1995-2000IMPORTANT SAFETY NOTICE RAGES cicates a sirong possibilty of savere personal injury or death it instructions are not followed. ‘CAUTION: Indicates a possibilty of personal injury or equioment damage instructions are not followed. NOTE: {Gives heiptul information Detailed doscriptions of etandard workshop procedures, safety principles and service operations are not included. Its important to note that this manual contains some warnings and cautions against some spectfic service mathads which ‘could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe, Please understand, that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda might bedone or ofthe possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. ‘Anyone using service procedures er tools, whether or not recommended by Honda must satisfy himsell horoughiy that either personal safaty nor vehicle safety will be jeopardized by the service method or tools selected.HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure thal the vehicle is in peak operating condition and the emission levels are within the standards set by the Califor- nia Air Resources Board, Sections 1 through 3 apply to the complete FOURTRAX, while sections 4 through 21 describe parts of the FOURTRAX, arouped according to location. Find the section you want on this page, nen tum to the table of contents on page 1 of that section, Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed proce- dures. If you don’t know the source of the trouble. go to section 22, Troubleshooting. obligation whatever. |_ without wntten permission CONTENTS oo "LUBRICATION E MAINTENANCE - E FUEL SYSTEM E ENGINE REMOVAL/INSTALLATION fz CYLINDER HEADIVALVES KE = " CYLINDER/PISTON CLUTCH/OIL PUMP/KICK STARTER ALTERNATORISTARTER CLUTCH/ GEARSHIFT LINKAGE. CRANKCASE/CRANKSHAFT/ GENERAL INFORMATION ictal FRONT WHEEL/SUSPENSION/STEERING BRAKES REAR WHEEL/SUSPENSION 2 mame E i coin Nine. Tee << FRONT DRIVING MECHANISM _E£ ‘Spectications Inchided in this publication ore = 4 Based onthe latest product Information avaible 5 _CTRX300FW) See te eee ero ea chances REAR DRIVING MECHANISM. E | any time without notice and without incurring any CARRIERS/FENDERS/MUFFLER No part of thie publication may be reproduced a | | tanmmion system HONDA MOTOR CO., LTD. z BATTERY/CHARGING SYSTEM E Service Publications Office 2 —— — E STARTER SYSTEM E 5. ss @| UGHTS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX1. GENERAL INFORMATION GENERAL SAFETY 1-1 TOOLS 1-10 SERVICE RULES 1-1 CABLE & HARNESS ROUTING 142 MODEL IDENTIFICATION 1-2 EMISSION CONTROL SYSTEMS (After'97) 1-18 [ SPECIFICATIONS 1-4 EMISSION CONTROL INFORMATION LABEL TORGHE VALUES 4.7 (After'97 California type only) 1419 GENERAL SAFETY Ps Ifthe engine must be running to do some work, make sure the area Is well-ventilated. Never run the engine in an enclosed area, The ‘exhaust contains poisonous carbon monoxide gas tha! may cause loss of consciousness and lead to death Pad ‘The battory ganerates hydrogen gas which can be highly explosive. Do nat smoke or alow flames or sparks near the battery. especialy while charging it. Peco * Inhaled asbestos fibars have been found to cause respiratory disease and cancer, Never use an air hase or dry brush to clean brake or clutch assemblies. + Use an OSHA-approved vacuum cleaner or altemate method approved by OSHA designed to minimize the hazard caused by aliborne asbestos fibers. PAG ‘Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or alow flames or sparks in your work area or where gasoline is Stored. & WARNING ‘The battery electrolyte contams sulfuric acid. Protect your eyes, skin and clothing. In the case of Conlact, fush thoroughly with water 4nd calla doctor if electroiyie gets in your eyes. SERVICE RULES Use genuine HONDA or HONDA-recommendad parts and lubricants or their equivalents. Parts that don't meet HONDA’s design specifications may cause damage to the vahicia. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the vehiole. Metric bolts, nuts and screws are not interchangeable with English fasteners, Install new gaskets, O-rings, cotter pins, and lock plates when reassembiing When tightening bolts or nuts, begin with the larger diameter or inner bolt frst. Then tighten to the specified torque diagonally in incremental steps, unless a particular sequence is specified ‘6. Ciean paris in non-flammable or high flash point solvent upon disassembly. 7. Lubricate any siding surfaces before reassembly. 8, Alter reassembly, check all pars for proper instalation and operation.GENERAL INFORMATION MODEL IDENTIFICATION ‘TAX300:GENERAL INFORMATION (1) The frame serial numbor is stamped on the front of the frame. 2)The engine serial number is siamped on the upper side of the right crankcase. (2) The carburetor identfication number is on the left side of the carburetor body.GENERAL INFORMATION SPECIFICATIONS | ETRXSOOFW DIMENSIONS | Oveal ength 110 mim PEin) So veral wt ‘9507 | 4,518 mm(4a9iny (140mm (49.7in] ater'97- | 1.157 mm (483m) vera eight "96-97 | 4068 mm(42in) (1,065 mm 427 ater'97 | 1077 mm (dain) [1.068 mm (420 Wheelbase ‘95-97 | 1.298 mm(48ain) (1,298 mm 48.7) After'97 | 1,238 mm (48.8 in) [1,235 mm (48.6 in)) Seat height ‘95-97 783 mm (30.8 in) {780 mm (30.7 inj} After'97 763 mm (30.8 in) 1788 mm (31.0 in)) Feet pag hat "95-97 | 908 mm (12.0in) Aner'97 | 267 mm(ii7in) (20mm (12.219) | chen ce "er 160 nme3in v ater'97 | HEOmm(E3in) (172mm (68) Dry welght 221 kg 487 b) ——_(299K9 627 8) FRAME ‘Type Double cradle _ Fim size Front 11x65 aT Rear axaoar (11x75 an) Susponson travel Front Ax ave! 190 mm (51 in) Rear fs Wave 120 mm (61) | Front ire size, pressure AT 23 x 8-11 8, 2.9 psi (0.20 ko/em?, 20 kPa) [AT 23 x 8-11 xs, 4.4 psi (0.30 kgicm?, 30 kPa) Rare size, pressure AAT 25 1-9, 2.9 ps (0.20 kgomé, 20 kPa) IAT 24 x8-11 « 29 psi (020 gion, 20 KPa) ‘with carg: 3.0 si (0 29 hyve 28 KPa Front brake Hydraulic operate leacngfaling shoe (Hyeraie operate eal acing sh) Rear brake Cable operate lesaingtaiing shoe Fuel tank cabacly 125 ers (43 US ga, 28Imp ga) Fue) reserve capacity 2.5 liters (0.7 US gal, 0,6 imp gal) ein Simm (025i (4mm (0.16 Castor ange 7 ez Camber angie oz 1 ‘Trail length 33.0 mm (1.26 in) [10.0 mm (0.39 in)] Tread Front 790 mm (31.1 in) [840 mm (33.1 in)] Rear 840 mm (33.1 in) {840 mm (33.1 in)]GENERAL INFORMATION [ } TRXa00FW © faene Type Gasoline, air-cooled 4-stroke Cylinder arrangement Single cylinder inclined 20° from vertical Bore x stroke 740 x 65.5 mim 2.81 x 2.58 in) Displacement 281.7 ¢0 (17.2 cusr) Compression ratio 80:1 oe Valve train ‘Overhead camshaft, chain driven ll capacity 2.5 (2.6 US at, 2.2 Imp at) at disassembly 22 It (2.3 US at, 1.3 Imp qt) after draining Lubrication systom Forced pressure and wet sump Gyinder compression 1,250-1,450 kPa (12.5-14.5 kgicm®, 178-206 psi) Yo Intake valve Opens: 11° BTDC | Closes 32° ABDC | at mmutt Exhaust valve Opens: 43° BEDC Closes 2° ATDC | Valve clearance Intake 0.15 mm (0.006 in) (Cold) Exhaust (0.18 mm (0.006 in) CARBURETOR | Type | Vacuum piston (VE) Identification number Throttle bore Main jet Stow jet Starter jet Pilot scrow initial opening Jet needle setting Fieat level Idle speed "95-97 Aier'97 vesic Except California type: VE91C California type: VES1D 32mm (1.3.in) #125 #40 #85 00 page 4-14 Sed groove from the lop 185 mm (0.73 in) ? 