Professional Documents
Culture Documents
AFS110KSF/MSF/KDF/MCF
1. General Information
4. Electrical System
A Few Words About Safety ················ 1-2 SPECIAL TOOL LIST ························ 1-15
How To Use This Manual ··················· 1-3 CABLE & HARNESS ROUTING ·········· 1-16
1-1
GENERAL INFORMATION
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.
1-2
GENERAL INFORMATION
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:
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.
1-3
GENERAL INFORMATION
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.
INSTRUCTION SYMBOL
Check the part for an inspection. Measure the part for an inspection.
1-4
GENERAL INFORMATION
MODEL IDENTIFICATION
• Model name: AFS110KSF/MSF/KDF/MCF
• Destination: Thailand, Laos, and Asia direct
TYPE FRONT DISC FRONT DRUM SPOKE WHEEL CAST WHEEL NONE-SHUTTER KEY
AFS110KSF O – O – –
AFS110MSF O – O – –
AFS110KDF – O O – O
AFS110MCF O – – O –
AFS110MCF shown:
1-5
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1,919 mm
Overall width KDF/ MCF 696 mm
KSF/ MSF 709 mm
Overall height 1,080 mm
Wheelbase 1,227 mm
Seat height 760 mm
Footpeg height 272 mm
Ground clearance 135 mm
Curb weight KDF/ KSF 95 kg
MSF 97 kg
MCF 98 kg
FRAME Frame type Back bone type
Front suspension Telescopic fork
Front axle travel 81 mm
Rear suspension Swingarm
Rear axle travel 82 mm
Front tire size 70/90 – 17 M/C 38P
Rear tire size 80/90 – 17 M/C 50P
Front tire brand NF63B Z (IRC), V357F (VEE)
Rear tire brand NR78Y D (IRC), V357RE (VEE)
Front brake KSF/MSF/ Hydraulic disc
MCF
KDF Mechanical leading trailing
Rear brake Mechanical leading trailing
Caster angle 26° 30’
Trail length 68 mm
Fuel tank capacity 3.7 liters
ENGINE Bore and stroke 50.000 x 55.597 mm
Displacement 109.17 cm3
Compression ratio 9.3 : 1
Valve train 2 valve, chain driven SOHC
Intake opens at 1 mm lift 5° BTDC
valve closes at 1 mm lift 30° ABDC
Exhaust opens at 1 mm lift 34° BBDC
valve closes at 1 mm lift 0° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper element
Engine dry weight KDF/ KSF 20.5 kg
MSF/ MCF 22.2 kg
Cylinder arrangement Single cylinder inclined 80° from vertical
FUEL SYSTEM Type PGM-FI
Throttle bore 22 mm
1-6
GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Automatic centrifugal type
Transmission Constant mesh, 4-speed
Primary reduction 4.059 (69/17)
Final reduction 2.642 (37/14)
Gear ratio 1st 2.615 (34/13)
2nd 1.555 (28/18)
3rd 1.136 (25/22)
4th 0.916 (22/24)
Gearshift pattern Left foot operated return system (rotary system;
only when the motorcycle is not running)
- N - 1 - 2 - 3 - 4 (- N)
ELECTRICAL Ignition system Full transistorized ignition
Starting system KDF/ KSF Kickstarter
MSF/ MCF Kickstarter with electric starter motor
Charging system Single phase output alternator
Regulator/rectifier Semiconductor type
Lighting system Alternator
ITEM SPECIFICATIONS
Throttle body identification number GQRQB
Idle air screw standard opening 2 turns out from fully seated position
Engine idle speed 1,400 ± 100 rpm
Throttle grip free play 2 – 6 mm
Fuel pressure at idle 263 – 316 kPa
Fuel pump flow (at 12 V) 82 cm3 minimum/10 seconds
EOT sensor resistance 20°C 2.5 – 2.8 kΩ
100°C 0.21 – 0.22 kΩ
IAT sensor resistance (20°C) 1 – 4 kΩ
Fuel injector resistance (20°C) 11 – 13 Ω
LUBRICATION SYSTEM
Unit: mm
ITEM STANDARD LIMIT
Engine oil capacity After draining 0.8 liter –
After disassembly 1.0 liter –
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 pump rotor Tip clearance – 0.15
Body clearance 0.15 – 0.21 0.26
Side clearance 0.03 – 0.09 0.15
CYLINDER HEAD/VALVES
Unit: mm
ITEM STANDARD LIMIT
Cylinder compression 0.8 MPa at 600 rpm –
Cylinder head warpage – 0.05
Valve clearance IN 0.10 ± 0.02 –
EX 0.15 ± 0.02 –
Valve stem O.D. IN 4.975 – 4.990 4.965
EX 4.955 – 4.970 4.945
1-7
GENERAL INFORMATION
ITEM STANDARD LIMIT
Valve guide I.D. IN/EX 5.000 – 5.012 5.03
Valve guide projection IN/EX 9.1 – 9.3 –
Valve seat width IN/EX 0.9 – 1.1 1.6
Valve spring free length IN/EX 30.62 29.7
Stem-to-guide clearance IN 0.010 – 0.037 0.065
EX 0.030 – 0.057 0.085
Camshaft Cam lobe height IN 32.204 – 32.424 32.18
EX 32.033 – 32.253 32.01
Cam chain Push rod O.D. 11.985 – 12.000 11.94
tensioner Spring free length 111.3 109.0
CYLINDER/PISTON
Unit: mm
ITEM STANDARD LIMIT
Cylinder I.D. 50.005 – 50.015 50.05
Out-of-round – 0.10
Taper – 0.10
Warpage – 0.05
Piston, Piston O.D. 49.980 – 49.995 at 10 mm from
49.91
piston rings, bottom of skirt
piston pin Piston pin bore I.D. 13.002 – 13.008 13.03
Piston pin O.D. 12.994 – 13.000 12.98
Piston-to-piston pin clearance 0.002 – 0.014 0.075
Piston ring-to-ring groove Top 0.015 – 0.045 0.09
clearance Second 0.015 – 0.045 0.09
Piston ring end gap Top 0.10 – 0.25 0.50
(Riken) Second 0.10 – 0.25 0.50
Oil (side rail) 0.20 – 0.70 1.10
Piston ring end gap Top 0.10 – 0.25 0.50
(Teikoku) Second 0.10 – 0.25 0.50
Oil (side rail) 0.10 – 0.35 0.80
Connecting rod small end I.D. 13.016 – 13.034 13.05
Connecting rod-to-piston pin clearance 0.016 – 0.040 0.07
Cylinder-to-piston clearance 0.010 – 0.035 0.10
CRANKSHAFT/TRANSMISSION/KICKSTARTER
Unit: mm
ITEM STANDARD LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.35 0.60
Connecting rod radial clearance 0 – 0.008 0.05
Runout – 0.10
Transmission Gear I.D. M2, M3 17.000 – 17.018 17.04
C1 18.000 – 18.018 18.04
C4 20.000 – 20.021 20.04
Bushing O.D. C1 17.966 – 17.984 17.94
Bushing I.D. C1 15.000 – 15.018 15.04
Gear-to-bushing clearance C1 0.016 – 0.052 0.10
Mainshaft O.D. at M3 16.966 – 16.984 16.95
Countershaft O.D. at C1
14.966 – 14.984 14.95
bushing
Gear-to-shaft clearance M3 0.016 – 0.052 0.09
Bushing-to-shaft clear-
C1 0.016 – 0.052 0.09
ance
1-8
GENERAL INFORMATION
ITEM STANDARD LIMIT
Shift fork/ Shift Shift fork I.D. 34.075 – 34.100 34.14
