTION:
Left: Black – Black
Right: Black – Black

STANDARD: 1.7 – 2.1 Ω (at 25°C/77°F)

If the resistance is out of specification, replace the grip
heater.

22-50
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

BCU
REMOVAL/INSTALLATION
BCU
Remove the front cross plate (page 7-8).
[2] [3] [5]
Disconnect the following:
– IMU 4P (Black) connector [1]
– Rear brake switch 4P connector [2]
– Rear wheel speed sensor 2P (Black) connector [3] [4]
[4]
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]. [1]

Disconnect the BCU 39P (Black) connector [1].

[4]
Release the tabs [2].
Open the cover [3] and remove the BCU [4].
Installation is in the reverse order of removal. [3]
[1]

[2]

[2]

BCU TRAY
Remove the following:
[4] [1]
– BCU: (page 22-51)
– TCM (DCT model only): (page 13-66)
[3]
Remove the trim clip [1].
Release the tab [2].
Remove the BCU tray [3] and collars [4].
Installation is in the reverse order of removal.

[2] [4]

22-51
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

POWER/GROUND LINE INSPECTION

BCU 39P (Black) CONNECTOR

G/Bu R/Bu

Bl/R
R/W IGNITION MAIN FUSE
SWITCH 30 A

BCU
IGN Bl/R R/Bl R
METER 10 A

BAT1 R/W R
CLOCK/TURN/
FOG/DRL 15 A
BAT2 R/Bu R
G HEATER 10 A

GND G/Bu

1. BCU Power Input Line Inspection

Disconnect the BCU 39P (Black) connector (page
22-51).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
39P (Black) connector terminal and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Black/red (+) – Ground (–)

STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open circuit in the Black/red wire
• Blown sub fuse METER 10 A
2. BCU Back-up Voltage Line Inspection
Turn the ignition switch OFF.
Measure the voltage between the wire harness side
39P (Black) connector terminal and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION:
Back-up 1: Red/white (+) – Ground (–)
Back-up 2: Red/blue (+) – Ground (–)
STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 3.
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

22-52
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

3. BCU Ground Line Open Circuit Inspection
Check the continuity between the wire harness side
39P (Black) connector terminal and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Green/blue – Ground

Is there continuity?
YES – Faulty BCU
NO – Open circuit in the Green/blue wire

BODY CONTROL SYSTEM

TROUBLESHOOTING INFORMATION
MCS INFORMATION
Refer to the PGM-FI system (page 4-6).

DTC READOUT

• 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 body control
system after erasing the PGM-FI DTC.
Test-ride the motorcycle and read the current DTC with
the MCS or MID. (Do not turn the ignition switch OFF
after test-riding).
Follow the DTC index (page 22-55).

22-53
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

BODY CONTROL SYSTEM DIAGRAM
BCU
RIGHT HANDLEBAR SWITCH Y
Gr SW1 Y REGULATOR G
2 (MF SEL_SW) ALTERNATOR
FUNCTION Y /RECTIFIER
SWITCH
CLOCK/TURN R
LEFT HANDLEBAR SWITCH /FOG/DRL15A
W SW2 R/W R R Bl Bl/G
HEADLIGHT 19 R
(DIMMER) 39 BAT1
DIMMER
SWITCH G HEATER MAIN FUSE
10A R 30A
PASSING LIGHT R/Bu
CONTROL 13 BAT2 BATTERY
SWITCH METER
W/Bl SW3 ING SW
FUNCTION 24 Bl/R 10A R/Bl R/Bl R
(MF UP) 26 ING
LEVER
(UP)
FUNCTION R/W
LEVER 38 ALARM
(DOWN) HORN/STOP REAR
VOICE 10A R/Bl OPTION
Bl/R
CONTROL 27 HORN_IN
SWITCH
Bl Bl
PAGE 1 HORN_OUT HORN
R/Bl R/Bl Y/W
SWITCH
Br SW4 CORNER LIGHT
22 Y/Bu R/Bl /ACC 10A
SEL LEFT (SEL_LEFT)
SWITCH HEAD LIGHT 15A
Bl/Y
BACK Bl/Br W
SWITCH 4 H/L_LO

SEL UP Bl/Bu Bu
20 H/L_HI HEADLIGHT
SWITCH
Br/W Br
SEL DOWN 11 DRL_OUT Except
SWITCH CRF1100A/AL/D/DL
W/R SW5 G
21 Bl/W
SEL RIGHT (SEL_RIGHT)
V Br/Bu
SWITCH 31 CL_1

ENT P Br/Bl
30 CL_2
SWTICH CORNERING
Y Bl LIGHT
29 CL_3
SKIP
SWITCH
Be Br
28 CL_LR
GOES
BACK G
SWITCH Lb Lb G RIGHT FRONT
16 W/L_FR
Lg SW6 TURNSIGNAL LIGHT
Except CH:HAZARD 23
SWITCH (HAZ/TURN) O O G LEFT FRONT
17 W/L_FL
CH:LIGHTING TURNSIGNAL LIGHT
SWITCH Lb Lb G RIGHT REAR
18 W/L_RR
TURN SIGNAL TURNSIGNAL LIGHT
CANCEL SWITCH O O G LEFT REAR
32 W/L_RL
TURNSIGNAL LIGHT
TURN SIGNAL
LEFT SWITCH FOG LIGHT

TURN SIGNAL Bu G
9 FOG_OUT
RIGHT SWITCH
Bl SW7 OPTION
8
HORN (HORN/FAVORITE)
SWITCH GRIP HEATER
Bl Y
7 GH
FAVORITE
SWITCH Gr Except CRF1100A/AL/D/DL
10 SG
FI RELAY
W
37 K_LINE
Bl/R
14 F_CAN_H
Bl G/Bu Br
15 F_CAN_L 12 LG
W
G/Bu
Y

DLC

Bl : Black Lg : Light green

Be : Beige O : Orange
ABS
ECM TCM SCU IMU METER MID Br : Brown P : Pink
MODULATOR
Bu : Blue R : Red
G : Green V : Violet
Gr : Gray W : White
DCT CRF1100A4/AL4/D4/DL4 Lb : Light blue Y : Yellow
model BCU 39P (Black) CONNECTOR (BCU SIDE)

22-54
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

BODY CONTROL SYSTEM DTC INDEX
• After confirming the MID displays, perform the
troubleshooting according to the DTC index.

MID Honda MIL Refer to

DTC DTC name
displays code blinks page
1-1 – – Ignition power failure (low voltage) 22-56
B1
1-2 – – Ignition power failure (high voltage) 22-56
3-1 – – Back-up 1 failure (low voltage) 22-57
B3
3-2 – – Back-up 1 failure (high voltage) 22-57
4-1 – – Back-up 2 failure (low voltage) 22-58
B4 4-2 – – Back-up 2 failure (high voltage) 22-58
4-3 – – Back-up 2 malfunction 22-59
Headlight dimmer/passing light control switch failure (low
11-1 – – 22-60
voltage)
B11
Headlight dimmer/passing light control switch failure (high
11-2 – – 22-61
voltage)
12-1 – – Turn signal switch failure (low voltage) 22-62
B12
12-2 – – Turn signal switch failure (high voltage) 22-63
17-1 – – Horn switch/Favorite switch failure (low voltage) 22-64
B17
17-2 – – Horn switch/Favorite switch failure (high voltage) 22-65
21-1 – – Right front turn signal light failure (short circuit) 22-66
B21
21-2 – – Right front turn signal light failure (open circuit) 22-67
22-1 – – Left front turn signal light failure (short circuit) 22-66
B22
22-2 – – Left front turn signal light failure (open circuit) 22-67
23-1 – – Right rear turn signal light failure (short circuit) 22-66
B23
23-2 – – Right rear turn signal light failure (open circuit) 22-67
24-1 – – Left rear turn signal light failure (short circuit) 22-66
B24
24-2 – – Left rear turn signal light failure (open circuit) 22-67
25-1 – – DRL failure (short circuit) 22-68
B25 25-2 – – DRL failure (open circuit) 22-69
25-3 – – DRL failure (internal circuit malfunction) 22-69
26-1 – – Fog light (option) failure (short circuit) 22-70
B26 26-2 – – Fog light (option) failure (open circuit) 22-71
26-3 – – Fog light (option) failure (internal circuit malfunction) 22-71
34-1 – – Grip heater load failure (short circuit) 22-72
B34 34-2 – – Grip heater load failure (open circuit) 22-73
34-3 – – Grip heater load failure (internal circuit malfunction) 22-74
35-1 – – Horn relay failure (short circuit) 22-74
B35
35-2 – – Horn relay failure (open circuit) 22-74
81-1 – – Function switch failure (low voltage) 22-75
B81
81-2 – – Function switch failure (high voltage) 22-76
Function lever/voice control switch/page switch failure
82-1 – – 22-77
(short circuit)
B82
Function lever/voice control switch/page switch failure
82-2 – – 22-78
(open circuit)
Sel left switch/Back switch/Sel up switch/Sel down switch
83-1 – – 22-79
failure (short circuit)
B83
Sel left switch/Back switch/Sel up switch/Sel down switch
83-2 – – 22-80
failure (open circuit)
Sel right switch/ENT switch/Skip switch/Goes back switch
84-1 – – 22-81
failure (short circuit)
B84
Sel right switch/ENT switch/Skip switch/Goes back switch
84-2 – – 22-82
failure (open circuit)
B91 101-2 – – BCU EEPROM malfunction 22-82
103-1 CAN communication malfunction
B93 103-2 U0001 103 4-66
103-3

22-55
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

BODY CONTROL SYSTEM DTC
TROUBLESHOOTING
• Before starting the troubleshooting, check for loose
or poor contact in the BCU related circuit.
DTC B1 IGNITION POWER FAILURE
DTC B1 (1-1) IGNITION POWER FAILURE (LOW
VOLTAGE)
Probable cause:
• Faulty battery or its related circuit
• Blown sub fuse METER 10 A
• Charging system malfunction
• Faulty BCU or its power/ground line
Symptom/Fail-safe function:
• Body control system works normally
1. Recheck DTC
Read the DTC.
Is the DTC B1 (1-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. BCU power/ground line Inspection
Check the BCU power/ground line (page 22-52).
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
NO – Repair the faulty parts.

DTC B1 (1-2) IGNITION POWER FAILURE (HIGH

VOLTAGE)
Probable cause:
• Faulty battery
• Charging system malfunction
• Faulty BCU
Symptom/Fail-safe function:
• Body control system works normally
1. Recheck DTC
Read the DTC.
Is the DTC B1 (1-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Charging System Inspection
Check the charging system (page 21-8).
Is the charging system normally?
YES – Faulty BCU
NO – Repair the faulty parts.

22-56
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B3 BACK-UP 1 FAILURE
DTC B3 (3-1) BACK-UP 1 FAILURE (LOW VOLTAGE)
Probable cause:
• Faulty battery or its related circuit
• Blown sub fuse CLOCK/TURN/FOG/DRL 15 A
• Charging system malfunction
• Faulty BCU or its power/ground line
Symptom/Fail-safe function:
• Headlight/turn signal light/fog light (option) works
normally
1. Recheck DTC
Read the DTC.
Is the DTC B3 (3-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. BCU power/ground line Inspection
Check the BCU power/ground line (page 22-52).
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
NO – Repair the faulty parts.

DTC B3 (3-2) BACK-UP 1 FAILURE (HIGH

VOLTAGE)
Probable cause:
• Faulty battery
• Charging system malfunction
• Faulty BCU
Symptom/Fail-safe function:
• Headlight/turn signal light/fog light (option) does not
work
1. Recheck DTC
Read the DTC.
Is the DTC B3 (3-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Charging System Inspection
Check the charging system (page 21-8).
Is the charging system normally?
YES – Faulty BCU
NO – Repair the faulty parts.

22-57
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B4 BACK-UP 2 FAILURE
DTC B4 (4-1) BACK-UP 2 FAILURE (LOW VOLTAGE)
Probable cause:
• Faulty battery or its related circuit
• Blown sub fuse G HEATER 10 A
• Charging system malfunction
• Faulty BCU or its power/ground line
Symptom/Fail-safe function:
• Grip heater works normally
1. Recheck DTC
Read the DTC.
Is the DTC B4 (4-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. BCU power/ground line Inspection
Check the BCU power/ground line (page 22-52).
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
NO – Repair the faulty parts.

DTC B4 (4-2) BACK-UP 2 FAILURE (HIGH

VOLTAGE)
Probable cause:
• Faulty battery
• Charging system malfunction
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater works normally
1. Recheck DTC
Read the DTC.
Is the DTC B4 (4-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Charging System Inspection
Check the charging system (page 21-8).
Is the charging system normally?
YES – Faulty BCU
NO – Repair the faulty parts.

22-58
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B4 (4-3) BACK-UP 2 FAILURE
Probable cause:
• Faulty battery
• Charging system malfunction
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater does not work
1. Recheck DTC
Read the DTC.
Is the DTC B4 (4-3) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Charging System Inspection
Check the charging system (page 21-8).
Is the charging system normally?
YES – Faulty BCU
NO – Repair the faulty parts.

22-59
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B11 HEADLIGHT DIMMER/
PASSING LIGHT CONTROL SWITCH
FAILURE

LEFT HANDLEBAR SWITCH

12P CONNECTOR BCU 39P (Black) CONNECTOR

W W

Gr Gr

W SW 2 (DIMMER) BCU
HEADLIGHT
DIMMER
SWITCH

PASSING
LIGHT
CONTROL
SWITCH Gr SG

DTC B11 (11-1)

HEADLIGHT DIMMER/PASSING LIGHT CONTROL
SWITCH FAILURE (LOW VOLTAGE)
Probable cause:
• Short circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Headlight works normally
1. Recheck DTC
Read the DTC.
Is the DTC B11 (11-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
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 07ZAJ-RDJA110

CONNECTION: White – Ground

Is there continuity?
YES – Short circuit in the White wire
NO – • Faulty left handlebar switch (headlight
dimmer/passing light control switch)
• Faulty BCU

22-60
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

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
Symptom/Fail-safe function:
• Headlight works normally
1. Recheck DTC
Read the DTC.
Is the DTC B11 (11-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Headlight Dimmer/Passing Light Control Switch
Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and left handlebar switch 12P connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: White – White

Gray – Gray
Is there continuity?
YES – • Faulty left handlebar switch (headlight
dimmer/passing light control switch)
• Faulty BCU
NO – Open circuit in the White or Gray wire

22-61
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B12 TURN SIGNAL SWITCH
FAILURE

LEFT HANDLEBAR SWITCH

12P CONNECTOR BCU 39P (Black) CONNECTOR

Lg Gr

Gr Lg

HAZARD SWITCH
(except CH)
LIGHTING SWITCH Lg SW 6
(CH) (HAZARD/TURN)
TURN SIGNAL
CANCEL SWITCH
BCU
TURN SIGNAL
LEFT SWITCH

TURN SIGNAL Gr SG
RIGHT SWITCH

DTC B12 (12-1)

TURN SIGNAL SWITCH FAILURE (LOW VOLTAGE)
Probable cause:
• Short circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Turn signal light works normally
• Lighting switch does not work (CH only)
1. Recheck DTC
Read the DTC.
Is the DTC B12 (12-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Turn Signal Switch Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Light green – Ground

Is there continuity?
YES – Short circuit in the Light green wire
NO – • Faulty left handlebar switch (turn signal
left/right switch, turn signal cancel
switch, or hazard switch/lighting switch)
• Faulty BCU

22-62
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B12 (12-2)
TURN SIGNAL SWITCH FAILURE (HIGH VOLTAGE)
Probable cause:
• Open circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Turn signal light works normally
• Lighting switch does not work (CH only)
1. Recheck DTC
Read the DTC.
Is the DTC B12 (12-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Turn Signal Switch Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and left handlebar switch 12P connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Light green – Light green

Gray – Gray
Is there continuity?
YES – • Faulty left handlebar switch (turn signal
left/right switch, turn signal cancel
switch, or hazard switch/lighting switch)
• Faulty BCU
NO – Open circuit in the Light green or Gray wire

22-63
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B17 HORN SWITCH/FAVORITE
SWITCH FAILURE

LEFT HANDLEBAR SWITCH

12P CONNECTOR BCU 39P (Black) CONNECTOR

Bl Bl

Gr Gr

Bl SW 7
HORN (HORN/FAVORITE)
SWITCH

BCU

FAVORITE
SWITCH
Gr SG

DTC B17 (17-1)

HORN SWITCH/FAVORITE SWITCH FAILURE (LOW
VOLTAGE)
Probable cause:
• Short circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Horn and favorite switch does not work
1. Recheck DTC
Read the DTC.
Is the DTC B17 (17-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Switch Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Black – Ground

Is there continuity?
YES – Short circuit in the Black wire
NO – • Faulty left handlebar switch (horn
switch or favorite switch)
• Faulty BCU

22-64
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B17 (17-2)
HORN SWITCH/FAVORITE SWITCH FAILURE (HIGH
VOLTAGE)
Probable cause:
• Open circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Horn and favorite switch does not work
1. Recheck DTC
Read the DTC.
Is the DTC B17 (17-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Switch Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and left handlebar switch 12P connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Black – Black

Gray – Gray
Is there continuity?
YES – • Faulty left handlebar switch (horn
switch or favorite switch)
• Faulty BCU
NO – Open circuit in the Black or Gray wire

22-65
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B21/B22/B23/B24
TURN SIGNAL LIGHT FAILURE

BCU 39P (Black) CONNECTOR TURN SIGNAL LIGHT 2P CONNECTORS

O (Left side)
Lb (Right front) Lb (Right rear)
Lb (Right side)
G

CONNECTOR COLLAR:
- O (Left side)
O (Left front) O (Left rear) - Lb (Right side)

W/L_FR Lb Lb Lb
RIGHT FRONT TURN
SIGNAL LIGHT
G G

W/L_FL O O
LEFT FRONT TURN
BCU SIGNAL LIGHT
G G

W/L_RR Lb Lb
RIGHT REAR TURN
SIGNAL LIGHT
G

W/L_RL O O
LEFT REAR TURN
SIGNAL LIGHT
G

DTC B21 (21-1)/B22 (22-1)/B23 (23-1)/B24 (24-1)

TURN SIGNAL LIGHT FAILURE (SHORT CIRCUIT)
Probable cause:
• Short circuit in the related wire
• Faulty turn signal light
• Faulty BCU
Symptom/Fail-safe function:
• Turn signal light does not work
• Normal units blink two times faster than usual
1. Recheck DTC
Read the DTC.
Is the DTC B21 (21-1)/B22 (22-1)/B23 (23-1)/B24
(24-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure

22-66
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

2. Turn Signal Light Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION:
Left side: Orange – Ground
Right side: Light blue – Ground
Is there continuity?
YES – Short circuit in the Orange or Light blue
wire
NO – • Faulty turn signal light
• Faulty BCU

DTC B21 (21-2)/B22 (22-2)/B23 (23-2)/B24 (24-2)

TURN SIGNAL LIGHT FAILURE (OPEN CIRCUIT)
Probable cause:
• Open circuit in the related wire
• Faulty turn signal light
• Faulty BCU
Symptom/Fail-safe function:
• Normal units blink two times faster than usual
1. Recheck DTC
Read the DTC.
Is the DTC B21 (21-2)/B22 (22-2)/B23 (23-2)/B24
(24-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Turn Signal Light Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and each turn signal light 2P connector.
Check for continuity between each turn signal light
2P connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION:
Left side: Orange – Orange
Green – Ground
Right side: Light blue – Light blue
Green – Ground
Is there continuity?
YES – • Faulty turn signal light
• Faulty BCU
NO – Open circuit in the Orange, Light blue, or
Green wires

22-67
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B25 DRL FAILURE

• Before troubleshooting, check the headlight unit

power/ground circuit (page 22-9).