1,400 = 100 rpm o —GENERAL INFORMATION DRIVETRAIN | Clutch Wet muti-plata, automatic centrifugal “Transmission S-speed constant mesh with rovoreo Primary reduction 2.407 (6527) Goar Ratio st 4.083 (49/12) 1 2.389 (4318) " 11609 (97720) iW 1.178.328) v 0.848 (205) | Reverse 5.997 (94/12 x 40721) Final revetion Front (TRXSOOFW) | 5.554 (19/19 x 38/10) Roar | 1.4¢2 (10/13) «3.889 (260) Gearshit pattern Lat foot operated return system, Forward N-S/L=1-2-0-4 Rovorso: NR [Front difecertia ol capacity 200 ce (6.8 02) at dsassemby) {180 ce (6.4 02) ater ering] [Front gear ease ai eapacty 200 ce (6.8 62) at disassembly] {190 ce (6 4.92) ater draining] Far final drive oll eapacty 10002 3.402) at disassembly | 90102 (8.062) aftor draining [ELECTRICAL Toniton De-CoI Ignition tring Inia 13° BTDC ate Ful advance 31° BTDC at 4,500 = 100 rpm Atterrator Capacity 0:22 KWI5.000 rpm Battory sav-real Spark plugs nGK DENSO Standard DPRIEAS Xe4EPR-UB Font cia Denveas orePrU $ oe DPROEAS. XO7EPR-UD ‘Spark plug gap (08-08 mn (0.091-0.035 in) a Headignt 12 28/25 x2 Talight revew Neutral indicator wvi7W verse indicator revirw | Oil high temperature inckcator 1vi7WTORQUE VALUES GENERAL INFORMATION ENGINE ty | Tread Da. Togs Item ty | Tm) Tee] tea 3 Remarks Engine oil drain bolt 7 12 25 26 8 Gil fter cover bolt 3 6 10 1.0 7 | NOTE? Clutch adfusting screw lock nut i 8 22 22 16 Valve adjusting lock mut 2 6 7 47 12 ‘Spark plug 1 12 18 18 13 Insulator band screw 1 5 4 4 29 Carburetor cover scraw 1 5 35 0.35 25 ‘Starting enrichment (SE) valve nut 1 14 25 0.25 18 Cylinder head cover (6 mm SH bolt) a 6 10 1.0 7 (6 mm flange bolt) 10 6 12 42 3 (Cylinder head (cap nut) 4 10 40 40 29 (socket bolt) 3 8 25, 25 18 ‘Cam sprocket bolt 2 t 20 20 44 | NOTE ‘Cam chain tensioner iter (mounting bolt) 2 6 10 1.0 iz (sealing bolt) 1 6 10 10 e | i pipe bott (BLACK) 1 t 2 12 9 ‘Oli pump assembyy bolt 2 5 z 07 5A il path pipe bolt 2 7 12 12 9 Gylinder mounting bott 2 6 10 1.0 7 Centrifugal clutch lock nut 1 20 120 120 e7 | NOTE 1704 (Change clutch lock nut 1 18 110 19 20 | NOTE 18 (Clutch spring bott 4 6 1 12 9 Reverse/neutral rotor bolt 1 6 12 12 9 | NOTET Right crankcase covar bot 12 6 10 10 7 Kick starter ratchet guice 2 6 12 12 9 Starter reduction gear cover bolt 5 6 10 10 7 Ignition puise generator socket bolt 2 5 6 os 4 | NOTE1 ‘Alternator stator bolt 3 6 10 10 7 Starter clutch Torx bolt 6 6 16 416 12 | NOTE Fiywhee! bot 1 12 10 10 | 80 Gearsnift return spring pin 1 8 22 22 16 Left crankcase cover Dott 9 6 10 10 7 ‘Side shatt cover bolt (TRXSCOFW) 4 6 10 1.0 7 OUTPUT GEAR (Output shaft boaring holder bolt 3 8 23 23 7 CCountershaft bearing lock nut 1 64 100 100 72 | NOTES ‘Output shatt bearing outer race lock nut 1 60 100 100 72 | NOTE 23 ‘Output shaft bearing inner race lock nut 1 28 75 75 54 | NOTE 23 Output gear case mounting bolt 3 8 32 32 23 Cranixcase bolt 13 6 10 140 | 7 Bearing set plate bot 2 6 2 42 9 | NOTES Cam chain guide holder boit 1 é 2 12 9 | NOTE ‘Neutral switon 1 10 13 13 9 Reverse switch 1 10 13 13 9 Oil temperature sensor 1 1 18 18 13GENERAL INFORMATION FRAME vty | Thread Dia Torque ] bai oy | oom Nem kom fe | Samet Engine bracket bot (ron) a 70 75 75 cam Engine bracket nut (upper) 2 10 5 75 3A Engine mounting nut (ront and upper) 2 10 6 75 54 Engine mounting nut (‘earluppor and rearlower) 2 10 6 75 54 Gearshit pedal bolt 1 6 18 16 12 Footpeg bolt 8 8 2% 33 24 Fuel valve 1 1 23 28 20 Exhaust muffler mounting bol 3 10 55 55 40 Exhaust pipe protector bolt 3 6 18 1B 13 NOTE DC consent 3 8 16 18 2 FRONT Handlebar upper holder bot 4 8 a 27 20 Handlebar switch housing screw 2 5 2 02 14 ‘Masier cylincer holder 2 6 2 | #412 9 Hanalabar grp end bolt 2 6 40 10 7 Throttle case cover 2 4 3 os | 25 Handlabar lever pivot bot 1 6 to | a | o7 Handlabar lover pivot bot lock nut 1 6 6 05 43 Wheo! nut 8 10 65 65 a7 ‘Who! hub mounting bol (TRXQOOFW) 4 6 10 wo | 7 Front arm mounting nut 8 8 3 3a 22 | Notes Front asm bal joint nut 4 2 30-36 | s0a6 | 22-26 | Tie-rod ball joint nut 4 12 55 55 | 40 NOTE 5, Tie-od lock nut 4 2 55, 55 40 Steering shaft upper holder bott 2 8 33 33 24 Steering shat rut 1 14 | 100-120 }100-120| 72-87 | NOTES Handlebar lower holder nut 2 10 40 49 29 | NOTES ‘Shock absorber mourting bolt upper 2 10 at at 22 | NOTES lower | 2 10 45 45 39 | NOTES. Master cylinder cover sorew 2 4 2 02 14 Brako hose bolt 3[4) 10 35 3.5 25 Whoo! eylindor bolt (TRX300) 4 6 8 08 8 ‘Adjust bok (TRX300) + 6 8 08 8 Front brake pane! bolt 8 8 29 29 21 | Notes dale nut 2 18 80-100 | 80-100 | 58-72 | NOTES Wheel oyinder assy, 6 mmbalt (TRX30FW) | 4 6 8 08 8 8 mmbolt (TRXSOOFW) | 4 8 7 7 2 Brake pipe jont nut 2 10 4 14 to | NoTe2 Brake nose/oreather tube clamp bot 4 6 12 12 ° Brake bieedar valve 2 8 6 08 43 REAR ‘Wheel nut 8 10 65 6s a7 Axle nousing bot 4 10 45 45 23 ‘ale locke rut (inner) 2 2 40 40 2 (outor) 2 Ps 10 | 130 | 84 | NOTES ale rut 2 18 | 140-100 | 140-100 101-10 Brake pane! crain bit 4 12 25 25 1% Brake panel rut 4 10 35 35 25 | Notes Shock absorber mount nut 2) 10 a | 45 | a3 | Notes Swingarm et pivot bot 4 30 ns | ns | as Swingarm ight pivot bot 1 20 4 oa 3 ‘Swingarm ight pivot tock nut 1 30 ms | os | a “rai hitch bot 5 | 1 15 75 s4 | NOTE 1-8GENERAL INFORMATION ©@ FRAME (cont'd) (1: TRXGO0FW t ‘Thread Dia. Torque er oy (mm) Nem kg-m tei Rone FRONT DIFFERENTIAL (TRXS00FW) Olfiter cap 1 20 2 12 9 Mourning bot (10 men) 4 10 49 4s 2 ‘ (8mm) 2 8 2 22 16 © | cappas rors 6 8 23 33 24 Ring gear bot 6 8 50 50 6 Prien bearing lock nut 1 60 wo | 0 | 7 |notes Prion jort nut 1 16 no | 10 | eo | Notes Drain bot 1 8 12 12 @ CO crerbat io: 2 10 we | 48 as | Nove: (@mm 6 8 2 | 26 19 FRONT GEAR CASE (TRX300FW) Oitfiter cap 1 20 2 42 ° Mounting bot (6 mm) 3 8 25 25 18 (6mm) 4 8 2 42 ° Drain bot 1 8 2 22 16 Cover tot 8 6 2 12 9 FINAL DRIVE Otter esp 1 30 12 12 ° Joint nut 4 10 45 45 a | notes Cover bolt (10 mm) 2 10 4 as | 35 | NoTEt (@mm) 6 8 26 26 19 Pinion bosring lock nut 1 60 10 | 100 | 7 |Notes Pinson ort nut 4 16 0) 10 | «eo | NOTE: © | crcinot 1 8 12 12 ° NOTE J: Aepy locking agent hg treads. ‘Apply oilto the flange and threade. 2 Sta 4: Letthand threads 5: Do not re-use. 8 Apply grease tothe flange threads. Torquo spoofications listen above are for the most important tightoning points. Ifa torque specification isnot isted, follow the standards given below. STANDARD TORQUE VALUES item Torque Nom tka-m, Rb) item “Torque Ne (ho-, feb) 5mm bot, rat 3 (035,36) Emm screw 4 (04, 29) q mmo, put 70 (4.9.7) ‘6 mm screw, 6 men flange bol 9 (09,65) _ . ‘with @ mem nod Bram bok, rut 2122, 16) ‘Emm flange bok nut BIZH To mm-bot, nut 35 (6.5.25) '& mm flange bot, nut 2 (27.20) 72 «| 70 mm flange bot, nut | 40 (4.0.29)GENERAL INFORMATION TOOLS SPECIAL DESCRIPTION Pin puller Remover weight Valve guide reamer, 5.5 mm Bearing remover, 17 mm Remover handle Remover weight Bearing remover, 15 mm Remover weight Clutch holdar ‘Clutch centar holder Attachment, 28 x 20 mm Cutch puller ‘Assembly collar Shaft puller Threaded adapter Shaft noder Lock nut wrench, 36 x 48 mim Lock nut wrench, 34 x 44mm Ball joint remover, 28 mm. Ball joint remover/installer Attachment Snap ring pliers Oil coal driver Base Swingarm lock nut wrench Difierentia inspection tool (NOTE 2) Shaft puller Pinion gear driver Lock nut wrench, 94 x 44 mm, Lock nut wrench, 44mm Lock nut wronch attachmont, 41 mim Pinion holder Oil seal driver (Alter 97 only) TOOL NUMBER 07936-MA70100 07936-3710200 (07984-2000001 or 07984-20000 07936-3710300 07936-3710100 07936-3710200 07937-KG10500 (07936~3710200 O7GMB-HA70100 O7HGE-001000A (07046-1870100 07933-HB3000A (07965-VM00100 (07981-ME4000A o7981-KF00200 (07924-MES0000 97916-MB00001 or (07916-MB00000 and (07916-HA2020A (07916-MES0001 or (97916-ME50000 and (07916-HADOOA ‘O7MAC-SL00200 or 07941~6820003, 07JMIF-HC5O110 (07945~3350300 (97914~3230001 (97965-MC70100 (07950-MB10000 (979084690008 ‘O7KMK-HC5O10A (07981-ME40000 or (07931-ME4000A (07945-HA00000 (97916-MES0001 or (07016-ME50000 and (07016-HAD010A (07916-0580208 07016-0580108 (07024-HA00001 or ‘07924-HADO0cO" O7JAD-PH8101 REF. SEC. 6 6 6 8, 13,14 8.1314 8,13,14 10 10 10 10 10 10, 14,15 1,14 " " 12 2 13 13 4 14,15 14,15 18 18 14,15 18 * Must be modified for section 15. Increase 4 holes to 10.5 mm (0.41 in). 