drum Shift fork claw thickness 4.85 – 4.95 4.60
Shift drum O.D. Left 23.940 – 23.980 23.92
Right 33.950 – 33.975 33.93
Kickstarter Pinion I.D. 20.000 – 20.021 20.08
Spindle O.D. 19.959 – 19.980 19.94
CLUTCH/GEARSHIFT LINKAGE
Unit: mm
ITEM STANDARD LIMIT
Manual clutch Disc thickness 2.00 – 2.20 1.82
Plate warpage – 0.20
Clutch spring free height 5.01 4.63
Primary driven gear I.D. 23.000 – 23.021 23.07
Clutch outer guide I.D. 16.991 – 17.009 17.049
O.D. 22.959 – 22.980 22.940
Mainshaft O.D. at clutch outer guide 16.966 – 16.984 16.87
Centrifugal Clutch drum I.D. 104.0 – 104.2 104.3
clutch Clutch weight lining thickness 1.5 1.0
One-way clutch drum I.D. 42.000 – 42.020 42.04
One-way clutch roller O.D. 4.990 – 5.000 4.97
Primary drive gear I.D. 19.030 – 19.058 19.11
Crankshaft O.D. at primary drive gear 18.967 – 18.980 18.92
ALTERNATOR/STARTER CLUTCH
Unit: mm
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss O.D. 45.660 – 45.673 45.642
FRAME & CHASSIS SPECIFICATIONS
FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm
ITEM STANDARD SERVICE LIMIT
Cold tire pressure Driver only 200 kPa –
Driver and passenger 200 kPa –
Axle runout – 0.2
Wheel rim runout Radial – 2.0
Axial – 2.0
Fork Spring free length KDF 293 281.3
KSF/MSF/MCF 294.3 282.5
Pipe runout – 0.2
Recommended fork KDF CN3# –
fluid KSF/MSF/MCF Honda Ultra Cushion Oil 10W –
Fluid level KDF 93 –
KSF/MSF/MCF 78 –
Fluid capacity KDF 61 ± 1 cm3 –
KSF/MSF/MCF 62 ± 1 cm3 –
Brake Brake drum I.D. 110.0 – 110.2 –
Brake lever freeplay 10 – 20 –
1-9
GENERAL INFORMATION
REAR WHEEL/BRAKE/SUSPENSION
Unit: mm
ITEM STANDARD SERVICE LIMIT
Cold tire pressure Driver only 225 kPa –
Driver and passenger 280 kPa –
Axle runout – 0.2
Wheel rim runout Radial – 2.0
Axial – 2.0
Drive chain Size/link RK420SL – 104RJ –
DID420AD2 – 104RB –
KMC420JB – 104 –
Slack 20 – 30 –
Brake Brake drum I.D. 110.0 – 110.2 111.0
Brake pedal freeplay 20 – 30 –
HYDRAULIC BRAKE
Unit: mm
ITEM STANDARD SERVICE LIMIT
Recommended brake fluid DOT 3 or 4 –
Brake disc thickness 3.3 – 3.7 3.0
Brake disc runout – 0.30
Master cylinder I.D. 11.000 – 11.043 11.055
Master piston O.D. 10.957 – 10.984 10.945
Caliper cylinder I.D. 33.96 – 34.01 34.02
Caliper piston O.D. 33.878 – 33.928 33.87
ITEM SPECIFICATIONS
Spark plug CPR6EA – 9S (NGK) /U20EPR9S (DENSO)
Spark plug gap 0.80 – 0.90 mm
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 1.5 V minimum
Ignition timing 5° BTDC at idle speed
BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS
Battery Type KSF/ KDF YTZ3/ FTZ3V
MSF/ MCF YTZ4V/ FTZ4V
Capacity YTZ3/ FTZ3V 12 V – 2.3–2.5 Ah (10HR)
YTZ4V/ FTZ4V 12 V – 3.0 Ah (20HR)
Current leakage 0.001 mA max.
Voltage Fully charged 13.0 – 13.2 V
Needs charging Below 12.4 V
Charging Normal 0.3 A/5 – 10 h
current Quick 3.0 A/0.5 h
Alternator Capacity 0.17 kW/5,000 rpm
Charging coil resistance (20°C) 0.2 – 1.0 Ω
1-10
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES
ITEM SPECIFICATIONS
Bulbs Headlight (High/Low) 12 V – 32/32 W
Position light KSF/MSF/MCF 12 V – 3.4 W x 2
Brake/tail light 12 V – 18/5 W
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Meter light 12 V – 1.7 W x 2
Turn signal indicator 12 V – 3.4 W x 2
High beam indicator 12 V – 1.7 W
Gear position indicator 12 V – 1.7 W x 4
Neutral indicator 12 V – 1.7 W
MIL 12 V – 1.7 W
Fuse Main 15 A
Sub 10 A
1-11
GENERAL INFORMATION
TORQUE VALUE
• Each fastener should be tightened to the standard torque value except the fasteners specified torque value.
• Q’TY: Quantity, DIA: Thread diameter (mm), TRQ: Tightening torque (N·m)
STANDARD TIGHTENING TORQUE
FASTENER TYPE TRQ FASTENER TYPE TRQ
5 mm hex bolt and nut 5.2 5 mm screw 4.2
6 mm hex bolt and nut 10 6 mm screw 9.0
8 mm hex bolt and nut 22 6 mm flange bolt 12
10 mm hex bolt and nut 34 8 mm flange bolt and nut 27
12 mm hex bolt and nut 54 10 mm flange bolt and nut 39
MAINTENANCE
ITEM Q'TY DIA TRQ REMARKS
Spark plug 1 10 16
Valve adjusting screw lock nut 2 5 9 Apply oil to the threads and
seating surface.
Engine oil drain bolt 1 12 24
Engine oil centrifugal filter cover bolt 3 5 5 Apply locking agent.
Throttle cable adjusting nut 1 6 4.5
Timing hole cap 1 14 6
Clutch adjusting lock nut 1 8 12
Air cleaner housing cover screw 5 5 1.1
Headlight aim adjusting bolt 1 4 2
Rear axle nut 1 12 59
FUEL SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Fuel tank mounting bolt 4 6 14
Injector mounting bolt 1 6 12
Fuel pump set plate nut 4 6 12 Î2-4
Throttle cable bracket screw 1 5 3.4
LUBRICATION SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Oil pump cover bolt 3 5 5
CYLINDER HEAD/VALVES
ITEM Q'TY DIA TRQ REMARKS
Cylinder head cover special bolt 2 6 10
Cylinder head cap nut 4 7 13 Apply oil to the threads and
seating surface.
Cam sprocket bolt 2 8 27 Apply oil to the threads and
seating surface.
Cam chain tensioner sealing bolt 1 14 22
Cam chain tensioner arm pivot bolt 1 8 16
Cam chain guide lower roller pivot bolt 1 6 10
Rocker arm shaft stopper bolt 2 6 5 Apply oil to the threads and
seating surface.
CYLINDER/PISTON
ITEM Q'TY DIA TRQ REMARKS
Cam chain guide roller pin bolt 1 8 10
Cylinder stud bolt 4 7 –
1-12
GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE
ITEM Q'TY THREAD TRQ REMARKS
Shift drum stopper arm bolt 1 6 10 Apply locking agent: Î2-25
Shift return spring pin 1 8 30
Gearshift cam plate socket bolt 1 6 17 Apply locking agent: Î2-25
Centrifugal clutch lock nut 1 14 54 Apply oil to the threads and
seating surface.
Clutch center lock nut 1 14 54 Apply oil to the threads and
seating surface.
Clutch lifter plate bolt 4 6 12
ALTERNATOR
ITEM Q'TY DIA TRQ REMARKS
Flywheel nut 1 10 40 Apply oil to the threads and
seating surface.
Starter clutch outer mounting torx bolt 6 6 16 Apply locking agent.