BCU 39P (Black) CONNECTOR HEADLIGHT 6P CONNECTOR

Br Br/W

HEADLIGHT
BCU DRL_OUT Br Br/W DRL
DRIVER

DTC B25 (25-1) DRL FAILURE (SHORT CIRCUIT)

Probable cause:
• Short circuit in the related wire
• Faulty headlight unit
• Faulty BCU
Symptom/Fail-safe function:
• DRL does not work
1. Recheck DTC
Read the DTC.
Is the DTC B25 (25-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. DRL Output Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Brown – Ground

Is there continuity?
YES – Short circuit in the Brown or Brown/white
wire
NO – Faulty BCU

22-68
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B25 (25-2) DRL FAILURE (OPEN CIRCUIT)
Probable cause:
• Open circuit in the related wire
• Faulty headlight unit
• Faulty BCU
Symptom/Fail-safe function:
• DRL does not work
1. Recheck DTC
Read the DTC.
Is the DTC B25 (25-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. DRL Output Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and headlight 6P connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Brown – Brown/white

Is there continuity?
YES – Faulty BCU
NO – Open circuit in the Brown or Brown/white
wire

DTC B25 (25-3) DRL FAILURE (INTERNAL CIRCUIT

MALFUNCTION)
Probable cause:
• Faulty headlight unit
• Faulty BCU
Symptom/Fail-safe function:
• DRL does not turn OFF
1. Recheck DTC
Read the DTC.
Is the DTC B25 (25-3) indicated?
YES – Faulty BCU
NO – Intermittent failure

22-69
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B26 FOG LIGHT (OPTION)
FAILURE

BCU 39P (Black) CONNECTOR

Bu

LEFT FOG
LIGHT
(option)

Bu/Bl G

BCU FOG_OUT Bu Bu/Bl G G

Bu/Bl G

RIGHT
FOG LIGHT
(option)

DTC B26 (26-1) FOG LIGHT (OPTION) FAILURE

(SHORT CIRCUIT)
Probable cause:
• Short circuit in the related wire
• Faulty fog light unit
• Faulty BCU
Symptom/Fail-safe function:
• Fog light does not work
1. Recheck DTC
Read the DTC.
Is the DTC B26 (26-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Fog Light Output Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Blue – Ground

Is there continuity?
YES – Short circuit in the Blue or Blue/black wire
NO – GO TO STEP 3.
3. Fog light Inspection
Check the fog light and related circuit.
Is the fog light OK?
YES – Faulty BCU
NO – Repair the faulty parts.

22-70
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B26 (26-2) FOG LIGHT (OPTION) FAILURE
(OPEN CIRCUIT)
Probable cause:
• Open circuit in the related wire
• Faulty fog light unit
• Faulty BCU
Symptom/Fail-safe function:
• Fog light does not work
1. Recheck DTC
Read the DTC.
Is the DTC B26 (26-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Fog Light Output Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and left and right fog light (option) 2P
connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Blue – Blue/black

Is there continuity?
YES – Open circuit in the Blue or Blue/black wire
NO – GO TO STEP 3.
3. Fog light inspection
Check the fog light and related circuit.
Is the fog light OK?
YES – Faulty BCU
NO – Repair the faulty parts.

DTC B26 (26-3) FOG LIGHT (OPTION) FAILURE

(INTERNAL CIRCUIT MALFUNCTION)
Probable cause:
• Faulty fog light unit
• Faulty BCU
Symptom/Fail-safe function:
• Fog light does not turn OFF
1. Recheck DTC
Read the DTC.
Is the DTC B26 (26-3) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Fog light Inspection
Check the fog light and related circuit.
Is the fog light OK?
YES – Faulty BCU
NO – Repair the faulty parts.

22-71
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B34 GRIP HEATER LOAD
FAILURE

BCU 39P (Black) CONNECTOR RIGHT GRIP HEATER

2P CONNECTOR
Bl

Y Bl

BCU GH Bl Bl

Y Bl
RIGHT GRIP
HEATER

Bl Y/R

Bl G G
LEFT GRIP
HEATER

G Y/R

LEFT GRIP HEATER 2P CONNECTOR

DTC B34 (34-1) GRIP HEATER LOAD FAILURE

(SHORT CIRCUIT)
Probable cause:
• Short circuit in the related wire
• Faulty grip heater
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater does not work
1. Recheck DTC
Read the DTC.
Is the DTC B34 (34-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Grip Heater Line Short Circuit Inspection
Check for short circuit in the following wires:
– Black wire between the BCU 39P (Black)
connector and right grip heater 2P connector
– Yellow and Yellow/red wires between the right
grip heater 2P connector and left grip heater 2P
connector
Are the wires OK?
YES – GO TO STEP 3.
NO – Short circuit in the Black, Yellow, or
Yellow/red wire

22-72
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

3. Grip Heater Resistance Inspection
Measure the grip heater resistance (page 22-50).
Is the grip heater OK?
YES – Faulty BCU
NO – Replace the faulty grip heater.

DTC B34 (34-2) GRIP HEATER LOAD FAILURE

(OPEN CIRCUIT)
Probable cause:
• Open circuit in the related wire
• Faulty grip heater
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater does not work
1. Recheck DTC
Read the DTC.
Is the DTC B34 (34-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
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
– Yellow and Yellow/red wires between the right
grip heater 2P connector and left grip heater 2P
connector
– Green wire between the left handlebar switch
12P connector and ground
TOOL:
Test probe 07ZAJ-RDJA110
Are the wires OK?
YES – GO TO STEP 3.
NO – Open circuit in the Black, Yellow, Yellow/
red, or Green wire
3. Grip Heater Resistance Inspection
Measure the grip heater resistance (page 22-50).
Is the grip heater OK?
YES – Faulty BCU
NO – Replace the faulty grip heater.

22-73
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B34 (34-3) GRIP HEATER LOAD FAILURE
(INTERNAL CIRCUIT MALFUNCTION)
Probable cause:
• Faulty grip heater
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater does not turn OFF
1. Recheck DTC
Read the DTC.
Is the DTC B34 (34-3) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Grip Heater Resistance Inspection
Measure the grip heater resistance (page 22-50).
Is the grip heater OK?
YES – Faulty BCU
NO – Replace the faulty grip heater.

DTC B35 HORN RELAY LOAD

FAILURE
DTC B35 (35-1) HORN RELAY LOAD FAILURE
(SHORT CIRCUIT)
Probable cause:
• Faulty horn
• Faulty BCU
Symptom/Fail-safe function:
• Horn does not turn OFF
1. Horn Inspection
Replace the horn with a known good one and
recheck.
Is the DTC B35 (35-1) indicated?
YES – Faulty BCU
NO – Faulty original horn

DTC B35 (35-2) HORN RELAY LOAD FAILURE

(OPEN CIRCUIT)
Probable cause:
• Faulty BCU
Symptom/Fail-safe function:
• Horn does not work
1. Recheck DTC
Read the DTC.
Is the DTC B35 (35-2) indicated?
YES – Faulty BCU
NO – Intermittent failure

22-74
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B81 FUNCTION SWITCH FAILURE

RIGHT HANDLEBAR
SWITCH 12P CONNECTOR BCU 39P (Black) CONNECTOR

Gr (SW7) Gr (SW7)

Gr (SG) Gr (SG)

Gr (SW7) SW 7
(HORN/FAVORITE)

FUNCTION
BCU
SWITCH

Gr (SG) SG

DTC B81 (81-1) FUNCTION SWITCH FAILURE

(SHORT CIRCUIT)
Probable cause:
• Short circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater does not work
• DRL and fog light (option) work normally
1. Recheck DTC
Read the DTC.
Is the DTC B81 (81-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Function Switch Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Gray (SW7) – Ground

Gray (SG) – Ground
Is there continuity?
YES – Short circuit in the Gray wire
NO – • Faulty right handlebar switch (function
switch)
• Faulty BCU

22-75
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B81 (81-2) FUNCTION SWITCH FAILURE
(OPEN CIRCUIT)
Probable cause:
• Open circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater does not work
• DRL and fog light (option) work normally
1. Recheck DTC
Read the DTC.
Is the DTC B81 (81-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Function Switch Line Open Circuit inspection
Check for continuity between the BCU 39P (Black)
connector and right handlebar switch 12P
connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION:
Signal line: Gray (SW7) – Gray (SW7)
Ground line: Gray (SG) – Gray (SG)
Is there continuity?
YES – • Faulty right handlebar switch (function
switch)
• Faulty BCU
NO – Open circuit in the Gray wire

22-76
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B82 FUNCTION LEVER/VOICE
CONTROL SWITCH/PAGE SWITCH
FAILURE

LEFT HANDLEBAR SWITCH

12P CONNECTOR BCU 39P (Black) CONNECTOR

W/Bl Gr

Gr W/Bl

FUNCTION
LEVER (UP) W/Bl SW 3 (MF UP)

FUNCTION
LEVER (DOWN)
BCU
VOICE CONTROL
SWITCH

PAGE SWITCH Gr SG

DTC B82 (82-1) FUNCTION LEVER/VOICE

CONTROL SWITCH/PAGE SWITCH FAILURE
(SHORT CIRCUIT)
Probable cause:
• Short circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater does not work
• DRL and fog light (option) work normally
1. Recheck DTC
Read the DTC.
Is the DTC B82 (82-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Function Lever/Voice Control Switch/Page
Switch Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: White/black – Ground

Is there continuity?
YES – Short circuit in the White/black wire
NO – • Faulty left handlebar switch (function
lever/voice control switch/page switch)
• Faulty BCU

22-77
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B82 (82-2) FUNCTION LEVER/VOICE
CONTROL SWITCH/PAGE SWITCH FAILURE (OPEN
CIRCUIT)
Probable cause:
• Open circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Grip heater does not work
• DRL and fog light (option) work normally
1. Recheck DTC
Read the DTC.
Is the DTC B82 (82-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Function Lever/Voice Control Switch/Page
Switch Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and left handlebar switch 12P connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: White/black – White/black

Gray – Gray
Is there continuity?
YES – • Faulty left handlebar switch (function
lever/voice control switch/page switch)
• Faulty BCU
NO – Open circuit in the White/black or Gray
wire

22-78
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B83 SEL LEFT SWITCH/BACK
SWITCH/SEL UP SWITCH/SEL DOWN
SWITCH FAILURE

LEFT HANDLEBAR SWITCH

12P CONNECTOR BCU 39P (Black) CONNECTOR

Br Gr

Gr Br

SEL LEFT SWITCH Br SW 4 (MF_LEFT)

BACK SWITCH
BCU
SEL UP SWITCH

SEL DOWN SWITCH Gr SG

DTC B83 (83-1) SEL LEFT SWITCH/BACK SWITCH/

SEL UP SWITCH/SEL DOWN SWITCH FAILURE
(SHORT CIRCUIT)
Probable cause:
• Short circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Sel left switch/back switch/sel up switch/sel down
switch do not work
1. Recheck DTC
Read the DTC.
Is the DTC B83 (83-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Sel Left Switch/Back Switch/Sel Up switch/Sel
Down Switch Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Brown – Ground

Is there continuity?
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

22-79
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B83 (83-2) SEL LEFT SWITCH/BACK SWITCH/
SEL UP SWITCH/SEL DOWN SWITCH FAILURE
(OPEN CIRCUIT)
Probable cause:
• Open circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Sel left switch/back switch/sel up switch/sel down
switch do not work
1. Recheck DTC
Read the DTC.
Is the DTC B83 (83-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Sel Left Switch/Back Switch/Sel Up switch/Sel
Down Switch Line Open Circuit inspection
Check for continuity between the BCU 39P (Black)
connector and left handlebar switch 12P connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Brown – Brown

Gray – Gray
Is there continuity?
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

22-80
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B84 SEL RIGHT SWITCH/ENT
SWITCH/SKIP SWITCH/GOES BACK
SWITCH FAILURE

LEFT HANDLEBAR SWITCH

12P CONNECTOR BCU 39P (Black) CONNECTOR

Gr Gr

W/R W/R

SEL RIGHT SWITCH W/R SW 5 (SEL_RIGHT)

ENT SWITCH
BCU
SKIP SWITCH

GOES BACK SWITCH Gr SG

DTC B84 (84-1) SEL RIGHT SWITCH/ENT SWITCH/

SKIP SWITCH/GOES BACK SWITCH FAILURE
(SHORT CIRCUIT)
Probable cause:
• Short circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Sel right switch/ENT switch/skip switch/goes back
switch do not work
1. Recheck DTC
Read the DTC.
Is the DTC B84 (84-1) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Sel Right Switch/ENT Switch/Skip Switch/Goes
Back Switch Line Short Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: White/red – Ground

Is there continuity?
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

22-81
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC B84 (84-2) SEL RIGHT SWITCH/ENT SWITCH/
SKIP SWITCH/GOES BACK SWITCH FAILURE
(OPEN CIRCUIT)
Probable cause:
• Open circuit in the related wire
• Faulty switch
• Faulty BCU
Symptom/Fail-safe function:
• Sel right switch/ENT switch/skip switch/goes back
switch do not work
1. Recheck DTC
Read the DTC.
Is the DTC B84 (84-2) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Sel Right Switch/ENT Switch/Skip Switch/Goes
Back Switch Line Open Circuit Inspection
Check for continuity between the BCU 39P (Black)
connector and left handlebar switch 12P connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: White/red – White/red

Gray – Gray
Is there continuity?
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:
• Faulty BCU
Symptom/Fail-safe function:
• Body control system works normally
1. Recheck DTC
Read the DTC.
Is the DTC B91 (101-2) indicated?
YES – Faulty BCU
NO – Intermittent failure

22-82
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

SCU
REMOVAL/INSTALLATION
Remove the main seat (page 2-5).
[3] [1]
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.

[2]

POWER/GROUND LINE INSPECTION

SCU 48P (Black) CONNECTOR

R/W Bl/R G

IGNITION MAIN
SWITCH FUSE 30 A

IGN Bl/R R/Bl

HORN/STOP 10 A

SCU BATT R/W R

CLOCK/TURN/
FOG/DRL 15 A
GND G

1. SCU power input line inspection

Disconnect the SCU 48P (Black) connector (page
22-83).
Turn the ignition switch ON.
Measure the voltage between the wire harness side
48P (Black) connector terminal and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Black/red (+) – Ground (–)

STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 2.
NO – • Open circuit in the Black/red wire
• Blown sub fuse HORN/STOP 10 A

22-83
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

2. SCU back-up voltage line inspection
Measure the voltage between the wire harness side
48P (Black) connector terminal and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Red/white (+) – Ground (–)

STANDARD: Battery voltage
Is there battery voltage?
YES – GO TO STEP 3.
NO – • Open circuit in the Red/white wire
• Blown sub fuse CLOCK/TURN/FOG/
DRL 15 A
3. SCU ground line open circuit inspection
Check the continuity between the wire harness side
48P (Black) connector terminal and ground.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Green – Ground

Is there continuity?
YES – Faulty SCU
NO – Open circuit in the Green wire

ELECTRONIC SUSPENSION SYSTEM

TROUBLESHOOTING INFORMATION
MCS INFORMATION
Refer to the PGM-FI system (page 4-6).

DTC READOUT

• 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
suspension system after erasing the PGM-FI DTC.
If the suspension indicator [1] lights or blinks, read the
DTC and stored data with the MCS.
To read the DTC with the MID, refer to the PGM-FI
system (page 4-7).
Perform the troubleshooting procedure by following the
electronic suspension system DTC index (page 22-87).

[1]

ERASING DTC
Refer to the PGM-FI system (page 4-8).
(The DTC can be erased only by GST or MCS.)

22-84
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

ELECTRONIC SUSPENSION SYSTEM
SYMPTOM TROUBLESHOOTING
When the suspension indicator lights up, but the MID
does not display the electronic suspension system
DTC, 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

22-85
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

ELECTRONIC SUSPENSION SYSTEM
DIAGRAM

Bl R R R/W

MAIN FUSE CLOCK/TURN

30A /FOG/DRL 15A

Bl/Gr
R R/Bl Bl/R R/W
9 IGN 43 BATT
IGNITION HORN/STOP
SWITCH 10A
BATTERY

Y
21 RR_SOL(-) REAR SUSPENSION
Gr SOLENOID
37 RR_SOL(+)

Br Br
FRONT SUSPENSION 39 FR_STRK_SEN2 17 FR_SOL(-) FRONT SUSPENSION
STROKE SENSOR Bl Bl
40 FR_STRK_SEN1 33 FR_SOL(+) SOLENOID

Bl
6 SVCC Br
REAR SUSPENSION Y 19 MOT(-) REAR SUSPENSION
14 JACK_STRK_SEN Bl
POSITION SENSOR Br 35 MOT(+) PRE-LOAD MOTOR
22 SGND

Bl/R Bl/R
10 CAN2_H
DLC Bl Bl
11 CAN2_L
Bl/R Bl/R
1 CAN1-H
Bl Bl
2 CAN1-L
ECM Bl/R
Bl

Bl/R
ABS
MODULATOR Bl

Bl/R SCU
IMU Bl

Bl/R
BCU Bl

Bl/R
Bl G
3 GND
METER Bl/R
Bl

Bl
MID Bl/R

Bl : Black
Br : Brown
G : Green
Gr : Gray
R : Red
W : White

SCU 48P (Black) CONNECTOR (SCU SIDE)

22-86
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

ELECTRONIC SUSPENSION SYSTEM
DTC INDEX
• After confirming the MID displays, perform the
troubleshooting according to the DTC index.

Suspension
MID MIL indicator Refer to
DTC DTC name
displays blinks page
Lights Blinks
U3003-00 – – VBAT too low
S1 U3500-00 – – SCU power input circuit voltage too low 22-88
U3501-00 – – VBU voltage too low
U3003-00 – – VBAT too high
S2 22-89
U3500-00 – – SCU power input circuit voltage too high
U0028-00 103 – CAN communication malfunction 22-89
PGM-FI CAN communication interruption
U0100-00 103 – 22-90
malfunction
ABS CAN communication interruption
U0121-00 103 – 22-90
malfunction
IMU CAN communication interruption
U0125-00 103 – 22-91
malfunction
S3
Meter CAN communication interruption
U0155-00 103 – 22-91
malfunction
PGM-FI CAN communication data
U0401-00 103 – 22-90
malfunction
U0415-00 103 – Meter CAN communication data malfunction 22-91
U0423-00 103 – ABS CAN communication data malfunction 22-90
U0432-00 103 – IMU malfunction 22-91
S4 C1420-00 – – Front suspension stroke sensor malfunction 22-92
Rear suspension position sensor
S6 C1430-00 – – 22-93
malfunction
S8 C1412-00 – – Front suspension solenoid malfunction 22-95
S9 C1413-00 – – Rear suspension solenoid malfunction 22-96
S10 C0530-00 – – Rear suspension pre-load motor malfunction 22-97
C1411-00 – – Unspecified solenoid malfunction 22-98
S11
U3000-00 – – SCU malfunction 22-98

22-87
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

ELECTRONIC SUSPENSION SYSTEM
DTC TROUBLESHOOTING
• Before starting the troubleshooting, check for loose
or poor contact in the SCU related circuit.

DTC 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
• Charging system malfunction
• Faulty SCU or its power/ground line
Symptom/Fail-safe function:
• Electronic suspension system does not function
1. Recheck DTC
Read the DTC.
Is the DTC S1 (U3003-00, U3500-00, U3501-00)
indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. SCU power/ground line Inspection
Check the SCU power/ground line (page 22-83).
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 SCU
NO – Repair the faulty parts.

22-88
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC S2 SCU POWER INPUT CIRCUIT
(HIGH VOLTAGE)
DTC S2 (U3003-00) VBAT TOO HIGH
DTC S2 (U3500-00) SCU POWER INPUT CIRCUIT
VOLTAGE TOO HIGH
Probable cause:
• Faulty battery
• Charging system malfunction
• Faulty SCU
Symptom/Fail-safe function:
• Electronic suspension system does not function
1. Recheck DTC
Read the DTC.
Is the DTC S2 (U3003-00, U3500-00) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Charging System Inspection
Check the charging system (page 21-8).
Is the charging system normally?
YES – Faulty SCU
NO – Repair the faulty parts.

DTC S3 CAN COMMUNICATION

MALFUNCTION
DTC S3 (U0028-00) CAN COMMUNICATION
MALFUNCTION
Probable cause:
• Faulty CAN communication line
• Faulty SCU
Symptom/Fail-safe function:
• Damping control function only operates without
using the CAN information (riding mode fixed)
1. CAN Communication Line Inspection
Check the CAN communication line (page 4-66).
Is the CAN communication line normal?
YES – Faulty SCU
NO – Repair the faulty parts.

