ABS Disabled (Conventional Mode)

 

During cruising (without braking) or in case of a malfunction with the ABS, the ECU stops operating. This is “Conventional Mode”.

 

When the caliper fluid pressure is to be increased, first the tappet of inlet solenoid valve opens (normally open). The brake fluid flows through the valve body as shown in the diagram below to increase the brake fluid pressure in the caliper. The master cylinder pressurizes to the brake caliper directly, increasing the braking force.

 

 

1. Brake Lever

 

2. Front Inlet Solenoid Valve

 

3. Pump Motor

 

4. Pump

 

5. Front Reservoir

 

6. Front Outlet Solenoid Valve

 

7. Front Caliper

 

GENERAL INFORMATION

 

Technical Information – ABS (Anti – Lock Brake System)

 

Riding Characteristics of ABS

 

ABS is designed to help prevent the wheels from locking up when hard brakes are applied while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.

 

Brake control function is identical to that of a conventional motorcycle. The brake lever is used for the front brake and the brake pedal for the rear brake.

 

Although the ABS provides stability while stopping by preventing wheel lock-up, remember the fol-lowing characteristics:

 

○ABS cannot compensate for adverse road conditions, misjudgement or improper application of brakes. You must take the same care as with motorcycles not equipped with ABS.

 

○ABS is not designed to shorten the braking distance. On loose, uneven or downhill surfaces, the stopping distance of a motorcycle with ABS may be longer than that of an equivalent motorcycle without ABS. Use special caution in such areas.

 

○ABS will help prevent wheel lock-up during straight-up braking, but it cannot control wheel slip which may be caused by braking during cornering. When turning a corner, it is better to limit braking to the light application of both brakes or not to brake at all. Reduce your speed before you get into the corner.

 

○The ECU integrated in the ABS compare vehicle speed with wheel speed. Since non-recommended tires can affect wheel speed, they may confuse the ECU, which can extend braking distance.

WARNING

 

Use of non-recommended tires may cause malfunctioning of ABS and can lead to extended braking distance. The rider could have an accident as a result. Always use recommended standard tires for this motorcycle.

 

NOTE

○When the ABS is functioning, you may feel a pulsing in the brake lever or pedal. This is normal. You need not suspend applying brakes.

○Immediately after turning the ignition switch on, you may hear a click of the relay operating. This is the sound of self-checking and is quite normal.

○ABS does not function at the speed of approx. 6 km/h or below. ○ABS does not function if the battery is discharged.

 

GENERAL INFORMATION 1-27

 

Unit Conversion Table

 

Prefixes for Units: Units of Length:

 

Prefix	Symbol		Power
mega	M	× 1 000
kilo	k	×	1 000
centi	c	×	0.01
milli	m	×	0.001
micro	µ	× 0.000001

 

 

Units of Mass:

 

kg	×	2.205	=	lb
g	×	0.03527	=	oz

 

Units of Volume:

 

L	×	0.2642	=	gal (US)
L	×	0.2200	=	gal (imp)
L	×	1.057	=	qt (US)
L	×	0.8799	=	qt (imp)
L	×	2.113	=	pint (US)
L	×	1.816	=	pint (imp)
mL	×	0.03381	=	oz (US)
mL	×	0.02816	=	oz (imp)
mL	×	0.06102	=	cu in

 

Units of Force:

 

N	×	0.1020	=	kg
N	×	0.2248	=	lb
kg	×	9.807	=	N
kg	×	2.205	=	lb

 

 

km	×	0.6214	=	mile
m	×	3.281	=	ft
mm	×	0.03937	=	in

 

Units of Torque:

 

N·m	×	0.1020	=	kgf·m
N·m	×	0.7376	=	ft·lb
N·m	×	8.851	=	in·lb
kgf·m	×	9.807	=	N·m
kgf·m	×	7.233	=	ft·lb
kgf·m	×	86.80	=	in·lb

 

Units of Pressure:

 

kPa	×	0.01020	=	kgf/cm²
kPa	×	0.1450	=	psi
kPa	×	0.7501	=	cmHg
kgf/cm²	×	98.07	=	kPa
kgf/cm²	×	14.22	=	psi
cmHg	×	1.333	=	kPa

 

Units of Speed:

 

km/h × 0.6214 = mph

 

 

Units of Power:

 

kW	×	1.360	=	PS
kW	×	1.341	=	HP
PS	×	0.7355	=	kW
PS	×	0.9863	=	HP

 

Units of Temperature:

 

PERIODIC MAINTENANCE 2-1

 

 

Periodic Maintenance

 

Table of Contents

 

.........................................................................................................................

