sure to position the throttle body assy holder clamps
• Be
in original position (see Throttle Body Assy Holder Instal-

•

lation in the Engine Top End chapter).
Run the leads and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).

3-124 FUEL SYSTEM (DFI)
Throttle Body Assy
a thin coat of grease to the throttle cable lower ends.
• Apply
Fit
the
cable end [A] and the decelerator cable
• end [B]accelerator
into the throttle pulley.

○The accelerator cable has a clamp [C].

the clamp securely.
• Install
Turn
the
throttle grip and make sure that the throttle pulley
• moves smoothly
and return by spring force.

the clamps [A] to the holes of delivery pipe.
• Install
Connect
the fuel injector connectors [B].
•

the removed parts (see appropriate chapters).
• Install
Adjust:
• Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)

FUEL SYSTEM (DFI) 3-125
Throttle Body Assy
Throttle Body Assy Disassembly

1. Throttle Body Assy
2. Subthrottle Valve Actuator
3. Main Throttle Sensor
4. Subthrottle Sensor
5. Fuel Injectors
6. Delivery Pipe Assy
7. Intake Air Pressure Sensor #1
8. Intake Air Pressure Sensor #2

NOTICE
Do not remove, disassemble or adjust the main
throttle sensor, subthrottle sensor, subthrottle
valve actuator, throttle link mechanism and throttle
body assy, because they are adjust or set surely at
the manufacturer. Adjustment of these parts could
result in poor performance, requiring replacement
of the throttle body assy.
the throttle body assy (see Throttle Body Assy
• Remove
Removal).
the delivery pipe assy mounting screws [A] to
• Remove
pull out the fuel injectors [B] from the throttle body assy
together with the delivery pipe assy [C].

NOTE

○Do not damage the insertion portions of the injectors
when they are pulled out from the throttle body.

3-126 FUEL SYSTEM (DFI)
Throttle Body Assy
the fuel injectors [A] from the delivery pipe assy
• Remove
[B].

NOTE

○Do not damage the insertion portions of the injectors
when they are pulled out from the delivery pipe assy.
NOTICE
Never drop the fuel injector especially on a hard
surface. Such a shock to the injector can damage
it.

Throttle Body Assy Assembly

assembling, blow away dirt or dust from the throttle
• Before
body and delivery pipe assy by applying compressed air.
the O-rings [A] of the joint pipe [B] with new ones.
• Replace
engine oil to the new O-rings, and insert it to the
• Apply
delivery pipes [C].

○Insert the joint pipe so that the short side [D] faces right
side.
○Left and right delivery pipes are identical.
the O-rings [A] of each fuel injector [B] with new
• Replace
ones.
engine oil to the new O-rings, insert them to the
• Apply
delivery pipe assy and confirm whether the injectors turn
smoothly or not.

the dust seals [A] with new ones.
• Replace
Apply
engine
to the new dust seals.
• Install the fueloilinjectors
• to the throttle body. along with the delivery pipe assy
• Tighten:
Torque - Delivery Pipe Assy Mounting Screws: 3.5 N·m
(0.36 kgf·m, 31 in·lb)

the throttle body assy (see Throttle Body Assy In• Install
stallation).

FUEL SYSTEM (DFI) 3-127
Air Cleaner
Air Cleaner Element Removal/Installation

to the Air Cleaner Element Replacement in the Pe• Refer
riodic Maintenance chapter.

Air Cleaner Element Inspection

the air cleaner element (see Air Cleaner Element
• Remove
Replacement in the Periodic Maintenance chapter).
check the element [A] for tears or breaks.
• Visually
If the element has any tears or breaks, replace the element.

Air Cleaner Oil Draining
A drain hose is connected to the bottom of the air cleaner
to drain water or oil accumulated in the cleaner part.
Visually check the catch tank [A] of the drain hose, if the
water or oil accumulates in the tank.
If any water or oil accumulates in the catch tank, remove
the catch tank from the drain hose and drain it.

•

WARNING
Oil on tires will make them slippery and can cause
an accident and injury. Be sure to reinstall the catch
tank after draining.

