Manual de Taller HONDA PCX150 MANUAL TALLER 2012

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How to use this manual

A Few Words About Safety

Service Information

The service and repair information contained in this manual is intended for use by qualified, professional technicians.

Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also

damage the vehicle 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 vehicle.

If you need to replace a part, use genuine Honda 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 vehicle. Any error or oversight while

servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

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 and repair procedures. Only you can decide whether or not you should

perform a given task.

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 vehicle up in the air. Any time you lift the vehicle, 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.

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.

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.

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How to use this manual

How To Use This Manual

This manual describes the service procedures for the WW125EX2/150-C.

Sections 1 and 3 apply to the whole scooter. Section 2 illustrates procedures for removal/installation of components that may be

required to perform service described in the following sections.

Section 4 through 21 describe parts of the scooter, grouped according to location.

Follow the Maintenance Schedule recommendations to ensure that the vehicle 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.

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.

SERVICE PUBLICATION OFFICE

Date of Issue: February, 2012

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.

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.

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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, NOGI #2 or

equivalent).

Example:

• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.

• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or

equivalent).

Example:

• Molykote® G-n Paste manufactured by Dow Corning U.S.A.

• Honda Moly 60 (U.S.A. only)

• Rocol ASP manufactured by Rocol Limited, U.K.

• Rocol Paste 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 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use fork or suspension fluid.

CONTENTS

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GENERAL INFORMATION

FRAME/BODY PANELS/EXHAUST SYSTEM

MAINTENANCE

PGM-FI SYSTEM

IGNITION SYSTEM

ELECTRIC STARTER

FUEL SYSTEM

LUBRICATION SYSTEM

COOLING SYSTEM

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

FINAL REDUCTION

ALTERNATOR/STARTER

CRANKCASE/CRANKSHAFT

ENGINE REMOVAL/INSTALLATION

FRONT WHEEL/SUSPENSION/STEERING

REAR WHEEL/BRAKE/SUSPENSION

HYDRAULIC BRAKE

BATTERY/CHARGING SYSTEM

LIGHTS/METERS/SWITCHES

WIRING DIAGRAM

INDEX

MEMO

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1. GENERAL INFORMATION

SERVICE RULES ··········································1-2

MODEL IDENTIFICATION ····························1-2

SPECIFICATIONS·········································1-4

TORQUE VALUES ········································1-9

LUBRICATION & SEAL POINTS ···············1-13

CABLE & HARNESS ROUTING·················1-15

TECHNICAL FEATURE······························1-21

EMISSION CONTROL SYSTEMS ··············1-22

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GENERAL INFORMATION

SERVICE RULES

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design

specifications may cause damage to the scooter.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the scooter. 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 1-15).

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.

MODEL IDENTIFICATION

Abbrev. term Full term

CBS Combined brake system

CKP sensor Crankshaft Position sensor

DLC Data Link Connector

DTC Diagnostic Trouble Code

ECM Engine Control Module

ECT sensor Engine Coolant Temperature sensor

HDS Honda Diagnostic System

IACV Idle Air Control Valve

IAT sensor Intake Air Temperature sensor

MAP sensor Manifold Absolute Pressure sensor

MIL Malfunction Indicator Lamp

PGM-FI Programmed Fuel Injection

SCS connector Service Check Short connector

TP sensor Throttle Position sensor

VS sensor Vehicle Speed sensor

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GENERAL INFORMATION

DESTINATION CODE

Throughout this manual, the following codes are used to identify individual types for each region.

SERIAL NUMBERS

DESTINATION CODE REGION

EU.K.

ED European direct sales

FFrance

KO Korea

U Australia, New Zealand

VEHICLE IDENTIFICATION NUMBER

E/ED/F type: REGISTERED NUMBER PLATE

U type: COMPLIANCE PLATE

ENGINE SERIAL NUMBER

THROTTLE BODY IDENTIFICATION NUMBER

COLOR LABEL

EMISSION CONTROL INFORMATION LABEL

KO type only:

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GENERAL INFORMATION

SPECIFICATIONS

GENERAL SPECIFICATIONS

ITEM SPECIFICATIONS

MODEL WW125EX2 WW150

DIMENSIONS Overall length 1,915 mm (75.4 in)

Overall width Except KO type 740 mm (29.1 in)

740 mm (29.1 in)

KO type 705 mm (27.8 in)

Overall height 1,090 mm (42.9 in)

Wheelbase 1,315 mm (51.8 in)

Seat height 760 mm (29.9 in)