1-10GENERAL INFORMATION COMMON DESCRIPTION TOOL NUWEER FER SES Fal ive gouge o74ct-ooronee 3 Vat gage aver 8.3mm orra2-ooto0ce é Vabre sing comoreser orver-s010000 6 Vane seat eater Comnercatyavaitie | 6 Diver ovras-oorooca 8.9.10, 12,19,14,18 oO Attachment, 42 x47 mm 07746-0010300 8,10, 11,12 Pott? mm tr7ee-an4naeo atte facia 243.26 ren Grrae-on'07e0 e pater putt ‘7ee3-3380000 3 Atachmon, 2426 mm cr7a6-anto7e0 ‘0 Atachman, 7276 ne 7748 20"0000 0 (| diver Zorn t77a6-a000"00 io ‘tachment 30 mm LD. trrae-0903c0 0 Prot 23m 7746-200000 2 Piot dom r7s6-2040800 0 tachment 37340 en tr7ae-a0'0200 10.11, 19,14 Prot 20m 7726-2040800 jamie Pilot, 30. mm (NOTE 2) 07746-0040700 nv Crees eaves aE trss8-s250001 ts tachment 32°35 wen 7706-anr0100 io Piot tom c7746-o04n200 toi tachment 8268 en 7746 a0'0800 ais Piot sem t7746-ao40600 2 Urvoreal bead breaker GHAH 380-08 5 tachment 2x85 nen rae a0'0%00 fo.14.18 © | Pecos 7746-o0stic0 ois ie iver 22 mm. 7746-o020100 iis ‘tachment 20mm. (NOTE2) trrae-one0sc0 is Ciiste batery charger einige 3 Bator teste Cr1t)-0010000 8 NOTE 4: TRXS00 only 2: TRXSOOFW only 1-11GENERAL INFORMATION CABLE & HARNESS ROUTING o: correct Note the following when routing cables and wirs hamesses: X: INCORRECT * A loose wire, harness or cabie can be a safety hazard, ‘After clamping, check each wire to be sure itis secure, + Do notsqueeze a wre against a weld o en ofits clamp x + Secure wes and wie Ramesses tothe tare wih tha Fespective wire bands at the designated locations. e Tighten the bands so that only the insulated surfaces contact the wires or wire hamessos. the nammess 100 tight or leaving excess sack + Protet wire and harnesses with eletea ope or tubes ilthey cortata sha edge oreomer Cleanthe ataching surface throughly bole applying tape + Do notuae a wire hamess with abroken insulate. Repair by wrapping tem vith protective tape o ooiacs them + Route wire hamesses to avoid sharp edges or comers. ‘Also avoid the prcected ends of bols era screws. + Keop the wiraharnesses away rom the exhaust ppe and ‘other hot parts CuW pLoway Gas 1-18 o e eEMISSION CONTROL INFORMATION LABEL (After '97 California type only) Tho Emission Control Information Label is located on the battory box cover under the seat GENERAL INFORMATIONLUBRICATION LUBRICATION DIAGRAM CAMSHAFT CRANKSHAFT OM FErER Q— lL PUMP: OL FILTER SCREEN MAINSHAFT SHIFT FORK SHAFT (COUNTERSHAFT 2-02. LUBRICATION SERVICE INFORMATION 24 OIL FILTER SCREEN 24 TROUBLESHOOTING 22 FRONT DIFFERENTIAL (TRX300/FW) ENGINE OIL LEVEL 2.3 REAR FINAL DRIVE OIL. 24 RIGRIKOE AFTER CHANGE: 2.3 FRONT GEAR CASE OIL (TRX300FW) 25 Ez LUBRICATION POINTS 26 SERVICE INFORMATION GENERAL | 6 ccc Ifthe engine must be running 10 do some work, ake sure thatthe area is wel-ventlated. Never run the engine in an enclosed area. ‘The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death, CAUTION Used engine of may cause skin cancer if repeatedly lef in contact wih the skin for prolonged periods. Akhougi this i unlikely unless you hhancle used oi on a daly bass, itis stil advisable fo thorcughyy wash you hands with soap and water as s00n as possible atter handing used oil + Section 8 shows how to service the oil pump. SPECIFICATIONS Engine Oil Capacity 2.5 lit(2.6 US qt, 2.2 Imp ql at disassembly 2.25 it (298 US qf, 1.98 Imp qt) at ol and fiter change ENGINE OIL VISCOSITIES 2.2 lit (2.3 US qt, 1.9 Imp at) after draining Engine Oll Recommendation Use Honda GN4 4-stroke oll or equivalent. API Service Classification: SF or SG Viscosity: SAE 10 W-40 ‘Other viscosities shown in he chartmay be Used when the average temperature in your riding area is within the incicated range. Rear Final Drive il capacity 100 cc (3.4 02) at disassembly {90 ce (3.0 02) after craining Oil recommendation Hypoic gear ail, SAE #80 Front Differential (TRX300FW) Oil capacity 200 cc (6.6 02) at disassembly 490 cc (6.4 02) after draining Oil recommendation Hypo gear all, SAE #80 Front Gear Case (TAX300FW) il capacity 200 ce (6 8 02) at disassembly 190 cc (6.4 02) after draining (Ol! recommendation Use Honda GN4 4-stroke oll or equivalent API Service Classification: SF or SG Viscosity: SAE 10 W-40LUBRICATION TORQUE VALUES Engine oii drain bolt Oil fiter cover Difforentialfinal drive/goar case ol filor cap Difforentialfinal drive of drain bolt Front gear case dain bolt TROUBLESHOOTING Engine oll level too tow — high oll consumption External ol leaks Wor piston rings = Oil not changed efton enough «= Faully head gasket 25 Nem (2.6 kgm, 18 fb) 10 Nem (1.0 kg-m, 7 fib) ~ Apply oil 412 Nem (1.2 kg-m, 9 tb) 12 Nem (1.2 kg-m, 9 ft) 22 Nem (2.2 kg-m, 16 te-lb) Engine oll contamination ior fiter not changed often enough + Hoad gasket faulty + Wom piston ringsLUBRICATION ENGINE OIL LEVEL lace the vehicle on lavel ground Check the cl level using the ol filler capidipstick by placing itinto the Mller hole without screwing iin Ifthe cillevelie below or near the laverlevel line on the dip- stick, add the recommended cil (page 2-1) up to the upper level line. ENGINE OIL & FILTER CHANGE Loans It the engine must be running 10 do some work, make ‘ure thal the area's well-ventilated. Neverrun theengine in an enclosed area. The exhaust contains poisonous ‘carbon monoxide gas that may cause loss of conscious- hess and lead to death, With tne vehicle on level ground, star the engine and let i Ide fora fow minutes. Stop the engine. move the oil filer cap and drain bolt Remove the three bolts attaching the al fiter cover, clfiter and spring. Discard the oil fiter. CAUTION Used engine of may cause skin cancer frepeateay let in ‘contact wit the skin ior prolonged periods. Although tis is unlikely uniess you handle used oilon a daly basi, is si! advisable fo thoroughly wash your hands with saqp and wator as soon 2s possiblo affor handling used oi. Drain the oll completely. Gently rock the unit side to side to help draining, Check that the sealing washer on the drain bol is in good condition and replace if necessary. Install the drain bolt. TORQUE: 25 Nm (2.5 kg-m, 18 ttb) Install the cil iter spring to the right crankcase cover. Meke sure that the O-rings are in good condition and replace if necessary Install a new oil fier with its “OUT-SIDE (TOWARDS, FILTER COVER)" mark facing out. FLIER, “OUTSIDE” MARK. OIL FILTER COVER, CAUTION Instaling the oll fiter backwards will result in severe engine damage. ‘Apaly ol to the cover bolt threads and O-rings. Install the oil fiter cover and tighton the cover bolts to the specified torque TORQUE: 10 Nem (1.0 kg-m, 7 ftib) 2-3LUBRICATION Fill the crankcase with the recommended oll irre Be lL CAPACITY: 2:5 lit (26 US qt, 2.2 Imp qt) at disassombly 2.25 It (2.38 US at, 1.98 Imp qt) atoll and fier change 2.2 lit (2.3 US qt, 1.8 Imp qt) after draining Instat the oll lar cap/dipstick. Start the engine and lett idle for 2 to 8 minutes. ‘Stop the engine and check that the oil level is at the upper level line on the dipstick Make sure there are no ol leaks, OIL FILTER SCREEN Remove the right crankcase cover (page 8-3) Remove the oil fiter screen and clean i Install the ol filter screen, Instal the right crankcase cover (page 8-23) FRONT DIFFERENTIAL (TRX3OOFW)/ REAR FINAL DRIVE OIL OIL CHANGE Fiont Use a sultabte oll guide under the drain bol! o prevent oll diferente sping onthe tame, Removathe ol filer cap andthe drain bolttocrainallol rom the gear casa, (Check ha he drain bot sealing washer Is in good corastion Tighten the drain bolt tothe specified torque. TORQUE: 12 N.m (1.2 kg-m, 9 ft-lb) Fill with the recommended oil to the standard level ol capaci: FRONT DIFFERENTIAL: 200 cc (6.8 oz at cisassombly 190 c¢ (6.4 2) after draining wo EAR FINAL DRIVE: 100 ce (24 62) at dleaosombly 8068 (3.0%) ater dining RECOMMENDED OL: lar SRS a wwe Install tho fillor cap. TORQUE: 