Air Cleaner Housing Removal

• Remove:
Fuel Tank (see Fuel Tank Removal)
•
•

ECU (see ECU Removal)
Connector Bracket [A]
Slide the clamp [B].
Disconnect:
Breather Hose [C]
Intake Air Temperature Sensor Connector [D]

• Remove:
Bolts [A] and Washers

3-128 FUEL SYSTEM (DFI)
Air Cleaner
the air cleaner housing clamp bolts [A] on both
• Loosen
sides.

up the air cleaner housing, and disconnect the air
• Lift
switching valve hose [A].
the clamp [B], and disconnect the drain hose [C].
• Slide
After
removing
the air cleaner housing, cover the clean
• cloth on the throttle
body assy.

Air Cleaner Housing Installation

the clamp bolt heads [A] outside as shown.
• Install
the air switching valve hose [B] and drain hose [C]
• Install
to the air cleaner housing.
the air cleaner housing on the throttle body assy.
•○Install
Push in the ducts touch the stopper of the throttle body

•

assy.
Tighten:
Torque - Air Cleaner Housing Clamp Bolts: 2.0 N·m (0.20
kgf·m, 18 in·lb)

the bolts [D] securely.
• Tighten
Run
the
leads and hoses correctly (see Cable, Wire, and
• Hose Routing
section in the Appendix chapter).
Install
the
removed
parts (see appropriate chapters).
•

FUEL SYSTEM (DFI) 3-129
Fuel Tank
Fuel Tank Removal

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential
for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (–) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
the ignition switch off.
• Turn
Wait
until
cools down.
• Disconnectthetheengine
battery
terminal (see Battery Removal
• in the Electrical System(–)chapter).
the fuel tank cap [A] to lower the pressure in the
• Open
tank.

○During tank removal, keep the tank cap open to release
pressure in the tank. This makes fuel spillage less.

the fuel out from the fuel tank with a commercially
• Draw
available pump [A].

○Use a soft plastic hose [B] as a pump intake hose in order
to insert the hose smoothly.

○Put the hose through the fill opening [C] into the tank and
draw the fuel out.

WARNING
Spilled fuel is flammable and can be explosive under certain conditions. The fuel can not be removed
completely from the fuel tank. Be careful for remained fuel spillage.

• Remove:
Side Cover (see Side Cover Removal in the Frame chapter)
Fuel Tank Cover (see Fuel Tank Cover Removal in the
Frame chapter)
Ignition Switch Cover (see Ignition Switch Cover Removal in the Frame chapter)
Fuel Tank Bolts [A]

3-130 FUEL SYSTEM (DFI)
Fuel Tank

• Remove:
Seat Bracket Bolts [A]
Seat Bracket [B]

• Remove:
Fuel Tank Bolt [A]
the clamps [B], and disconnect the drain hose [C]
• Slide
and breather hose [D].

• Disconnect the fuel pump lead connector [A].

sure to place a piece of cloth around the fuel hose joint.
• Be
off the dirt of the surface [A] around the connection
• Wipe
using a cloth or a soft brush.

FUEL SYSTEM (DFI) 3-131
Fuel Tank
When removing with flat tip screwdriver
Insert the flat tip screwdriver [A] into slit on the joint lock
[B].
Turn the driver to disconnect the joint lock.
When removing with fingers
Open and push up [C] the joint lock with your fingers.

•
•
•

NOTICE
Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.

• Pull [A] the fuel hose joint [B] out of the outlet pipe.
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
the fuel tank cap.
• Close
Remove
the fuel tank, and place it on a flat surface.
•○Do not apply
the load to the fuel pipe of the fuel pump.
Clean
the
pipe
• Cover the pipe [A].
and the hose joint [B] with the vinyl bags
• [C] to keep it clean.

Fuel Tank Installation

the above WARNING (see Fuel Tank Removal).
• Note
that the damper [A] is in place on the relay box.
• Check
If the dampers and trim are damaged or deteriorated, re-

•

place them.
Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

3-132 FUEL SYSTEM (DFI)
Fuel Tank
the vinyl bags on the pipe and fuel hose joint.
• Remove
Check
the
joint lock for deformation and wear.
• If the joint lock
is deformed, replace the fuel hose with a

•
•

new one.
Check that there are no flaws, burrs, and adhesion of
foreign materials on the pipe [A].
Apply engine oil to the pipe.

the fuel hose joint [A] straight onto the fuel outlet
• Insert
pipe until the hose joint clicks.
• Push [B] the joint lock [C] until the hose joint clicks.

and pull [A] the hose joint [B] back and forth more
• Push
than two times, and make sure it is locked and does not
come off.