ENGINE REMOVAL/INSTALLATION
ITEM Q'TY DIA TRQ REMARKS
Drive sprocket fixing plate bolt 2 6 12
Engine hanger nut 3 10 59
FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Exhaust pipe joint nut 2 8 27
Muffler cover bolt 2 6 10
Exhaust pipe stud bolt 2 6 – Î3-15
Throttle cable lock nut 1 6 3
1 10 3
Chain cover mounting bolt 1 6 7
CRANKSHAFT/TRANSMISSION/KICKSTARTER
ITEM Q'TY DIA TRQ REMARKS
Cam chain guide sprocket spindle 1 6 10
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
ITEM Q'TY DIA TRQ REMARKS
Front brake arm nut 1 6 10
Brake lever pivot bolt 1 5 1
Brake lever pivot nut 1 5 4.5
Handlebar weight screw 2 6 9
Steering stem lock nut 1 26 83 For tigthten sequence Î3-23
Steering stem top thread 1 26 25
Bottom bridge pinch bolt 4 10 64
Handlebar post nut 1 10 59 Self lock-nut
Front axle nut 1 12 59 Self lock-nut
Front brake disc socket bolt 4 8 42 Pre-coated (ALOC) bolt,
replace with a new one.
Fork socket bolt 2 8 20 Apply locking agent.
Fork cap bolt 2 20 22
Front spoke 36 BC2.9 3.2
Brake hose clamp bolt 1 6 12 Pre-coated (ALOC) bolt,
replace with a new one.
1-13
GENERAL INFORMATION
REAR WHEEL/BRAKE/SUSPENSION
ITEM Q'TY DIA TRQ REMARKS
Rear axle nut 1 12 59 Self lock-nut
Driven sprocket bolt 4 8 32 Self lock-nut
Driven flange stud bolt 4 8 – Î3-24
Rear brake stopper arm nut 2 8 22
Rear brake arm bolt 1 6 10 Self lock-nut
Shock absorber upper mounting bolt 2 10 24
Shock absorber lower mounting nut 2 10 24
Swingarm pivot nut 1 12 59
Rear spoke 36 BC3.2 3.2
BRAKE SYSTEM
ITEM Q'TY DIA TRQ REMARKS
Caliper bleed valve 1 8 5.4
Pad pin 1 10 17
Caliper bracket pin bolt 1 8 17 Pre-coated (ALOC) bolt,
replace with a new one.
Caliper mounting bolt 2 8 30 Pre-coated (ALOC) bolt,
replace with a new one.
Brake hose oil bolt 2 10 34
Master cylinder reservoir cap screw 2 4 1.5
Front brake lever pivot bolt 1 6 1
Front brake lever pivot nut 1 6 5.9
Front brake light switch screw 1 4 1.2
Front brake hose clamp bolt 1 6 12 Pre-coated (ALOC) bolt,
replace with a new one.
PGM-FI SYSTEM
ITEM Q'TY DIA TRQ REMARKS
EOT sensor 1 10 14
O2 sensor 1 12 24.5
ELECTRIC STARTER
ITEM Q'TY DIA TRQ REMARKS
Starter motor case screw 3 5 4.2
Starter motor cable screw 1 4 2
LIGHTS/METERS/SWITCHES
ITEM Q'TY DIA TRQ REMARKS
Key shutter socket bolt 1 6 9 Pre-coated (ALOC) bolt,
replace with a new one.
Front turn signal light screw 4 5 1.1
Combination meter screw 3 5 1.1
OTHERS
ITEM Q'TY DIA TRQ REMARKS
Sidestand pivot bolt 1 10 18
Sidestand pivot nut 1 10 44
1-14
GENERAL INFORMATION
1-15
dummyhead
GENERAL INFORMATION
HEADLIGHT 9P
CONNECTOR
HORN WIRE
IGNITION SWITCH
4P CONNECTOR
COMBINATION METER
SUB HARNESS
CONNECTORS:
– COMBINATION METER 9P CONNECTOR
– COMBINATION METER 6P CONNECTOR
1-16
dummyhead
GENERAL INFORMATION
DISC BRAKE TYPE
LEFT HANDLEBAR
FRONT BRAKE LIGHT
SWITCH WIRE
SWITCH WIRE
STARTER SWITCH 3P
(Black) CONNECTOR HORN SWITCH 2P
(ELECTRIC STARTER (BLACK) CONNECTOR
TYPE ONLY)
HORN WIRE
SPEEDOMETER
CABLE
COMBINATION METER
SUB HARNESS
CONNECTORS:
– COMBINATION METER 9P CONNECTOR
– COMBINATION METER 6P CONNECTOR
1-17
dummyhead
GENERAL INFORMATION
DRUM BRAKE TYPE
THROTTLE CABLE
15°
SPEEDOMETER CABLE
COMBINATION METER
SUB HARNESS
COMBINATION METER
SUB HARNESS
SPEEDOMETER CABLE
COMBINATION METER
SUB HARNESS
1-18
dummyhead
GENERAL INFORMATION
DISC BRAKE TYPE
THROTTLE CABLE
15°
HANDLEBAR
SPEEDOMETER CABLE
COMBINATION METER
SUB HARNESS
COMBINATION METER
SUB HARNESS
COMBINATION METER
SUB HARNESS
SPEEDOMETER CABLE
1-19
dummyhead
GENERAL INFORMATION
IGNITION SWITCH 4P
CONNECTOR
CONNECTORS:
– COMBINATION METER 9P CONNECTOR
– COMBINATION METER 6P CONNECTOR
TP SENSOR 3P
(BLACK) CONNECTOR
1-20
dummyhead
GENERAL INFORMATION
INJECTOR 2P (Black)
CONNECTOR
CRANKCASE
BREATHER HOSE
CKP SENSOR
CONNECTORS
DLC CONNECTOR
GEAR POSITION
SWITCH 6P
CONNECTOR
GEAR POSITION
CRANKCASE ALTERNATOR 2P
SWITCH WIRE
BREATHER HOSE CONNECTOR
1-21
dummyhead
GENERAL INFORMATION
KICKSTARTER TYPE
REGULATOR/ IGNITION COIL
RECTIFIER
TP SENSOR WIRE
O2 SENSOR
CONNECTOR
1-22
dummyhead
GENERAL INFORMATION
1-23
dummyhead
GENERAL INFORMATION
KICKSTARTER TYPE
BATTERY
BATTERY SUB
HARNESS
SUB FUSE 10 A
BATTERY
BATTERY SUB
HARNESS
STARTER RELAY
SUB FUSE 10 A
1-24
GENERAL INFORMATION
TECHNICAL FEATURE
FUEL PUMP SYSTEM WITH A FUEL FILTER BLOCKAGE REMINDER FUNCTION
FUEL TANK
BREATHER FILTER
FUEL PUMP
FUEL LEVEL
BREATHER
PORTION
BREATHER
PASSAGE
PUMP CHAMBER
To FUEL INJECTOR
FUEL FILTER
The fuel pump system of this model consists of the following components:
– Fuel pump chamber
– Fuel filter
– Breather portion
– Breather passage
– Breather filter
Under normal condition, the fuel pump chamber sucks fuel through the fuel filter and then supplies it to the injector.
When the fuel filter is clogged, the fuel is sucked into the pump chamber through the breather passage in order to
keep the vehicle running. The breather filter is located in the upper inner side of fuel tank. When the fuel is consumed
to the point where the breather filter is exposed above the fuel level, a certain amount of air will be drawn into the
pump chamber via the breather filter and breather passage. This incoming air produces "a lack of fuel", which impairs
engine performance in order to notify the rider of the fuel filter blockage. This symptom works as a reminder for the
filter replacement.
