26. ACB110CB-A ADDENDUM 26
A FEW WORDS ABOUT SAFETY··············26-2
CABLE & HARNESS ROUTING··············· ROUTING··············· 26-12
HOW TO USE THIS THIS MANUAL ····················26-3 ····················26-3
BRAKE CALIPER CALIPER ······················· ·································· ·············· ··· 26-13
MODEL IDENTIFICATION IDENTIFICATION ························ ··························26-4 ··26-4
BRAKE PAD ························· ····································· ···················· ········ 26-15
SPECIFICATIONS SPECIFICATIONS ························ ···································· ···············26-6 ···26-6
WIRING DIAGRAM ························ ··································· ···········26-17 26-17
LUBRICATION & SEAL POINTS··············26-11
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ACB110CB-A ADDENDUM ACB110CB-AADDENDUM
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.
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 and 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 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.
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ACB110CB-A ADDENDUM
How To Use This Manual This addendum contains information for ACB110-A. Refer to ANC110 BDV/BSV/BCV-7 SHOP MANUAL (No.62KVBGM8) or ANC110BDT/BST/BCT-6 SHOP MANUAL (No.62KVBAM7) for service procedures and data not included in this addendum. 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 prevent damage to your vehicle, other property, or the environment.
symbol. The purpose of this message is to help
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATI ON 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: JAN, 2010
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ACB110CB-A ADDENDUM
MODEL IDENTIFICATION
The frame serial number is stamped on the seat stay as shown.
FRAME SERIAL NUMBER
The engine serial number is stamped on the lower left side of the crankcase.
ENGINE SERIAL NUMBER
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ACB110CB-A ADDENDUM The carburetor identification number is stamped on the left side of the carburetor body.
CARBURETOR IDENTIFICATION NUMBER
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ACB110CB-A ADDENDUM
GENERAL SPECIFICATIONS DIMENSIONS
FRAME
ENGINE
CARBURETOR DRIVE TRAIN
ELECTRICAL
26-6
ITEM Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Curb weight Frame type Front suspension Front axle travel Rear suspension Rear axle travel Front tire size Rear tire size Tire brand Front Rear Front brake Rear brake Caster angle Trail length Fuel tank capacity Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust opens valve closes Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Carburetor type Throttle bore Clutch system Drive belt ratio Final reduction Ignition system Starting system Charging system Regulator/rectifier Lighting system
at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift
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SPECIFICATIONS 1,897 mm (74.7 in) 682 mm (26.8 in) 1,083 mm (42.6 in) 1,273 mm (50.1 in) 758 mm (29.8 in) 257 mm (10.1 in) 133 mm (5.2 in) 100 kg (220.5 lbs) Under bone type Telescopic fork 81 mm (3.2 in) Unit swing 75.0 mm (2.95 in) 80/90 - 14M/C40P 90/90 - 14M/C46P NR73T Z (IRC) NR73T (IRC) Hydraulic disc brake Mechanical leading trailing 26°40’ 80.0 mm (3.15 in) 3.6 liter (0.95 US gal, 0.79 lmp gal) 50.0 x 55.0 mm (1.97 x 2.17 in) 108.0 cm3 (6.59 cu-in) 11.0 : 1 2 valve, single chain driven SOHC 5° BTDC 30° ABDC 30° BBDC 0° ATDC Forced pressure and wet sump Trochoid Liquid cooled Paper filter 27.3 kg (60.2 lbs) CV (constant velocity) 22 mm (0.9 in) or equivalent Dry, automatic centrifugal clutch 2.53:1 - 0.85: 1 10.625 (51/18 x 45/12) DC-CDI Kickstarter with electric starter motor Single phase output alternator SCR shorted/single phase, half wave rectification Alternator
ACB110CB-A ADDENDUM
LUBRICATION SYSTEM SPECIFICATIONS ITEM Engine oil capacity
After draining After disassembly
Recommended engine oil
Oil pump rotor
Tip clearance Body clearance Side clearance
STANDARD 0.7 liter (0.7 US qt, 0.6 lmp qt) 0.8 liter (0.8 US qt, 0.7 lmp qt) API classification: SE, SF or SG (except oils labeled as energy conserving on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MB 0.15 (0.006) 0.15 – 0.21 (0.006 – 0.008) 0.05 – 0.10 (0.002 – 0.004)
Unit: mm (in) SERVICE LIMIT – –
–
0.20 (0.008) 0.35 (0.014) 0.12 (0.005)
FUEL SYSTEM SPECIFICATIONS ITEM Carburetor identification number Main jet Slow jet SE thermal valve resistance Float level Pilot screw opening Idle speed PAIR control valve specified vacuum Throttle grip free play
SPECIFICATIONS AVK2CP #105 #35 3.2 – 5.6 (20°C/68°F) 13.0 mm (0.51 in) See page 1-15 1,700 ± 100 min-1 (rpm) 60 kPa (450 mmHg) 2 – 6 mm (0.1 – 0.2 in)
COOLING SYSTEM SPECIFICATIONS ITEM Radiator and engine Reserve tank Radiator cap relief pressure Thermostat Begin to open Fully open Valve lift Recommended coolant Coolant capacity
SPECIFICATIONS 0.49 liter (0.52 US qt, 0.43 lmp qt) 0.20 liter (0.21 US qt, 0.18 lmp qt) 108 – 137 kPa (1.1 – 1.4 kgf/cm2, 16 – 20 psi) 74 – 78 °C (165 – 172 °F) 100 °C (212 °F) 8 mm (0.3 in) minimum Honda PRE-MIX COOLANT
CYLINDER HEAD/VALVES SPECIFICATIONS ITEM
IN/EX IN/EX IN/EX IN EX IN EX IN EX IN/EX IN EX IN/EX
STANDARD 912 kPa (9.3 kgf/cm2, 132.3 psi) at 550 min-1 (rpm) – 10.000 – 10.015 (0.3937 – 0.3943) 9.972 – 9.987 (0.3926 – 0.3932) 0.013 – 0.043 (0.0005 – 0.0017) 32.542 – 32.782 (1.2812 – 1.2906) 32.263 – 32.503 (1.2702 – 1.2796) 0.16 ± 0.02 (0.006 ± 0.001) 0.25 ± 0.02 (0.010 ± 0.001) 4.975 – 4.990 (0.1959 – 0.1965) 4.955 – 4.970 (0.1951 – 0.1957) 5.000 – 5.012 (0.1969 – 0.1973) 0.010 – 0.037 (0.0004 – 0.0015) 0.030 – 0.057 (0.0012 – 0.0022) 9.1 – 9.3 (0.36 – 0.37)
IN/EX IN/EX IN/EX
0.7 – 0.9 (0.03 – 0.04) 31.53 (1.241) 38.33 (1.509)
Cylinder compression Cylinder head warpage Rocker Rocker arm I.D. arm Rocker arm shaft O.D. Arm to shaft clearance Camshaft Cam lobe height Valve, valve guide
Valve clearance Valve stem O.D. Valve guide I.D. Stem-to-guide clearance
Valve guide projection above cylinder head Valve seat width Valve spring free length Inner Outer
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Unit: mm (in) SERVICE LIMIT – 0.05 (0.002) 10.04 (0.395) 9.91 (0.390) 0.08 (0.003) 32.52 (1.280) 32.24 (1.269) – – 4.90 (0.193) 4.90 (0.193) 5.03 (0.198) 0.08 (0.003) 0.10 (0.004) – 1.5 (0.06) 30.66 (1.207) 37.04 (1.458)
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ACB110CB-A ADDENDUM
CYLINDER/PISTON SPECIFICATIONS ITEM I.D. Out-of-round Taper Warpage Piston, piston Piston O.D. rings, piston Piston O.D. measurement point pin Piston pin bore I.D. Piston pin O.D. Piston-to-piston pin clearance Piston ring-to-ring Top groove clearance Second Piston ring end gap Top Second Oil (side rail) Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance Cylinder