22-89
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC S3 (U0100-00) PGM-FI CAN COMMUNICATION
INTERRUPTION MALFUNCTION
DTC S3 (U0401-00) PGM-FI CAN COMMUNICATION
DATA MALFUNCTION
Probable cause:
• Faulty CAN communication line
• Faulty ECM
• Faulty SCU
Symptom/Fail-safe function:
• Damping control function only operates without
using the CAN information (riding mode fixed)
1. CAN Communication Line Inspection
Check the CAN communication line (page 4-66).
Is the CAN communication line normal?
YES – • Faulty ECM
• Faulty SCU
NO – Repair the faulty parts.

DTC S3 (U0121-00) ABS CAN COMMUNICATION

INTERRUPTION MALFUNCTION
DTC S3 (U0423-00) ABS CAN COMMUNICATION
DATA MALFUNCTION
Probable cause:
• Faulty CAN communication line
• Faulty ABS modulator
• Faulty SCU
Symptom/Fail-safe function:
• Damping control function only operates without
using the CAN information (riding mode fixed)
1. CAN Communication Line Inspection
Check the CAN communication line:
– CAN communication line (page 4-66)
– ABS CAN communication line (page 4-68)
Is the CAN communication line normal?
YES – • Faulty ABS modulator
• Faulty SCU
NO – Repair the faulty parts.

22-90
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC S3 (U0125-00) IMU CAN COMMUNICATION
INTERRUPTION MALFUNCTION
DTC S3 (U0432-00) IMU CAN COMMUNICATION
DATA MALFUNCTION
Probable cause:
• Faulty CAN communication line
• Faulty IMU
• Faulty SCU
Symptom/Fail-safe function:
• Damping control function only operates without
using the CAN information (riding mode fixed)
1. CAN Communication Line Inspection
Check the CAN communication line:
– CAN communication line (page 4-66)
– IMU CAN communication line (page 4-69)
Is the CAN communication line normal?
YES – • Faulty IMU
• Faulty SCU
NO – Repair the faulty parts.

DTC S3 (U0155-00) METER CAN COMMUNICATION

INTERRUPTION MALFUNCTION
DTC S3 (U0415-00) METER CAN COMMUNICATION
DATA MALFUNCTION
Probable cause:
• Faulty CAN communication line
• Faulty meter
• Faulty SCU
Symptom/Fail-safe function:
• Damping control function only operates without
using the CAN information (riding mode fixed)
1. CAN Communication Line Inspection
Check the CAN communication line:
– CAN communication line (page 4-66)
– Meter CAN communication line (page 4-70)
Is the CAN communication line normal?
YES – • Faulty meter
• Faulty SCU
NO – Repair the faulty parts.

22-91
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC S4 FRONT SUSPENSION
STROKE SENSOR MALFUNCTION

FRONT SUSPENSION STROKE

SCU 48P (Black) CONNECTOR SENSOR 2P CONNECTOR

Bl Br Br/Bl Br

FR_STRK_SEN 1 Bl Br LPS1-1
FRONT SUSPENSION
SCU
STROKE SENSOR
FR_STRK_SEN 2 Br Br/Bl LPS1-2

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
Symptom/Fail-safe function:
• Electronic suspension system does not work
1. Recheck DTC
Read the DTC.
Is the DTC S4 (C1420-00) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Front Suspension Stroke Sensor Line
Inspection
Check the open and short circuit between the SCU
48P (Black) connector and front suspension stroke
sensor 2P connector.
TOOL:
Test probe 07ZAJ-RDJA110

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 Ω?
YES – Faulty SCU
NO – Faulty front suspension stroke sensor

22-92
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC S6 REAR SUSPENSION
POSITION SENSOR MALFUNCTION

REAR SUSPENSION POSITION

SCU 48P (Black) CONNECTOR SENSOR 3P CONNECTOR

Y Bl Br Bl Y

Br

SVCC Bl
REAR SUSPENSION
SCU JACK_STRK_SEN Y POSITION SENSOR
SGND Br

DTC S6 (C1430-00) REAR SUSPENSION POSITION

SENSOR MALFUNCTION
Probable cause:
• Open or short circuit in the related wire
• Faulty rear suspension position sensor
• Faulty SCU
Symptom/Fail-safe function:
• Electronic suspension system does not work
1. Recheck DTC
Read the DTC.
Is the DTC S6 (C1430-00) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Rear Suspension Position Sensor Line
Inspection
Check the open or short circuit between the SCU
48P (Black) connector and rear suspension position
sensor 3P connector.
TOOL:
Test probe 07ZAJ-RDJA110

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

22-93
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

3. Rear Suspension Position Sensor Resistance
Inspection 1
Measure the resistance at the rear suspension
position sensor side 3P connector terminals.
CONNECTION: Black – Brown
Is the resistance within 3.5 – 6.5 kΩ?
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
Sum the measured value.
Is the total value the same as the value in step
3?
YES – Faulty SCU
NO – Faulty shock absorber (rear suspension
position sensor)

22-94
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC S8 FRONT SUSPENSION
SOLENOID MALFUNCTION

FRONT SUSPENSION
SCU 48P (Black) CONNECTOR SOLENOID 2P CONNECTOR

Br

Bl
Br/Bl Br

FR_SOL(+) Bl Br/Bl SOL1-P

FRONT SUSPENSION
SCU SOLENOID
FR_SOL(–) Br Br SOL1-N

DTC S8 (C1412-00) FRONT SUSPENSION

SOLENOID MALFUNCTION
Probable cause:
• Open or short circuit in the related wire
• Faulty front suspension solenoid
• Faulty SCU
Symptom/Fail-safe function:
• Electronic suspension system does not work
1. Recheck DTC
Read the DTC.
Is the DTC S8 (C1412-00) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Front Suspension Solenoid Line Inspection
Check the open or short circuit between the SCU
48P (Black) connector and front suspension
solenoid 2P connector.
TOOL:
Test probe 07ZAJ-RDJA110

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 Ω?
YES – Faulty SCU
NO – Faulty front suspension solenoid

22-95
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC S9 REAR SUSPENSION
SOLENOID MALFUNCTION

REAR SUSPENSION
SCU 48P (Black) CONNECTOR SOLENOID 2P CONNECTOR

Gr
Y Gr

RR_SOL(+) Gr SOL0-P
REAR SUSPENSION
SCU SOLENOID
RR_SOL(–) Y SOL0-N

DTC S9 (C1413-00) REAR SUSPENSION SOLENOID

MALFUNCTION
Probable cause:
• Open or short circuit in the related wire
• Faulty rear suspension solenoid
• Faulty SCU
Symptom/Fail-safe function:
• Electronic suspension system does not work
1. Recheck DTC
Read the DTC.
Is the DTC S9 (C1413-00) indicated?
YES – GO TO STEP 2.
NO – Intermittent failure
2. Rear Suspension Solenoid Line Inspection
Check the open or short circuit between the SCU
48P (Black) connector and rear suspension solenoid
2P connector.
TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: Gray – Gray

Yellow – Yellow
Are the wires OK?
YES – GO TO STEP 3.
NO – Open or short 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 Ω?
YES – Faulty SCU
NO – Faulty rear suspension solenoid

22-96
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

DTC S10 REAR SUSPENSION PRE-
LOAD MOTOR MALFUNCTION

REAR SUSPENSION PRE-LOAD

SCU 48P (Black) CONNECTOR MOTOR 2P CONNECTOR

Br Bl

Br Bl

MOT (+) Bl +
REAR SUSPENSION
SCU PRE-LOAD MOTOR
MOT (–) Br –

DTC S10 (C0530-00) REAR SUSPENSION PRE-

LOAD MOTOR MALFUNCTION
Probable cause:
• Rear suspension pre-load operation malfunction
• Open or short circuit in the related wire
• Faulty rear suspension pre-load motor
• Faulty SCU
Symptom/Fail-safe function:
• Electronic suspension system does not work
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
Check the open or short circuit between the SCU
48P (Black) connector and rear suspension pre-load
motor 2P connector.
TOOL:
Test probe 07ZAJ-RDJA110

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

22-97
 dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

3. Rear Suspension Pre-load Motor Resistance
Inspection
Measure the resistance at the rear suspension pre-
load motor side 2P connector terminals.
Is the motor resistance with in 0.5 – 5 Ω?
YES – Faulty SCU
NO – Faulty shock absorber (rear suspension
pre-load motor)

DTC S11 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
Symptom/Fail-safe function:
• Electronic suspension system does not work
1. Probable Cause Parts Inspection
Check the following.
– Front suspension solenoid (page 22-95)
– Rear suspension solenoid (page 22-96)
– Rear suspension pre-load motor (page 22-97)
Are the parts normal?
YES – Faulty SCU
NO – Repair the faulty parts.
DTC S11 (U3000-00) SCU MALFUNCTION
Probable cause:
• Faulty SCU
Symptom/Fail-safe function:
• Electronic suspension system does not work
1. Recheck DTC
Read the DTC.
Is the DTC S11 (U3000-00) indicated?
YES – Faulty SCU
NO – Intermittent failure

22-98
dummyhead

LIGHTS/METERS/SWITCHES/OTHER ELECTRONIC CONTROL UNITS

GPS ANTENNA
REMOVAL/INSTALLATION
Remove the front upper cover (page 2-21).
[2] [1]
Release the wire band [1].
Disconnect the GPS connector [2] and remove the GPS
antenna [3].
Installation is in the reverse order of removal.

• When installing the GPS antenna, clean the GPS 10 mm [3]

antenna and headlight attaching surface. (0.4 in)
• 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. [3] [4]
• Route the wire properly (page 1-32).

22-99
dummyhead

MEMO
dummytext

23. IMMOBILIZER SYSTEM (HISS)

SERVICE INFORMATION ···························23-2 DIAGNOSTIC CODE INDICATION ············· 23-9

SYSTEM LOCATION···································23-3 TROUBLESHOOTING ······························ 23-10

SYSTEM DIAGRAM ····································23-4 HISS INDICATOR ····································· 23-11

KEY REGISTRATION PROCEDURES ·······23-5 IMMOBILIZER RECEIVER························ 23-11

23

23-1
 dummyhead

IMMOBILIZER SYSTEM (HISS)

SERVICE INFORMATION
IMMOBILIZER SYSTEM (HISS)

GENERAL
• When checking the HISS, follow the steps in the troubleshooting flow chart (page 23-10).
• Keep the immobilizer key away from the other motorcycle's immobilizer key when using it. The jamming of the key code signal
may occur and the proper operation of the system will be obstructed.
• The key has built-in electronic part (transponder). Do not drop and strike the key against a hard material object, and do not leave
the key on the dashboard in the car, etc. where the temperature will rise. Do not leave the key in the water for a prolonged time
such as by washing the clothes.
• The ECM as well as the transponder keys must be replaced if all transponder keys have been lost.
• The system does not function with a duplicated key unless the code is registered into the transponder with the HISS.
• The ECM can store up to four key codes. (The four keys can be registered.)
• If the ECM is replaced, perform the following procedure.
– Crank pulse initialize learning procedure (page 4-84) (ED, KO only)
– Key Registration Procedure (page 23-5)
• Do not modify the HISS as it can cause the system failure. (The engine cannot be started.)
• Refer to the ignition system inspection (page 5-7).
• Refer to the ignition switch servicing (page 22-25).
• 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 O = Orange P = Pink R = Red V = Violet
W = White Y = Yellow

23-2
dummyhead

IMMOBILIZER SYSTEM (HISS)

SYSTEM LOCATION

ENGINE STOP SWITCH

– IGNITION SWITCH
– IMMOBILIZER RECEIVER

FUSE BOX
– FI 15 A

STARTER RELAY SWITCH

– MAIN FUSE 30 A

ECM

DLC

BATTERY

FI RELAY
POWER BOX
– ST-MAG 10 A

23-3
 dummyhead

IMMOBILIZER SYSTEM (HISS)

SYSTEM DIAGRAM

Bl/Gr Bl
ECM
BATTERY

Br Bl Y Gr Bu P Y G
Bl/R

Y/R O/Bu
FI RELAY Br/Bl
FI 15 A G/O
W R/Bu
DLC
R R/Bl Bl
MAIN IGNITION ST-MAG
FUSE SWITCH 10 A G
30 A
G/Bu
Bl: Black
Br: Brown
Bu: Blue
G: Green
Gr: Gray
P: Pink
HISS IMMOBILIZER
R: Red
INDICATOR RECEIVER
W: White
Y: Yellow
METER

23-4
dummyhead

IMMOBILIZER SYSTEM (HISS)

KEY REGISTRATION PROCEDURES
When the key has been lost, or additional spare key is required:
1. Obtain a new transponder key.
2. Grind the key in accordance with the shape of the original key.
3. Connect the SCS short connector to the DLC (page 23-9).
4. Open the throttle grip 5 ° to 60 ° and hold it.
5. Turn the ignition switch ON with the original key. The HISS indicator comes on and it remains on.
• The code of the original key recognized by the ECM.
• If there is any problem in the immobilizer system (HISS), the system will enter the diagnostic mode and the indicator will remain
on for approx. ten seconds, then it will indicate the diagnostic code (page 23-9).
6. Wait two seconds or more, then completely close the throttle grip.
7. Wait two seconds or more, then open the throttle grip fully and hold.
8. Wait two seconds or more, then the indicator remains on for approx. two seconds, then it blinks four times repeatedly.

ON

OFF

2 sec.

• The immobilizer system (HISS) enters the registration mode. Registrations of all key except the original key inserted in the
ignition switch are cancelled (Registration of the lost key or spare key is cancelled).
The spare key must be registered again.
• Complete the step 5 through 7 within 25 seconds. If 25 seconds or more have passed, restart from the step 4.
9. Turn the ignition switch OFF and remove the key. Completely close the throttle grip.
10.Open the throttle grip 5 ° to 60 ° and hold.
11.Turn the ignition switch ON with a new key or the spare key (Never use the key registered in previous steps). The indicator
comes on for two seconds then it blinks four times repeatedly.

ON

OFF

2 sec.
• The new key or spare key is registered in the ECM.
• If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten
seconds, then it will indicate the diagnostic code (page 23-9).
• Keep the other transponder key away from the immobilizer receiver more than 50 mm (2.0 in).
12.Turn the ignition switch OFF and remove the key. Completely close the throttle grip.
13.Repeat the steps 10 and 11 when you continuously register the other new key.
The ECM can store up to four key codes (The four keys can be registered).
14.Turn the ignition switch OFF, then completely close the throttle grip. Disconnect the SCS short connector.
15.Turn the ignition switch ON with the registered key.
• The immobilizer system (HISS) returns to the normal mode.
16.Check that the engine can be started using all registered keys.

23-5
 dummyhead

IMMOBILIZER SYSTEM (HISS)

When the ignition switch is faulty:
1. Obtain a new ignition switch assembly.
2. Remove the ignition switch (page 22-25).
3. Connect the SCS short connector to the DLC (page 23-9).
4. Set the original (registered) key near the immobilizer receiver so that the transponder in the key can communicate with the
receiver.
5. Open the throttle grip 5 ° to 60 ° and hold it.
6. Connect a new ignition switch to the wire harness and turn it to ON with a new transponder key (keep the ignition switch away
from the receiver). The HISS indicator comes on and it remains on.
• The code of the original key recognized by the ECM.
• If there is any problem in the immobilizer system (HISS), the system will enter the diagnostic mode and the indicator will remain
on for approx. ten seconds, then it will indicate the diagnostic code (page 23-9).
7. Wait two seconds or more, then completely close the throttle grip.
8. Wait two seconds or more, then open the throttle grip fully and hold.
9. Wait two seconds or more, then the indicator remains on for approx. two seconds, then it blinks four times repeatedly.

ON

OFF

2 sec.
• The immobilizer system (HISS) enters the registration mode. Registrations of all key except the original key set near the receiver
are cancelled.
• Complete the procedure 6 through 8 within 25 seconds. If 25 seconds or more have passed, restart from the step 5.
10.Turn the ignition switch OFF and remove the key. Completely close the throttle grip.
11.Install the ignition switch (page 22-25).
12.Open the throttle grip 5 ° to 60 ° and hold it.
13.Turn the ignition switch ON with a first new key. The indicator comes on for two seconds then it blinks four times repeatedly.

ON

OFF

2 sec.
• The first new key is registered in the ECM.
• If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten
seconds, then it will indicate the diagnostic code (page 23-9).
14.Turn the ignition switch OFF then completely close the throttle grip. Disconnect the SCS short connector.
15.Turn the ignition switch ON (with the first new key registered in step 13). The HISS indicator comes on for two seconds then it
goes off.
• The immobilizer system (HISS) returns to the normal mode.
16.Turn the ignition switch OFF and connect the SCS short connector.
17.Open the throttle grip 5 ° to 60 ° and hold it.
18.Turn the ignition switch ON (with the first new key registered in step 13). The HISS indicator comes on and it remains on.
• The code of the first new key is recognized by the ECM.
• If there is any problem in the immobilizer system (HISS), the system will enter the diagnostic mode and the indicator will remain
on for approx. ten seconds, then it will indicate the diagnostic code (page 23-9).
19.Wait two seconds or more, then completely close the throttle grip.
20.Wait two seconds or more, then open the throttle grip fully and hold.

23-6
dummyhead

IMMOBILIZER SYSTEM (HISS)

21.Wait two seconds or more, then the indicator remains on for approx. two seconds, then it blinks four times repeatedly.
• The immobilizer system (HISS) enters the registration mode. Registration of the original key used in step 4 is cancelled.
• Complete the procedure 18 through 20 within 25 seconds. If 25 seconds or more have passed, restart from the step 17.
22.Turn the ignition switch OFF and remove the key. Completely close the throttle grip.
23.Open the throttle grip 5 ° to 60 ° and hold it.
24.Turn the ignition switch ON with a second new key (Never use the key registered in previous step). The indicator comes on for
two seconds then it blinks four times repeatedly.
• The second new key is registered in the ECM.
• If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten
seconds, then it will indicate the diagnostic code (page 23-9).
• Keep the other transponder key away from the immobilizer receiver more than 50 mm (2.0 in).
25.Repeat the steps 22 through 24 when you continuously register the other new key.
The ECM can store up to four key codes (The four keys can be registered).
26.Turn the ignition switch OFF, then completely close the throttle grip. Disconnect the SCS short connector.
27.Turn the ignition switch ON with the registered key.
• The immobilizer system (HISS) returns to the normal mode.
28.Check that the engine can be started using all registered keys.

When all keys have been lost:

1. Obtain a new ECM and new key set.
2. Replace the ignition switch with a new one (page 22-25).
3. Replace the ECM with a new one (page 4-77).
4. Turn the ignition switch ON with a first new key. The HISS indicator comes on for two seconds, then it blinks four times
repeatedly.
• The first new key is registered in the ECM.
• If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten
seconds, then it will indicate the diagnostic code (page 23-9).
5. Turn the ignition switch OFF and remove the first new key.
6. Turn the ignition switch ON with a second new key. The HISS indicator comes on for two seconds, then it blinks four times
repeatedly.
• The second new key is registered in the ECM.
• If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten
seconds, then it will indicate the diagnostic code (page 23-9).
7. Turn the ignition switch OFF and remove the second new key.
• The system will not enter the normal mode unless the two keys are registered in ECM.
• The third new key cannot be continuously registered. When it is necessary to register the third key, follow the procedures "When
the key has been lost, or additional key is required" (page 23-5).
8. Check that the engine can be started using all registered keys.
9. Replace the remaining key set parts.

23-7
 dummyhead

IMMOBILIZER SYSTEM (HISS)

When the ECM is faulty:
1. Obtain a new ECM and two new transponder keys.
2. Grind the keys in accordance with the shape of the original key.
3. Replace the ECM with a new one (page 4-77).
4. Turn the ignition switch ON with a first new key. The HISS indicator comes on for two seconds, then it blinks four times
repeatedly.
• The first new key is registered in the ECM.
• If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten
seconds, then it will indicate the diagnostic code (page 23-9).
5. Turn the ignition switch OFF and remove the first new key.
6. Turn the ignition switch ON with a second new key. The HISS indicator comes on for two seconds, then it blinks four times
repeatedly.
• The second new key is registered in the ECM.
• If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain for approx. ten
seconds, then it will indicate the diagnostic code (page 23-9).
7. Turn the ignition switch OFF and remove the second new key.
• The system will not enter the normal mode unless the two keys are registered in ECM.
• The third new key cannot be continuously registered. When it is necessary to register the third key, follow the procedures "When
the key has been lost, or additional key is required" (page 23-5).
8. Check that the engine can be started using all registered keys.