Periodic Maintenance Chart...................................................................................................	2-3
Torque and Locking Agent......................................................................................................	2-6
Specifications	2-11
Special Tools..........................................................................................................................	2-13
Periodic Maintenance Procedures..........................................................................................	2-14
Fuel System (DFI)................................................................................................................	2-14
Air Cleaner Element Cleaning...........................................................................................	2-14
Throttle Control System Inspection...................................................................................	2-15
Engine Vacuum Synchronization Inspection.....................................................................	2-16
Idle Speed Inspection.......................................................................................................	2-18
Idle Speed Adjustment......................................................................................................	2-18
Fuel Hose Inspection (fuel leak, damage, installation condition)......................................	2-19
Evaporative Emission Control System (California Model)...................................................	2-19
Evaporative Emission Control System Inspection............................................................	2-19
Cooling System....................................................................................................................	2-20
Coolant Level Inspection...................................................................................................	2-20
Radiator Hose Damage and Installation Condition Inspection..........................................	2-21
Air Suction System..............................................................................................................	2-21
Air Suction System Damage Inspection............................................................................	2-21
Engine Top End...................................................................................................................	2-21
Valve Clearance Inspection..............................................................................................	2-21
Valve Clearance Adjustment.............................................................................................	2-23
Clutch...................................................................................................................................	2-26
Clutch Operation Inspection..............................................................................................	2-26
Wheels/Tires........................................................................................................................	2-26
Air Pressure Inspection.....................................................................................................	2-26
Wheel/Tire Damage Inspection.........................................................................................	2-27
Tire Tread Wear, Abnormal Wear Inspection....................................................................	2-27
Wheel Bearing Damage Inspection..................................................................................	2-28
Drive Train...........................................................................................................................	2-28
Drive Chain Lubrication Condition Inspection...................................................................	2-28
Drive Chain Slack Inspection............................................................................................	2-29
Drive Chain Slack Adjustment..........................................................................................	2-29
Wheel Alignment Inspection.............................................................................................	2-30
Drive Chain Wear Inspection............................................................................................	2-31
Chain Guide Inspection.....................................................................................................	2-31
Brake System......................................................................................................................	2-32
Brake Fluid Leak (Brake Hose and Pipe) Inspection........................................................	2-32
Brake Hose and Pipe Damage and Installation Condition Inspection...............................	2-32
Brake Operation Inspection..............................................................................................	2-33
Brake Fluid Level Inspection.............................................................................................	2-33
Brake Pad Wear Inspection..............................................................................................	2-34
Brake Light Switch Operation Inspection..........................................................................	2-34
Suspensions........................................................................................................................	2-35
Front Forks/Rear Shock Absorber Operation Inspection..................................................	2-35
Front Fork Oil Leak Inspection..........................................................................................	2-35
Rear Shock Absorber Oil Leak Inspection........................................................................	2-35
Steering System..................................................................................................................	2-36
Steering Play Inspection...................................................................................................	2-36
Steering Play Adjustment..................................................................................................	2-36

 

PERIODIC MAINTENANCE

 

 

Steering Stem Bearing Lubrication...................................................................................	2-37
Electrical System.................................................................................................................	2-37
Spark Plug Condition Inspection.......................................................................................	2-37
Lights and Switches Operation Inspection........................................................................	2-38
Headlight Aiming Inspection.............................................................................................	2-40
Sidestand Switch Operation Inspection............................................................................	2-41
Engine Stop Switch Operation Inspection.........................................................................	2-42
Others..................................................................................................................................	2-43
Chassis Parts Lubrication.................................................................................................	2-43
Bolts, Nuts and Fasteners Tightness Inspection...............................................................	2-44
Replacement Parts..............................................................................................................	2-45
Air Cleaner Element Replacement....................................................................................	2-45
Fuel Hose Replacement...................................................................................................	2-45
Coolant Change................................................................................................................	2-46
Radiator Hose and O-ring Replacement...........................................................................	2-48
Engine Oil Change............................................................................................................	2-49
Oil Filter Replacement......................................................................................................	2-49
Brake Hose and Pipe Replacement..................................................................................	2-50
Brake Fluid Change..........................................................................................................	2-51
Master Cylinder Rubber Parts Replacement....................................................................	2-52
Caliper Rubber Parts Replacement..................................................................................	2-54
Spark Plug Replacement..................................................................................................	2-56

 

PERIODIC MAINTENANCE 2-3

 

Periodic Maintenance Chart

 

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.