STANDARD 50.000 – 50.010 (1.9685 – 1.9689) – – – 49.975 – 49.995 (1.9675 – 1.9683) 10.0 (0.39) from bottom of skirt 13.002 – 13.008 (0.5119 – 0.5121) 12.994 – 13.000 (0.5116 – 0.5118) 0.002 – 0.014 (0.0001 – 0.0006) 0.015 – 0.045 (0.0006 – 0.0018) 0.015 – 0.045 (0.0006 – 0.0018) 0.10 – 0.25 (0.004 – 0.0020) 0.10 – 0.25 (0.004 – 0.0020) 0.20 – 0.70 (0.008 – 0.028) 0.005 – 0.035 (0.0002 – 0.0014) 13.010 – 13.028 (0.5122 – 0.5129) 0.010 – 0.034 (0.0004 – 0.0013)
Unit: mm (in) SERVICE LIMIT 50.10 (1.972) 0.05 (0.002) 0.05 (0.002) 0.05 (0.002) 49.95 (1.967) – 13.04 (0.513) 12.96 (0.510) 0.02 (0.001) 0.08 (0.003) 0.08 (0.003) 0.45 (0.018) 0.45 (0.018) – 0.09 (0.004) 13.05 (0.514) 0.05 (0.002)
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS ITEM Drive belt width Movable drive face
Clutch Driven pulley
STANDARD
Bushing I.D. Boss O.D. Weight roller O.D. Lining thickness Clutch outer I.D. Face spring free length Driven face O.D. Movable driven face I.D.
19.0 (0.75) 22.035 – 22.085 (0.8675 – 0.8695) 22.010 – 22.025 (0.8665 – 0.8671) 17.92 – 18.08 (0.706 – 0.712) – 125.0 – 125.2 (4.92 – 4.93) 111.4 (4.39) 33.965 – 33.985 (1.3372 – 1.3380) 34.000 – 34.025 (1.3386 – 1.3396)
Unit: mm (in) SERVICE LIMIT 18.0 (0.71) 22.11 (0.871) 21.98 (0.865) 17.5 (0.69) 2.0 (0.08) 125.5 (4.94) 108.0 (4.25) 33.94 (1.336) 34.06 (1.341)
FINAL REDUCTION SPECIFICATIONS Unit: mm (in) ITEM Final reduction oil capacity
After draining After disassembly
Recommended final reduction oil
SPECIFICATIONS 0.10 liter (0.11 US qt, 0.09 lmp qt) 0.12 liter (0.13 US qt, 0.11 lmp qt) API classification: SE, SF or SG (except oils labeled as energy conserving on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MB
CRANKCASE/CRANKSHAFT SPECIFICATIONS Crankshaft
26-8
ITEM Connecting rod side clearance Connecting rod radial clearance Runout
STANDARD 0.10 – 0.35 (0.004 – 0.014) 0.004 – 0.016 (00002 – 0.0006) –
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Unit: mm (in) SERVICE LIMIT 0.55 (0.022) 0.05 (0.002) 0.10 (0.004)
ACB110CB-A ADDENDUM
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ITEM Minimum tire tread depth Cold tire pressure Driver only Driver and passenger Axle runout Wheel rim runout Radial Axial Fork Spring free length Pipe runout Recommended fluid Fluid level Fluid capacity
STANDARD – 200 kPa (2.00 kgf/cm2, 29 psi) 200 kPa (2.00 kgf/cm2, 29 psi) – – – 311.3 (12.26) – Fork fluid 82 (3.2) 68 ± 1 cm3 (2.3 ± 0.03 US oz, 2.4 ± 0.04 Imp oz)
Unit: mm (in) SERVICE LIMIT To the indicator – – 0.2 (0.01) 2.0 (0.08) 2.0 (0.08) 305.1 (12.01) 0.2 (0.01) – – –
REAR WHEEL/SUSPENSION SPECIFICATIONS ITEM Minimum tire tread depth Cold tire pressure Driver only Driver and passenger Wheel rim runout Radial Axial
STANDARD – 225 kPa (2.25 kgf/cm2, 33 psi) 225 kPa (2.25 kgf/cm2, 33 psi) – –
Unit: mm (in) SERVICE LIMIT To the indicator – – 2.0 (0.08) 2.0 (0.08)
BRAKE SYSTEM SPECIFICATIONS ITEM Brake lever freeplay Brake drum I.D. Specified brake fluid Brake disc Master cylinder Caliper
STANDARD 10 – 20 (0.4 – 0.8) 130.0 – 130.2 (5.12 – 5.13) DOT 3 or 4 3.3 – 3.7 (0.13 – 0.15) – 11.000 – 11.043 (0.4331 – 0.4348) 10.957 – 10.984 (0.4314 – 0.4324) 32.030 – 32.080 (1.2610 – 1.2630) 31.948 – 31.998 (1.2578 – 1.2598)
Thickness Warpage Cylinder I.D. Piston O.D. Cylinder I.D. Piston O.D.