23-8
dummyhead

IMMOBILIZER SYSTEM (HISS)

DIAGNOSTIC CODE INDICATION
Turn the ignition switch OFF.
Remove the main seat (page 2-5).
Remove the dummy connector [1] from the DLC.
Short the DLC terminals using a special tool.
TOOL:
SCS short connector [2] 070MZ-0010300

CONNECTION: Yellow – Green/blue

Open the throttle grip 5 ° to 60 ° and hold it.
Turn the ignition switch ON with the properly registered
key. [1] [2]
The HISS indicator will come on for approx. ten
seconds then it will start blinking to indicate the
diagnostic code if the system is abnormal.
The blinking frequency is repeated.
The HISS indicator remains on when the system is
normal (The system is in the normal mode and the
diagnostic code does not appear).

DIAGNOSTIC CODE
When the system (ECM) enters the diagnostic mode
from the normal mode:
BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE
ECM data is Faulty ECM Replace the ECM
ON abnormal
OFF
10 sec.
Code signals Faulty Follow the
cannot send or immobilizer troubleshooting
receive receiver or wire (page 23-10)
harness
Identification Jamming by the Keep the other
code does not other motorcycle's
match transponder transponder key
away from the
immobilizer receiver
Secret code does
more than 50 mm
not match
(2.0 in)

When the system (ECM) enters the diagnostic mode

from the registration mode:
BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE
Registration is The key is Use a new key or
ON overlapped already cancelled key
OFF
registered
properly
10 sec.
Code signals Faulty Follow the
cannot send or immobilizer troubleshooting
receive receiver or wire (page 23-10)
harness
Registration is The key is Use a new key
impossible already
registered on the
other system

23-9
 dummyhead

IMMOBILIZER SYSTEM (HISS)

TROUBLESHOOTING
The HISS indicator comes on for approx. two seconds then it goes off, when the ignition switch is turned ON
with the properly registered key and the HISS functions normally. If there is any problem or the properly
registered key is not used, the indicator will remains on.
HISS indicator does not come on when the ignition switch is turned ON
1. Meter Initial Operation Inspection
Check the meter initial operation (page 22-15).
Is the initial operation displayed?
YES – GO TO STEP 2.
NO – Check the meter power and ground lines (page 22-16).
2. PGM-FI DTC Inspection
Check the MIL indicated.
Does the MIL indicated?
YES – Check the PGM-FI DTC (page 4-6).
NO – Check the ECM power/ground lines (page 4-78).

HISS indicator remains on with the ignition switch turned ON

1. Immobilizer Receiver Jamming Inspection
Check that there is any metal obstruction or the other motorcycle transponder key near the immobilizer
receiver and key.
Is there any metal obstruction or the other transponder key?
YES – Remove it and recheck.
NO – GO TO STEP 2.
2. First Transponder Key Inspection
Turn the ignition switch ON with the spare transponder key and check the HISS indicator.
The indicator should came on for 2 seconds then go off.
Is the indicator go off?
YES – Faulty first transponder key
NO – GO TO STEP 3.
3. Diagnostic Code Inspection
Perform the diagnostic code indication procedure (page 23-9).
Check that the HISS indicator comes on then it starts blinking.
Is the indicator brinks or stay lit?
Brinks– Read the diagnostic code (page 23-9).
Stay lit– GO TO STEP 4.
4. PGM-FI DTC Inspection
Check the MIL indicated.
Does the MIL indicated?
YES – Check the PGM-FI DTC (page 4-6).
NO – Faulty ECM

23-10
dummyhead

IMMOBILIZER SYSTEM (HISS)

Diagnostic code is indicated (Code signals cannot send or receive)
1. Immobilizer Receiver Power Input Line Inspection
Check the immobilizer receiver power input line (page 23-12).
Is the input line normal?
YES – GO TO STEP 2.
NO – Open or short circuit in the Yellow or Yellow/red wire
2. Immobilizer Receiver Ground Line Inspection
Check the immobilizer receiver ground line (page 23-12).
Is the ground line normal?
YES – GO TO STEP 3.
NO – Open circuit in the Green/orange or Gray wire
3. Immobilizer Receiver Signal Line Inspection
Check the immobilizer receiver signal lines (page 23-12).
Are the signal lines normal?
YES – GO TO STEP 4.
NO – Open or short circuit in the Pink, Blue, Orange/blue wire
4. Immobilizer Receiver Inspection
Replace the immobilizer receiver with a know good one (page 23-13).
Perform the diagnostic code indication procedure (page 23-9).
Is the Diagnostic code indicated?
YES – Replace the ECM with a known good one and recheck.
NO – Faulty original immobilizer receiver

HISS INDICATOR
POWER INPUT LINE INSPECTION
Inspect the meter power/ground line (page 22-16).
HISS INDICATOR LINE INSPECTION
Check the No PGM-FI DTC indicated.

IMMOBILIZER RECEIVER
Remove the fuel tank (page 7-7).
[1]
Turn the ignition switch OFF.
Disconnect the immobilizer receiver 4P (Black)
connector [1].

23-11
 dummyhead

IMMOBILIZER SYSTEM (HISS)

POWER INPUT LINE INSPECTION
Turn the ignition switch ON.
[1]
Measure the voltage between the immobilizer receiver
4P (Black) connector [1] and ground at the wire side.
CONNECTION: Yellow (+) – Ground (–)
There should be approx. 5 V.
Y

GROUND LINE INSPECTION

Disconnect the ECM 33P (Black) connector (page 4-
[1] [2]
77).
Check for continuity between the immobilizer receiver
4P (Black) connector [1] and 33P (Black) connector [2]
terminals at the wire side.
CONNECTION: Gr – B23 Gr
B23
There should be continuity at all times.

SIGNAL LINE INSPECTION

Turn the ignition switch ON.
[1]
Measure the voltage between the immobilizer receiver
4P (Black) connector [1] and ground at the wire side.
CONNECTION: Pink (+) – Ground (–)
There should be approx. 5 V.
P

Disconnect the ECM 33P (Gray) connector (page 4-77).

[1] [2]
Check for continuity between the immobilizer receiver
4P (Black) connector [1] and 33P (Gray) connector [2]
terminals at the wire side.
TOOL:
Test probe 07ZAJ-RDJA110 Bu
C14
CONNECTION: Blue – C14
There should be continuity.

23-12
dummyhead

IMMOBILIZER SYSTEM (HISS)

Check for continuity between the ECM 33P (Gray)
connector [1] and ground at the wire side.

TOOL:
Test probe 07ZAJ-RDJA110

CONNECTION: C14 – Ground C14

There should be no continuity.

[1]

REMOVAL/INSTALLATION
Remove the top bridge (page 17-45).
[1] [3]
Remove the harness cover [1].
Remove the screws [2] and the immobilizer receiver [3].
Installation is in the reverse order of removal.

[2]

REPLACEMENT PARTS FOR

PROBLEM
Replacement parts
Ignition
Problem Transponder Immobilizer Fuel filler Seat lock
ECM switch Key set
Key receiver cap cylinder
assembly
One Key has been
lost, or additional
spare key is
required
All key has been
lost
ECM is faulty
Immobilizer
receiver is faulty
Ignition switch is
faulty
Fuel filler cap is
faulty
Seat lock is faulty

23-13
dummyhead

MEMO
dummytext

24. WIRING DIAGRAMS

WIRING DIAGRAM (MT model) ·················24-2 PGM-FI SYSTEM DIAGRAM ······················ 24-8

WIRING DIAGRAM (DCT model) ···············24-5

24

24-1
 dummytext

WIRING DIAGRAMS
WIRING DIAGRAM (MT model)
WIRING DIAGRAMS

POWER SUPPLY:

ECM (A-27 SUBVBRLY)

SIDESTAND SWITCH

ECM (C-10 TBWRLY)

IGNITION

ECM (A-4 ST_INH)

ECM (A-1 TBW+B)

ECM (A-8 SUBVB)

FUEL PUMP UNIT

SWITCH

ECM (A-13 FAN)

ECM (A-12 FLR)

WELD JOINT_2
WELD JOINT_2
BAT

FAN MOTOR
VS SENSOR
IGNITION SWITCH

IG
BAT ON

1 R/Bl
B11 R
ON

21 Gr/Bu

11 Bu/Bl
39 Br/Bl

Br/Bl

Br/Bl
49 Br/G
Bl/R

Y/W

Y/W

Y/R
V/Y
G

V
OFF
2P

Z06

32
50

33

13
6

2
BRAKE/TAILLIGHT Br
LICENSE LIGHT LOCK
Z06 G
LEFT REAR TURN SIGNAL LIGHT

1 R/Bl
RIGHT REAR TURN SIGNAL LIGHT

B11 R
BRAKE/TAILLIGHT
LICENSE LIGHT
BCU (27 HORN_IN)
FRONT BRAKE SWITCH
REAR BRAKE SWITCH 8 Bl/R
(CH) HEADLIGHT DRIVER (PO)
METER (ALARM)
(CRF1100A4/AL4) SCU (9 IGN)

ABS MODULATOR (7 IG) A01 R/G

(CRF1100A4/AL4) SCU (43 BATT) B21 R/W

METER (IGN)
MID (IGN) 6 Bl/R
BCU (26 IGN)
IMU (+12V)
BCU (13 BAT2) B22 R/Bu
BCU (39 BAT1) B21 R/W
ABS MODULATOR (18 FSR +B) B19 R/G

METER (BAT) B21 R/W

MID (BATT)

ABS MODULATOR (9 MR +B) B18 R/Y

HEADLIGHT DRIVER (IGN1) 7 Y/Bu

C/LIGHT DRIVER (IGN 2) 22 Y/W

ACCESSORY SOCKET
(CRF1100A2/AL2/A4/AL4)

REAR OPTION Z06 G

REAR OPTION
B12 R/Bu

B21 R/W
R

R
B01

B02

G/R
B18 R/Y

Bl
R
B11
3
4

4P

4P A: 30A MAIN FUSE

B12 R/Bu

Bl B: 30A ABS-M

(CRF1100A4/AL4)
R

21 Gr/Bu
11 Bu/Bl

B14 R/Bu

B15 R/Bu

B22 R/Bu

B14 R/Bu

B15 R/Bu
2 Br/Bl

39 Br/Bl

Y/Bu
49 Br/G
B16 R/W

B21 R/W

B16 R/W
50 Y/W

Y/W

R/Bl

Bl/R

R/Bl

Bl/R
A01 R/G
Y/R
33 V/Y
B01

B01

B13 W

W
Bl

Bl
Z06 G

Z06 G

R
R

R
V
STARTER
RELAY

B01
B01

B01

B13
B11
B

32

13

22
3

8
SWITCH

B12 R/Bu
2 Br/Bl
5 Y/W
4 G/R

B19 R/G
Bl

Bl
Z06 G

Z06 G

R
G
R
Y
Y
200 Y
B00 W

B02
B00 W 101 Bl

Z01
B11
203
201

3
E: 15A CLOCK/TURN/FOG/DRL
B01
B01
B00

B00

B12
G

R/W
R/W
R/W
R/W
R/W
F: 10A G HEATER

G
G
G
G
G
G
B00 Bl STARTER 3P 3P G: 10A CORNER LIGHT/ACC
Z01

Z06

Bl Gr
B21
B21
B21
B21
B21

Z06
Z06
Z06
Z06
Z06
Z06
MOTOR H: 10A METER
I: 15A HEAD LIGHT
J: 10A SUB VB

R
R
201 Y
REGULATOR/ K: 20A FAN

B11
B11
102 Bl/Gr

102 Bl/Gr

20A
RECTIFIER L: 10A TBW
24P W 24P W M: 10A FUEL PUMP
C D 12P 12P

200 Y

203 Y
N: 10A ST-MAG
SUB VB FAN TBW FUEL O: 10A ABS MAIN
102

BATTERY RELAY RELAY RELAY RELAY

E F G H I J K L M N O P P: 10A HORN/STOP

JUNCTION 2 JUNCTION 1 BREATH_B11 STARTER FI RELAY

C: 30A MAIN2 (BACK_UP) (GND_RR) RELAY
GND GND ABS FSR+
REG RR D: 15A FI GND ALTERNATOR
POWER BOX

24-2
 8P

24-3
23 Bl/R M01 Bl/R

SWITCH
CLUTCH
Z02 Bl/G Z03 G
2 Br/Bl
2 Br
2 Bl 2 Br 2 Br

SWITCH
CLUTCH
2 Br

(CRUISE)
M05 Bl/Br M05 Bl 2 Br
2 Br/Bl
2 Br
dummytext

2 Br/Bl
2 Br
2 Br
2 Br
WELD JOINT_2
WIRING DIAGRAMS

2 Br
2 Br

4P
ENGINE ELECTRICAL:

15 Y

SENSOR
M03 Bl

DUMMY
24 Gr

SHIFT STROKE
2 Br FRONT BRAKE SWITCH (CRUISE)

Bl
2P
30 Y/Bu ENGINE STOP SWITCH
2 Br STARTER SWITCH
24 Gr CRUISE MAIN SWITCH
SET/- CRUISE CONTROL LEVER

PAIR CONTROL
RES/+ CRUISE CONTROL LEVER

SOLENOID VALVE
10 W ENGINE STOP SWITCH
37
CRUISE MAIN SWITCH

2-1
2 73 W SET/- CRUISE CONTROL LEVER
74 W RES/+ CRUISE CONTROL LEVER

Br
19 Gr STARTER SWITCH
35 15 Y IMMOBILIZER RECEIVER (Vcc)
24 Gr IMMOBILIZER RECEIVER (1 GND)

1-1
2 63 P IMMOBILIZER RECEIVER (RxDT)
41 Bu IMMOBILIZER RECEIVER (TxCT)

6P
8P

36 2 Br Br 2 70 Br 70 Y/R VCC1

IGNITION COIL
1-2
2 37 Bu/R R 37 69 P 69 Y/Bl SG1
35 Bu/Bl Bl 35 68 W 68 W/R VCC2

Br/Bl
36 Bu/W W 36 67 Gr 67 W/Bl SG2
GRIP APS

38 38 Bu/Y Y 38 66 Bu 66 Bu/W APS1

2-2
2 2 Br/Bl Br 2 65 Y 65 Gr APS2
2P

Bl
2P
Z02 Bl Z02 Bl
24 Gr 11 Bu/Bl 11 Bl/W
43 Lg

ECT SENSOR
Bu
2P
IAT

44 Y

Bl
3P
24 Gr
FAN MOTOR SENSOR

24 Gr
45 Lg
15 Y

MAP SENSOR
6P
4P

GND

TP
TPS1 112 52 Bu/Bl Z05 G W
TPS2 111 51 Bu/W HT
VCC 108 54 Y 28 W W
SG 110 55 Lg LAF

SENSOR
29 Bl Bl

SG
27 Gr Gr

TBW UNIT
4P

109 Bu GND
56 Bu Z05 G W
113 Bu 53 R HT
31 W W
LAF

2P
42 Bl Bl

SG
40 Gr Gr
LEFT A/F SENSOR RIGHT A/F SENSOR

Gr
2P

FUEL
16 Bu 18 Y B-1 PCS
2 Br 30 Y/Bu B-2 EX-AI
53 R B-3 TMOP

INJECTOR 1
56 Bu B-4 TMOM
33P Bl

B-5

Gr
2P
B-6
16 Bu B-7 INJ1
17 P 17 P B-8 INJ2

FUEL
2 Br B-9
38 Y B-10 IG2-2
36 W B-11 IG1-2
Z05 G/Bu B-12 LG

INJECTOR 2
55 Lg B-13 TPSSG
A09 Bu/Y B-14 FVW
A10 Bu/Bl B-15 RVW
58 Y B-16 PCP
59 W B-17 PCM
15 Y B-18 VCC
ECM_B

76 Lg B-19 NEUTRAL
43 Lg B-20 TW
M05 Bl B-21 CLUTCH CRUISE
37 R B-22 IG2-1
24 Gr B-23 SG
B-24
54 Y B-25 TPS SVCC
B-26
52 Bu/Bl B-27 TPS1
51 Bu/W B-28 TPS2
73 W B-29 CRUISE
75 W B-30 DRUMANG
60 G B-31 STOP
B-32
B-33 IG1-1
2P

35 Bl
11 Bl/W 11 Bu
Z02 Bl Z02 Bl 49 Br/G A-1 TBW+B
A-2
26 Br/Bl A-3 HS
FAN MOTOR
5 Y/W A-4 ST INH
39P Bl

A-5
19 Gr A-6 START
67 Gr A-7 APS2SG
32 V A-8 SUBVB
Z04 G A-9 PG
Z08 G A-10 PG
2 Br A-11 IGP
39 Br/Bl A-12 FLR
21 Gr/Bu A-13 FAN
28 W A-14 VH1
45 Lg A-15 PB
26 Br/Bl A-16 HS
44 Y A-17 TA
23 G A-18 SSTAND
25 Y A-19 SCS
69 P A-20 APS1SG
A-21
Z02 G
ECM_A

Z04 G A-22 PG
Z02 G Z04 G A-23 PG
Z08 G A-24 PG
29 Bl A-25 PP-1
Z03 G 66 Bu A-26 APS1
33 V/Y A-27 SUBVBRLY
C31 Bl A-28 DIAG CANL
C41 Bl/R A-29 DIAG CANH
Z04 G C12 Bl A-30 FRM CANL
FR METER PG
GND GND GND

C22 Bl/R A-31 FRM CANH

70 Br A-32 APS1VCC
A-33
Z05 G/Bu A-34
Z05 G/Bu A-35
27 Gr A-36 COM-1
A-37
Z08 G 65 Y A-38 APS2
68 W A-39 APS2VCC
GND GND
SENS FI-PG

48 Bu C-1 MOP
C-2
C-3
C-4
33P Gr

C-5 IMOV
C-6
C-7
C-8
C-9
50 Y/W C-10 TBWRLY
C-11
47 R C-12 MOM
C-13
41 Bu C-14 IMOAU
63 P C-15 IMOID
34 P C-16 VSP
C-17
ECM_C

M01 Bl/R C-18 CLUTCH

JUNCTION 2 C-19
(FRM_CANH) C22 Bl/R
C-20
40 Gr C-21 COM-2
31 W C-22 VH-2
JUNCTION 2 C12 Bl C-23
(FRM_CANL) C-24
C-25
71 G C-26 STOP2
10 W C-27 ENG STOP SW
M03 Bl C-28 SSTRK
Bl

46 Bl/R C-29 POT

2P

M04 Y/W C-30 SPINDLE

18 Y 74 W C-31 CR _RES/+
CONTROL

2 Br 42 Bl C-32 IPP-2
C-33
EVAP PURGE
SOLENOIDVALVE

15 Y M04 Y/W
15 Y
15 Y
15 Y
15 Y
(FI-VCC)

15 Y 76 Lg
SHIFT

15 Y
WELD JOINT_15
SWITCH
SPINDLE

Z09

SWITCH
NEUTRAL

24 Gr
24 Gr
24 Gr
24 Gr
24 Gr
24P W

24 Gr
(FI-SG)

24 Gr
12P

24 Gr
24 Gr Z03 Bl/W
Bl
3P

JUNCTION 1
SENSOR

25 Y
RESERVE

25 Y Z02 G Z03 Bl/W

61 R 56 R/Bl
(SCS)

25 Y 13 Y/R 13 Y/R

Z03 Bl/W
13 Y/R

C41 Bl/R 61 R METER (FUEL RES)

C42 Bl/R
UNIT
FUEL
PUMP

24P W

C43 Bl/R 34 P METER (SP-SIG)