Periodic Inspection

 

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

See

first

(× 1 000 mile)

Page

INSPECTION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Fuel System

Air cleaner element - clean

•

•

•

2-14

Throttle control system (play, smooth

year

•

•

•

•

2-15

return, no drag) - inspect

Engine vacuum synchronization - inspect

•

•

•

2-16

Idle speed - inspect

•

•

•

•

2-18

Fuel leak (fuel hose and pipe) - inspect

year

•

•

•

•

2-19

Fuel hose and pipe damage - inspect

year

•

•

•

•

2-19

Fuel hose and pipe installation condition -

year

•

•

•

•

2-19

inspect

Evaporative Emission Control System

(CAL)

Evaporative emission control system

•

•

•

•

•

•

•

2-19

function - inspect

Cooling System

Coolant level - inspect

•

•

•

•

2-20

Coolant leak (radiator hose and pipe) -

year

•

•

•

•

2-21

inspect

Radiator hose damage - inspect

year

•

•

•

•

2-21

Radiator hose installation condition -

year

•

•

•

•

2-21

inspect

Air Suction System

Air suction system damage - inspect

•

•

•

2-21

Engine Top End

Valve clearance - inspect

Every 42 000 km (26 000 mile)

2-21

Clutch

Clutch operation (play, disengagement,

•

•

•

•

2-26

engagement) - inspect

Wheels and Tires

Tire air pressure - inspect

year

•

•

•

2-26

Wheel/tire damage - inspect

•

•

•

2-27

Tire tread wear, abnormal wear - inspect

•

•

•

2-27

Wheel bearing damage - inspect

year

•

•

•

2-28

Drive Train

Drive chain lubrication condition - inspect #

Every 600 km (400 mile)

2-28

Drive chain slack - inspect #

Every 1 000 km (600 mile)

2-29

Drive chain wear - inspect #

•

•

•

2-31

 

PERIODIC MAINTENANCE

 

Periodic Maintenance Chart

 

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

See

first

(× 1 000 mile)

Page

INSPECTION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Drive chain guide wear - inspect

•

•

•

2-31

Brake System

Brake fluid leak (brake hose and pipe) -

year

•

•

•

•

•

•

•

2-32

inspect

Brake hose and pipe damage - inspect

year

•

•

•

•

•

•

•

2-32

Brake hose and pipe installation condition

year

•

•

•

•

•

•

•

2-32

- inspect

Brake operation (effectiveness, play, no

year

•

•

•

•

•

•

•

2-33

drag) - inspect

Brake fluid level - inspect

6 months

•

•

•

•

•

•

•

2-33

Brake pad wear - inspect #

•

•

•

•

•

•

2-34

Brake light switch operation - inspect

•

•

•

•

•

•

•

2-34

Suspensions

Front forks/rear shock absorber operation

•

•

•

2-35

(damping and smooth stroke) - inspect

Front forks/rear shock absorber oil leak -

year

•

•

•

2-35

inspect

Steering System

Steering play - inspect

year

•

•

•

•

2-36

Steering stem bearings - lubricate

2 years

•

2-37

Electrical System

Spark plug condition - inspect

•

•

•

2-37

Lights and switches operation - inspect

year

•

•

•

2-38

Headlight aiming - inspect

year

•

•

•

2-40

Sidestand switch operation - inspect

year

•

•

•

2-41

Engine stop switch operation - inspect

year

•

•

•

2-42

Others

Chassis parts - lubricate

year

•

•

•

2-43

Bolts and nuts tightness - inspect

•

•

•

•

2-44

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

 

*: For higher odometer readings, repeat at the frequency interval established here.

 

PERIODIC MAINTENANCE 2-5

 

Periodic Maintenance Chart

 

Periodic Replacement Parts

 

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

See

first

(× 1 000 mile)

Page

CHANGE/REPLACE ITEM

Every

(0.6)

(7.5)

(15)

(24)

(30)

Air cleaner element #

2 years

2-45

Fuel hose

4 years

•

2-45

Coolant

3 years

•

2-46

Radiator hose and O-ring

3 years

•

2-48

Engine oil #

year

•

•

•

•

•

2-49

Oil filter

year

•

•

•

•

•

2-49

Brake hose and pipe

4 years

•

2-50

Brake fluid

2 years

•

•

2-51

Rubber parts of master cylinder and caliper

4 years

•

2-52,

2-54

Spark plug

•

•

•

•

2-56

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

 

*: For higher odometer readings, repeat at the frequency interval established here.

 

PERIODIC MAINTENANCE

 

Torque and Locking Agent

 

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc.

 

Letters used in the “Remarks” column mean:

 

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.

 

L: Apply a non-permanent locking agent to the threads. Lh: Left-hand threads

 

MO: Apply molybdenum disulfide oil solution.

 

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10: 1)

 

R: Replacement Parts

 

S: Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease).

SS: Apply silic