Unit: mm (in) SERVICE LIMIT – 131.0 (5.16) – 3.0 (0.12) 0.10 (0.004) 11.055 (0.4352) 10.945 (0.4309) 32.090 (1.2634) 31.94 (1.257)
BATTERY/CHARGING SYSTEM/ALTERNATOR SPECIFICATIONS Battery
ITEM Capacity Current leakage Voltage
Fully charged Needs charging Normal Quick
Charging current Alternator Capacity Charging coil resistance Lighting coil resistance Regulator/rectifier regulated voltage (Lighting output)
SPECIFICATIONS 12 V – 3.0 Ah/3.5 Ah 0.5 mA max. 13.0 – 13.2 V Below 12.4 V 0.3 A/5 – 10 h 3.0 A/0.5 h 0.140 kW/5,000 min-1 (rpm) 0.2 – 1.0 (20°C/68°F) 0.1 – 0.8 (20°C/68°F) 12.6 – 13.6 V/5,000 min-1 (rpm)
IGNITION SYSTEM SPECIFICATIONS ITEM
SPECIFICATIONS CR7EH-9 (NGK), U22FER9 (DENSO) 0.80 – 0.90 mm (0.031 – 0.035 in) 100 V minimum 0.7 V minimum 14° BTDC at idle speed
Spark plug Spark plug gap Ignition coil peak voltage CKP sensor peak voltage Ignition timing
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ACB110CB-A ADDENDUM
ELECTRIC STARTER SYSTEM SPECIFICATION ITEM Starter motor brush length
STANDARD 7.0 (0.28)
Unit: mm (in) SERVICE LIMIT 3.5 (0.14)
LIGHTS/METERS/SWITCHES SPECIFICATION Bulbs
Fuse ECT sensor resistance
26-10
ITEM Headlight Tail/brake light Front turn signal light Rear turn signal light Instrument light High beam indicator Turn signal indicator Coolant temperature warning indicator Main fuse Sub fuse at 40 °C (104 °F) at 100 °C (212 °F)
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SPECIFICATIONS 12 V – 35/35 W 12 V – 5W/10W x2 12 V – 10 W x 2 12 V – 10 W x 2 12 V – 1.7 W x 2 12 V – 1.7 W 12 V – 3.4 W x 2 LED 15 A x 1 10 A x 1 1.0 – 1.3 k 0.1 – 0.2 k
ACB110CB-A ADDENDUM
LUBRICATION & SEAL POINTS FRAME MATERIAL Multi-purpose grease with extreme pressure (recommended: EXCELIGHT EP2 manufactured by KYODO YUSHI, japan. or Shell ALVANIA EP2 or equivalent) Grease(Shell BEARING GREASE HD or equivalent) Multi-purpose grease
Silicone grease
Brake fluid (DOT 3 or DOT 4)
Fork fluid Adhesive(Honda bond A or equivalent)
LOCATION Steering bearing race Steering stem dust seal lip
REMARKS Spread each 3 g minimum Spread each 3 g minimum
Speedometer gear box inside Front wheel dust seal lip Front wheel axle sliding surface Front wheel distance collar whole surface Front wheel bearing sliding area Speedometer gear box seal lip Rear brake cam and shaft Rear brake anchor pin shaft Rear brake dust seal lip Rear brake lever pivot screw sliding surface Equalizer rod pivot screw sliding surface Throttle cable-to-throttle drum sliding area Seat catch contact area Centerstand pivot area Sidestand pivot area Rear brake cable cap boot inside Front brake lever-to-master piston contacting area Front brake lever pivot sliding area Brake caliper pin sliding area Brake caliper pad pin O-ring whole surface. Brake caliper dust seal whole surface Brake equalizer cable cap boot inside Speedometer cable Throttle cable boot inside Throttle cable inside Master cylinder inside and sliding area Brake caliper piston seal whole surface Brake caliper piston whole surface Master cylinder piston cup Fork dust seal and oil seal lips Fork spring seat O-ring whole surface Handlebar grip rubber inside Air cleaner connecting hose-to-housing mating area