This system eliminates the need of fuel filter replacement according to a fixed interval, as the rider will experience the
symptom and notice the filter blockage during vehicle usage.
The driveability remains normal as long as the fuel level in tank is maintained above the breather filter because no air
will be drawn into the pump chamber, even when the fuel filter is clogged.
If the fuel in tank is sufficient but such symptom as poor engine performance, lack of fuel, or engine start failure exist,
perform the fuel supply test.
If the fuel filter is replaced, the ECM must be initialized to avoid the rich of fuel.
1-25
GENERAL INFORMATION
MAINTENANCE SCHEDULE
• 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.
• Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this
manual.
1-26
2. FUEL & ENGINE
2-1
FUEL & ENGINE
FUEL LINE
FUEL & ENGINE
2-2
FUEL & ENGINE
FUEL SUPPLY TEST
• If the fuel in tank is sufficient but such symptom as poor
engine performance, lack of fuel, or engine start failure
exist, perform the following.
• Perform the fuel pressure test. Î2-3
If the fuel pressure is within specification, perform the fuel
flow inspection. Î2-3
• Perform the fuel flow inspection in the specified fuel
quantity. Î2-3
2-3
FUEL & ENGINE
12 N·m
2-4
FUEL & ENGINE
FUEL FILTER
2-5
FUEL & ENGINE
FUEL TANK
14 N·m
2-6
FUEL & ENGINE
AIR CLEANER
1.1 N·m
• Discard the air cleaner element in accordance with the maintenance schedule. Î1-26
• Replace the element any time if it is excessively dirty or damaged.
• Lower side cover Î3-6
2-7
FUEL & ENGINE
THROTTLE BODY
2-8
FUEL & ENGINE
3.4 N·m
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• Do not remove the white painted screw and TP sensor. Removing them can cause throttle body malfunction.
• Do not loosen or tighten the white painted nut of the throttle drum. Loosening or tightening it can cause throttle body
malfunction.
• TP sensor reset procedure Î2-10
2-9
FUEL & ENGINE
TP SENSOR RESET PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, TP sensor reset mode won’t start by follow-
ing the procedure below.
• Lower side cover Î3-6
[A]
• Connector cover from the DLC [A]
• Connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
[A]
Y/Bu G/O
[B]
• Turn the ignition switch ON then disconnect the
jumper wire from the EOT sensor 2P connector within 10
seconds while the MIL is blinking (reset receiving pattern).
[B] • Check for the MIL blinks.
After disconnecting the jumper wire, the MIL should start
blinking. (reset completed pattern)
If the jumper wire is connected for more than 10 seconds,
the MIL will stay ON (unsuccessful pattern). Try again from
within 10 sec. the first.
• Check the engine idle speed.
1.3 sec.
2-10
FUEL & ENGINE
ECM INITIALIZING PROCEDURE
• Make sure that DTC is not stored in ECM. If the DTC is
stored in ECM, ECM initializing mode won’t start.
• Perform this procedure when any of the following fuel
related part is replaced with a new one.
[A] – Idle air screw
– Fuel pump/fuel filter
– Injector
– O2 sensor
• Perform this procedure when any of the following engine
part is replaced or is overhauled.
– Cylinder head
[A] – Valves/valve guides/valve seat
– Cylinder/piston/piston ring
• Center cover Î3-5
• Disconnect the dummy connector from the DLC [A] and
connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
• Open the throttle grip fully and hold.
• The MIL should come on and then start blinking rapidly.
Open and hold. Within 5 seconds after rapid blinking starts, close the
throttle grip and hold for more than 3 seconds.
• If the MIL does not start blinking rapidly, turn the ignition
switch OFF and try again.
• If you can not restart the procedure, recheck if the DTC is
not stored in ECM.
MIL ON Rapid blink • If the DTC is not stored but you still can not restart the
procedure, replace the ECM with a known-good one and
try again.
• When the ECM initializing is successful, the MIL will repeat
one short blink.
• If the successful pattern is indicated, turn the ignition
switch OFF.
Within 5 seconds after • If altitude is higher than 2,000 m, perform the altitude
rapid blink starts, close setting. Î2-12
and hold for more than • Check the engine idle speed.
3 seconds.
Successful pattern
(One short blink repeats)
2-11
FUEL & ENGINE
ALTITUDE SETTING
• Make sure that DTC is not stored in ECM. If stored, the
ECM cannot enter the setting mode.
• The setting will fail if the engine is started during the
procedure.
[A] • Select the appropriate MODE which meets the situation de-
scribed below.
MODE1: 0 – 2,000 m above sea level
MODE2: 2,000 – 2,500 m above sea level
MODE3: 2,500 – 3,500 m above sea level
MODE4: 3,500 m or higher above sea level
• Center cover Î3-5
[A] • Disconnect the dummy connector from the DLC [A] and
connect the special tool to the DLC.
SCS connector: 070PZ-ZY30100
Open
• Open the throttle grip fully and hold.
and • The MIL should come on and then start blinking rapidly.
hold. MODE1: Within 5 seconds after rapid blinking starts, close
the throttle grip and hold for more than 3 seconds.
MIL ON Rapid blink MODE2, 3, 4: Within 5 seconds after rapid blinking starts,
snap the throttle grip (close for 0.5 second/open for 0.5
second) as specified times, then close and hold for more
than 3 seconds.
MODE2: Snap 1 time
MODE3: Snap 2 times
MODE 1: MODE 2, 3, 4:
MODE4: Snap 3 times
Close 0.5 sec. • If the MIL does not start blinking rapidly, turn the ignition
Open 0.5 sec. switch OFF and try again.
Close and hold. • If you can not restart the procedure, recheck if the DTC is
not stored in the ECM.
• If the DTC is not stored but you still can not restart the
Within 5 seconds procedure, replace the ECM with a known-good one and
after rapid blink Within 5 seconds after rapid
try again.
starts, close and blink starts, snap (close 0.5 • The MIL will repeat the short blinks as the number of the se-
hold for more than sec./open 0.5 sec.), close and lected MODE.
3 seconds. hold for more than 3 seconds. • If the desired successful pattern is indicated, turn the
ignition switch OFF.
MODE 2: Snap 1 time • If the MIL starts blinking slowly during this step before
MODE 3: Snap 2 times successful pattern is indicated, turn the ignition switch OFF
MODE 4: Snap 3 times and try again.
Successful patterns (Short blinks repeat): • If the number of MIL blink and the number of desired MODE
is different, turn the ignition switch OFF and try again.
MODE 1: • Turn the idle air screw to the specified opening and check
the engine idle speed.
MODE 2:
MODE 3:
MODE 4:
2-12
FUEL & ENGINE
INJECTOR
2-13
FUEL & ENGINE
LUBRICATION SYSTEM
SYSTEM DIAGRAM
OIL PUMP
OIL CENTRIFUGAL
FILTER
2-14
FUEL & ENGINE
ENGINE OIL LEVEL CHECK
24 N·m
2-15
FUEL & ENGINE
ENGINE OIL CENTRIFUGAL FILTER CHANGE
5 N·m
2-16
FUEL & ENGINE
OIL PUMP
5 N·m
2-17
FUEL & ENGINE
CYLINDER HEAD
VALVE CLEARANCE
• Inspect and adjust the valve clearance while the engine is
cold (below 35 °C).
• Cylinder head cover Î3-6
2-18
FUEL & ENGINE
CYLINDER HEAD COVER
10 N·m
CAMSHAFT/ROCKER ARM
• Cylinder head cover Î2-19
• Left crankcase rear cover Î3-12
• Camchain tensioner sealing washer bolt.
• Set the piston to the TDC (Top Dead Center) on the
compression stroke.