Footpeg height 260 mm (10.2 in)

Ground clearance 130 mm (5.1 in)

Curb weight

Except KO type 128 kg (282.2 lbs)

129 kg (284.4 lbs)

KO type 130 kg (286.6 lbs)

FRAME Frame type Under bone type

Front suspension Telescopic fork

Front axle travel 89 mm (3.5 in)

Rear suspension Unit swing

Rear axle travel 79 mm (3.1 in)

Front tire size 90/90 - 14M/C 46P

Rear tire size 100/90 - 14M/C 57P

Tire brand Front SS-560F (IRC)

TT900F (DUNLOP)

Rear SS-560R (IRC)

TT900A (DUNLOP)

Front brake Hydraulic disc brake

Rear brake Mechanical leading trailing

Caster angle 27°00’

Trail length 86 mm (3.4 in)

Fuel tank capacity 5.9 liter (1.56 US gal, 1.30 lmp gal)

ENGINE Bore and stroke 52.4 x 57.9 mm

(2.06 x 2.28 in)

58.0 x 57.9 mm

(2.28 x 2.28 in)

Displacement 125 cm

(7.6 cu-in)

153 cm

(9.3 cu-in)

Compression ratio 11.0 : 1 10.6 : 1

Valve train 2 valve, single chain driven SOHC

Intake valve opens at 1 mm (0.04 in) lift 5° BTDC

closes at 1 mm (0.04 in) lift 35° ABDC

Exhaust valve opens at 1 mm (0.04 in) lift 30° BBDC

closes at 1 mm (0.04 in) lift 0° TDC

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Liquid cooled

Air filtration Viscous paper filter

Engine dry weight 29.8 kg (65.7 lbs) 30.1 kg (66.4 lbs)

FUEL

DELIVERY

SYSTEM

Type PGM-FI (Programmed Fuel Injection)

Throttle bore 24 mm (0.9 in) 26 mm (1.0 in)

DRIVE TRAIN Clutch system Dry, automatic centrifugal clutch

Drive belt ratio 2.60 : 1 - 0.82 : 1 2.45 : 1 - 0.81 : 1

Final reduction 11.271

(53/17 x 47/13)

10.552

(53/17 x 44/13)

ELECTRICAL Ignition system Full transistorized

Starting system Electric starter

Charging system Triple phase output alternator

Lighting system Battery

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GENERAL INFORMATION

PGM-FI SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

FUEL SYSTEM SPECIFICATIONS

LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)

COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS

Engine idle speed 1,700 ± 100 min

-1

(rpm)

ECT sensor resistance (40°C/104°F) 1.0 – 1.3 kΩ

(100°C/212°F) 0.1 – 0.2 kΩ

Fuel injector resistance (20°C/68°F) 11 – 13 Ω

ITEM SPECIFICATIONS

Spark plug WW125EX2 CPR7EA-9 (NGK)/U22EPR-9 (DENSO)

WW150 CPR7EA-9 (NGK)

Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)

Ignition coil peak voltage 100 V minimum

Ignition timing 12° BTDC at idle speed

ITEM SPECIFICATIONS

Throttle body identification number WW125EX2 GQY3A

WW150 GQMHA

Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)

Fuel pressure at idle 294 kPa (3.0 kgf/cm

, 43 psi)

Fuel pump flow (at 12 V) 98 cm

(3.31 US oz, 3.45 Imp oz) minimum/10 seconds

ITEM STANDARD SERVICE LIMIT

Engine oil capacity After draining 0.8 liter (0.8 US qt, 0.7 lmp qt) –

After disassembly 0.9 liter (1.0 US qt, 0.8 lmp qt) –

After oil strainer removal 0.9 liter (1.0 US qt, 0.8 lmp qt) –

Recommended engine oil Honda "4-stroke motorcycle oil" or an

equivalent

API classification: SG or higher

(except oils labeled as energy conserving

on the circular API service label)

Viscosity: SAE 10W-30

JASO T 903 standard: MB

–

Oil pump rotor Oil pump body I.D. 23.150 – 23.180 (0.9114 – 0.9126) –

Outer rotor O.D. 22.970 – 23.000 (0.9043 – 0.9055) –

Body-to-outer rotor clearance 0.15 – 0.21 (0.0059 – 0.0083) 0.35 (0.014)

Oil pump body depth 7.020 – 7.090 (0.2764 – 0.2791) –

Outer rotor height 6.960 – 6.980 (0.2740 – 0.2748) –

Side clearance 0.040 – 0.130 (0.0016 – 0.0051) 0.15 (0.006)