WARNING
Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is installed correctly on the delivery pipe.

•
•

If it comes off, reinstall the hose joint.
Connect the fuel pump lead connector and the battery (–)
terminal (see Battery Installation in the Electrical System
chapter).
Install the removed parts (see appropriate chapters).

Fuel Tank and Cap Inspection

the tank cap.
• Open
Visually
• damage.inspect the gasket [A] on the tank cap for any

•

Replace the tank cap if gasket is damaged.
Check to see if the water drain pipe [B] and fuel breather
pipe [C] in the tank are not clogged. Check the tank cap
breather also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.

NOTICE
Do not apply compressed air to the air vent holes
[D] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.

FUEL SYSTEM (DFI) 3-133
Fuel Tank
Fuel Tank Cleaning

WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame anywhere near the working area. Do not use gasoline
or low flash-point solvents to clean the tank.

• Remove:
Fuel Tank (see Fuel Tank Removal)
•
•
•
•

Fuel Pump (see Fuel Pump Removal)
Pour some high flash-point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
Draw the solvent out of the fuel tank.
Dry the tank with compressed air.
Install:
Fuel Pump (see Fuel Pump Installation)
Fuel Tank (see Fuel Tank Installation)

3-134 FUEL SYSTEM (DFI)
Evaporative Emission Control System (Equipped Models)
The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.

Parts Removal/Installation

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch off. Do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.

NOTICE
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
the hoses according to the diagram of the sys• Connect
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.

Hose Inspection

to the Evaporative Emission Control System In• Refer
spection in the Periodic Maintenance chapter.

Purge Valve Inspection

• Refer to the Purge Valve Inspection.
Canister Inspection

to the Evaporative Emission Control System In• Refer
spection in the Periodic Maintenance chapter.

COOLING SYSTEM 4-1

Cooling System
Table of Contents
Exploded View........................................................................................................................
Coolant Flow Chart.................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Coolant ...................................................................................................................................
Coolant Deterioration Inspection.......................................................................................
Coolant Level Inspection...................................................................................................
Coolant Draining ...............................................................................................................
Coolant Filling ...................................................................................................................
Pressure Testing ...............................................................................................................
Cooling System Flushing ..................................................................................................
Coolant Reserve Tank Removal .......................................................................................
Coolant Reserve Tank Installation ....................................................................................
Water Pump............................................................................................................................
Water Pump Removal .......................................................................................................
Water Pump Installation ....................................................................................................
Water Pump Inspection.....................................................................................................
Water Pump Impeller Disassembly/Assembly ..................................................................
Water Pump Impeller Inspection .......................................................................................
Water Pump Housing Disassembly ..................................................................................
Water Pump Housing Assembly .......................................................................................
Mechanical Seal Inspection ..............................................................................................
Radiator ..................................................................................................................................
Radiator and Radiator Fan Removal ................................................................................
Radiator and Radiator Fan Installation .............................................................................
Radiator Inspection ...........................................................................................................
Radiator Cap Inspection ...................................................................................................
Radiator Filler Neck Inspection .........................................................................................
Thermostat .............................................................................................................................
Thermostat Removal.........................................................................................................
Thermostat Installation......................................................................................................
Thermostat Inspection ......................................................................................................
Hose and Pipes ......................................................................................................................
Hose Installation ...............................................................................................................
Hose Inspection ................................................................................................................
Water Temperature Sensor ....................................................................................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Inspection .............................................................................

4-2
4-4
4-6
4-7
4-8
4-8
4-8
4-8
4-8
4-8
4-9
4-9
4-9
4-10
4-10
4-10
4-12
4-12
4-12
4-12
4-13
4-13
4-14
4-14
4-15
4-15
4-16
4-16
4-17
4-17
4-17
4-18
4-19
4-19
4-19
4-20
4-20
4-20

4

4-2 COOLING SYSTEM
Exploded View

COOLING SYSTEM 4-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13

Fastener
Radiator Fan Mounting Bolts
Fitting Bolt
Thermostat Housing Bolts
Thermostat Housing Cover Bolts
Coolant Drain Bolt (Cylinder)
Water Temperature Sensor
Water Hose Fitting Cover Bolts
Oil Passage Cover Bolts
Water Pipe Bolts
Water Pump Cover Bolts