• Turn the crankshaft counterclockwise until the index lines
on the cam sprocket is aligned with the top surface of the
cylinder head.
This position can be obtained by confirming that there is
slack in the rocker arms. If there is no slack, turn the crank-
shaft again until the correct position is obtained.
2-19
FUEL & ENGINE
27 N·m
• Remove the bolt, cam sprocket from the camshaft and cam chain off the cam sprocket.
• Hold the cam sprocket by using the special tool.
Universal holder: 07725-0030000
• Remove the camshaft from the cylinder head while holding the rocker arms to ease removal.
• Inspect cam sprocket, camshaft and camshaft bearings for damage, abnormal wear, deformation, burning or
clogs in oil passages.
• Measure each part according to cylinder head/valves specification. Replace any part if it is out of service limit.
• Install the camshaft into the cylinder head with its groove facing forward while holding the rocker arms to
ease installation.
• Install and tighten the cam sprocket bolt to specified torque.
• Camshaft inspection.
2-20
FUEL & ENGINE
13 N·m
2-21
FUEL & ENGINE
9.1-9.3 mm
5 N·m
2-22
FUEL & ENGINE
CAM CHAIN TENSIONER
22 N·m
16 N·m
2-23
FUEL & ENGINE
CYLINDER/PISTON
176.0 ± 1.0 mm
2-24
FUEL & ENGINE
CLUTCH/GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER
• Install aligning clutch adjuster/lifter boss with the hole in the right crankcase cover.
• Adjust the clutch system lock nut after installing the right crankcase cover.
2-25
FUEL & ENGINE
CLUTCH
• Clutch system can be serviced with the engine installed on the frame.
• Right crankcase Î2-25
• Engine oil centrifugal filter cover Î2-16
• Remove the centrifugal lock nut using the special tool.
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar: 07716-0020500
Clutch center holder: 07HMB-HB70100
• Hold clutch lifter and remove the clutch center locknut using the special tool.
Universal holder: 07725-0030000
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar: 07716-0020500
• Remove the centrifugal clutch outer, manual clutch and the oil separator plate as an assembly.
2-26
FUEL & ENGINE
54 N·m
Align
54 N·m
• Align the cut-outs of the primary gear and sub gear as shown, then engage the primary drive/ driven gears.
Install the centrifugal clutch outer, manual clutch and the oil separator plate as an assembly.
• Install the clutch center lock nut. Hold the clutch plate and tighten the clutch center lock nut to specific
torque using the special tools.
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar: 07716-0020500
Clutch center holder: 07HMB-HB70100
• , Install the lock washer onto the crankshaft while align its inner tab with the groove of the clutch weight
assembly. Lock washer "OUT SIDE" mark facing out.
• Hold clutch lifter and install the clutch center locknut using the special tool.
Universal holder: 07725-0030000
Lock nut wrench, 20 x 24 mm: 07716-0020100
Extension bar: 07716-0020500
• Align the lock washer tab against the centrifugal clutch lock nut groove.
2-27
FUEL & ENGINE
CENTRIFUGAL CLUTCH
• Align spring retainer/ spring to the clutch outer while aligning the retainer groove with the pin.
2-28
FUEL & ENGINE
MANUAL CLUTCH
Turn 45°
12 N·m
2-29
FUEL & ENGINE
Turn 45°
12 N·m
2-30
FUEL & ENGINE
GEARSHIFT LINKAGE
Align
6.5±1 mm
17 N·m
10 N·m
6.5±1 mm
from tip
• Clutch Î2-26
• Gearshift pedal Î2-25
• Holding down the gearshift arm to ease the removal.
• Align the gearshift cam plate with stopper plate pins.
• Set the return spring end along with the crankcase wall.
• Gearshift pedal inspection.
2-31
FUEL & ENGINE
ALTERNATOR/STARTER CLUTCH
Align
Align
[B]
40 N·m
[A]
2-32
FUEL & ENGINE
16 N·m
2-33
FUEL & ENGINE
CRANKCASE/CRANKSHAFT
10 mm
• Crankshaft inspection.
• Connecting rod inspection.
2-34
FUEL & ENGINE
CRANKSHAFT RUNOUT INSPECTION
• Place the crankshaft on a stand of V-blocks and measure
the runout using a dial gauge.
• SERVICE LMIT: 0.10 mm
30 mm
46 mm 120 mm
TRANSMISSION/KICKSTARTER
2-35
FUEL & ENGINE
MAINSHAFT
• Transmission inspection.
COUNTERSHAFT
• Transmission inspection.
2-36
FUEL & ENGINE
KICKSTARTER
• Kickstarter inspection.
2-37
FUEL & ENGINE
ENGINE UNIT
59 N·m
12 N·m
12 N·m
2-38
3. FRAME & CHASSIS
HANDLEBAR ···································3-21
3-1
FRAME & CHASSIS
BODY PANELS
FRAME & CHASSIS
[1]
[2]
[12]
[4]
[9]
[11]
[8]
[3] [15]
[13]
[6]
[16]
[17] [14]
3-2
FRAME & CHASSIS
TOP HANDLEBAR COVER
• Rearview mirrors.
3-3
FRAME & CHASSIS
0 – 1.25 mm
3-4
FRAME & CHASSIS
CENTER COVER
3-5
FRAME & CHASSIS
LOWER SIDE COVER
GRAB RAIL
3-6
FRAME & CHASSIS
FRONT FENDER A
AFS110KDF
FRONT FENDER B
3-7
FRAME & CHASSIS
BODY COVER
Left side shown:
3-8
FRAME & CHASSIS
LUGGAGE BOX
AFS110MSF/ MCF:
3-9
FRAME & CHASSIS
REAR FENDER
3-10
FRAME & CHASSIS
DRIVE CHAIN COVER
SEAT
3-11
FRAME & CHASSIS
LEFT CRANKCASE REAR COVER
FOOTPEG BAR
3-12
FRAME & CHASSIS
PASSENGER FOOTPEG HOLDER
Right side shown:
BATTERY COVER
AFS110MSF/ MCF:
3-13
FRAME & CHASSIS
CENTERSTAND
3-14
FRAME & CHASSIS
SIDESTAND
18 N·m
44 N·m
EXHAUST PIPE/MUFFLER
11 N·m
29.5 ± 1.0 mm
27 N·m
3-15
FRAME & CHASSIS
FRONT WHEEL
AFS110KSF/ MSF/ MCF:
59 N·m
13.0 ± 1.0 mm
• Align the speedometer gearbox grove with the boss on the fork leg.
3-16
FRAME & CHASSIS
[B]
[A]
42 N·m
• Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft
and drive the bearing out of the wheel hub.
Remover head, 12 mm: 07746-0050300
Bearing remover shaft: 07746-0050100
• Drive in a new left bearing [A] squarely with its marked side facing up until it is fully seated
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 12 mm: 07746-0040200
• Install the distance collar
• Drive in a new right bearing [B] squarely with its sealed side facing up until its inner race is seated on the
distance collar. (Pack all bearing cavities with grease.)
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 12 mm: 07746-0040200
• Wheel disassembly and inspection.
3-17
FRAME & CHASSIS
AFS110KDF:
59 N·m
10 ± 1.0 mm
• Align the brake panel slot with the left fork leg.
3-18
FRAME & CHASSIS
FORK
64 N·m
3-19
FRAME & CHASSIS
78 mm
(KSF/MSFMCF)
93 mm (KDF)
22 N·m
(KDF)
20 N·m
3-20
FRAME & CHASSIS
HANDLEBAR
AFS110KSF/ MSF/ MCF:
9 N·m
59 N·m
FRONT REAR
3-21
FRAME & CHASSIS
AFS110KDF:
9 N·m
1 N·m
4.5 N·m
59 N·m
FRONT REAR
3-22
FRAME & CHASSIS
STEERING STEM
[B]
[A]
83 N·m
23 Balls
29 Balls
[E]
3-23
FRAME & CHASSIS
REAR WHEEL
59 N·m
22 N·m
3-24
FRAME & CHASSIS
[B]
[A]
32 N·m
6 ± 1.0 mm
• Install the bearing remover head into the wheel bearing. From the opposite side, install the bearing remover
shaft and drive the bearing out of the wheel hub.