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Spread each 0.2 - 0.3 g Spread 0.2 - 0.3 g
Apply 0.1 - 0.2 g Apply 1.5 g minimum
Spread each 0.1 g Spread 0.4 g minimum
Fill up 0.1 g Fill up 0.2 g minimum
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ACB110CB-A ADDENDUM
CABLE & HARNESS ROUTING RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE
SPEEDOMETER CABLE HORN WIRE
FRONT BRAKE HOSE
BATTERY POSTIVE (+) CABLE
REAR BRAKE CABLE
STARTER RELAY SWITCH WIRE
THROTTLE CABLE
MAIN WIRE HARNESS TO BE BUTTED
THROTTLE CABLE
TO BE BUTTED
FRONT BRAKE HOSE
REAR BRAKE CABLE
FRONT BRAKE HOSE
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ACB110CB-A ADDENDUM
BRAKE CALIPER REMOVAL Avoid spilling fluid on painted, plastic, or rubber parts. Place a shop towel over these parts whenever the system is serviced.
Drain the brake fluid. Remove the following: – – – –
Brake pads Oil bolt/sealing washers Brake caliper mounting torx bolts Brake caliper
INSTALLATION Install the front brake caliper onto the left fork leg. Install new brake caliper mounting bolts and tighten them to the specified torque. TORQUE:30 N·m (3.1 kgf·m, 22 lbf·ft) Connect the brake hose to the brake caliper with the oil bolt and new sealing washers. Tighten the oil bolt while pushing the brake hose eyelet joint against the stopper.
Tighten the oil bolt to the specified torque. TORQUE:34 N·m (3.5 kgf·m, 25 lbf·ft) Install the brake pads (page 1-15) Fill the brake fluid and bleed the hydraulic system
BRAKE HOSE BRAKE CALIPER
OIL BOLT 34 N·m (3.5 kgf·m, 25 lbf·ft)
SEALING WASHERS
BRAKE CALIPER MOUNTING BOLTS 30 N·m (3.1 kgf·m, 22 lbf·ft)
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26-13
ACB110CB-A ADDENDUM DISASSEMBLY/ASSEMBLY Remove the following: – Caliper bracket – Bracket pin boots – Pad spring Place a shop towel over the piston. Do not use high Position the caliper body with the piston facing down pressure air or bring and apply small squirts of air pressure to the fluid inlet the nozzle too close to remove the piston. to the inlet.
Remove the dust seal and piston seal.
Assembly is in the reverse order of disassembly. • Apply silicone grease to the dust seal and bracket pin boots. • Apply brake fluid to the piston and piston seal. • Replace the dust seal and piston seal with new ones.
DUST SEAL * BRACKET PIN BOOT CALIPER BRACKET Install the caliper piston with its opened end facing the brake pads.