ITEM SPECIFICATIONS

Coolant capacity Radiator and

engine

WW125EX2 0.51 liter (0.54 US qt, 0.45 lmp qt)

WW150 0.48 liter (0.51 US qt, 0.42 lmp qt)

Reserve tank 0.18 liter (0.19 US qt, 0.16 lmp qt)

Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm

, 16 – 20 psi)

Thermostat Begin to open 74 – 78 °C (165 – 172 °F)

Fully open 100 °C (212 °F)

Valve lift 8 mm (0.3 in) minimum

Recommended antifreeze High quality ethylene glycol antifreeze containing silicate-free

corrosion inhibitors

Standard coolant concentration 1:1 (mixture with distilled water)

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GENERAL INFORMATION

CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)

CYLINDER/PISTON SPECIFICATIONS

WW125EX2:

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder compression 1,098 kPa (11.2 kgf/cm

, 159.3 psi) at

850 min

-1

(rpm)

–

Cylinder head warpage – 0.05 (0.002)

Camshaft Cam lobe height IN 33.616 – 33.856 (1.3235 – 1.3329) –

EX 33.393 – 33.633 (1.3147 – 1.3241) –

Valve,

valve

guide

Valve clearance IN 0.10 ± 0.02 (0.004 ± 0.001) –

EX 0.24 ± 0.02 (0.009 ± 0.001) –

Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.90 (0.193)

EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)

Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)

Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)

EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)

Valve guide

projection

above

cylinder head

WW125EX2 IN/EX 10.55 – 10.85 (0.415 – 0.427) –

WW150 IN/EX 11.05 – 11.35 (0.435 – 0.447) –

Valve seat width IN/EX 0.90 – 1.10 (0.035 – 0.043) 1.5 (0.06)

Valve spring free length IN/EX 36.94 (1.454) –

ITEM STANDARD SERVICE LIMIT

Cylinder I.D. 52.400 – 52.410 (2.0630 – 2.0634) 52.50 (2.067)

Out-of-round – 0.05 (0.002)

Taper – 0.05 (0.002)

Warpage – 0.05 (0.002)

Piston, piston

rings, piston

Piston O.D. 52.370 – 52.390 (2.0618 – 2.0626) 52.35 (2.061)

Piston O.D. measurement point 6.5 (0.26) from bottom of skirt –

Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)

Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)

Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)

Piston ring-to-ring

groove clearance

Top 0.015 – 0.055 (0.0006 – 0.0022) 0.08 (0.003)

Second 0.015 – 0.055 (0.0006 – 0.0022) 0.08 (0.003)

Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.0010) 0.45 (0.018)

Second 0.25 – 0.45 (0.010 – 0.0018) 0.65 (0.026)

Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –

Cylinder-to-piston clearance 0.01 – 0.04 (0.0004 – 0.0016) 0.09 (0.004)

Connecting rod small end I.D. 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)

Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.05 (0.002)

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GENERAL INFORMATION

WW150:

Unit: mm (in)

DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS

Unit: mm (in)

FINAL REDUCTION SPECIFICATIONS

Unit: mm (in)

CRANKCASE/CRANKSHAFT SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder I.D. 58.000 – 58.010 (2.2835 – 2.2839) –

Out-of-round – 0.05 (0.002)

Taper – 0.05 (0.002)

Warpage – 0.05 (0.002)

Piston, piston

rings, piston

Piston O.D. 57.970 – 57.990 (2.2822 – 2.2831) –

Piston O.D. measurement point 6.5 (0.26) from bottom of skirt –

Piston pin bore I.D. 14.002 – 14.008 (0.5513 – 0.5515) 14.04 (0.553)

Piston pin O.D. 13.994 – 14.000 (0.5509 – 0.5512) 13.96 (0.550)

Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)

Piston ring-to-ring

groove clearance

Top 0.015 – 0.055 (0.0006 – 0.0022) 0.08 (0.003)

Second 0.015 – 0.055 (0.0006 – 0.0022) 0.08 (0.003)

Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.0010) 0.45 (0.018)

Second 0.38 – 0.52 (0.015 – 0.0020) –

Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –

Cylinder-to-piston clearance 0.01 – 0.04 (0.0004 – 0.0016) 0.09 (0.004)

Connecting rod small end I.D. 14.010 – 14.028 (0.5516 – 0.5523) 14.06 (0.554)

Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.05 (0.002)