12 Nem (1.2 kg-m, 9 ft-lb) Front Remove the oil guide, iterental only: FRONT GEAR CASE OIL (TRX300FW) LEVEL CHECK Place the vehicle on level ground. Remove the oil chock bolt and check that the oll flows out ‘of the chock bolt hole Itmere isnoollflow, remove the filer cap and ad oil slowly through the of filer hole unt the oil starts to flow out of the ‘check hove. Stop adding oll andinstallthe ol checkboltand the filer cap. OIL CHANGE Remove the oll filer cap and the drain bot Drain the oil completely. Check thatthe drain bok sealing washer isin good condition and install the drain Dot TORQUE: 22 Nim (2.2 kg-m, 16 f-1b) Flemove the check bolt and fl ne gear case with the recom: mended oi OIL CAPACITY: 200 cc (6.8 oz) at disassembly 490 ce (6.4 02) after draining RECOMMENDED OIL: Honda GN4 4-stroke oll or equivalent API Service Classification: SF or SG Viscosity: SAE 10 W-40 NOTE Use this spectied capacity only 2 a guide. Always add oll unlit flows out of ‘he ol checkbot hole, allow itto stop lowing out, henreinstll he ol check bot Roinetall the ol filer cap. TORQUE: 12 Nem (1.2 kg-m, 9 ftb) LUBRICATIONLUBRICATION LUBRICATION POINTS Use general purpose grease when no ether specification is ivan. Apply cil or grease to any 2 sliding surfaces and cables not shown here, CONTROL CABLES Periodically, disconnect the throttle, choke, rear brake and reverse selector cables at their upper ends. Thoroughly lu- bricate the cables and their pivot points wth a commercially aveilabie cable lubricant or light weight oll * Apply slicone grease, * Apply muitpurpose grease NLGI No. 8 (page 12-20, 12-23) mi (CaBiE LusricanT} a) i THROTTLE CABLE! BRAKE CAWancHoR PN — THROTTLE CAB eninentien i CHOKE CABLE! Pivors) |EVERISE SELECTOR \ EVER THRQTILE Lever PIVOr \ wg PINION Jon SWING ARM PIVOT BEARINGS! DUST SEALS [FRONT REAR KICK STARTER Joint WHEEL HUB/BRAKE DRUM Sam (COVER (OUST SEAL/ REAR AXLE SHAFT BAAKE PEDAL SPLINE Pivorbust SEALS. a) ‘STEERING UPPER BUSHING) STEERING SHAFT SPLINE! DUST SEALS DRIVE SHAFT SPLINES (TFX300FW) Sama WHEEL HUB (OUST SEALY, -ERONT BRAKE WATERPROOF SEAL’ SHAKE SHOE-TO-BRAKE BACKING PLATE! + BRAKE ADJUSTERS. 2-63. MAINTENANCE ‘SERVICE INFORMATION MAINTENANCE SCHEDULES FUEL LINE FUEL STRAINER SCREEN ‘THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER ELEMENT AIR CLEANER HOUSING DRAIN TUBE SPARK PLUG VALVE CLEARANCE ENGINE IDLE SPEED CYLINDER COMPRESSION BRAKE FLUID 34 BRAKE SHOE WEAR 342 33 BRAKE SYSTEM 343 3-7 REVERSE LOCK SYSTEM 344 3-7 SKID PLATES 345 3:7 CLUTCH SYSTEM 345 3-8 SUSPENSION 345 3-8 SPARK ARRESTER CLEANING 346 39 WHEELS/TIRES a7 3-9 STEERING SHAFT HOLDER BEARING 347 340 STEERING SYSTEM a7 341 HEADLIGHT AIM 348 342 NUTS, BOLTS, FASTENERS a4 a2 SERVICE INFORMATION GENERAL AA WARNING © ‘+ Support the vehicle in an upright postion on level ground before starting any work. + {Cthe engine must be running to do some work, make sure that the area is well-ventlated. Never run the engine in an enclosed area. ‘The exhaust contains poisonous carbon monoxide gas that may cause lose of consciousness and lead 19 death. Engine oll and fiter Front differential (TRXS00FW) Rear final drive oi Front geer case oll (TRX300FW) SPECIFICATIONS Air cleaner element oll recommendation Spark plug gap: Spark plug See page 2-3 Soe page 2-4 Sco page 2-5 Use Honda Foam Fiter Oil or an equivalent 0.8-0.9 mm (0.031-0.035 in) For Cold cimate For Bonded Standard high speed steering (beiow 5° C41" F) DPRIERS DPROEAS PTE XQdEPRUS XOTEPRB KeoEPaUS | Valve clearance: Idle speed: Cylinder compression Throttle lever free play: Front brake lever froo play: Rear (parking) brake lever free play: Rear brake pedal free play: Reverse selector lever froe play: 0.15 mm (0.006 in) 1,400 = 100 rpm 1,250-1,480 kPa (12.5-14.5 kglem?, 178-206 psi) 3-8 mm (8-5/6 in) 25-30 mm (1-1-1/4 in) 45-20 mm (61@-3/4 in) 15-20 mm (618-3/4 in) 2-Amm (1/16-178 in) 3-1MAINTENANCE Tre size: === Front Rear [TTRxa00— _ ATZ3 x 6-11 AT25 x 1.9% [Frrxa00Fw — (AT24 x 9-11 Tre pressure: -————_— Stancard Warimum Maxamum "TAX300 [Fronv/Rean 29 psi 2565 3.3 psi (0.20.g/om® 20 kPa) | (0.17kglem’, 17hPa) | (0.28kg/om, 29 KPa) TRXSO0FW | Front 4.4 psi 3.8651 5.0 psi (0.30 kg/cm?, 30 kPa) | (0.26 kglem?, 26 kPa) (0.34 kglom?, 34 kPa) i Rear 29 psi 25 psi 33 psi | (0.20 ko/em?20kPa)_| (O.A7kg'cm*. 17 KPa) _| (0.28 kg/om?. 28 KPa) Teen: TRX300:5 mm (02 in) ‘TRXS3O0FW: 4 mm (0.2 in) TORQUE VALUES ‘Clutch adjusting screw lock nut Valve adjusting lock nut ‘Spark plug Tre fod lock nut 22 Nim (22 kg-m, 16 feb) 7 Nem (1.7 kg-m, 12 -D) 18 Nem (1.8 kg-m, 13-1) 59 Nem (5.5 kg-m, 40-1)MAINTENANCE MAINTENANCE SCHEDULES ‘The maintenance intervals shown in the folowing schedules are based upon average riding conditions. Vehicles subjected to se- vere use, or ridden in unusually dusty areas, require more frequent servicing. TRX300 (95 - '97) Porform the Pr-ride Inspection in the Owner's Manual at each schadulod maintenance period, |: Inspect and Clean, Adjust, Lubricate or Replace, if necessary INITIAL SERVICE REGULAR ©:Cean F:Replace (crERIGD [SERVICE PERIO| poeta page A: Adjust _L: Lubricate: EVERY operation) operating days) =| FUELUNE YEARI ~ a [FUEL STAAINER SOREEN YEARC 37 7 THROTTLE OPEAATION i a7 ie CARBURETOR CHOKE 1 38 [CATR CLEANER NOTE? e 38 |_AIR CLEANER HOUSING DRAIN TUBE NOTE2 _ 1 38 [SPARK PLUG. | 1 30 7 WAVE CLEARANCE 1 i ed ENGINE OIL a Ri 23 | EGNE OIL FLTER a R 23 =| icine LE SPEED 1 1 ant FINAL DRIVE Ot. oe, 2 =| anake FLUID NOTES i aa ~ | Brake shoe wean one [ oe BRAKE SYSTEM i 1 sa | REVERSE LOCK SYSTEM ! 1 a4 ‘SKID PLATES i o 315 Lure SYSTEM i i ers USPENSION 1 os |_ SPARK ARRESTER | | c se e NUTS, BOLTS, FASTENERS T 1 1 a8 WHEELSTRES 1 1 eit =| STEER NG SHAFT HOLDER BEARING YEAR ei? «| STEERING SYSTEM YEAR! | S17 * Should be serviced by an authorized Honda daalay, unless the owner has proper tools and service data and is mechanically qualiied. “inthe interest of safety, we recommend these tems be serviced only by an authorized Honda dealer, NOTES: 1. Service more frequently when riding in dusty areas, sand or snow. 2. Service more frequently alter riding in very wet or muddy conditions, 3, Replace every 2 years. Replacemant roquires mechanical skiMAINTENANCE TRX300FW ('95 — '97) Pertorm the Pre-ride Inspection in the Owner's Manual at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary INTIAL SERVICE | REGULAR C:Clean Fe Replace (FRERIOR 4, |SERVCEFERIOD| potertopage |_A® Adjust Lubricate EVERY ‘operation) _|_operating days) - = ruecune YEAR | at "FUEL STRAINER SCREEN YEARC 37 [= INROTTie oPenaTiON i i 37 CARRUAETOR CHOKE T i ED [Nore ¢ 38 NOTE 2 | 1 38 7 - | 1 x9 | 7 i 310 R a Ba ~TENGINE OW ALTER A A a ENGINE IDLE SPEED 1 1 eit FINAL DRIVE OL AND FRONT DIFPERENTIA“ | ~ VEART ae at 2 VEARSA = + | BRAKE FLUID - NOTES tL 312 RAKE S-OE WEAR NEAR ona BRAKE SYSTEM i 4 ae = REVERSE Lock SYSTEM i i a4 SKID PLATES: i 316 =| euros syste i i a8 # SUSPENSION [ 1 315 7 Seanic ARRESTER [—~e 316 NUTS, BOLTS, FASTENERS i I a6 = [WHEEL SmiRES po a7 STEERING SHAFT HOLDER BEARING I a7 STEERING SYSTEM [aveaR ai? * Should be serviced by an authorized Honda dealer, unless the owner has proper tecls and serviee data and ie mochenicelly qualified. “in the interest of safety, we recommend these items be serviced only by an authorized Honda dealer. NOTES: 1. Service more frequently when riding in dusty areas, sand or snow, 2 Service more frequently after riding In very wet or muddy conditions, 3. Replace every 2 years. Replacement requires mechanical skil.MAINTENANCE — INTACT: TRX300 (After '97) (Cram ns Prevaspeon inte Owe Marla ch scheded mainenrc peed | nsib os, 04m rete nee ©:Clean R: Replace Ac Adjust L Lubcate FREQUENCY | WHICHEVER TNTAL —_] — REGULAR MAINTENANCE COMES HAST | MARNTENKWCE INTERNAL ~ a 100 oo