PISTON SEAL
BLEED VALVE 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
* BRACKET PIN BOOT PAD SPRING
CALIPER BODY CALIPER PISTON
*: Apply 0.4 g minimum of silicone grease
INSPECTION Check the caliper cylinder for scoring, scratches or damage. Measure the caliper cylinder I.D. SERVICE LIMIT: 32.090 mm (1.2634 in) Check the caliper piston for scoring, scratches or damage. Measure the caliper piston O.D. SERVICE LIMIT: 31.94 mm (1.257 in)
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ACB110CB-A ADDENDUM
BRAKE PAD BRAKE PAD REPLACEMENT Check the brake fluid level in the reservoir as this operation causes the level to rise.
Push the caliper piston in the direction as shown to allow installation of new brake pads.
BRAKE CALIPER
Remove the pad pin from the brake caliper.
PAD PIN
Remove the brake pads from the brake caliper.
BRAKE PADS Always replace the Install new brake pads so that they are set on the brake brake pads in pairs caliper bracket and bracket pin. to assure even disc pressure.
Set the pads
BRACKET PIN
BRAKE PADS
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ACB110CB-A ADDENDUM Install the pad pin by pushing the brake pads against the pad spring to align the pad pin holes on the pads and caliper hole.
PAD PIN After the brake pad Tighten the pad pin to the specified torque. replacement, check the brake operation TORQUE:18 N·m (1.8 kgf·m, 13 lbf·ft) by applying the brake lever.
PAD PIN
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ACB110CB-A ADDENDUM
WIRING DIAGRAM
b L
) E E S ( V T L A N V E L R M A E H M T C I R R E R A H N T E S T
Y / G
r B
r B
I N I M P l 3 B
T H ) G I L W 0 E 1 K V A 2 ( R 1 B
T H ) G I W L 5 L I V 2 A 1 T ( Y / G
G
G
G
O
N R U T T H R G I ) A L E W L R 0 A 1 T N V F G I 2 E 1 L S (
b Y G L O / G
I N I M
l B
H
b O Y L / G G
O / G
l B / R R / Y W / G R / g L G / Y W / P G / u B Y / u B
Y W
A
R O N T A O L I E E T S I N L N E U G I G P
Y / u B G P 2
W / R
R W / R l B / R R / Y
P 5
M R F ) T T C E ( N A L E R O U O T A C R R E E O N I P S G N M N E E E T S
W / G G
A 5 1 R R l B l B / R
G / u B
A 0 1
W / P
1 T A B
l B / R
T A B
R
P C 2 r P G W
l B / R P 2
R
N R O H
G W / u B I W / u B N W / Y I W / Y M G G P R 3
g L
l r B B Y
l r B B Y
G N I H T C T H I G W I L S
R O T A N R E T L
G N E
I N I M P 3 l B
R H E T C R T I A T W S S
l B
Y W
P 2
G
W / R
L E V R E L O L S E N E U F S
L Y A N A N L R G I E U T S R
C P W
R R
R E T Y A R L A T E S R
N H O I C T I T I N W G I S
P 8 1
O / G G
l B
G
2 1
X O B E S U F
) M C I ( E L U D O M L O R T N O C N O I T I N G I
Y / l B
Y / u B
Y A . R 5 3 E / T H T A 0 . A 3 B V
K R G A U P L S P
G
G Y W R
P 4 G
N O I T I I L N O G I C
N P 6
W / G I W / G N I M G G P 3 G
P D 3 N G
/ R O R T E I A F L I U T G C E E R R
T H ) G I L W 0 E 1 K V A 2 1 R ( B
r B
O / G
D P N U A T H S C N T E I W D O I W D S S
T H G I L L A R N A E G ) I R S W T N 0 1 H G G R V G I U 2 1 R T (
T S l B E P 3
1 C
I N I M
U
P9
r b g r O B O L L P G R
G :
R G g W / b Y G / W / L O / u g / L G Y B L Y
r G l B
P 2
G
N N I E E K U E R E L R N G B G A T T W N Y M A / O A H H K N R D G G I R R I I B O L L P G N
R W / G g b Y G / W / L O / u g / L G Y B L Y