ITEM STANDARD SERVICE LIMIT

Drive belt width 22.0 (0.87) 21.0 (0.83)

Movable drive face Bushing I.D. 23.989 – 24.052 (0.9444 – 0.9469) 24.08 (0.948)

Boss O.D. 23.960 – 23.974 (0.9433 – 0.9439) 23.93 (0.942)

Weight roller O.D. 19.92 – 20.08 (0.784 – 0.791) 19.5 (0.77)

Clutch Lining thickness – 2.0 (0.08)

Clutch outer I.D. 125.0 – 125.2 (4.92 – 4.93) 125.5 (4.94)

Driven pulley Face spring free length 103.1 (4.06) –

Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)

Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)

ITEM SPECIFICATIONS

Final reduction oil capacity After draining 0.12 liter (0.13 US qt, 0.11 lmp qt)

After disassembly 0.14 liter (0.15 US qt, 0.12 lmp qt)

Recommended final reduction oil Honda "4-stroke motorcycle oil" or an equivalent

API classification: SG or higher

(except oils labeled as energy conserving on the circular API

service label)

Viscosity: SAE 10W-30

JASO T 903 standard: MB

ITEM STANDARD SERVICE LIMIT

Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)

Connecting rod radial clearance 0.004 – 0.016 (00002 – 0.0006) 0.05 (0.002)

Runout – 0.10 (0.004)

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GENERAL INFORMATION

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)

REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

Unit: mm (in)

HYDRAULIC BRAKE SPECIFICATIONS

Unit: mm (in)

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT

Minimum tire tread depth – 1.5 (0.06)

Cold tire pressure Driver only 200 kPa (2.00 kgf/cm

, 29 psi) –

Driver and passenger 200 kPa (2.00 kgf/cm

, 29 psi) –

Axle runout – 0.2 (0.01)

Wheel rim runout Radial – 2.0 (0.08)

Axial – 2.0 (0.08)

Fork Spring free length 291.8 (11.49) –

Pipe runout – 0.2 (0.01)

Recommended fluid Honda Ultra Cushion Oil 10W –

Fluid level 75 (2.95) –

Fluid capacity 122.0 ± 2.5 cm

(4.13 ± 0.05 US oz, 4.29 ± 0.05 Imp oz)

–

ITEM STANDARD SERVICE LIMIT

Minimum tire tread depth – 2.0 (0.08)

Cold tire pressure Driver only 225 kPa (2.25 kgf/cm

, 33 psi) –

Driver and passenger 250 kPa (2.50 kgf/cm

, 36 psi) –

Wheel rim runout Radial – 2.0 (0.08)

Axial – 2.0 (0.08)

Brake Brake lever freeplay 10 – 20 (0.4 – 0.8) –

Brake drum I.D. 130.0 – 130.2 (5.12 – 5.13) 131.0 (5.16)

ITEM STANDARD SERVICE LIMIT

Specified brake fluid DOT 3 or 4 –

Brake disc Thickness 3.5 ± 0.2 (0.14 ± 0.008) 3.0 (0.12)

Warpage 0.10 (0.004) 0.30 (0.001)

Front brake

master cylinder

Cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)

Piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)

CBS master

cylinder

Cylinder I.D. 11.000 – 11.043 (0.4331 – 0.4348) 11.055 (0.4352)

Piston O.D. 10.957 – 10.984 (0.4314 – 0.4324) 10.945 (0.4309)

Caliper Cylinder I.D. Upper 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)

Center/

lower

22.650 – 22.700 (0.8917 – 0.8937) 22.710 (0.8941)

Piston O.D. Upper 25.318 – 25.368 (0.9968 – 0.9987) 25.31 (0.996)

Center/

Lower

22.585 – 22.618 (0.8892 – 0.8905) 22.56 (0.888)

ITEM SPECIFICATIONS

Battery Capacity 12 V – 6 Ah (10HR)

Current leakage 0.1 mA max.

Voltage Fully charged 13.0 – 13.2 V

Needs charging Below 12.4 V

Charging

current

Normal 0.6 A/5 – 10 h

Quick 3 A/1 h

Alternator Capacity WW125EX2 0.329 kW/5,000 min

-1

(rpm)

WW150 0.343 kW/5,000 min

-1

(rpm)

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GENERAL INFORMATION

LIGHTS/METERS/SWITCHES SPECIFICATIONS

TORQUE VALUES

• Torque specifications listed below are for specified fasteners.

• Others should be tightened to standard torque values listed above.