12P

C31 Bl
C32 Bl FRONT BRAKE SWITCH
JUNCTION 1

60 G REAR BRAKE SWITCH

C33 Bl
71 G REAR BRAKE SWITCH (CRUISE)
(DIAG-CANH) (DIAG-CANL)
Bl
3P

A09 Bu/Y ABS MODULATOR (12 FPO)

15 Y/R 15 Y A10 Bu/Bl ABS MODULATOR (3 RPO)
D17 W 75 W
24 G 24 Gr
GP SENSOR

C43 Bl/R SCU (10 CAN2-H)

C33 Bl SCU (11 CAN2-L)

15 Y ABS MODULATOR (14 SCS)

Bl
3P

20 W JUNCTION 2 (K-LINE)
Z05 G
34 P C42 Bl/R
6P

6 Bl/R 20 W
C32 Bl
Z05 G/Bu
DLC

Z06 G Z06 G 2 Br
23 G/W 23 G 25 Y
Bl
2P

Z05 G/Bu
Z05 G
SWITCH

VS SENSOR

Z05 G/Bu
SIDESTAND
BREATH_Z05

M02 Bl METER (OIL PRESS)

58 Y
59 W
15 Y
3P Gr

CKP

M02 Bl
SENSOR
15 Y
47 R
24 Gr
48 Bu

EOP SWITCH
46 Bl/R

G
6P Bl

JUNCTION 1 (GND_RR) Z06 G

15
54
61
52
53
R
G
Br
Bu

STARTER RELAY 5 Y/W

Y/R

FI RELAY 2 Br/Bl

H FUSE 6 Bl/R

SUB VB RELAY 32 V

SUB VB RELAY 33 V/Y

-

FAN RELAY 11 Bu/Bl

PO
SG

VCC

FAN RELAY 2 Br/Bl

FAN RELAY 21 Gr/Bu
EGCA

TBW RELAY 49 Br/G

TBW RELAY 50 Y/W

FUEL RELAY 13 Y/R

FUEL RELAY 39 Br/Bl

2 Br/Bl
26 Br/Bl
DIODE

26 Br/Bl
(POWER BOX)
 12P
MID

LIGHT
LIGHT
F08 Bu F08 W

1
SENSOR

SOCKET
OPEN AIR

LEFT FRONT

LEFT
TURN SIGNAL
TURN SIGNAL
RIGHT FRONT

ACCESSORY

2
GND
PO
IGN 1
HI
LO
TEMPERATURE
dummytext

USB
GPS
NOT USE
NOT USE
F-CAN H
GND
IGN

F-CAN L
HEADLIGHT DRIVER
DRL 6P

GND
CL_3
CL_2
CL_1
CL_LR
IGN2

GPS ANTENNA
59
60

C/LIGHT DRIVER
METER
F09 W/Bl F13 W/Bl

USB CONNECTOR

3
BATT 7P

(Except CRF1100A/AL)
(CRF1100A2/AL2/A4/AL4)

WELD JOINT_Z02
Bl
Bl

Z02
AIR TEMP (-)
AIR TEMP (+)
OIL PRESS
NOT USE
F-CAN-2 (L)
F-CAN-2 (H)
F-CAN-1 (L)
F-CAN-1 (H)
ALARM
FUEL RES
PARKING
ABS RR OFF
ABS
SP-SIG
GND
IGN

FOGLIGHT DUMMY
FUEL UNIT
BAT

W06

2P
8
7

6P
Z02
F02
F01
F03

4
G
O
2P

G
20P

Bl/Y
Bl/R

2P
Bl/Br
Br/W
Bl/Bu

Z03 G
C19 Bl

Z02 G
Z02 G

C29 Bl/R
6 Bl/R
B21 R/W
W07 Lb

Z02 G
F07 Bl
F04 Br

22 Y/W

5
6

22 Bl/W

F06 Br/Bl
77
61
64
34

F05 Br/Bu

2P O
Z03

Z02
Z02
Z02
Z02
Z02
Z02
Z02
C11
A07
A02
B21

C19
C29
C21
D23

M02
RIGHT

DUMMY

G
G
G
G
G
G
G
Z02 G
Y
P
G

Bl
Bl
Bl
FOGLIGHT

59 W/Bl
60 Bl/W
G/Y

57 Bu/Bl
Bl/R
Bl/R
R/Bl
Bl/R
R/W

W/G

60 Bl/W
59 W/Bl
R/Bu
W/Bu

6
2P Lb
FRAME ELECTRICAL:

2P

Z02 G
W06 O
F09 W/Bu F09 Br

7
( C/LIGHT )
Z02 G
W07 Lb

Z02 G
57 Bu/Bl

8
9
10
B21 R/W B21 R/W
F12 W/R F12 W/R 7 Y/Bu 7 Bl/Y

11
Bl
12P
57 Bu 57 Bu/Bl
W06 O W06 O
W07 Lb W07 Lb
F01 W F01 Bl/Br

12
F02 Bu F02 Bl/Bu
F03 Br F03 Br/W
( C/LIGHT ) ( C/LIGHT )
F04 Be F04 Br

13
( C/LIGHT ) ( C/LIGHT )
F05 V F05 Br/Bu
( C/LIGHT ) ( C/LIGHT )
F06 P F06 Br/Bl
( C/LIGHT ) ( C/LIGHT )

14
F07 Y F07 Bl
Bl
4P

F10 W/G F10 Bl

15
C21 Bl/R C21 Bl/R
C11 Bl C11 Bl

16
F11 W/Y F11 Lg ( C/LIGHT ) ( C/LIGHT )

17
22 Y/W 22 Bl/W
Bl
12P

6 Bl/R 6 Bl/R
( H/L_POS )
8 Bl/R 8 Bl/R

18
A02 W/Bu A02 W/Bu
M02 Bl D23 G/Y
M02 Bl
77 Y 77 Y

19
61 R 61 R/Bl
64 Bu 64 R/Bu

20
A07 W/G A07 W/G
34 P 34 P
FRONT

F24 G/Bu F24 Gr

Z03 G Z03 G
Z02 G Z02 G
SUSPENSION
STROKE SENSOR
(CRF1100A4/AL4)

12P

S10 Bl S10 Br
S10 Br LPS1-1
S11 Br S11 Br/Bl S11 Br/Bl LPS1-2
GND Z02 G Z02 G

(Except
H03 Y/R H03 Y

2P

GRIP
LEFT
HEATER_L

HEATER

CRF1100A/AL)
(CRF1100A4/AL4)
(CRF1100A4/AL4)

24 Gr 24 G/Bl
1

10 W 10 W/Bu
LEVER

12: ENT SWITCH

13: SKIP SWITCH
6: PAGE SWITCH

8: BACK SWITCH

15: HORN SWITCH

2

9: SEL UP SWITCH
7: SEL LEFT SWITCH

16: FAVORITE SWITCH

11: SEL RIGHT SWITCH
10: SEL DOWN SWITCH
3: FUNCTON LEVER UP

14: GOES BACK SWITCH

LEFT HANDLEBAR SWITCH
3. CRUISE MAIN SWITCH

LIGHTING SWITCH (CH)

1. ENGINE STOP SWITCH

4: FUNCTON LEVER DOWN

2. SET/- CRUISE CONTROL

73 W 73 W/Bl

5: VOICE CONTROL SWITCH

19: TURN SIGNAL LEFT SWITCH

17: HAZARD SWITCH (Except CH)
1: HEADLIGHT DIMMER SWITCH

20: TURN SIGNAL RIGHT SWITCH

18: TURN SIGNAL CANCEL SWITCH
4

74 W 74 W
2: PASSING LIGHT CONTROL SWITCH
LEVER

F24 Gr F24 G/Bu

RIGHT HANDLEBAR SWITCH

F16 Gr F16 Bu
6. STARTER SWITCH
5. FUNCTION SWITCH

SOL1-N S13 Br S13 Br

FRONT
6

S12 Br/Bl S12 Bl

2P
2P

SOL1-P 19 Gr 19 Bl
4. RES/+ CRUISE CONTROL

SOLENOID
SUSPENSION

(CRF1100A4/AL4)
2 Br
4P

2 Br/Bl
BRAKE
FRONT

62 Bl 72 W 72 W
(CRUISE)

HORN

Z03 Bl 8 Bl/R 8 Bl/R

60 G/Y 60 Bl/G
60 G/Y
BRAKE
FRONT

Z02 G
SWITCH SWITCH

Z03 Bl
Z03 G
GND
2P

(CRF1100A4/AL4) H03 Y H03 Y

GRIP
(Except

H02 Bl H02 Bl
RIGHT

Z04 G HEATER_R
HEATER

Z05 G/Bu
CRF1100A/AL)

Bl
4P

Z05 G/Bu
Z07 G 24 Gr 24 G/O GND
FR METER PG SENS ABS
GND GND GND GND GND

15 Y 15 Y/R Vcc
63 P 66 P RxDT
41 Bu 41 O/Bu
RECEIVER

TxCT
Bl
2P

A03 W A03 W
A04 Bu A04 Bu
- +
FRONT WHEEL
IMMOBILIZER SPEED SENSOR

Bl

Z05 G/Bu 1. GND

4P

C15 Bl 2. CANL
IMU

C21 Bl/R C25 Bl/R 3. CANH

6 Bl/R 4. +12V
C22 Bl/R
C23 Bl/R
Bl
2P

(CRF1100A4/AL4)
C24 Bl/R
64 Bu 64 R/Bu
FUEL

24P
LEVEL

C25 Bl/R Z03 G Z03 G

(FRM_CANH)
SENSOR

C28 Bl/R
12P
W

JUNCTION 2

20 W
20 W
(K-LINE)

20 W

A09 Bu/Y ECM (B-14FVW)

A10 Bu/Bl ECM (B-15 RVW)

C11 Bl
C12 Bl
24P

73 W ECM (B-29 CRUISE)

C13 Bl
(CRF1100A4/AL4) 60 G ECM (B-31 STOP)
12P

C14 Bl
19 Gr ECM (A-6 START)
W

JUNCTION 2

C15 Bl
(FRM_CANL)

C18 Bl

C12 Bl ECM (A-30 FRM CANL)

C22 Bl/R ECM (A-31 FRM CANH)
41 Bu ECM (C-14 IMOAU)
63 P ECM (C-15 IMOID)

71 G ECM (C-26 STOP2)

10 W ECM (C-27 ENG STOP SW)
WELD JOINT_15 (FI-VCC) 15 Y 74 W ECM (C-31 CR RES/+)

JUNCTION 1 (FI-SG) 24 Gr
4P

8 Bl/R 8 Bl
REAR

60 G 60 Bl/G
JUNCTION 1 (FI-SG) 24 Gr
72 W 72 Br
DLC (K-LINE) 20 W 71 G 71 Br/G
REAR
BRAKE
BRAKE SWITCH
SWITCH (CRUISE)

Bl
2P

(CRF1100A4/AL4)
JUNCTION 1 (DIAG-CANH) C43 Bl/R
A06 W A06 W
A05 Bu A05 Bu
- +

(CRF1100A4/AL4)
JUNCTION 1 (DIAG-CANH) C33 Bl
REAR WHEEL

Bl
18P
SPEED SENSOR

JUNCTION 1 (SCS) 25 Y B19 R/G 18 FSR +B

A03 W 17 FVWS
VS SENSOR 34 P A07 W/G 16 MODE IND
A06 W 15 RVWS
WELD JOINT 2 2 Br 25 Y 14 SCS
A02 W/Bu 13 IND
RESERVE SENSOR 61 R A09 Bu/Y 12 FPO
EOP SWITCH M02 Bl C13 Bl 11 CAN-L
Z07 G 10 GND
B18 R/Y 9 MR +B
A04 Bu 8 FVWB
O FUSE A01 R/G A01 R/G 7 IG
A05 Bu 6 RVWB
20 W 5 DIAG
ABS MODULATOR

60 G/Y 4 BLS
A10 Bu/Bl 3 RPO
C23 Bl/R 2 CAN-H
Z07 G 1 MOTOR GND
BREATH_Z05

Z05 G/Bu
Z05 G/Bu
62 Bl 1 HORN_OUT
Bl

F16 Gr 2 SW1(MF SEL_SW)

39P

3 P_OUT
F01 W 4 H/L_LO
5 ACC_OUT
6 OP_SW2
H02 Bl 7 GH
F10 Bl 8 SW7 (HORN/FAVORITE)
57 Bu 9 FOG_OUT
F24 Gr 10 SG
F03 Br 11 DRL_OUT
Z05 G/Bu 12 LG
B22 R/Bu 13 BAT2
C28 Bl/R 14 F_CAN_H
C18 Bl 15 F_CAN_L
W07 Lb 16 W/L_FR
W06 O 17 W/L_FL
W03 Lb 18 W/L_RR
F08 W 19 SW2 (DIMMER)
F02 Bu 20 H/L_HI
F12 W/R 21 SW5(SEL_RIGHT)
BCU

F09 Br 22 SW4(SEL_EFT)
F11 Lg 23 SW6(HAZ/TURN)
(CRF1100A4/AL4)

F13 W/Bl 24 SW3(MF UP)

25 OP_SW1
6 Bl/R 26 IGN
8 Bl/R 27 HORN_IN
( C/LIGHT )
F04 Be 28 CL_LR
( C/LIGHT )
F07 Y 29 CL_3
( C/LIGHT )
7
8

F06 P 30 CL_2
Z06
Z06

B21
B21
B21
B21

( C/LIGHT )
F05 V 31 CL_1
W05 O 32 W/L_RL
G
G

B18 R/Y
B19 R/G
6 Bl/R
22 Y/W
Bl/R
R/W
R/W
R/W
R/W

Y/Bu

B22 R/Bu

33
34
35
36
20 W 37 K-LINE
F14 R/W 38 ALARM
B21 R/W 39 BAT1
P FUSE
I FUSE

G FUSE
H FUSE

F FUSE
B FUSE

C24 Bl/R 1 CAN1-H

Bl

C14 Bl 2 CAN1-L
48P

Z04 G 3 GND
4 RR_STRK_SEN_2
5 RR_STRK_SEN_1
S15 Bl 6 SVCC
ABS FSR+ FUSE (20A)

7 TEST
JUNCTION 1 (GND_RR)
JUNCTION 1 (GND_RR)

JUNCTION 2 (BACK_UP)
JUNCTION 2 (BACK_UP)
JUNCTION 2 (BACK_UP)
JUNCTION 2 (BACK_UP)

8 TEST
(CRF1100A4/AL4)

8 Bl/R 9 IGN
C43 Bl/R 10 CAN2-H
C33 Bl 11 CAN2-L
12
13
S08 Y 14 JACK_STRK_SEN
15
16 TEST
S13 Br 17 FR_SOL (-)
18
S06 Br 19 MOT (-)
20 TEST
S04 Y 21 RR_SOL (-)
S24 Br 22 SGND
23 TEST
24
SCU

25
26 TEST
27
28
S08 Y
S04 Y

S15 Bl
S05 Bl

S24 Br
S06 Br
S03 Gr

29
77

30
Z06
W05

31
32
Y
8

Z06 G
O
G
2P
2P

8 Bl/R
Z06

F14 R/W
B21 R/W

S12 Bl 33 FR_SOL (+)

3P Gr

Z06 G

34
W03 Lb

S05 Bl 35 MOT (+)

Bl/R

36
8P

S03 Gr 37 RR_SOL (+)

38
S11 Br 39 FR_STRK_SEN2
S08 Y
S07 Bl
S05 Bl
S03 Bl
S04 W

S09 Br
S06 Br

2P O
2P Lb

S10 Bl 40 FR_STRK_SEN1
2P W

41 TEST
42 TEST
Z06 G
60 G/Y

8 Bl/R

B21 R/W 43 BATT

Z06
W05

DUMMY

44
45
Z06 G
W03 Lb

46 TEST
O
G
Z06 G
8 Br

47
3P Bl

48 TEST
SOL0-P
SOL0-N

PRE-LOAD MOTOR

POSITION SENSOR
REAR SUSPENSION
REAR SUSPENSION

REAR OPTION
REAR

TAIL
REAR

STOP
LEVEL

LIGHT

LIGHT
LIGHT

12V 5W
SOLENOID

BRAKE/
LICENSE
ADJUSTER
SUSPENSION

TAILLIGHT

LEFT REAR
SUSPENSION
(CRF1100A4/AL4)

RIGHT REAR

TURN SIGNAL
TURN SIGNAL

24-4
WIRING DIAGRAMS
 dummytext

WIRING DIAGRAMS
WIRING DIAGRAM (DCT model)
POWER SUPPLY:

IGNITION SWITCH

ECM (A-27 SUBVB_RLY)

SIDESTAND SWITCH

ECM (C-10 TBWRLY)

BAT ON

ECM (C-9 DCTRLY)

ECM (A-8 SUBVB1)

ECM (A-4 ST_INH)

ECM (A-1 TBW+B)

TCM (A-8 SUBVB)

FUEL PUMP UNIT

IGNITION

TCM (A-14 PVB)

ECM (A-13 FAN)

ECM (A-12 FLR)
WELD JOINT_2
WELD JOINT_2
SWITCH

TCM (A-3 PVB)

ON

FAN MOTOR
VS SENSOR
BAT
OFF

IG
LOCK
BRAKE/TAILLIGHT

1 R/Bl
LICENSE LIGHT

B11 R
Z06 G

21 Gr/Bu

11 Bu/Bl
LEFT REAR TURN SIGNAL LIGHT

Br/Bl
Br/Bl

39 Br/Bl
49 Br/G
5 Y/W

50 Y/W
Bl/R

Y/R
V/Y
W
G

V
RIGHT REAR TURN SIGNAL LIGHT

D01

D02
Z06

32

32

33

13
BRAKE/TAILLIGHT

2
2
LICENSE LIGHT
BCU (27 HORN_IN) 2P
FRONT BRAKE SWITCH
REAR BRAKE SWITCH
8 Bl/R

1 R/Bl
(CH) HEADLIGHT DRIVER (PO)

B11 R
METER (ALARM)
(CRF1100D4/DL4) SCU (9 IGN)

ABS MODULATOR (7 IG) A01 R/G

BCU (13 BAT2) B22 R/Bu
ABS MODULATOR (18 FSR +B) B19 R/G

(CRF1100D4/DL4) SCU (43 BATT) B21 R/W

ABS MODULATOR (9 MR +B) B18 R/Y

METER (IGN)
MID (IGN)
BCU (26 IGN) 6 Bl/R
IMU (+12V)

BCU (39 BAT1) B21 R/W

METER (BAT)
B21 R/W
MID (BATT)

HEADLIGHT DRIVER (IGN1) 7 Y/Bu

C/LIGHT DRIVER (IGN 2)

22 Y/W
ACCESSORY SOCKET
(CRF1100D2/DL2/D4/DL4)
B12 R/Bu
B17 R/W
R

R
B01

B02

REAR OPTION Z06 G

G/R
B18 R/Y

Bl
R

B11 R
B11 R
REAR OPTION B21 R/W
4P
B11
3
4
B12 R/Bu

21 Gr/Bu
B17 R/W

A: 30A MAIN FUSE

11 Bu/Bl

B14 R/Bu

B15 R/Bu

B22 R/Bu

B14 R/Bu

B15 R/Bu
2 Br/Bl

39 Br/Bl

Y/Bu
49 Br/G
B16 R/W

B21 R/W

B16 R/W
50 Y/W

Y/W

R/Bl

Bl/R

R/Bl

Bl/R
A01 R/G
13 Y/R
33 V/Y
R

B01 R

W
B13 W
4P

Bl

Bl
Z06 G

R
R

R
V
V
Bl B: 30A ABS-M
B01

B01
B01

B01

B13
Z06

B11
32
32

22
3

8
A STARTER
RELAY BREATH_B11
B SWITCH

B19 R/G
R
B00 W

(CRF1100D4/DL4)
B00 W 101 Bl

B02
B12 R/Bu
2 Br/Bl
B17 R/W

5 Y/W
4 G/R
D01 W

Bl

Bl
Z06 G

Z06 G
D02 Y

Z06 G
G
R
Y
Y
Y
G

B00 Bl

Z01
B11

3
203
201
200

3
STARTER F: 15A CLOCK/TURN/FOG/DRL
Z01

Z06

MOTOR G: 10A G HEATER

3P 3P H: 10A CORNER LIGHT/ACC
R/W
R/W
R/W
R/W
R/W

Bl Gr I: 10A METER
G
G
G
G
G
G

Y
J: 15A HEAD LIGHT
B21
B21
B21
B21
B21
Z06
Z06
Z06
Z06
Z06
Z06

20A
201
K: 10A SUB VB
102 Bl/Gr

102 Bl/Gr

C: 30A MAIN2
L: 20A FAN
D: 30A DCT-M REGULATOR/
102

Y
C D E 24P W 24P W RECTIFIER M: 10A TBW
E: 15A FI BATTERY
12P 12P F G H I J K L M N O P Q N: 10A FUEL PUMP

200

203
O: 10A ST-MAG
SUB VB FAN TBW FUEL
RELAY RELAY RELAY RELAY P: 10A ABS MAIN
JUNCTION 2 JUNCTION 1 Q: 10A HORN/STOP
GND GND GND (BACK_UP) (GND RR)
REG PG DCT STARTER FI RELAY ABS FSR+ POWER BOX
ALTERNATOR RELAY RELAY