r G O b L
L A N G I H S C N T I R W U T S
W
R
L W P 3
R W
G / Y Y / G
g L
l B
O H
l B
P 3
T A B
Y r B
L H
r B u B W
H C N T I R O W H S
R H E C T M I M I W D S
L H I H P O 3 L
B W N K O E E M T C L E D I O A L U E L E L R E H C B Y B G R W R O
L l u B Y B G R W O C
H M G / C C I Y T I Y T / W G S S R E T E H R O E S R R U L A F P O C T S H O g L C H T I T l A W B S B N E H R O R E S L O R U O H F P C W /
L
u H H B C T o I W L W S i u R H B E M R O M I ) O L I N D H ( L O
b u O L G B W
C
I N I M
H L C T I W S W L A N
P 6
O r G b L
R
G I S N R U T l Y / G B
I I B G B G
u G B
P 3
G b L
) W T 5 3 H / G I W L 5 3 D V A 2 E 1 ( H
E N L R A O U N ) T R I ) R T T A G G O O A W W I N R T 4 T I N N 7 S I . . A R T E A A 1 3 L N E P M N L C O R C I I T H V U E R M G D D L V 2 O A 2 E I U U E 1 C 1 N N I L ( F M R T I ( T W I
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A H B R C T l 1 I T B / A W R B S N O I K R F O T N F C L I O O N O O L C G I
O G
Y l / G B
E H K C A T I R W B S T T N H O G R I F L
R O L L O C
T
/ b G W IB W / u L Y B
u G B W
I N I M P 3
T H G I L T L A N N O ) G R I F W S 0 T 1 N H V R G 2 I U 1 R T (
R N
R O T A N C I O I D ) R ) N ) T N R A I W O W W T U N 7 4 L 4 I . M . . A T A 1 A 3 3 M C T E I N V B V V U G 2 F 2 L 2 I D I E 1 1 H 1 L L ( N I I ( S (
R E T E M O D E E P S
l Y B / G O G
H E C K T I A W R S B T R H A G E I R L
T H G I L L T A N N ) O G I R W S F 0 N T 1 V R F 2 U E 1 L T (
L
H H C T I 1 C W S G N I T H G I L
r B Y
R ) O N H L ( O C
26-17
MEMO
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INDEX
INDEX BATTERY/CHARGING SYSTEM/ALTERNATOR SPECIFICATIONS ························································26-9 BRAKE CALIPER························································26-13 BRAKE PAD································································26-15 BRAKE SYSTEM SPECIFICATIONS ···························26-9 CABLE & HARNESS ROUTING ·································26-12 COOLING SYSTEM SPECIFICATIONS·······················26-7 CRANKCASE/CRANKSHAFT SPECIFICATIONS ·······26-8 CYLINDER HEAD/VALVES SPECIFICATIONS ···········26-7 CYLINDER/PISTON SPECIFICATIONS·······················26-8 ELECTRIC STARTER SYSTEM SPECIFICATION ····26-10 FINAL REDUCTION SPECIFICATIONS·······················26-8
A B
C
E
F
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS························································ 26-9 FUEL SYSTEM SPECIFICATIONS······························ 26-7 GENERAL SPECIFICATIONS······································ 26-6 IGNITION SYSTEM SPECIFICATIONS ······················· 26-9 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/ CLUTCH SPECIFICATIONS ········································ 26-8 LIGHTS/METERS/SWITCHES SPECIFICATIONS···· 26-10 LUBRICATION & SEAL POINTS································ 26-11 LUBRICATION SYSTEM SPECIFICATIONS··············· 26-7 MODEL IDENTIFICATION ··········································· 26-4 REAR WHEEL/SUSPENSION SPECIFICATIONS ······ 26-9 WIRING DIAGRAM····················································· 26-17 G
I
K
L
M
R
W
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2-1
2