Bearing remover head, 12 mm: 07746-0050300
Bearing remover shaft: 07746-0050100
• Drive in a new right bearing [A] squarely with its sealed side facing up until it is fully seated.
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 12 mm: 07746-0040200
• Install the distance collar
• Drive in a new left bearing [B] squarely with its sealed side facing up until it is fully seated.
Driver: 07749-0010000
Attachment, 37 x 40 mm: 07746-0010200
Pilot, 12 mm: 07746-0040200
• Wheel disassembly and inspection.
3-25
FRAME & CHASSIS
REAR SUSPENSION
24 N·m
24 N·m
SWINGARM
59 N·m
3-26
FRAME & CHASSIS
FRONT BRAKE
FRONT BRAKE FLUID REPLACEMENT
• Turn the handlerbar until the reservoir is parallel to the ground before removing the reservoir cap.
• Connect a bleed hose to the bleed valve. Loosen the bleed valve and pump the brake lever until no more
fluid flows out of the bleed valve.
• Details instruction of the brake fluid replacement.
34 N·m
• Install the brake master cylinder and holder with the "UP" mark facing up. Align the edge of the master
cylinder with the punch mark on the handlebar.
3-27
FRAME & CHASSIS
1 N·m
5.9 N·m
1.2 N·m
17 N·m
• Install brake pads so that they are set on the brake caliper bracket and bracket pin.
3-28
FRAME & CHASSIS
30 N·m
34 N·m
5.4 N·m
3-29
FRAME & CHASSIS
REAR BRAKE
DRUM BRAKE
10 N·m
3-30
4. ELECTRICAL SYSTEM
4-1
ELECTRICAL SYSTEM
PGM-FI SYSTEM
ELECTRICAL SYSTEM
4-2
ELECTRICAL SYSTEM
PGM-FI SYSTEM LOCATION
TP SENSOR ECM
DLC
THROTTLE BODY
INJECTOR
EOT SENSOR
4-3
ELECTRICAL SYSTEM
PGM-FI SYSTEM DIAGRAM
MAIN FUSE
R/Y
15 A R G
BATTERY
SUB FUSE
R/Y
10 A
W R/Y Bl/R Bl
REGULATOR/
RECTIFIER R R Bl/Bu
W
IGNITION
SWITCH
ALTERNATOR G
Bl/Bu
IGP 1
FL 8 Br FUEL PUMP
(8) Y
TP SENSOR G/O
5 THR INJECTOR (12)
4 TA P/G
INJ 16
MIL
Y/Bu W/Bu
24 TO WARN 18
(7)
EOT SENSOR
G/O Bu/Y
31 SG PCP 12
Y/R W/Y CKP
6 VCC PCM 23
SENSOR
(21) Bl Bl/O
3 O2
O2 SENSOR
ECM
Bu P/Bu
15 SCS IGPLS 11
Y
30 K-LINE
DLC
GEAR POSITION
SWITCH IGNITION COIL
Lg/R
29 NSW
2 LG 9 PG1 10 PG2
SPARK PLUG
G/Bl G G
A11 A1
Bl : BLACK Br : BROWN
Y: YELLOW O: ORANGE
Bu : BLUE Lb : LIGHT BLUE
G: GREEN Lg : LIGHT GREEN A22 A12
( ) : MIL number R: RED P: PINK
W: WHITE Gr : GRAY
A33 A23
: Engine does not start when detecting MIL
33P CONNECTOR A
: Short terminals for reading MIL (ECM side / male terminal)
4-4
ELECTRICAL SYSTEM
DTC TROUBLESHOOTING
DTC 7-1 (EOT SENSOR LOW VOLTAGE)
G/O Y/Bu
G/O Y/Bu
5V
Y/Bu
TO-SENSOR
ECM
EOT sensor
SG2
G/O
Yes ▼
• Check the EOT sensor voltage with MCS. No • Replace the EOT sensor with a new one Î4-11,
• Is the voltage about 0 V indicated? ► and recheck.
Yes ▼
4-5
ELECTRICAL SYSTEM
DTC 7-2 (EOT SENSOR HIGH VOLTAGE)
G/O Y/Bu
G/O Y/Bu
5V
Y/Bu
TO-SENSOR
ECM
EOT sensor
SG2
G/O
Yes ▼
No ▼
4-6
ELECTRICAL SYSTEM
DTC 8-1 (TP SENSOR LOW VOLTAGE)
TP Sensor Diagram
G/O Y/R
5V
VCC
Y/R
THL
TP sensor Y/G ECM
SG1
G/O
Yes ▼
Yes ▼
No ▼
4. TP Sensor Inspection
4-7
ELECTRICAL SYSTEM
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
TP Sensor Diagram
Y Y/R Y G/O
G/O Y/R
5V
VCC
Y/R
THL
TP sensor Y ECM
SG1
G/O
Yes ▼
No ▼
3. TP Sensor Inspection
Yes ▼
4-8
ELECTRICAL SYSTEM
DTC 12-1 (INJECTOR)
Injector Diagram
A B Bl/Bu P/G
Bl/Bu
Injector ECM
INJ
P/G
Yes ▼
Yes ▼
No ▼
• Connection: A – B No
• Faulty fuel injector
• Is the resistance within 11 – 13 Ω (20°C)? ►
Yes ▼
4-9
ELECTRICAL SYSTEM
DTC 21-1 (O2 SENSOR)
O2 Sensor Diagram
Bl/O Bl/O
O2-SENSOR
Bl Bl/O
ECM
O2 sensor
Yes ▼
No ▼
3. O2 Sensor Inspection
Yes ▼
4-10
ELECTRICAL SYSTEM
ECM
EOT SENSOR
14 N·m
4-11
ELECTRICAL SYSTEM
O2 SENSOR
24.5 N·m
4-12
ELECTRICAL SYSTEM
IGNITION SYSTEM
IGNITION SYSTEM LOCATION
IGNITION SWITCH
REGULATOR/RECTIFIER
ECM
SPARK PLUG
CKP SENSOR
MAIN FUSE 15A
P/Bu
R/Y G R/W IGNITION COIL
BATTERY
RECGULATOR/
SPARK PLUG
RECTIFIER
Bl/Y
W/Y
Bu/Y
G/Bl G
CKP SENSOR
ECM
4-13
ELECTRICAL SYSTEM
SPARK PLUG REPLACEMENT
• Lower side cover Î3-5
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
IGNITION TIMING
4-14
ELECTRICAL SYSTEM
ELECTRICAL STARTER
ELECTRICAL STARTER SYSTEM LOCATION
STARTER SWITCH
STARTER RELAY
BATTERY
IGNITION SWITCH
STARTER MOTOR
MAIN FUSE 15 A
R R/Y R
RECGULATOR/
RECTIFIER
STARTER
RELAY
G R
BATTERY
IGNITION SWITCH
Bl/Bu R
R/W
G: Green
Y/R G R: Red
STARTER W: White
SWITCH Bl: Black
STARTER MOTOR
Y: Yellow
Bu: Blue
4-15
ELECTRICAL SYSTEM
ELECTRICAL STARTER TROUBLESHOOTING
STARTER MOTOR DOES NOT TURN
Yes ▼
• Replace the starter relay with a new one, and • Faulty original starter relay.
Yes
recheck.