24-5
 SHIFT DOWN SWITCH (-) D13 Bl
SHIFT UP SWITCH (+) D24 Gr

11 Bl/W 11 Bu

2P
Z02 Bl Z02 Bl
dummytext

2 Br

FAN MOTOR
2 Br
2 Br
2 Br
2 Br/Bl
2 Br
2 Br/Bl

Bl
2P
2 Br
2 Br

VALVE
30 Y/Bu
WELD JOINT_2

2 Br
2 Br 2 Br

SOLENOID
2 Br/Bl
2 Br

PAIR CONTROL
2 Br FRONT BRAKE SWITCH (CRUISE)
37

2-1
ENGINE ELECTRICAL:

2 D24 Gr A/M SWITCH

D SWITCH ENGINE STOP SWITCH
D20 V N SWITCH STARTER SWITCH
CRUISE MAIN SWITCH

Br
24 Gr SET/- CRUISE CONTROL
35 LEVER
10 W ENGINE STOP SWITCH RES/+ CRUISE CONTROL

1-1
2
CRUISE MAIN SWITCH LEVER
73 W SET/- CRUISE CONTROL
LEVER

6P
36 2 Br 2 Br 74 W RES/+ CRUISE CONTROL
LEVER

IGNITION COIL
1-2
2 37 Bu/R 37 R 19 Gr STARTER SWITCH
35 Bu/Bl 35 Bl 70 Br 70 Y/R VCC 1
8P

69 P 69 Y/Bl SG1

Br/Bl
36 Bu/W 36 W 68 W 68 W/R VCC 2
67 Gr 67 W/Bl SG2
38 38 Bu/Y 38 Y 66 Bu 66 Bu/W APS 1
65 Y 65 Gr
GRIP APS

2-2
2 APS 2
2 Br/Bl 2 Br
24 Gr IMMOBILIZER RECEIVER (GND)
63 P IMMOBILIZER RECEIVER (RxDT)
24 Gr 41 Bu IMMOBILIZER RECEIVER (TxCT)
15 Y IMMOBILIZER RECEIVER (Vcc)

2P Bl
43 Lg
Z02 Bl Z02 Bl
2P

ECT
11 Bu/Bl 11 Bl/W

SENSOR
FAN MOTOR

24 Gr
Bl

D07 Bu D11 Bu
4P

3P Bl
45 Lg
D06 Gr D10 Gr
15 Y

MAP
SENSOR
D05 Y D09 Y
No.2 LINEAR SOLENOID VALVE

D08 W D08 W/R

TPS1 112
3P

D24 Gr

TP
TPS2 111 52 Bu/Bl D14 R

6P
D15 Y/R
No.1 LINEAR SOLENOID VALVE CLUTCH
SENSOR

VCC 108 51 Bu/W

LINE EOP

SENSOR
SG 110 54 Y
55 Lg D24 Gr
EOP
No.1

D09 Y/G
3P Gr

TBW UNIT
D15 Y/R
CLUTCH

SENSOR
No.2

109 Bu 56 Bu

2P
D24 Gr
113 Bu 53 R D10 Bl
3P Gr
SENSOR

D15 Y/R
CLUTCH EOP

Gr
2P

FUEL
16 Bu
44 Y
IAT

2 Br 24 Gr
2P Bu

INJECTOR 1
SENSOR

Gr
2P
17 P

FUEL
2 Br

INJECTOR 2
GND
Z02 G Z05 G W

FR
4P

GND
HT
Z02 G 28 W W
LAF
29 Bl Bl

SG
27 Gr Gr
LEFT A/F SENSOR

Z04 G

PG
GND

GND
Z05 G W
4P

HT
31 W W
LAF
Z05 G/Bu 42 Bl Bl

GND
SENS
Z05 G/Bu SG
40 Gr Gr
RIGHT A/F SENSOR

Z08 G

GND
Z08 G D19 P/Bu A-1 SFTMOP
D18 Y/Bu A-2 SFTMOM
A-3 PVB

FI/DCT-PG
D01 W
A-4 VCC
33P Bl

D15 Y/R
D05 Y A-5 LSOL1P
D07 Bu A-6 LSOL2P
2 Br A-7 IGP
32 V A-8 SUBVB
D08 W A-9 LSOL1M
D06 Gr A-10 LSOL2M
Z05 G/Bu A-11 LG
D19 P/Bu A-12 SFTMOP
D18 Y/Bu A-13 SFTMOM
D01 W A-14 PVB
A-15
A-16
A-17
D16 P A-18 NM1P
A-19 LSOLIHN
TCM_A

D03 Bu
A-20
C51 Bl A-21 PT CANL
A-22 SG
Bl

D24 Gr
2P

Z08 G A-23 PG
18 Y Z08 G A-24 PG
2 Br A-25
A-26
A-27
A-28
A-29
VALVE

A-30
A-31
CONTROL

76 Lg A-32 NEUTRAL
SOLENOID

C61 Bl/R A-33 PT CANH

EVAP PURGE

B-1
Bl
3P

C16 Bl B-2 FRM CANL

D15 Y 20 W B-3 K-LINE
D22 Y B-4
33P Gr

D24 Gr B-5
DUMMY

B-6
75 W B-7 DRUMANG
SHIFT PEDAL

D10 Bl B-8 PC2

B-9
ANGLE SENSOR

D22 Y B-10 SFTPANG

B-11
B-12
C26 Bl/R B-13 FRM CANH
D15 Y/R B-14
D15 Y/R B-15
D15 Y/R B-16
D15 Y B-17
D15 Y D14 R B-18 PLINE
TCM_B

D15 Y/R D09 Y/G B-19 PC1

(DCT-VCC)

D15 Y D12 W B-20 SPDL

D11 Bu B-21 TOIL
WELD JOINT_D15

15 Y B-22
15 Y B-23
15 Y B-24
15 Y D17 P B-25 NM2P
15 Y B-26
(FI VCC)

15 Y B-27
B-28
B-29
WELD JOINT_15

D24 Gr B-30
D24 Gr D20 V B-31 RANGE
D24 Gr D13 Bl B-32 HSFT
D24 Gr B-33
D24 Gr
D24 Gr
D24 Gr
D24 Gr 18 Y B-1 PCS
(DCT-SG)

D24 Gr 30 Y/Bu B-2 EX-AI

D24 Gr 53 R B-3 TMOP
WELD JOINT_D24

D24 Gr 56 Bu B-4 TMOM

33P Bl

D24 Gr B-5
B-6
16 Bu B-7 INJ1
JUNCTION 2 17 P B-8 INJ2
(FRM_CANH) C22 Bl/R B-9
38 Y B-10 IG2-2
JUNCTION 2 C26 Bl/R 36 W B-11 IG1-2
(FRM_CANH) Z05 G/Bu B-12 LG
55 Lg B-13 TPSSG
A09 Bu/Y B-14 FVW
A10 Bu/Bl B-15 RVW
20 W B-16 PCP
24P

58 Y
20 W 59 W B-17 PCM
15 Y B-18 VCC
12P

20 W B-19
ECM_B

(K-LINE)

20 W B-20 TW
W

43 Lg
JUNCTION 2

B-21
37 R B-22 IG2-1
JUNCTION 2 24 Gr B-23 SG
(FRM_CANL) C12 Bl B-24
JUNCTION 2 54 Y B-25 TPS SVCC
C16 Bl B-26
(FRM_CANL) 52 Bu/Bl B-27 TPS1
51 Bu/W B-28 TPS2
24 Gr 73 W B-29 CRUISE
24 Gr B-30
24 Gr 60 G B-31 STOP
24 Gr B-32
24P W

24 Gr 35 Bl B-33 IG1-1
(FI SG)

24 Gr
24 Gr
12P

24 Gr
49 Br/G A-1 TBW+B
JUNCTION 1

A-2
25 Y 26 Br/Bl A-3 HS
25 Y 5 Y/W A-4 ST INH
39P Bl

(SCS)

25 Y A-5
19 Gr A-6 START
67 Gr A-7 APS2SG
32 V A-8 SUBVB
Z04 G A-9 PG
Z08 G A-10 PG
2 Br A-11 IGP
39 Br/Bl A-12 FLR
21 Gr/Bu A-13 FAN
28 W A-14 VH-1
C41 Bl/R 45 Lg A-15 PB
C42 Bl/R 26 Br/Bl A-16 HS
24P W

C43 Bl/R 44 Y A-17 TA

23 G A-18 SSTAND
A-19 SCS
12P

25 Y
C31 Bl 69 P A-20 APS1SG
C32 Bl A-21
JUNCTION 1
ECM_A

Z04 G A-22 PG
C33 Bl Z04 G A-23 PG
Z08 G A-24 PG
29 Bl A-25 IPP 1
(DIAG-CANH) (DIAG-CANL)

66 Bu A-26 APS1
33 V/Y A-27 SUBVBRLY
C31 Bl A-28 DIAG CANL
C41 Bl/R A-29 DIAG CANH
C12 Bl A-30 FRM CANL
MOTOR

C22 Bl/R A-31 FRM CANH

70 Br A-32 APS1VCC
Bl
2P

A-33
D19 Bu A-34
A-35
SHIFT CONTROL

D18 Y 27 Gr A-36 COM-1

A-37
65 Y A-38 APS2
68 W A-39 APS2VCC
Bl
3P

15 Y/R D15 Y
D17 W 75 W 48 Bu C-1 MOP
C-2
24 G D24 Gr C-3
C-4
TR SENSOR
33P Gr

C-5 IMOV
C-6
C-7
C-8
D02 Y C-9 DCTRLY
50 Y/W C-10 TBWRLY
C-11
Bl
3P

47 R C-12 MOM
C-13
Z05 G 41 Bu C-14 IMOAU
34 P
6 Bl/R 63 P C-15 IMOID
34 P C-16 VSP
VS SENSOR

C-17
ECM_C

C-18
D03 Bu C-19 LSOL INH
Bl
2P

D04 W C-20 POIL

Z06 G Z06 G 40 Gr C-21 COM-2
31 W C-22 VH-2
23 G/W 23 G C-23
C51 Bl C-24 PT CANL
C61 Bl/R C-25 PT CANH
71 G C-26 STOP2
10 W C-27 ENG STOP SW
SWITCH

C-28
46 Bl/R C-29 POT
SIDESTAND

C-30
74 W C-31 CR RES/+
42 Bl C-32 IPP-2
Gr
3P

C-33
58 Y
CKP

59 W
15 Y
SENSOR

76 Lg
SWITCH
Z09
NEUTRAL

DCT RELAY D01 W

34 P METER (SP-SIG)
DCT RELAY D02 Y 61 R METER (FUEL RES)
25 Y ABS MODULATOR (14 SCS)
JUNCTION 1 (GND_RR) Z06 G
SENSOR

Bl
3P
RESERVE

STARTER RELAY 5 Y/W

Z02 G Z03 Bl/W
61 R 56 R/Bl
I FUSE 6 Bl/R
13 Y/R 13 Y/R
Bl/W

FI RELAY 2 Br/Bl
Bl
3P

24 Gr
EOP

D04 W
FUEL PUMP UNIT

SUB VB RELAY 32 V 15 Y
SENSOR

SUB VB RELAY 32 V
D24 Gr 24 G/Bl
SUB VB RELAY 33 V/Y D16 P D16 P
INNER

3P Bl

32 V D15 Bl/W
SENSOR
MAINSHAFT

D24 Gr
FAN RELAY 11 Bu/Bl D17 P
OUTER

3P Bl

FAN RELAY 2 Br/Bl 32 V

SENSOR

FAN RELAY 21 Gr/Bu

MAINSHAFT

TBW RELAY 49 Br/G

D24 Gr 24 Bu
D12 W D12 W
TBW RELAY 50 Y/W D15 Y 15 Bl
3P Bu
SHIFT SPINDLE

Bl
2P
ANGLE SENSOR

FUEL RELAY 13 Y/R

15
46
24
48
47

D11 Bu
EOT

D24 Gr
Y
R

Gr

FUEL RELAY 39 Br/Bl

Bu
SENSOR

Bl/R

60 G FRONT BRAKE SWITCH

REAR BRAKE SWITCH
6P Bl

2 Br/Bl 71 G REAR BRAKE SWITCH (CRUISE)

26 Br/Bl 20 W ABS MODULATOR (5 DIAG)
15
54
61
52
53

DIODE

26 Br/Bl 20 W BCU (37 K-LINE)

ABS MODULATOR (12 FPO)
(POWER BOX)

A09 Bu/Y
R

G
Br
Bu

Y/R

A10 Bu/Bl ABS MODULATOR (3 RPO)

C43 Bl/R SCU (10 CAN2-H)
C33 Bl SCU (11 CAN2-L)
-

PO
SG

C42 Bl/R
6P

VCC

20 W
C32 Bl
Z05 G/Bu
DLC

2 Br
25 Y
EGCA

Z05 G/Bu
Z05 G/Bu
Z05 G
BREATH_Z05

24-6
WIRING DIAGRAMS
 12P
F08 Bu F08 W

1
SENSOR

MID

24-7
LEFT FRONT

2
USB
GPS
NOT USE
NOT USE
F-CAN H
GND
IGN
GND
PO
IGN 1
HI
LO

BATT

F-CAN L

Z02
W06
LIGHT

GPS ANTENNA
USB CONNECTOR
HEADLIGHT DRIVER
DRL 6P

G
O
GND
CL_3
CL_2
CL_1
CL_LR
IGN 2
METER

7P

TURN SIGNAL LIGHT

59
60

C/LIGHT DRIVER
F09 W/Bl F13 W/Bl

3
TURN SIGNAL
RIGHT FRONT

Bl
Bl
OPEN AIR TEMPERATURE

(CRF1100D2/DL2/D4/DL4)
AIR TEMP (-)
AIR TEMP (+)
OIL PRESS
F-CAN-2 (L)
F-CAN-2 (H)
F-CAN-1 (L)
F-CAN-1 (H)

NOT USE
ALARM
FUEL RES
PARKING
ABS RR OFF
ABS
SP-SIG
GND
IGN

FUEL UNIT
BAT

LEFT
8
7

6P
Z02
F02
F01
F03

2P O
Z02 G
W07 Lb

4
FOGLIGHT
2P

Z03 G
G

C19 Bl
20P

Bl/Y

C29 Bl/R
6 Bl/R
Bl/R

B21 R/W
Bl/Br
Br/W
Bl/Bu
dummytext

Z02 G
F07 Bl
F04 Br

5
Z02 G
W06 O
6

22 Bl/W

F06 Br/Bl
77
61
64
34

F05 Br/Bu
Z03

C11
A07
A02
B21

C19
C29
C21
D23

M02
RIGHT

DUMMY
DUMMY

SOCKET
WIRING DIAGRAMS

Y
P
G

Bl
Bl
Bl
FOGLIGHT

59 W/Bl
60 Bl/W
G/Y

Bl/R
Bl/R
R/Bl
Bl/R
R/W

W/G

60 Bl/W
59 W/Bl
R/Bu
W/Bu

6
2P Lb

ACCESSORY
FRAME ELECTRICAL:

2P
2P
F09 W/Bu F09 Br

7
(Except CRF1100D/DL)
Z02 G
W07 Lb

Z02 G
Z02 G

2P
57 Bu/Bl
57 Bu/Bl

8
9
Z02 G
22 Y/W

10
F12 W/R F12 W/R B21 R/W B21 R/W

11
Bl
7 Y/Bu 7 Bl/Y

12P
57 Bu 57 Bu/Bl
W06 O W06 O
W07 Lb W07 Lb

12
F01 W F01 Bl/Br
F02 Bu F02 Bl/Bu
F03 Br F03 Br/W Z02 G

13
( C/LIGHT ) ( C/LIGHT ) Z02 G
F04 Be F04 Br
( C/LIGHT ) ( C/LIGHT ) Z02 G
F05 V F05 Br/Bu
( C/LIGHT ) ( C/LIGHT ) Z02 G
F06 P F06 Br/Bl
WELD

Z02 G

14
( C/LIGHT ) ( C/LIGHT )
JOINT_Z02

F07 Y F07 Bl Z02 G

Z02 G
F10 W/G F10 Bl

Bl
4P

15
C21 Bl/R C21 Bl/R
C11 Bl C11 Bl

16
( C/LIGHT )

F11 W/Y F11 Lg ( C/LIGHT ) ( C/LIGHT )

17
22 Y/W 22 Bl/W
Bl
12P

6 Bl/R 6 Bl/R
8 Bl/R 8 Bl/R

18
A02 W/Bu A02 W/Bu
D23 G/Y D23 G/Y
M02 Bl

19
77 Y 77 Y
61 R 61 R/Bl
64 Bu 64 R/Bu

20
A07 W/G A07 W/G
34 P 34 P
F24 G/Bu F24 Gr
FRONT

D13 Bl/Bu D13 Bl Z03 G Z03 G

21
Z02 G Z02 G
SUSPENSION
(CRF1100D4/DL4)

22
STROKE SENSOR

12P

D24 G/W D24 Gr S10 Bl S10 Br

S10 Br LPS1-1
S11 Br S11 Br/Bl S11 Br/Bl LPS1-2

(Except
GND Z02 G Z02 G
D24 Gr D24 G/W
H03 Y/R H03 Y

2P

GRIP
LEFT
HEATER_L

HEATER
1

21:
20:
2
3. N SWITCH
2. D SWITCH

SHIFT
1. A/M SWITCH

(CRF1100D4/DL4)
(CRF1100D4/DL4)

SWITCH
SWITCH
SWITCH
SWITCH
3

12: ENT SWITCH

D20 V D20 Bl/Bu

13: SKIP SWITCH

6: PAGE SWITCH

8: BACK SWITCH

15: HORN SWITCH

9: SEL UP SWITCH
24 Gr 24 G/Bl

7: SEL LEFT SWITCH

16: FAVORITE SWITCH

19: TURN SIGNAL LEFT

11: SEL RIGHT SWITCH
10: SEL DOWN SWITCH
LEVER

TURN SIGNAL RIGHT

14: GOES BACK SWITCH
4

CRF1100D/DL) 22: SHIFT UP SWITCH (+)

3: FUNCTION LEVER UP
10 W 10 W/Bu

18: TURN SIGNAL CANCEL

LIGHTING SWITCH (CH)
LEFT HANDLEBAR SWITCH

DOWN SWITCH (-)

4: FUNCTION LEVER DOWN
5: VOICE CONTROL SWITCH
2: PASSING LIGHT CONTROL

17: HAZARD SWITCH (Except CH)