FRAME/BODY PANELS/EXHAUST SYSTEM

MAINTENANCE

PGM-FI SYSTEM

ITEM SPECIFICATIONS

Bulbs Headlight 12 V – 35/30 W x 2

Position light 12 V – 5 W x 2

Tail/brake light 12 V – 5 W/21W

License light 12 V – 5 W

Front turn signal light 12 V – 21 W x 2

Rear turn signal light 12 V – 21 W x 2

Instrument light LED

PGM-FI malfunction indicator lamp (MIL) LED

High beam indicator LED

Turn signal indicator LED

Coolant temperature indicator LED

Idling stop indicator LED

Fuse Main fuse 1 10 A

Main fuse 2 30 A

Sub fuse 10 A x 3, 15 A x 1

FASTENER TYPE

TORQUE

FASTENER TYPE

TORQUE

N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)

5 mm hex bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)

6 mm hex bolt and nut

(Include SH flange bolt)

10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)

6 mm flange bolt

(Include NSHF) and nut

12 (1.2, 9)

8 mm hex bolt and nut 22 (2.2, 16)

10 mm hex bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)

12 mm hex bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Front reflex reflector mounting nut

(U type only)

2 6 1.5 (0.15, 1.1) U-nut

Tail/brake light unit mounting screw 4 4 1 (0.1, 0.7)

Exhaust pipe joint nut 2 7 29 (3.0, 21) For tightening sequence;

See page 2-13

Muffler mounting bolt 3 10 49 (5.0, 36) For tightening sequence;

See page 2-13

Exhaust pipe stud bolt 2 7 – See page 2-13

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Spark plug 1 10 16 (1.6, 12)

Valve adjusting screw lock nut 2 5 10 (1.0, 7) Apply oil to the threads and

seating surface.

Engine oil drain bolt 1 12 24 (2.4, 18)

Engine oil strainer screen cap 1 30 20 (2.0, 15)

Final reduction oil check bolt 1 8 23 (2.3, 17)

Final reduction oil drain bolt 1 8 23 (2.3, 17)

Air cleaner housing cover screw 7 5 1.1 (0.11, 0.8)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

ECT sensor 1 10 12 (1.2, 9)

2 sensor 1 12 24.5 (2.5, 18)

1-10

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GENERAL INFORMATION

ELECTRIC STARTER

FUEL SYSTEM

LUBRICATION SYSTEM

COOLING SYSTEM

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

FINAL REDUCTION

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Sidestand switch bolt 1 6 10 (1.0, 7) ALOC bolt: replace a with

new one.

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Fuel pump set plate nut 4 6 12 (1.2, 9) For tightening sequence;

See page 7-9

Air cleaner housing mounting bolt 2 6 11 (1.1, 8)

Rear inner fender socket bolt

- Air cleaner side 1 6 3.5 (0.36, 2.6)

Sensor unit torx screw 3 5 3.4 (0.35, 2.5)

Throttle cable bracket mounting screw 1 5 3.4 (0.35, 2.5)

IACV torx screw 2 4 2.1 (0.21, 1.5)

Insulator band bolt 2 5 5 (0.51, 3.7)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Oil pump mounting bolt 2 6 10 (1.0, 7)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Radiator drain bolt 1 10 1 (0.1, 0.7)

Radiator base screw 1 4 0.8 (0.08, 0.6)

Radiator top cover screw 4 4 3.2 (0.33, 2.4)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Camshaft stopper bolt 1 6 10 (1.0, 7)

Rocker arm shaft stopper bolt 2 5 5 (0.51, 3.7) Apply oil to the threads and

seating surface.

Cam sprocket socket bolt 2 5 8 (0.82, 5.9) Apply oil to the threads and

seating surface.

Cam chain tensioner lifter screw 1 6 4 (0.41, 3.0)

Water pump holder bolt 2 6 10 (1.0, 7)

Cylinder head nut 4 8 27 (2.8, 20) Apply oil to the threads and

seating surface.

Cylinder head sealing bolt 1 12 32 (3.3, 24)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Cylinder stud bolt 4 8 – See page 11-6

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Drive pulley face nut 1 14 59 (6.0, 44) Apply oil to the threads and

seating surface.

Clutch/driven pulley nut 1 28 54 (5.5, 40)

Clutch outer nut 1 12 49 (5.0, 36)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m, lbf·ft)

Final reduction case bolt 6 8 23 (2.3, 17)

Final reduction oil drain bolt 1 8 23 (2.3, 17)

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