►
• Does the Starter motor turn?
No ▼
4-16
ELECTRICAL SYSTEM
STARTER MOTOR
1.2 N·m
4-17
ELECTRICAL SYSTEM
BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEM LOCATION
REGULATOR/RECTIFIER
BATTERY
ALTERNATOR
G: Green
To IGNITION SWITCH
R: Red
W: White
MAIN FUSE 15 A Y: Yellow
G R
To LIGHT
SWITCH
G R/Y R W Y
BATTERY
RECGULATOR/ R
RECTIFIER ALTERNATOR
4-18
ELECTRICAL SYSTEM
BATTERY
4-19
ELECTRICAL SYSTEM
LIGHTING SYSTEM
2 N·m
4-20
ELECTRICAL SYSTEM
BULB REPLACEMENT
4-21
ELECTRICAL SYSTEM
HEADLIGHT AIM
up
down
SPEEDOMETER
4-22
ELECTRICAL SYSTEM
4-23
ELECTRICAL SYSTEM
Bl
• Route the fuel level sensor wires into the guides properly.
4-24
ELECTRICAL SYSTEM
FUEL METER TROUBLESHOOTING
FUEL METER NEEDLE DOES NOT MOVE
A (G) B (Y/W)
FULL
• Check the G, Y/W and Bl/Bu wire. No • Faulty G, Y/W or Bl/Bu wire
• Is there no open or short circuit? ►
Yes ▼
• Connection: A – B
No • Replace the fuel level sensor with a new one
• Standard: FULL 6 – 10 Ω, EMPTY 90 – 100 Ω
► Î4-24, and recheck.
• Does the Standard resistance exist?
Yes ▼
4-25
ELECTRICAL SYSTEM
ELECTRICAL COMPONENT
IGNITION SWITCH
5.1 N·m
9 N·m
• Install the key shutter while aligning the grooves with the tabs.
• Install the ignition switch by aligning the boss and hole of the frame.
4-26
ELECTRICAL SYSTEM
GEAR POSITION SWITCH
HORN
4-27
MEMO
INDEX
dummytext
INDEX
A Few Words About Safety······································1-2 FUEL TANK ·························································2-6
A
ENGINE OIL CHANGE ········································· 2-15 SPARK PLUG REPLACEMENT ····························· 4-14
ENGINE OIL LEVEL CHECK ································· 2-15 SPECIAL TOOL LIST··········································· 1-15
ENGINE OIL STRAINER SCREEN CHANGE ··········· 2-15 SPECIFICATIONS·················································1-6
ENGINE UNIT ···················································· 2-38 SPEEDOMETER················································· 4-22
EXHAUST PIPE/MUFFLER ··································· 3-15 STEERING STEM ··············································· 3-23
FORK ······························································· 3-19 TECHNICAL FEATURES······································ 1-25
F T
5-1
AFS110KSF-J (TH,LO,AD)
FRONT REAR
TURN STOP BRAKE
SIGNAL GROUND
LIGHT IGNITION LIGHT REGULATOR
RELAY SWITCH BATTERY
SWITCH SWITCH RECTIFIER 12V 3.0AH
O2 SUB MAIN
SENSOR
G
FUSE FUSE
BAT2
BAT1
VO2
VO1
10A 15A
Bl/Bu
Bl/R
G
6P
Bl
Bl
Bl
G/Y
Bl
G/Bl
2P
G
R/Y
R
Bl
W
G
R
Y
G
GR
Bl
Bl/R
R/Y
R/Y
R
Bl/Bu
Bl/R
Bl
Bl
Bl
Bl
G/Y
MIL INDICATOR
Bl
W/Bu 1P
12V 1.7W Bl
4P
Bl
METER LIGHT
Bl/Bu
Bl/O
G/Y
Bl/R
Bl
Y
Bl
Bl/R
R/Y
12V 1.7W
G
G
G/Y
Bl
METER LIGHT
12V 1.7W Y
G RIGHT REAR
GEAR POSITION TURN SIGNAL LIGHT
Bl/R
R/Y
12W 10W
G
INDICATOR
P
4TH 12V 1.7W
Bl Lb
G
W/Bu
3RD 12V 1.7W
Bl 9P
BRAKE/TAIL LIGHT
Bl Bl
Y Y
6P 12V 18W/5W
Bl/Bu Lb Lb
2ND 12V 1.7W Bl G G G
G G
P P G/Y G/Y G/Y
W/Bu W/Bu Y Y Y
Y/R
1ST 12V 1.7W Bl/Bu Bl/Bu O O
Bl
Y/R Y/R
Lg/R Lg/R
NEUTRAL Lg/R
G
12V 1.7W Bl
O
6P
HI BEAM Lb Lb
INDICATOR Bu G/Y G/Y LEFT REAR
G
12V 1.7W W/Bu W/Bu TURN SIGNAL LIGHT
O O 12V 10W
RIGHT TURN
Lb Y/W Y/W
SIGNAL INDICATOR G
12V 3.4W
LEFT TURN G
SIGNAL INDICATOR O
12V 3.4W
Bl
FUEL METER Y/W
G
W
G
RIGHT FRONT Lb 2P
W/Bu
Bl/Bu
Lg/R
Y/R
P
TURN SIGNAL LIGHT G
12 10W
Bu/Y
W/Y
W
G
6P
Bl
9P
W/Bu
Bl/Bu
Lg/R
Y/R
P
Lb Lb
Bu/Y
W/Y
Bl/Bu
Bu Bu Bu
P/G
HEAD LIGHT G G G
Bl/Bu
Bl/Bu
Y/W
P/Bu
12 32W/32W
Br
G
W
W W W
2P
O 5P
Bu/Y
O Bl
Bl 4 3
Y 2
Lg
1
N
W/Y
LEFT FRONT
Bu
Gr
Lg
Lb
W
Bl
Bl/Bu
Bl/Bu
O
Y
G
TURN SIGNAL LIGHT O
W/Bu
Bl/Bu
Bu/Y
P/Bu
Y/Bu
Lg/R
G/Bl
Bl/O
W/Y
G/O
G/O
P/G
Y/R
3P
Bu
3P 3P
Br
12 10W
G
G
Y
3P R Bl HORN INJECTOR
Bl/Bu
G/Bl
FUEL
Bu
Y
Y/Bu
HL
WL
BAT
LO
HI
W
WR
HO
G/O
G/O
Y/R
LEVEL
Y
SG(TO)
TO
WARN
N SW
SG(THL)
LG
SCS
K-LINE
PG1
PG2
O2
THR
VCC
Bl Bl
COIL SWITCH
DIMMER TURN HORN FUEL PUMP POSITION