1: HEADLIGHT DIMMER SWITCH
5

SET
D23 Bl D23 G/Y

8P
Z03 Bl/Br Z03 G
6. CRUISE MAIN SWITCH
4. ENGINE STOP SWITCH
5. SET/- CRUISE CONTROL

GND
RIGHT HANDLEBAR SWITCH

73 W 73 W/Bl
9.
8.
7.

BRAKE
SWITCH
PARKING
7
LEVER

74 W 74 W
F24 Gr F24 G/Bu
SOL1-N S13 Br

FRONT
S12 Br/Bl

2P
2P

SOL1-P

SOLENOID
STARTER SWITCH
8
FUNCTION SWITCH

F16 Gr F16 Bu

SUSPENSION

(CRF1100D4/DL4)
S12 Bl
S13 Br
9
RES/+ CRUISE CONTROL

19 Gr 19 Bl
62 Bl

HORN
2 Br
4P

Z03 Bl 2 Br/Bl
BRAKE
FRONT

72 W 72 W
Z02 G
8 Bl/R 8 Bl/R
Z03 Bl 60 G/Y 60 Bl/G
60 G/Y
SWITCH BRAKE
FRONT

Z03 G
(CRUISE) SWITCH

(CRF1100D4/DL4) H03 Y
2P
GRIP
(Except

Z04 G H02 Bl
RIGHT
HEATER

Z05 G/Bu
Bl
CRF1100D/DL)

4P

Z05 G/Bu
Z07 G 24 Gr 24 G/O GND
FR METER PG SENS ABS
GND GND GND GND GND

15 Y 15 Y/R Vcc
63 P 66 P RxDT
41 Bu 41 O/Bu
RECEIVER

TxCT
WELD JOINT_D24 (DCT-SG) D24 Gr

WELD JOINT_D24 (DCT-SG) D24 Gr

Bl
2P

A03 W A03 W
A04 Bu A04 Bu
- +

WELD JOINT_15 (FI VCC) 15 Y

FRONT WHEEL
IMMOBILIZER SPEED SENSOR

Bl

Z05 G/Bu 1. GND

4P

C15 Bl 2. CANL
IMU

C21 Bl/R C25 Bl/R 3. CANH

6 Bl/R 4. +12V
C22 Bl/R
24P

C23 Bl/R
Bl
2P

(CRF1100D4/DL4)
C24 Bl/R
12P

64 Bu
FUEL

64 R/Bu
LEVEL

C25 Bl/R Z03 G Z03 G

W
SENSOR

JUNCTION 2
(FRM_CANH)

C28 Bl/R
C26 Bl/R

C16 Bl TCM (B-2 FRM_CANL)

C26 Bl/R TCM (B-13 FRM_CANH)
D20 V TCM (B-31 RANGE)
D13 Bl TCM (B-32 HSFT)
A09 Bu/Y ECM (B-14 FVW)
A10 Bu/Bl ECM (B-15 RVW)

C11 Bl
C12 Bl
73 W ECM (B-29 CRUISE MAIN/SET-)
24P

C13 Bl
(CRF1100D4/DL4) 60 G ECM (B-31 STOP)
C14 Bl
12P

19 Gr ECM (A-6 START)

C15 Bl
W

JUNCTION 2
(FRM_CANL)

C18 Bl
C16 Bl
C12 Bl ECM (A-30 FRM CANL)
C22 Bl/R ECM (A-31 FRM CANH)
JUNCTION 2 (K-LINE) 20 W 41 Bu ECM (C-14 IMOAU)
63 P ECM (C-15 IMOID)
JUNCTION 2 (K-LINE) 20 W

71 G ECM (C-26 STOP2)

JUNCTION 1 (FI_SG) 24 Gr 10 W ECM (C-27 ENG STOP SW)
74 W ECM (C-31 CR RES/+)
JUNCTION 1 (FI_SG) 24 Gr

WELD JOINT_2 2 Br
4P

8 Bl/R 8 Bl
REAR

60 G 60 Bl/G
JUNCTION 1 (SCS) 25 Y
72 W 72 Br
71 G 71 Br/G
REAR
BRAKE

JUNCTION 1 (CRF1100D4/DL4)
BRAKE SWITCH

C43 Bl/R
SWITCH (CRUISE)

Bl
2P

(DIAG-CANH)
A06 W A06 W
A05 Bu A05 Bu
- +

JUNCTION 1 (CRF1100D4/DL4)
(DIAG-CANL) C33 Bl
REAR WHEEL

Bl
18P
SPEED SENSOR

RESERVE SENSOR 61 R B19 R/G 18 FSR +B

A03 W 17 FVWS
VS SENSOR 34 P A07 W/G 16 MODE IND
A06 W 15 RVWS
25 Y 14 SCS
A02 W/Bu 13 IND
A09 Bu/Y 12 FPO
C13 Bl 11 CAN-L
Z07 G 10 GND
B18 R/Y 9 MR +B
A04 Bu 8 FVWB
P FUSE A01 R/G A01 R/G 7 IG
A05 Bu 6 RVWB
20 W 5 DIAG
ABS MODULATOR

60 G/Y 4 BLS
A10 Bu/Bl 3 RPO
C23 Bl/R 2 CAN-H
Z07 G 1 MOTOR GND
BREATH_Z05

Z05 G/Bu
Z05 G/Bu
62 Bl 1 HORN_OUT
Bl

F16 Gr 2 SW1(MF SEL_SW)

39P

3 P_OUT
F01 W 4 H/L_LO
5 ACC_OUT
6 OP_SW2
H02 Bl 7 GH
F10 Bl 8 SW7(HORN/FAVORITE)
57 Bu 9 FOG_OUT
F24 Gr 10 SG
F03 Br 11 DRL_OUT
Z05 G/Bu 12 LG
B22 R/Bu 13 BAT2
C28 Bl/R 14 F_CAN_H
C18 Bl 15 F_CAN_L
W07 Lb 16 W/L_FR
W06 O 17 W/L_FL
W03 Lb 18 W/L_RR
F08 W 19 SW2(DIMMER)
F02 Bu 20 H/L_HI
(CRF1100D4/DL4)

F12 W/R 21 SW5(SEL_RIGHT)

BCU

F09 Br 22 SW4(SEL_EFT)
F11 Lg 23 SW6(HAZ/TURN)
F13 W/Bl 24 SW3(MF UP)
25 OP_SW1
6 Bl/R 26 IGN
8 Bl/R 27 HORN_IN
( C/LIGHT )
F04 Be 28 CL_LR
( C/LIGHT )
F07 Y 29 CL_3
Z06 G
Z06 G

( C/LIGHT )
B18 R/Y
B19 R/G
22 Y/W
6 Bl/R
8 Bl/R
B21 R/W
B21 R/W
B21 R/W
B21 R/W

7 Y/Bu

B22 R/Bu

F06 P 30 CL_2
( C/LIGHT )
F05 V 31 CL_1
W05 O 32 W/L_RL
33
34
I
J

B
H
G

35
36
20 W 37 K-LINE
FUSE
FUSE
FUSE
FUSE
FUSE
Q FUSE

F14 R/W 38 ALARM

B21 R/W 39 BAT1

C24 Bl/R 1 CAN1-H

Bl

ABS FSR+ FUSE (20A)

C14 Bl 2 CAN1-L
48P

JUNCTION 1 (GND_RR)
JUNCTION 1 (GND_RR)

Z04 G 3 GND
JUNCTION 2 (BACK_UP)
JUNCTION 2 (BACK_UP)
JUNCTION 2 (BACK_UP)
JUNCTION 2 (BACK_UP)

4 RR_STRK_SEN_2
5 RR_STRK_SEN_1
S15 Bl 6 SVCC
7 TEST
8 TEST
(CRF1100D4/DL4)

8 Bl/R 9 IGN
C43 Bl/R 10 CAN2-H
C33 Bl 11 CAN2-L
12
13
S08 Y 14 JACK_STRK_SEN
15
16 TEST
S13 Br 17 FR_SOL (-)
18
S06 Br 19 MOT (-)
20 TEST
S04 Y 21 RR_SOL (-)
S24 Br 22 SGND
23 TEST
24
SCU

25
26 TEST
27
28
S08 Y
S04 Y

S15 Bl
S05 Bl

S24 Br
S06 Br
S03 Gr

29
77

30
Z06
W05

31
32
Y
8

Z06 G
O
G
2P
2P

8 Bl/R
Z06

F14 R/W
B21 R/W

S12 Bl 33 FR_SOL (+)

3P Gr

Z06 G

34
W03 Lb

S05 Bl 35 MOT (+)

Bl/R

36
8P

S03 Gr 37 RR_SOL (+)

38
S11 Br 39 FR_STRK_SEN2
S08 Y
S07 Bl
S05 Bl
S03 Bl
S04 W

S09 Br
S06 Br

2P O
2P Lb

S10 Bl 40 FR_STRK_SEN1
2P W

41 TEST
42 TEST
Z06 G
60 G/Y

8 Bl/R

B21 R/W 43 BATT

Z06
W05

DUMMY

44
45
Z06 G
W03 Lb

46 TEST
O
G
Z06 G
8 Br

47
3P Bl

48 TEST
SOL0-P
SOL0-N

PRE-LOAD MOTOR

POSITION SENSOR
REAR SUSPENSION

REAR SUSPENSION

REAR OPTION
REAR

TAIL
STOP
REAR

LEVEL

LIGHT

LIGHT
LIGHT

12V 5W
SOLENOID

BRAKE/
LICENSE
ADJUSTER
SUSPENSION

TAILLIGHT

LEFT REAR
SUSPENSION
(CRF1100D4/DL4)

RIGHT REAR

TURN SIGNAL
TURN SIGNAL
dummytext

WIRING DIAGRAMS
PGM-FI SYSTEM DIAGRAM
MT model:
FUEL PUMP 10A A W R A W W
MAIN2 R/Bu
FAN 20A B B
R/Bu
30A
TBW 10A C R/Bu
C
SUB VB 10A D R/W
D
Br/Bl Br/Bl
FI RELAY
FI 15A Bl
W R/Bu Br
R R/Bl Bl Br Br
EVAP PURGE Br/Bl
MAIN 30A IGNITION ST-MAG CONTROL Br
SWITCH 10A SOLENOID FUEL FAN
A11 IGP VALVE RELAY
Bl RELAY
Bl/G
Bl PCS B1 Y Br Bu/Bl
Y/R
METER Y
MAP Lg A15 PB EX-AI B2 Y/Bu Br Bl/W
10A SENSOR Gr
Bl/R PAIR CONTROL G
SOLENOID VALVE FUEL PUMP FAN
BATTERY Bl/R FLR A12 Br/Bl UNIT MOTOR
HORN/STOP IAT Y A17 TA
SENSOR Gr FAN A13 Gr/Bu
10A Br
ECT Lg B20 TW
SENSOR Br FUEL INJECTOR 1
Gr INJ1 B7 Bu
Y
Y R DIODE Y B18 VCC Br
Y (POWER BOX) INJ2 B8 P FUEL INJECTOR 2

Br/Bl A3 HS Br
REGULATOR/ LEFT A/F 1-1
RECTIFIER Bl A25 IPP-1 IG1-1 B33 Bl Bu/Bl
ALTERNATOR SENSOR Gr A36 COM-1
Br Br/Bl
W W A14 VH-1 1-2
IG1-2 B11 W Bu/W
IGNITION
Br
Br/Bl A16 HS IG2-1 B22 R Bu/R 2-1 COIL
RIGHT A/F Bl C32 IPP-2
SENSOR Br Br/Bl 2-2
Gr C21 COM-2 Y Bu/Y
IG2-2 B10
W W C22 VH-2 FRONT
G WHEEL
G G/Bu B12 LG SPEED W
G/O SENSOR Bu W
Y/R FVW B14 Bu/Y
IMMOBILIZER O/Bu Bu C14 IMOAU REAR ABS Y
RECEIVER P C15 IMOID WHEEL MODULATOR
W
Y/R Y SPEED Bu Bl/R
GP W B30 DRUMANG
SENSOR Bl
SENSOR RVW B15 Bu/Bl
G Gr Bl/R
SHIFT Y VS P
STROKE Bl C28 SSTRK SENSOR G
SENSOR Bl/R
(OPTION) Gr VSP C16 P Bl
Bu C1 MOP METER
Y/R P Bl/R
Bl
EGCA Bl/R C29 POT
Bl/R
G MID Bl
R C12 MOM
Bl/R
CKP Y
B16 PCP
ECM IMU Bl
SENSOR Y
W B17 PCM Bl/R
BCU Bl
W/Bl W B29 CRUISE
CRUISE SET/- SWITCH Bl/R
SCU Bl

CRUISE MAIN SWITCH FRM CANH A31 Bl/R

Gr
FRM CANL A30 Bl Bl
W C31 CR RES/+
CRUISE RES/+ SWITCH
G/Bl Gr B23 SG
SUBVB_RLY A27 V/Y R/W
ENGINE STOP SWITCH
G/Bl W/Bu W C27 ENG STOP SW
STARTER SWITCH SUB VB
Bl Gr A6 START RELAY
FRONT BRAKE SWITCH G
V
Bl/R Bl/G
SUBVB A8 V
Bl/R Bl
Bl/G G B31 STOP
REAR BRAKE SWITCH G/Y
Br
NEUTRAL B19 Lg G NEUTRAL
Bl FRONT BRAKE SWITCH
SWITCH(CRUISE)
Bl Br/Bl W G C26 STOP2 SPINDLE C30 Y/W G SHIFT SPINDLE
REAR BRAKE Y
SWITCH(CRUISE) SWITCH
STARTER Br
Bl Bl Bl/Br Bl B21 CLUTCH CRUISE
RELAY W
SWITCH CLUTCH SWITCH CLUTCH SWITCH
G/R (CRUISE) SCS A19 Y Y
G Bl/G Bl/R C18 CLUTCH
Bl DIAG CANH A29 Bl/R Bl/R
G G/W G A18 SSTAND
STARTER SIDESTAND DIAG CANL A28 Bl Bl
STARTER RELAY SWITCH PG A9 G G/Bu
MOTOR Y/W A4 ST INH PG A10 G
G R/Bu
DLC SCS SHORT
Y/W C10 TBWRLY PG A22 G CONNECTOR
PG A23 G
TBW
RELAY PG A24 G

1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11
G Be : Beige Lg : Light green
TMOP B3 R
12 13 14 15 16 17 18 19 20 21 22 14 15 16 17 18 19 20 21 22 23 24 25 26 12 13 14 15 16 17 18 19 20 21 22 Br/G A1 TBW+B Bl : Black O : Orange
23 24 25 26 27 28 29 30 31 32 33 27 28 29 30 31 32 33 34 35 36 37 38 39 23 24 25 26 27 28 29 30 31 32 33 Bu/W Bu A26 APS1 TMOM B4 Bu Br : Brown P : Pink
Y/R Br A32 APS1VCC TPS1 B27 Bu/Bl Bu : Blue R : Red
ECM 33P (Gray) ECM 39P (Black) ECM 33P (Black) Y/Bl P A20 APS1SG G : Green V : Violet
GRIP APS TPS2 B28 Bu/W
CONNECTOR C CONNECTOR A CONNECTOR B Gr Y A38 APS2 TPS Gr : Gray W : White
W/R TPS_SVCC B25 Y
W A39 APS2VCC
(ECM SIDE) (ECM SIDE) (ECM SIDE) W/Bl A7 APS2SG Lg TBW UNIT Lb : Light blue Y : Yellow
Gr TPSSG B13

24-8
 dummytext

WIRING DIAGRAMS
DCT model:
FUEL PUMP 10A A W R A W W
MAIN2 R/Bu R/Bu
FAN 20A B 30A B
R/Bu
TBW 10A C DCT-M C
R/W
SUB VB 10A D 30A D
W R/W
Br/Bl Br/Bl
FI 15A FI RELAY Bl Br
W R/Bu Br
R R/Bl Bl Br Br
EVAP PURGE Br/Bl
Y/R A4 VCC IGP A7
MAIN 30A IGNITION ST-MAG CONTROL Br
SOLENOID FUEL FAN Y Y/R
SWITCH 10A A11 IGP
Bl VALVE RELAY RELAY TR SENSOR W B7 DRUMANG
Bl/G
Y Br G Gr
Bl PCS B1 Y/R Bu/Bl Y Bl SHIFT CONTROL
METER Y SHIFT SPINDLE MOTOR
MAP Lg A15 PB EX-AI B2 Y/Bu Br Bl/W W W B20 SPDL
10A SENSOR Gr ANGLE SENSOR Bu
Bl/R PAIR CONTROL G Y SFTMOP A1 P/Bu Bu
SOLENOID VALVE FUEL PUMP FAN SHIFT PEDAL P/Bu
BATTERY Br/Bl UNIT MOTOR Y B10 SFTPANG SFTMOP A12
Bl/R FLR A12 ANGLE SENSOR
HORN/STOP IAT Y A17 TA Gr SFTMOM A2 Y/Bu
SENSOR Gr FAN A13 Gr/Bu Y Y/R
10A Br
SFTMOM A13 Y/Bu Y
ECT Lg
CLUTCH LINE
B20 TW R B18 PLINE
SENSOR Br FUEL INJECTOR 1 EOP SENSOR Gr
Gr INJ1 B7 Bu Y/R
Y No.1
Y R DIODE Y B18 VCC Br No.1 CLUTCH LINEAR
Y (POWER BOX) EOP SENSOR Y/G B19 PC1 SOLENOID
INJ2 B8 P FUEL INJECTOR 2 Gr
Y/R VALVE
Br/Bl A3 HS Br No.2 CLUTCH B8 PC2
LSOL1P A5 Y
REGULATOR/ LEFT A/F 1-1 EOP SENSOR
Bl
Bl A25 IPP-1 IG1-1 B33 Bl Bu/Bl Gr LSOL1M A9 W W/R
ALTERNATOR RECTIFIER SENSOR Gr A36 COM-1
Br Br/Bl
W W A14 VH-1 1-2 LSOL2P A6 Bu
IG1-2 B11 W Bu/W EOT Bu B21 TOIL
IGNITION SENSOR LSOL2M A10 Gr
Br Gr
Br/Bl A16 HS IG2-1 B22 R Bu/R 2-1 COIL No.2
RIGHT A/F V Br/W LINEAR
Bl C32 IPP-2 Br
SENSOR Br/Bl 2-2 INNER SOLENOID
Gr C21 COM-2 Y Bu/Y
IG2-2 B10 MAINSHAFT P A18 NM1P VALVE
W W C22 VH-2 FRONT Gr
G WHEEL SENSOR
G G/Bu B12 LG SPEED W V
G/O SENSOR Bu W OUTER
Y/R FVW B14 Bu/Y MAINSHAFT P B25 NM2P
IMMOBILIZER O/Bu Bu C14 IMOAU REAR ABS Y Gr
RECEIVER SENSOR
P C15 IMOID WHEEL W MODULATOR
SPEED Bu Bl/R
SENSOR Bl Gr
EOP Y RVW B15 Bu/Bl
W C20 POIL N SWITCH
SENSOR Bl/R Bl/Bu V B31 RANGE
Gr VS P D SWITCH
SENSOR G
Bl/R
Bu C1 MOP
VSP C16 P
METER
Bl A/M SWITCH TCM
P Bl/R G/W
Y/R
Bl
EGCA Bl/R C29 POT SHIFT_UP SWITCH(+)
Bl/R
G MID Bl Bl/Bu Bl B32 HSFT
R C12 MOM
Bl/R
CKP Y
B16 PCP
ECM IMU Bl G/W
SENSOR Y
Bl/R SHIFT_DOWN SWITCH(-)
W B17 PCM BCU Bl NEUTRAL
W/Bl W B29 CRUISE Bl/R SWITCH
Gr A22 SG
CRUISE SET/- SWITCH SCU Bl NELTRAL A32 Lg
W B3 K-LINE
FRM CANH A31 Bl/R Bl/R B13 FRM_CANH
CRUISE MAIN SWITCH Gr FRM CANL A30 Bl Bl Bl B2 FRM_CANL
W C31 CR RES/+ PT CANH C25 Bl/R Bl/R A33 PT_CANH
CRUISE RES/+ SWITCH PT CANL C24 Bl Bl A21 PT_CANL
G/Bl Gr B23 SG LSOL INH C19 Bu Bu A19 LSOLINH
ENGINE STOP SWITCH SUBVB_RLY A27 V/Y R/W
G/Bl W/Bu W C27 ENG STOP SW
STARTER SWITCH SUB VB
Bl Gr A6 START RELAY
FRONT BRAKE SWITCH G
V
Bl/R Bl/G
SUBVB A8 V V A8 SUBVB
Bl/R Bl Bl/G G B31 STOP
REAR BRAKE SWITCH G/Y DCTRLY C9 Y R/W