Tang] reserva Sg ten 20 7.000 2000 | 0° (TEMS = NOTE HOURS 20 100 200 ~[RUELUNE 1 7 [FUEL STRANER SCREEN 2 w wo LLLTHROTTLE OPERATION 1 37 £ [= [eanaureTon choxe i 33 © | An cuEANeR NOTE t t 38 E | | ASSES FOUN |notea T 1 + B SPARK PLUG 1 1 39 & [7 Lvauve coearance SS i i 310 3 [_| eNnawwe on R a R 23 "E ENGINE IDLE SPEED L t 1 REAR FINAL GEAR CASE OWL BRAKE FLUID BRAKE SHOE WEAR | BRAKESYSTEM REVERSE LOCK SYSTEM SKID PLATE, ENGINE GUARD CLUTCH SYSTEM ‘SUSPENSION ‘SPARK ARRESTER NUTS, BOLTS, FASTENERS WHEELSITIRES ‘STEERING SHAFT HOLDER BEARING STEERING SYSTEW AD eet ecb aires re cr oo iret ropa can evn da eee ctor ue, “into iar of ay, wo recommend thee tema bo sarcad ot by your Honda dealer NOTES: 1. Service more frequently when riding in dusty areas, sand of snow. 2. Servica more frequently ater riding in very wet or muddy conditions, 3. Replace avery 2 years. Replacement requires mechanical s g é z 8 8 3 3-5MAINTENANCE TRX300FW (After ’97) Perform the Pre-ride Inspection in the Owner's Manual at each scheduled maintenance period. |: Inspect (clean, adjust, lubricate or replace if nocessary). wep (era a COMES FIRST | MAINTENANCE | INTERVAL mp | ae gers ee km 250 1,000 2,000 page we a a a | FUEL LINE: 1 37 @ |* | FUEL STRAINER SOREEN c 37 B > [THROTTLE OPeRaTion i 7 E = ewan one ss #7 AIRCLEANER NOTE? c c 38 3 ‘SPARK PLUG. I i 1 38 @ |= | VALVE CLEARANCE i 1 1 BHO = [_[_ENGINE on a R a 23 DRIVE SHAFT BOOTS: [FRONT GEAR CASE OIL, REAR FINAL GEAR CASE OIL, AND DIFFERENTIAL O1L BRAKE FLUID. BRAKE SHOE WEAR BRAKE SYSTEM REVERSE LOCK SYSTEM ‘SKID PLATES, ENGINE ‘QUARD_ (CLUTCH SYSTEM ‘SUSPENSION SPARK AFRESTER NON-EMISSION RELATED ITEMS NUTS, BOLTS, FASTENERS WHEELSITIRES ‘STEERING SHAFT HOLDER BEARING il SYSTEM + Shiould be serviced by your Honda dealer, unless the owner has proper tools and service data and is mecharicelly qualified. “In the interest of safety, we recommend thaso items be serviced only by your Honda dealer. NOTES: 1, Service more frequently when riding in dusty areas, sand or snow. 2. Sorvice more frequenty after rickng In very Wet or muddy conditions. 3. Replace every 2 years. Replacement requires mechanical sil. 3-6MAINTENANCE FUEL LINE a © Check te tel ne Replace iti it shows signs of deterioration, damage or leaks. & FUEL STRAINER SCREEN e Tum mete vave OFF Romove the fue! cup, O-ring and fter screen, and dain the {gascline into a suitable container Eom + Gasoline is extremely flammable and is explosive under certan conditions. Work in 2 wel-ventilated area with the engine stopped. Do not smoke or allow names or sparks in your working area or whore gasoline is stored. + Wipe up spilled gasoline at ance. Wash the cup and fitersereen in clean nen-fammabie or w high lath point colvont Reinstall the seraen Install a new O-1ing into the fuel valve body. Reinstal the fuel cup, making sure the new O-ring isin place. Hand-tighton the ful cup securaly, but do not overtighten. COvertightoning cculd damage the O-ring and fuel leakage may resuit After instaling, turn the fuel valve ON and che are no fuel leaks, THROTTLE OPERATION ‘Check for smooth thratte lever operation wih complete oO ‘opening and automatic closing in all steering positions. ‘Make sure there is no deterioration, damage or kinking in the throttle cable. Replace any damaged parts. Disconnect the throtle cable at the upper end, ‘Thoroughly lubricats the cable and pivot point with a com: mercaly available cablo lubricant. © Insta the throtle cable inthe reverse order of removal Make sure the throtle lever free play is 3-8 mm (1/8-8/16 in) atthe tip of the throttle ever that there ino aeons can bo made alt po dtr Ge Siti the utter oot of he cab aster Loosen the lock nut and adjust the throttle cable tree play by turing the cable adjuster. Tighten the lock nut and install te rubber boot securalyMAINTENANCE Major adjustments are made with the lower adjuster Remove the fuel tank (page 4-3). ‘Adjust by loosening the lock rut and turning the adjuster. Tighten the lock nut and recheck throttle operation. Install the fuel tank and check throttle free play again. CARBURETOR CHOKE The choke system uses a fuel enrichment circuit contrallad by a starting enrichment (SE) valve. The SE valve opens tho ‘enrichment circuit via a cable whan the choke lever on the handleber is moved to the loft Check for smooth choke lever operation and lubricate the choke cable t required Inepeet the cable for oracks which could allow moisture to enter. Replace the cable f necesaary, Do CHOKE LEVER AIR CLEANER ELEMENT Remove the seat by pling the seat latch lever Release the retaining clips from the air cleaner housing cover and remove the cover, Loosen the air cloaner elamant band screw. Bann Fiemove the element holder attaching screw and remove SCREW| the air cleaner element assembly from the housing. Remove the element holder by turning it counterclockwise, Remove the element band and separate the element from the element core. 3-8MAINTENANCE Wash the element in non-flammable or high flash point sol e@ vent, squeeze out the solvent thoroughly, and allow the element to dry. Soak the lament in 21-26 ce (0.7-0.9 02) of Pro Honda Foam Filter Oil or an equivalent oll (page 2-1) and squeeze ut the excess oil thoroughly, 5. ay a-E- -Q-E a aes . WASHIN SQUEEZE PRO. SQUEEZE SOLVENT OUT HONDA OUT SOLVENT FOAM EXCESS THOROUGHLY FLTEROL On Place the element onto the core and replace the element 4 ‘band and holder, Install the element in the air cleaner housing Install he air cleaner housing cover and clips Install the seat. AIR CLEANER HOUSING DRAIN TUBE ° Romove the drain plug from the air cleaner housing to ‘empty ary deposits. Insta the drain plug Service frequently when riding in wet or muddy areas, © SPARK PLUG CENTER ELECTRODE oecanm -L CHECK: GaP Disconnect ine spark plug cap and remove the spark plug. | fo0si-0035in cern Visually inspect the spark plug electrodes tor wear si0e The center electrode should have square edges and the side electrode should have a constant thickness, Diseard the spark plugif there is apparent wear or Ifthe insu lator is eracked oF chipped. Measure the gap witn a wire-type teeler gauge and adjust it necessary by caretully bending the sice electrode. \ ERIC CHAS: w SPARK PLUG GAP) T 0.8-0.9 mm (0.031-0.035 in) RECOMMENDED REPLACEMENT PLUG: NGK: DPREEA-9 (DPR7EA-9, DPRSEA-9) DENSO: X2EPR-U9 (X22EPR-U9, X27EPR-US) With the seating washer attached, thread the spark plug in by hand to prevent crossthreading, Tighten the spark plug to the specified torque. oO TORQUE: 18 N.m (1.8 kg-m, 13 ft-lb) 3-9MAINTENANCE VALVE CLEARANCE NOTE Inspect and adjust the valve clearance while the engine is ecld (below 35°C/95"F) Remove the fuel tank (page 4-3). Feemove the intake and exhaust valve ediusting hole covers, remove the timing holo cap. TAXs00: Remove the crankshatt hole cap. TAXcooew: Remove the reduction shatt cao. ICRANKSHAT REDUCTION HOLE CAP, SHAFT CAP INDEX MARK TAX300; Rotate the crankshaft clockwise TAXQCOFW: Rotate the starter reduction chatt counterclockwise, using @ 6mm hex wrench, ‘Align the “T° mark on the rotor with the index mark. Make ‘sure the piston is at TDC on the compression stroke. If not, rae the crankshaft 360° (1 full turn) and align the “T° mark gain Inspect the intake and exhaust valve clearances by nserting a fester gauge between the adjusting screw and valve stem, VALVE CLEARANCE: 0.15 mm (0.006 in) 3-10MAINTENANCE ‘Adjust by loosening the lock nut and tuming the adjusting ‘Screw untd there isa slight drag on the feeler gauge. Hold the adjusting screw and tighten the lock nut. TORQUE: 17 N.m (1.7 kg-m, 12 f-lb) Racheck the valve clearance. Inspect the condition of the O-rings anc! replace any that are wom or damaged, Install he valve agjusting hole covers. Install the following: TRX300: —crankshaft hole cap TRXOO0FW: —reduction shatt cap timing hole cap fuel tank (page 4-3) ENGINE IDLE SPEED ES Ifthe engine must be running 10 do some work, make ‘sure that the area is well-ventilated. Never run the engine jin an enclosed area. The exkaust coniains poisonous ‘carbon monoxide gas that may cause loss of conscious ness and load to death NoTE * Inspect and adjust the idle speed afte all other engine mantenanca items have been pertormad and are with in specifications. + The engine must be warm fo accurate ile speed inspec. tion and adjustment, THROTTLE STOP SCREW] Warm up the engine for about ten minutes. Tum the tote stop screw as roquired to obtain tho epocitiod ide speed. IDLE SPEED: 1,400 + 100 rpmMAINTENANCE CYLINDER COMPRESSION ES If the engine must be running to do some work, make ‘sure thatthe area is welt-ventiated. Never tun te engine jn an enclosed area. The exhaust contains poisonous ‘carbon monoxide gas that may cause loss of conscious: ness and lead to deatn. Warm up the engine. Stop the engine and remave the spark plug, Insiall a compression gauge. ‘Open the throtle all the way and crank the engine with the starter motor unt the gauge reading slope reg, Usually $7 seconds COMPRESSION PRESSURE: 1,250-1,450 kPa (12.5-14.5 kg/em?, 178-206 psi) Low compression ean be caused by: blown cylinder head gasket —improper valve adjustment —valve leakage om pision ring or eylinder High compression can be caused by: carbon deposits In cambuston chamber or on piston head BRAKE FLUID Check thatthe brake ful reservoir is ul. f the levels rear tho lower evel mark, fil the reservoir upto the upper level mark ‘Check the entire system for leaks if the level Is low. CAUTION * When acting brake fluid, be sure the reservoir is fevel before the cap is removed, or brake fluid may spil out + Use only OOT 3 or 4 brake fu fram a sealed container * Avoid spilling fui on painted, plastic, or rubber parts. Place a shop towel over hese parts whenever the sYS- fom is serviced, * Never allow contamination (dit, waiter, etc.) enter the Drake fuid reserve, BRAKE SHOE WEAR FRONT BRAKE Remove the brake shoe lining inspection hole cap and in spect the lining thickness, Lining thickness: STANDARD: 4,0 mm (0.18 in) SERVICE LIMIT: 4.0 mm (0.04 in) If either lining is wom beyond the lr ‘must be replaced. both brake shoos 3-12 — 'UPPER LEVEL MARK LOWER LEVEL MARKMAINTENANCE REAR BRAKE INDEX MARK Replace the braka shoes ifthe indicator plate aligns with the brake panel index mark when the rear brake lever or pedal is applied BRAKE SYSTEM FRONT BRAKE Measure the distance the brake lever moves before the brake starts to take held Free play, measured at the tip of tho front brake lavar, should be within standard, FREE PLAY: 25-30 mm (1~1-1/4 in) If the brake lever free play is excessive and the brake linings are not worn beyond the recommended limit, adjust the brake shoe lining-to-drum clearance. Remove the inspection hole plug and line up the hole with (one of the brake adjusters and turn the brake shoe adjuster up with a screwdhiver until the stioes lock. then back off three stops. Spin the wheel manually to make sure the brake does not drag. Line up the inspection hole with the second adjuster and repeat the procedure. Recheck the brake levar free play If fra play is stl exces- sive after adjusting the brake lining clearance, there is Probably air in the brake system and it must be bled out (Gection 12) After checking, install the inspection hole cap securely in the drum while pushing the cap with a screnhiver REAR BRAKE ‘Check the cable, beake lover and brake pedal for loose con- nections, excessive play or other damage. Replace or repair i necessary, 15-20" Disconnect the brake cables at the brake lever or pedal ends. ff we-a/4in Thoroughyy lubricate the cables and their pivot points with commercially avalable cabie lubricant, Install the cables. ‘Measure the rear (parking) brake lever tree play at the end of the brake lever EAR BRAKE LEVER FREE PLAY: 15-20 mm (S/8-2/4 in) 3-13MAINTENANCE Minor adjustments can be mado with tho upper adjuster. Side the rubber cover off the agjustar, loosen the lock nut and adjust. ‘Major adjustments should be made withthe lower adjusting ‘nutat the rear brake arm, Measure the prake pedal tree play at the end of the brake pedal and adjust as required. BRAKE PEDAL FREE PLAY: 15-20 mm (6/8-3/4 in) ‘Adjust the rear brake lover and pedal foo play by turing tho agjusting nuts atthe lower ond of the cables, Mako sure the cut-out of each adjusting nut is seated on tha brake arm pin, REVERSE LOCK SYSTEM Check tne reverse selector cable and lever fora loose cor nection, excessive play or other damage. Replace or repair necessary Measure the reverse selector lever tree play atthe lever end near the cable FREE PLAY: 2-4 mm (1/16-1/8 in) 2-4 mm (1716-178 in)MAINTENANCE ‘Adjust by loosening tha lock nut and turning the edjusting aut o Tighten the lock nut securely bad SKID PLATES The skid plates protect the angina, rear final gear case and ‘ear brake panel trom rocks. (Chacck the plates for cracks, damage or looseness at inter Yu vals shown in the Maintenance Schedule. Replace the plates if they are cracked or damaged. Ifthe plate bolts are loose, tignten them, CLUTCH SYSTEM ES If the engine must be running to do some work, make ‘sure that the area is wol-ventilated. Never run tho engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of conscious- ness and lead (0 death, SKID PLATES Loosen the clutch adjusting screw lock nut. Slowly tum the adjusting scrow countorclockwise until recistance is fol. Thon turn tho adjusting screw clockwise 1/4 turn, and tighten tho lock nut. TORQUE: 22 Nim (2.2 ka-m, 16 ft-lb) AAtter adjustment, start the engine and check for proper clutch operation ( SUSPENSION ES * Do not ride a vehicle with faulty suspension. + Locse, wom or damaged suspension parts impair vehicle ‘stabiity and control ‘Chock the action of the front/rear shock atscorber by com: prossing thom saveral times. Check the entire shock absorber assembly for leaks or & damage. Replace damaged components which cannot be repaired Tighton all nuts and botts.MAINTENANCE SWINGARM BEARINGS Raise the rear wheels off the ground by placing a jack or blook under the engine. Move the rear axle sideways, forward, and backward using moderate force to see i he wheel and swingarm bearings. are wom, Replace the bearings it there is any play. SPARK ARRESTER CLEANING ENGI + Ifthe engine must be running to do sore work, make ‘sure that the area is well-ventilated. Nover run tho engine in an enciosed area. The exhaust contains polsonous carbon monoxide gas that may cause loss of consciousness and lead to death, + Do not touch exhaust components while the exhaust systom is hot. + Perform this operation in a well-ventilated area, free from fre hazards. + Use adequate eye protection Remove the bolt Block the end of the mutfier with 2 shop tonel Stat the engine with the transmission in neutral, and purge ‘accumulated carton from the muffler by momentarily rev: ving the engine severel times. ‘Stop the engine and allow the exhaust system to cool Install the bolt securelyMAINTENANCE WHEELS/TIRES (Check the tires for cuts, embedded rails, or other damage. CCheok the tire pressure. Tie pressure should be checked when the tires are COLD. Adjust accordingly. Tre pressure: ‘nit: pei (kglem®, KPa) Tao TAXS00FW (FrontRear) | Front Rear Standard [2.9 (020, 20) [44 (030,50) [29 (020,20 Minimum |25 (0.17, 17) [3.8 (0.26, 26) [2.5 (0.17, 17) Maxenum [3:3 (023, 28) [5.0 0:34, 34) [3.3 (023, 23) 4.4 (0.20, 30) |3.6 (0.25, 26) Raise the whaels off the ground and check the hub or knuelte and axle beanngs for excessve play oF abnormal Replace any faulty parts (sections 11 and 13) STEERING