SWITCH SIGNAL SWITCH
VCC
THR
SG
BAT
HO
SWITCH DLC
ECM TP EOT
SENSOR SENSOR
SWITCH CONTINUITY
FRONT
STOP REAR
TURN LIGHT
SIGNAL GROUND BRAKE
SWITCH IGNITION LIGHT REGULATOR
RELAY BATTERY
SWITCH SWITCH RECTIFIER 12V 3.0AH
O2 SUB MAIN
SENSOR
G
FUSE FUSE
BAT2
BAT1
10A 15A
VO2
VO1
Bl/Bu
Bl/R
G
6P
Bl
Bl
Bl
G/Y
Bl
G/Bl
2P
G
R/Y
R
Bl
W
G
R
Y
G
GR
Bl
Bl/R
R/Y
R/Y
R
Bl/Bu
Bl/R
Bl
Bl
Bl
Bl
MIL INDICATOR W/Bu 1P
4P
Bl Bl
12V 1.7W
Bl/Bu
Bl/O
G/Y
Bl/R
Bl
METER LIGHT Y
Bl
Bl/R
R/Y
G
12V 1.7W G
METER LIGHT Y
12V 1.7W G RIGHT REAR
TURN SIGNAL LIGHT
Bl/R
R/Y
GEAR POSITION 12W 10W
G
INDICATOR P
4TH 12V 1.7W Bl Lb
G
W/Bu
3RD 12V 1.7W Bl 9P
BRAKE/TAIL LIGHT
Bl Bl
Y Y
6P 12V 18W/5W
Bl/Bu Lb Lb
Bl G G G
2ND 12V 1.7W G G
P P G/Y G/Y G/Y
W/Bu W/Bu Y Y Y
Y/R O O
Bl/Bu Bl/Bu
1ST 12V 1.7W Bl
Y/R Y/R
Lg/R Lg/R
Lg/R
NEUTRAL Bl
G
12V 1.7W O
6P
Lb Lb
HI BEAM Bu G/Y G/Y LEFT REAR
INDICATOR G W/Bu W/Bu TURN SIGNAL LIGHT
12V 1.7W O O 12V 10W
RIGHT TURN Lb Y/W Y/W
G
SIGNAL INDICATOR
12V 3.4W
G
LEFT TURN O
SIGNAL INDICATOR
12V 3.4W
Bl
Y/W
FUEL METER
G
W
G
RIGHT FRONT Lb 2P
W/Bu
Bl/Bu
Lg/R
Y/R
P
TURN SIGNAL LIGHT G
12 10W
Bu/Y
W/Y
W
G
6P
POSITION LIGHT Y Bl
12V 3.4W G 9P
W/Bu
Bl/Bu
Lg/R
Y/R
P
Lb Lb
Bu/Y
W/Y
Bl/Bu
Bu Bu Bu
P/G
HEAD LIGHT G G G
Bl/Bu
Bl/Bu
Y/W
P/Bu
12 32W/32W
Br
G
W
W W W
2P
O 5P
Bu/Y
O Bl
Bl 4 3
Y 2
Lg
1
POSITION LIGHT G
12V 3.4W Y N
W/Y
LEFT FRONT
Bu
Gr
Lg
Lb
W
Bl
Bl/Bu
Bl/Bu
O
Y
G
TURN SIGNAL LIGHT O
W/Bu
Bl/Bu
Bu/Y
P/Bu
Y/Bu
Lg/R
G/Bl
Bl/O
W/Y
G/O
G/O
P/G
Y/R
3P
Bu
3P 3P
Br
12 10W
G
G
Y
3P R Bl HORN INJECTOR
Bl/Bu
G/Bl
Bu
FUEL
Y
Y/Bu
HL
WL
BAT
LO
HI
W
WR
HO
G/O
G/O
Y/R
LEVEL
Y
4P 33P SENSOR
F/P
R IGNITION ALTERNATOR GEAR
3P 2P
FL
IGP
PCP
PCM
IGPLS
INJ
SG(TO)
TO
WARN
N SW
SG(THL)
LG
SCS
K-LINE
PG1
PG2
O2
THR
VCC
Bl Bl
COIL SWITCH
DIMMER TURN HORN FUEL PUMP
POSITION
SWITCH SIGNAL SWITCH
VCC
THR
SG
BAT
HO
SWITCH DLC
ECM TP EOT
SENSOR SENSOR
SWITCH CONTINUITY
FRONT
STOP STARTER REAR
TURN LIGHT SWITCH BRAKE
SIGNAL GROUND STARTER
SWITCH IGNITION LIGHT REGULATOR RELAY
RELAY SWITCH SWITCH RECTIFIER BATTERY
O2 SUB MAIN 12V 3.0AH
SENSOR
G
FUSE FUSE
BAT2
BAT1
10A 15A
VO2
VO1
3P
Bl 5P
Bl/Bu
Bl/R
G
6P
Bl
Bl
Bl
Y/R
G/Y
G
Bl
G/Bl
2P
Bl/Bu
W/R
Y/R
R/Y
R
G
Bl
W
G
R
Y
G
GR
Bl
R
R
Bl/R
R/Y
R/Y
R
Bl/Bu
Bl/R
Bl
Bl
Bl
Bl
MIL INDICATOR W/Bu 1P
4P
Bl Bl
12V 1.7W
Bl/Bu
Bl/O
G/Y
Bl/R
Bl
METER LIGHT Y
Bl
Bl/R
R/Y
12V 1.7W G
2P
METER LIGHT Y Bl
12V 1.7W G RIGHT REAR
TURN SIGNAL LIGHT
Bl/Bu
Bl/R
R/Y
Y/R
GEAR POSITION 12W 10W
INDICATOR P
4TH 12V 1.7W Bl Lb
G
W/Bu
3RD 12V 1.7W Bl 9P
BRAKE/TAIL LIGHT
Bl Bl
Y Y
6P 12V 18W/5W
Bl/Bu Lb Lb
Bl G G G
2ND 12V 1.7W G G
P P G/Y G/Y G/Y
W/Bu W/Bu Y Y Y
Y/R O O
Bl/Bu Bl/Bu
1ST 12V 1.7W Bl
Y/R Y/R
Lg/R Lg/R
Lg/R
NEUTRAL Bl
G
12V 1.7W O
6P
Lb Lb
HI BEAM Bu G/Y G/Y LEFT REAR
INDICATOR G W/Bu W/Bu TURN SIGNAL LIGHT
12V 1.7W O O 12V 10W
Y/R Y/R
RIGHT TURN Lb Y/W Y/W
G
SIGNAL INDICATOR
12V 3.4W
G
LEFT TURN O
SIGNAL INDICATOR
12V 3.4W
Bl
Y/W
FUEL METER
G
W
G
RIGHT FRONT Lb 2P
W/Bu
Bl/Bu
Lg/R
Y/R
P
TURN SIGNAL LIGHT G
12 10W
Bu/Y
W/Y
W
G
6P
POSITION LIGHT Y Bl
12V 3.4W G 9P
R/W
G
W/Bu
Bl/Bu
Lg/R
Y/R
P
Lb Lb
Bu/Y
W/Y
2P
Bl/Bu
Bu Bu Bu
P/G
HEAD LIGHT G G G
Bl/Bu
Bl/Bu
Y/W
P/Bu
12 32W/32W
Br
G
W
R/W
W W W
G
2P
O 5P
Bu/Y
O Bl
Bl 4 3
Y 2
Lg
1
POSITION LIGHT G
12V 3.4W Y N
W/Y
LEFT FRONT
Bu
Gr
Lg
Lb
W
Bl
Bl/Bu
Bl/Bu
O
Y
G
TURN SIGNAL LIGHT O
W/Bu
Bl/Bu
Bu/Y
P/Bu
Y/Bu
Lg/R
G/Bl
Bl/O
W/Y
G/O
G/O
P/G
Y/R
3P
Bu
3P 3P
Br
12 10W
G
G
Y
3P R Bl HORN INJECTOR
Bl/Bu
G/Bl
Bu
FUEL
Y
Y/Bu
HL
WL
BAT
LO
HI
W
WR
HO
G/O
G/O
Y/R
LEVEL
Y
4P 33P SENSOR
F/P
R IGNITION ALTERNATOR
3P 2P
GEAR
FL
IGP
PCP
PCM
IGPLS
INJ
SG(TO)
TO
WARN
N SW
SG(THL)
LG
SCS
K-LINE
PG1
PG2
O2
THR
VCC
Bl Bl
COIL SWITCH
DIMMER TURN HORN FUEL PUMP
SIGNAL POSITION
SWITCH SWITCH
VCC
THR
SG
STARTER
BAT
HO
SWITCH DLC
MOTOR
ECM TP EOT
SENSOR SENSOR
SWITCH CONTINUITY
COMBINATION SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH STARTER SWITCH