DCT
Bl RELAY
W A3 PVB PG A23 G
G W W A14 PVB PG A24 G
Bl Y
Br W G C26 STOP2
STARTER FRONT BRAKE REAR BRAKE LG A11 G/Bu
Br
RELAY Bl SWITCH SWITCH W
SWITCH (CRUISE) (CRUISE)
G/R SCS A19 Y Y
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
Bl DIAG CANH A29 Bl/R Bl/R
G G/W G A18 SSTAND 12 13 14 15 16 17 18 19 20 21 22 12 13 14 15 16 17 18 19 20 21 22
STARTER SIDESTAND DIAG CANL A28 Bl Bl 23 24 25 26 27 28 29 30 31 32 33 23 24 25 26 27 28 29 30 31 32 33
STARTER RELAY SWITCH PG A9 G G/Bu
MOTOR Y/W A4 ST INH PG A10 G
G R/Bu
DLC SCS SHORT TCM 33P (Black) TCM 33P (Gray)
Y/W C10 TBWRLY PG A22 G CONNECTOR CONNECTOR A CONNECTOR B
PG A23 G
TBW (TCM SIDE) (TCM SIDE)
RELAY PG A24 G
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 G Be : Beige Lg : Light green
12 13 14 15 16 17 18 19 20 21 22 14 15 16 17 18 19 20 21 22 23 24 25 26 12 13 14 15 16 17 18 19 20 21 22
A1 TBW+B
TMOP B3 R Bl : Black O : Orange
Br/G
23 24 25 26 27 28 29 30 31 32 33 27 28 29 30 31 32 33 34 35 36 37 38 39 23 24 25 26 27 28 29 30 31 32 33
Bu/W Bu A26 APS1 TMOM B4 Bu Br : Brown P : Pink
Y/R Br A32 APS1VCC TPS1 B27 Bu/Bl Bu : Blue R : Red
ECM 33P (Gray) ECM 39P (Black) ECM 33P (Black) Y/Bl P A20 APS1SG G : Green V : Violet
GRIP APS TPS2 B28 Bu/W
CONNECTOR C CONNECTOR A CONNECTOR B Gr Y A38 APS2 TPS Gr : Gray W : White
TPS_SVCC B25 Y
(ECM SIDE) (ECM SIDE) (ECM SIDE) W/R W A39 APS2VCC Lb : Light blue Y : Yellow
W/Bl Gr A7 APS2SG TPSSG B13 Lg TBW UNIT

24-9
INDEX
dummytext

INDEX
A/F SENSOR ································································4-73 DCT DTC INDEX ························································ 13-10
A D

ABS DTC INDEX···························································20-9 DCT DTC TROUBLESHOOTING······························· 13-12

ABS DTC TROUBLESHOOTING ·······························20-13 DCT RELAY ······························································· 13-68
ABS INDICATOR CIRCUIT TROUBLESHOOTING ···20-11 DCT SYMPTOM TROUBLESHOOTING ······················ 13-3
ABS MODULATOR ·····················································20-27 DCT TROUBLESHOOTING INFORMATION ··············· 13-7
ABS TROUBLESHOOTING INFORMATION················20-6 DIAGNOSTIC CODE INDICATION ······························ 23-9
ACCESSORY SOCKET DRIVE CHAIN······························································· 3-18
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4) ···············22-47 DRIVE CHAIN SLIDER················································· 3-21
AIR CLEANER ································································3-5 DUAL CLUTCH/PRIMARY DRIVEN GEAR ··············· 13-51
AIR CLEANER HOUSING ············································7-14 ECM·············································································· 4-77
E

ALTERNATOR CHARGING COIL ······························21-10 ECT SENSOR ······························································ 4-75

ALTERNATOR COVER ················································11-4 EGCA ··········································································· 4-76
Apple CarPlayTM TROUBLESHOOTING ·······················22-4 ELECTRONIC SUSPENSION SYSTEM
BALANCER···································································14-6 DIAGRAM ··································································· 22-86
B

BATTERY······································································21-6 ELECTRONIC SUSPENSION SYSTEM DTC

BCU·············································································22-51 INDEX········································································· 22-87
BODY CONTROL SYSTEM DIAGRAM······················22-54 ELECTRONIC SUSPENSION SYSTEM DTC
BODY CONTROL SYSTEM DTC INDEX ···················22-55 TROUBLESHOOTING················································ 22-88
BODY CONTROL SYSTEM DTC ELECTRONIC SUSPENSION SYSTEM SYMPTOM
TROUBLESHOOTING ················································22-56 TROUBLESHOOTING················································ 22-85
BODY CONTROL SYSTEM TROUBLESHOOTING ELECTRONIC SUSPENSION SYSTEM
INFORMATION ···························································22-53 TROUBLESHOOTING INFORMATION ····················· 22-84
BODY PANEL LOCATIONS ···········································2-3 EMISSION CONTROL SYSTEMS ······························· 1-79
BRAKE FLUID·······························································3-21 ENGINE IDLE SPEED·················································· 3-14
BRAKE FLUID REPLACEMENT/AIR BLEEDING ········19-6 ENGINE INSTALLATION ··········································· 16-12
BRAKE LIGHT SWITCH ···············································3-23 ENGINE OIL ································································· 3-11
BRAKE LOCK OPERATION (DCT model) ···················3-23 ENGINE OIL FILTER···················································· 3-12
BRAKE PAD/DISC ························································19-8 ENGINE REMOVAL ····················································· 16-4
BRAKE PADS WEAR ···················································3-22 EOP SENSOR ···························································· 13-65
BRAKE SWITCH·························································22-40 EOP SWITCH (MT model)·········································· 22-24
BRAKE SYSTEM ··························································3-22 EOT SENSOR ···························································· 13-65
BRAKE/TAILLIGHT·····················································22-13 EVAP PURGE CONTROL SOLENOID VALVE/
CABLE & HARNESS ROUTING ···································1-32 CANISTER ··································································· 7-22
C

CAM CHAIN TENSIONER LIFTER·····························10-11 EVAPORATIVE EMISSION CONTROL SYSTEM ······· 3-16
CAMSHAFT ································································10-12 EXHAUST GAS CONTROL ACTUATOR CABLE ········ 3-17
CHARGING SYSTEM INSPECTION ····························21-8 FAN RELAY·································································· 8-12
F

CKP SENSOR·······························································4-83 FI RELAY······································································ 4-81

CLUTCH········································································12-8 FLYWHEEL ·································································· 11-6
CLUTCH EOP SENSOR·············································13-64 FORK·········································································· 17-20
CLUTCH EOP SENSOR COVER (DCT model) ···········2-27 FRONT BRAKE CALIPER·········································· 19-19
CLUTCH INITIALIZE LEARNING (TCM) ····················13-68 FRONT CENTER COWL·············································· 2-12
CLUTCH LEVER·························································12-23 FRONT CROSS PLATE ················································· 7-8
CLUTCH OIL FEED PIPE ···········································13-39 FRONT FENDER·························································· 2-23
CLUTCH OIL FILTER (DCT model)······························3-13 FRONT LOWER COVER ············································· 2-14
CLUTCH SWITCH (MT model) ···································22-43 FRONT MASTER CYLINDER ···································· 19-13
CLUTCH SYSTEM (MT model) ····································3-25 FRONT NUMBER STAY (ID/IN only) ··························· 2-55
COMPONENT LOCATION FRONT SIDE COWL (CRF1100A/AL/D/DL) ················ 2-13
ALTERNATOR/STARTER CLUTCH ························11-3 FRONT UPPER COVER ·············································· 2-21
CLUTCH/GEARSHIFT LINKAGE (MT model) ·········12-3 FRONT WHEEL·························································· 17-13
CRANKCASE/TRANSMISSION/BALANCER ··········14-4 FRONT WINKER COVER ············································ 2-15
CRANKSHAFT/PISTON/CYLINDER························15-3 FUEL INJECTOR·························································· 7-17
CYLINDER HEAD/VALVE/CAMSHAFT ···················10-3 FUEL LEVEL SENSOR ·············································· 22-24
DUAL CLUTCH TRANSMISSION (DCT model) ······13-4 FUEL LINE ····································································· 3-4
ENGINE REMOVAL/INSTALLATION·······················16-3 FUEL LINE INSPECTION··············································· 7-4
FRONT WHEEL/SUSPENSION/STEERING ···········17-3 FUEL PUMP UNIT·························································· 7-8
FUEL SYSTEM···························································7-3 FUEL RELAY································································ 7-14
HYDRAULIC BRAKE················································19-3 FUEL TANK ···································································· 7-7
REAR WHEEL/SUSPENSION ·································18-3 GEARSHIFT ARM/GEARSHIFT PEDAL···················· 12-21
G

COOLANT REPLACEMENT···········································8-5 GEARSHIFT LINKAGE

25
COOLING SYSTEM······················································3-15 CLUTCH/GEARSHIFT LINKAGE (MT model) ······· 12-18
CRANKCASE ASSEMBLY ·········································14-26 DUAL CLUTCH TRANSMISSION (DCT model) ···· 13-58
CRANKCASE BREATHER ·············································3-5 GP SENSOR (MT model) ············································· 4-79
CRANKCASE SEPARATION······································14-11 GPS ANTENNA ·························································· 22-99
CRANKPIN BEARING ··················································15-9 GRIP APS····································································· 4-80
CRANKSHAFT······························································15-4 GRIP HEATER
CUSHION LINKAGE ···················································18-17 (CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4) ··············· 22-47
CYLINDER COMPRESSION ········································10-4 HANDLEBAR································································ 17-4
H

CYLINDER HEAD COVER ···········································10-4 HEADLIGHT ································································· 22-6

CYLINDER HEAD/CAM CHAIN TENSIONER············10-18 HEADLIGHT AIM·························································· 3-24

25-1
 dummytext

INDEX
HEEL GUARD ······························································ 2-26 REAR SEAT UNDER COVER ······································ 2-34
HISS INDICATOR ······················································ 23-11 REAR SIDE COWL······················································· 2-30
HORN ········································································· 22-46 REAR SIDE INNER COVER········································· 2-33
HSTC·········································································· 22-46 REAR WHEEL ······························································ 18-4
IAT SENSOR································································ 4-75 REGULATOR/RECTIFIER············································ 21-9
I

IGNITION COIL ······························································ 5-9 RIGHT CRANKCASE COVER

IGNITION SWITCH ···················································· 22-25 CLUTCH/GEARSHIFT LINKAGE (MT model) ········· 12-4
IGNITION SYSTEM INSPECTION································· 5-7 DUAL CLUTCH TRANSMISSION (DCT model) ···· 13-41
IGNITION TIMING ························································ 5-13 RIGHT HANDLEBAR SWITCH··································· 22-33
IMMOBILIZER RECEIVER········································· 23-11 RIGHT REAR ENGINE COVER ··································· 2-27
IMU ··············································································· 4-73 ROCKER ARM······························································ 10-8
INNER COVER······························································· 2-9 SARI GUARD (ID only) ················································· 2-56
S

INNER PANEL COVER················································ 2-17 SCREEN ADJUST RAIL

INSULATOR ······························································· 10-26 (CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4) ················· 2-19
KEY REGISTRATION PROCEDURES ························ 23-5 SCU ············································································ 22-83
K

KNUCKLE GUARD······················································· 2-22 SEAT CATCH HOOK/SEAT LOCK CYLINDER ··········· 2-30
LEFT HANDLEBAR SWITCH····································· 22-26 SEAT RAIL···································································· 2-43
L

LEFT REAR COVER ···················································· 2-26 SECONDARY AIR SUPPLY SYSTEM

LICENSE LIGHT························································· 22-12 FUEL SYSTEM ························································ 7-19
LINEAR SOLENOID VALVE ······································ 13-47 MAINTENANCE ······················································· 3-15
LUBRICATION & SEAL POINTS ································· 1-28 SERVICE INFORMATION
LUBRICATION SYSTEM DIAGRAM······························ 9-3 ALTERNATOR/STARTER CLUTCH ························ 11-2
MAIN JOURNAL BEARING·········································· 15-6 ANTI-LOCK BRAKE SYSTEM (ABS)······················· 20-2
M

MAIN SEAT ···································································· 2-5 BATTERY/CHARGING SYSTEM····························· 21-2

MAIN STEP ·································································· 2-27 CLUTCH/GEARSHIFT LINKAGE (MT model) ········· 12-2
MAINSHAFT SENSOR··············································· 13-62 COOLING SYSTEM ··················································· 8-2
MAINTENANCE SCHEDULE········································· 3-2 CRANKCASE/TRANSMISSION/BALANCER ·········· 14-2
MAP SENSOR······························································ 4-74 CRANKSHAFT/PISTON/CYLINDER························ 15-2
METER/MID ······························································· 22-13 CYLINDER HEAD/VALVE/CAMSHAFT ··················· 10-2
MIDDLE COWL ······························································ 2-7 DUAL CLUTCH TRANSMISSION (DCT model) ······ 13-2
MIL CIRCUIT TROUBLESHOOTING··························· 4-72 ELECTRIC STARTER ················································ 6-2
MODEL IDENTIFICATION ············································· 1-3 ENGINE REMOVAL/INSTALLATION ······················ 16-2
MUD GUARD ······························································· 2-38 FRAME/BODY PANELS/EXHAUST SYSTEM··········· 2-2
MUFFLER/EXHAUST PIPE ········································· 2-45 FRONT WHEEL/SUSPENSION/STEERING ··········· 17-2
NEUTRAL SWITCH (DCT model) ······························ 13-66 FUEL SYSTEM ·························································· 7-2
N

NEUTRAL SWITCH (MT model) ································ 22-44 HYDRAULIC BRAKE ··············································· 19-2
NUTS, BOLTS, FASTENERS ······································ 3-33 IGNITION SYSTEM···················································· 5-2
OIL PRESSURE INSPECTION ······································ 9-5 IMMOBILIZER SYSTEM (HISS) ······························ 23-2
O

OIL PUMP ······································································ 9-5 LIGHTS/METERS/SWITCHES/OTHER

OIL PUMP DRIVEN GEAR············································· 9-8 ELECTRONIC CONTROL UNITS ···························· 22-2
OIL STRAINER······························································· 9-9 LUBRICATION SYSTEM ··········································· 9-2
OPEN AIR TEMPERATURE SENSOR ······················ 22-23 MAINTENANCE ························································· 3-2
PANNIER BRACKET PGM-FI SYSTEM ······················································· 4-2
P

(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)················· 2-37 REAR WHEEL/SUSPENSION ································· 18-2

PARKING BRAKE CALIPER (DCT model) ················ 19-25 SERVICE RULES ··························································· 1-2
PARKING BRAKE LEVER (DCT model)···················· 19-23 SHIFT CONTROL MOTOR/REDUCTION GEARS····· 13-55
PARKING BRAKE SWITCH (DCT model) ················· 22-43 SHIFT SPINDLE ANGLE SENSOR···························· 13-64
PGM-FI SYMPTOM TROUBLESHOOTING··················· 4-9 SHIFT SPINDLE SWITCH (MT model)························· 4-80
PGM-FI SYSTEM DIAGRAM ······································· 24-8 SHOCK ABSORBER ···················································· 18-9
PGM-FI SYSTEM DTC INDEX····································· 4-10 SIDESTAND
PGM-FI SYSTEM DTC TROUBLESHOOTING············ 4-17 FRAME/BODY PANELS/EXHAUST SYSTEM········· 2-54
PGM-FI TROUBLESHOOTING INFORMATION············ 4-5 MAINTENANCE ······················································· 3-26
PILLION SEAT ······························································· 2-5 SIDESTAND SWITCH ················································ 22-44
PILLION STEP ····························································· 2-29 SKID PLATE ································································· 2-25
PISTON/CYLINDER ··················································· 15-12 SPARK PLUG ································································· 3-6
PRIMARY DRIVE GEAR SPECIAL TOOL LIST ··················································· 1-30
CLUTCH/GEARSHIFT LINKAGE (MT model)······· 12-16 SPECIFICATIONS ·························································· 1-6
DUAL CLUTCH TRANSMISSION (DCT model)···· 13-54 STARTER CLUTCH······················································ 11-8
RADIATOR COOLANT················································· 3-14 STARTER MOTOR························································· 6-7
R

RADIATOR RESERVE TANK ······································ 8-11 STARTER RELAY ························································ 6-11

RADIATOR/COOLING FAN ··········································· 8-7 STARTER RELAY SWITCH ··········································· 6-9
REAR BRAKE CALIPER ············································ 19-21 STATOR ······································································· 11-5
REAR BRAKE PEDAL················································ 19-16 STEERING HEAD BEARINGS ····································· 3-33
REAR CARRIER STEERING STEM······················································· 17-45
(CRF1100A2/AL2/A4/AL4/D2/DL2/D4/DL4)················· 2-37 SUB VB RELAY ···························································· 4-83
REAR CENTER COWL ················································ 2-35 SUSPENSION ······························································ 3-26
REAR FENDER A ························································ 2-38 SWINGARM································································ 18-21
REAR FENDER B ························································ 2-40 SYSTEM DIAGRAM
REAR MASTER CYLINDER ······································ 19-17 ANTI-LOCK BRAKE SYSTEM (ABS)······················· 20-4

25-2
dummytext

INDEX
BATTERY/CHARGING SYSTEM ·····························21-5 TR SENSOR······························································· 13-63
DUAL CLUTCH TRANSMISSION (DCT model) ······13-6 TRANSMISSION ························································ 14-13
ELECTRIC STARTER ················································6-5 TROUBLESHOOTING
IGNITION SYSTEM ····················································5-5 ALTERNATOR/STARTER CLUTCH························ 11-2
IMMOBILIZER SYSTEM (HISS)·······························23-4 BATTERY/CHARGING SYSTEM ···························· 21-3
SYSTEM FLOW PATTERN ············································8-3 CLUTCH/GEARSHIFT LINKAGE (MT model) ········· 12-2
SYSTEM LOCATION COOLING SYSTEM··················································· 8-2
ANTI-LOCK BRAKE SYSTEM (ABS)·······················20-3 CRANKCASE/TRANSMISSION/BALANCER ·········· 14-3
BATTERY/CHARGING SYSTEM ·····························21-5 CRANKSHAFT/PISTON/CYLINDER ······················· 15-2
DUAL CLUTCH TRANSMISSION (DCT model) ······13-5 CYLINDER HEAD/VALVE/CAMSHAFT··················· 10-2
ELECTRIC STARTER ················································6-4 ELECTRIC STARTER················································ 6-3
IGNITION SYSTEM ····················································5-4 FRAME/BODY PANELS/EXHAUST SYSTEM ·········· 2-2
IMMOBILIZER SYSTEM (HISS)·······························23-3 FRONT WHEEL/SUSPENSION/STEERING ··········· 17-2
LIGHTS/METERS/SWITCHES/OTHER HYDRAULIC BRAKE ··············································· 19-2
ELECTRONIC CONTROL UNITS ····························22-3 IGNITION SYSTEM ··················································· 5-3
PGM-FI SYSTEM ·······················································4-3 IMMOBILIZER SYSTEM (HISS) ···························· 23-10
SYSTEM TESTING·························································8-4 LUBRICATION SYSTEM ··········································· 9-2
TANK FRONT COVER ···················································2-6 REAR WHEEL/SUSPENSION································· 18-2
T

TANK SIDE COVER (CRF1100A/AL/D/DL)··················2-24 TURN SIGNAL LIGHT ················································ 22-11

TBW RELAY ·································································4-82 VALVE CLEARANCE ····················································· 3-7
V

TCM ············································································13-66 VS SENSOR································································· 4-79

TECHNICAL FEATURES··············································1-82 WATER PUMP ····························································· 8-11
W

THERMOSTAT ·······························································8-6 WHEEL SPEED SENSOR·········································· 20-24

THROTTLE BODY ························································7-16 WHEELS/TIRES ··························································· 3-33
THROTTLE OPERATION ···············································3-4 WINDSCREEN ····························································· 2-18
TOOL BOX····································································2-26 WIRING DIAGRAM (DCT model) ································· 24-5
TORQUE VALUES························································1-16 WIRING DIAGRAM (MT model) ··································· 24-2

25-3
 Honda Motor Co., Ltd. 2020
Published by Honda Motor Co., Ltd. Book number : 62MKS02
Printed in Japan 2020.05