SHAFT HOLDER BEARING Raige the front wheels of the ground and make sure that the handlobar rotatos frooly. ‘Make sure the cables oo not interfere withthe rotation of the handlebar. If the handlebar moves unevenly, binds or hs horizontal BEARING ‘movement, check the steering shaft hoider bushing and steer- ing beering, and replace them if necessary (page 11-27). STEERING SYSTEM TOE-IN Remove the front fendor (pago 16-1), Pace the vehicle on level ground with the front wheels tac Ing straight ahead, Mark the centers ofthe tres with chalk to indicate the axle contor hoight. Align the toe-in gauge wth the marks on the thes as shown, Check the readings on the gauge scales. Siowly move the vahicle back unt the wheels have tured 180° so the marks on the tites are aligned with the gauge height on the rear side TOEAN GAUGE 3-17MAINTENANCE Measure the toesin on the rear part of the tires at the same points. FRONT : we TOEAN: TAX300; 5 mm (0.2 in) ‘TAXSOOFW: 4 mm (0.2 in) When the toe-in is out of specification, adjust it by changing the length ofthe te-reds equally by turning the tie-rod whie holding tha ball joint Tighten the lock nuts, TORQUE: 55 N-m (5.5 kg-m, 40 ft-lb) Ales finally tightening the lock nuts, make sure the bal jomts| ‘operate properly by rotating the tie-rods. HEADLIGHT AIM ‘Adjust the vertical beam by turning each adiusting screw on the headtight cover NUTS, BOLTS, FASTENERS Tighten bolts, nuts and fasteners al the regular intervals shown in the Maintenance Schedule (pages 3-3 and 3-4) oe (Check that al chassis nuts and bolts are tightened to their correct torque values (pages 1-7 thru 1-9). Check that all cotter pins and safety clips are in place. iss wine sina ies amass iano @MEMOFUEL SYSTEM4. FUEL SYSTEM (& | SERVICE inronmation 41 CARBURETOR DISASSEMBLY 46 ‘TROUBLESHOOTING 42 CARBURETOR ASSEMBLY 410 FUEL TANK 4-3. CARBURETOR INSTALLATION 413 AIR CLEANER HOUSING 4-4 PILOT SCREW ADJUSTMENT 415 CARBURETOR REMOVAL 4-5 HIGH ALTITUDE ADJUSTMENT a7 SERVICE INFORMATION GENERAL Sy *+ Gasoline is extremely flammable and is explosive under certain conditions. Work in a wel-ventiated area with the engine stopped. Do not smoke or alow flames or sparks in the work area or where gasolne is sored. * Hhthe engine must be ruming to do some work, mnake sure that the area is well-ventilated. Never run the engine In an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loxs of canscieusnass and lead 10 death. CAUTION Do not bend or twist control cables. Darnaged control cables will not operate smoothly and may suck or bind * Ifthe vehicle isto be stored for more than one month, drain the float chamber. The carburetor fioat chamber has a drain serow that can be loosened to drain gasoline. Be sure to drain all gasoline into a sultable container. Fuel left in the float chamber may ‘cause clogged jets resulting in hard starting or poor driveability complaints, * When disassembling fuel system parts, note the locations of the O-rings. Replace them with new O-rings during reassembly. SPECIFICATIONS Fu! tank capacity Fuel reserve capacity 12.5 lt (23 US gal, 2.7 Imp. gal) 2.5 lt (0.7 US gal, 0.5 Imp. gal) a identification mark L \VESIG (After 97 California type VE91D) Type ~ f ‘Vacuum piston (VE) 7 7 ‘Throttle bore a _ 32 mm (1.3 in) © natives 185 mm (731) Plot screw Fifal opening See page 415 Idle speed 1,400 = 100mm Main jet — #125 7 SSS a © 5 Tra ore TeS Tamia [et needle soting es Sal yonve hon he op & 4-1FUEL SYSTEM FUEL SYSTEM TORQUE VALUES Fuel valve lock nut Insulator band screw Carburetor cover screw ‘Starting enrichment (SE) valve nut 28 Nm (2.8 kg-m, 20 ft-b) 4.Nim (0.4 kgm, 2.9 thib) 3.5 Nem (0.85 kg-m, 2.5 fo) 2.5 Nem (0.25 kg-m, 1.8 feb) TOOL Common Float level gauge (07401-0010000 TROUBLESHOOTING Engine cranks but won't start Aftertring + No fuel to carburetor * Engine flooded wth fuel ‘No spark at plug (ignition system faulty) * Clogged air cleaner * intake air leak * Improper choke operation * Improper throttle operation Engine idles roughly, runs poorly or etalle += Improper choke operation * Ignition maltunetion * Fuel contaminated * Intake alt leak + incorrect idle speed + incorrect plot serew acjustment * Low cylinder compression tering enrichment (SE) valve siuck open Damaged starting enrichment (SE) valve seat ich mixture * Lean mixture + Clogged carburetor Mistiring during acceleration + Ignition system faulty + Loan mixture AAfterburn during deceleration + Ignition system faulty + Lean mixture Poor performance (driveability) and poor fuel economy + Fuel system clogged + Ignition system faulty + Air cleaner clogged 4-2 * Ignition matfunction + Carburetor malfunction = Lean mixture Rich micture Lean mixture Clogged fuel jets + Faulty foat valve * Float level too low * Blocked fue! fll cap vent hole + Clogged fuel strainer screen = Restricted fueling * Clogged air vant tube: * Intake air leak + Vacuum piston stuck closed Rich mixture + Clogged air cleaner “+ Worn jet needie or needie jot + Faulty foat vaive + Float level too high + Starting enrichment (SE) valve stuck open + Damaged starting enrichment (SE) valve seat + Clogged air jet Incorrect fast idle speed + Incorroct choke cable tree play + Starting enrichment (SE) valve stuck or camagedFUEL SYSTEM FUEL TANK REMOVAL we Femoral an it te cor Pa elt se ver tection tan Tin te tl ave OFF and dcr! oul ne, Re @ rove ela weaning bk ae ark EX = Gas. ain SINE EE re ee re © Saihecala tine oar sa Cunteaats Se Reo tg Ses eke ce + Wipe up spilled gasoline ai once. MOUNTING BOLT Uso 2 dan pan and check that fl fws fool out ofthe tual valve by turning te uel valve ON. S Ifflow is restricted, ean the fuel strainer screen (page 37). wx a Drain fuel from the fuel tank into a suitable container. ae Remove the fuel valve by loosening the valve nut a, e& Remove end clean the steiner. y uel vate e Non} INSTALLATION o t.55 Il te sant an va andtgien hs ul vate ok BQJ . Auton specter ‘ TORQUE: 28 N.m (2.8 kg-m, 20 ft-1b) FUEL STRAINER Fl the fuet tank, tum the fuel vaive ON and check ‘or leaks. Check the vent hole in the fuel cap for blockage, Install the fuel tank by sliding its front hooks into the rubber cushions on the frame and tighten the fuo! tank mounting @ bot Connect the fue! fine Io the fuel valve, “Tum the fuel valve ON and make sure that there are ne fu! leaks. 4-3FUEL SYSTEM AIR CLEANER HOUSING REMOVAL Remove the fuel tank (page 4-3) Remove the fuel tank bracket. Loosen the air cleaner intake duct and connecting tube band, Froe the intake duct and connecting tube from the frame ‘and carburetor. Romove the air cloaner housing mounting bolts Excopt Ater‘7 Free the crankcase breather tube from the camp. Cavioms pe! After ‘97 Disconnect the crankcase breather tube from the Caitomia type: crankcase. remove the air cleaner housing by pulling upward 10 clear the trame pipes. 4-4FUEL SYSTEM INSTALLATION Install ne air cleaner housing in the reverse orcer of removal ELEMENT ELEMENT CORE ‘AIR CLEANER HOUSING INTAKE DUCT CARBURETOR REMOVA! Remove the fuel tank (page 4-3) Remove the fuel tank bracket (page 4-4) Loosen the connecting tube and insulator bands, Pull the carburetor upward. CAUTION Do not let dirt and dust enter the engine through the ‘intake por, or the engine may be damaged.FUEL SYSTEM Loosen the starting enrichment (SE) valve nut and remove the SE valve from the carburetor, then discount the air vent tube. Remove the carburetor cover screw and the cover. Do notkink or Disconnect the throitie cable end from the throttle drum, (9 ete Pemove ho ote cable fom the cabuttor body by removing the adjuster Remove the carburetor from the frame, CARBURETOR DISASSEMBLY STARTING ENRICHMENT (SE) VALVE Disconnect the choke cable end from the SE valve and remove the valve spring 4-6 SEVALVENUT § AIR VENT TUBE: ADJUSTER SPRING SE VALVE |FUEL SYSTEM (Check the SE valve for nicks, grooves or other damage, Check the valve seat for wear. Check the O-ring for wear or damage. ‘The SE valve and O-ring must be replaced as a set FLOAT AND JETS Remove the four screws and the float chamber. Remove the following ~ baffle float pin float float vaive Inspect the float valve for grooves and nicks, and replace if necessary. Inspect the operation of the float valve. "VALVE SEAT 4-7FUEL SYSTEM Do net overtighten. 4-8 Remove the following main jot — needle jet holder — needle jot =slow jet = plug starter jet “Turntho pilot crewin andrecordthe number oftusbatore it seats fight. Use this as a reference for reinstallation. ‘Damage to the pilot screw seat will occur ifthe plot screw Is tightaned against the seat Remove the pilot serew. Inspect the pitt screw and each jet. Replace them if they are worn or damaged. Blow opon allots with comprossod air. PRIMER KNOB Remove the screws and the primer knob. Check the diaphragm for tears or other demage. DIAPHRAGM/VACUUM PISTON NOTE ‘The diaphragm’vacuum piston can be removed without removing the float chamber. Remove the vacuum chamber caver by removing the fourFUEL SYSTEM Remove the compression saring and diaphragm/vacuum piston, Inspectthe vacuum piston for wear, nicks, or other damage. Make sure the piston moves up and down freely in the ‘chamber. Push the jet needle holder down and turn it counterciock- wise 90 degrees with an 8 mm socket. Then remove the eedle Noider, jet needle and washer trom the diaphragry vacuum piston SPRING JET NEEDLE waiter Inspect the jet needle for excessive wearat the tp or other DIAPHRAGM damage. (Check for a tom diaphragm or other deterioration a wnser / Biow open al carburetor body openings with compressed aitFUEL SYSTEM CARBURETOR ASSEMBLY 25Num (0.25 kg-m, 1 8b) VACUUM CHAMBER COVER JET NEEDLE CLIP FLOAT VALVE WASHER JET NEEDLE ‘STARTER JET AL NEEDLE JET f = - EEDLE JET PRIMER KNOB NEED. SLOW JET f fecben PLOT scREW ; NaINJET DRAIN SCREW PLE 4-10DIAPHRAGM/VACUUM PISTON Install the needle clip on the jet needle. ‘STANDARD SETTING: 3rd groove from the top Install the washer, jat needle, spring and jet needle holder to the vacuum piston. Push the jet needle holder in and turn k 90 dagrees clock- wise. Install the diaphragm/piston in the vacuum chamber, allon- ing the diaphragm tab with the groove of the carburetor Hold the vacuum piston up to almost full open so the da~ phragm is not pinched by the chamber cover. Do notpinch Install the chamber cover with the spring, aligning its tab ‘me ciaphragm with the hole inthe carburetor, and secure with at leact two {unde screns before releasing the vacuum piston. Insiall the remaining vacuum chamber cover screws. verneEoAe 3 cur JET NEEDLE SPRING SPRING i ee OIAPHRAGM VACUUM PISTONFUEL SYSTEM PRIMER KNOB Install thopprimerknob with the spring nto the ficat chamber ‘Do not pinch the diaphragm when installing the screws. Tighten the screws securely. DIAPHRAGM. FLOAT AND JETS: Install the folowing: ~ starter jot ~plug ~slow jet = neadle jt, need jet holder main jet NOTE Handle al jete with care. They can easily be scored or scratched. Install the plot sorew and retum it 10 is original position a: noted during removal Perform pilot screw adjustment if a new pict screw i: installed (page 4-15). Install the float and fcat valve in the carburetor body, then install the float arm pin through the body and float, Install the battle FLOAT LEVEL INSPECTION With the float valve seated and the float arm just touching the valve, measure the float level with the float vel gaugo ‘as shown. ‘SPECIFICATION: 18.5 mm (0.73 in) TOOL: Float level gauge ‘07401-00100 ‘The float cannot be adjusted. place the foat assembly tthe float level is out of specit- cation, 4-12FUEL SYSTEM Install a new O-ring in the float chamiver. Intall the float chambo,, aligning the overtlow tube with tho hole in the bate as shown, Install the four float chamber screws. STARTING ENRICHMENT (SE) VALVE ‘SE VALVE ) Install the spring over the choke cable and connect the cable end to the SE valva, ‘Move the choke lever all the way to the right and left and make sure that the SE valve operates propery CABLE O-RING. CARBURETOR INSTALLATION . ADWUSTER Donothiok Install the throttie cable adjuster to the carouretor body. ‘or isthe Connect the throttle cable end to the throtla drum, throtte cable, ‘Apply groase to the throttle cable ond, Install the carouretor cover. Tighten the scraw. TORQUE: 3.5 Nem (0.35 kg-m, 2.5 Fb)FUEL SYSTEM ‘Apply multpurpose grease to the SE valve end as shown, Install the SE valve and tighten the valve nut. TORQUE: 2.5 N-m (0.25 kg-m, 1.8 F-b) Connect the air vent tube to the carburetor. § AIR VENT TUBE Install the carburetor by aligning its intake pipe boss withthe insulator groove, ‘Sot the pin ofthe insulator band inthe groove of the insulator and install the band, Tighten the insulator band screw to the specified torque. TORQUE: 6 Nem (0.4 kg-m, 2.9 f-lb) Intall the carburetor connecting tube and tighten the tube band. Route the drain tube correctly (page 1-15). ‘Adjust the throtte lever tree play (page 3-7) Install the fuel tank bracket and fuel tank (page 4-3). 4-14ww PILOT SCREW ADJUSTMENT Do not ovetigton, FUEL SYSTEM iim Ifthe engine musi be running fo do some work, make ‘sure thal the area is well-ventilated. Never nn the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of conscious- ness and lead to death "95 ~'97: NOTE ra i Ss J€_—H______________ tino stor screw The pilot screw is factory pre-set. Adjustment is not nec- ge essary unless the carouretor is ovemaulad or a new pllat screw is installed, “Turn the pliot screw clockwise until it seats ightly and back tout 2-1/4 turns, ‘Damage to the pilot screw seat will occur ifthe pilot scrow is tightened against the sat. This is an initial setting prior to the final plot screw adjustment Warm the engine up to operating temperature, ‘Stop the engine and connect a tachometer according to the tachometer manufacturer's instructions. Start the engine and adjust the idle speed with the throttle slop screw. IDLE SPEED: 1,400 + 100 rpm Tum the pilot screw clockwise until you near the engine miss or decrease in speed, tnen turn counterclockwise unt! the engine again misses or decreases in speed. Center the pilot screw exactly between these two extreme positions. It idle speed changes alter adjusting the pilot screw, readjust the throttle stop scrow. 4-15FUEL SYSTEM 4-16 After '9; NOTE ~The pilot screw is factory pre-set. Agjusimant is nat necessary unless the carburetor Is overhauled or @ Trew pilot screw is installed. ‘+ Use a tachometer with graduations of 50 ppm or small fer that will accurately indicate a 50 rpm change. 1. Tum the pilot screw clockwise unt it seats lightly. Then back it out to the specification given. This is an initial setting prior to the inal pilot screw adjustment. t Screw seat will occur ifthe pilot ‘scrow is tightoned against the coat. INITIAL OPENING: Except California type: 2-1/4 turns out California type: 2-1/2 turns out 2. Warm up the engine to sufficient operating tempera ture. Stop and go riding for 10 minutes is sufficient. 4. Stop the engine and connect a tachometer according to the tachometer manufacturer's instructions. 4, Start tho engine and adjust the idle speed with the throttle stop screw. IDLE SPEED: 1,400 + 100 RPM 5. Tum the pilot screw in oF out slowly to obtain the high- est engine speed. 6. Readjust the idlo speed with the throttle stop screw. 7, Tum the pilot screw in gradually unti the engine speed «drops 100 rpm. 8. Turn the pilot screw counterclockwise to the final opening, FINAL OPENING: Except California type: 9/4 turn out California type: 3/4 turn out 9. Reeadjust the idle speed with the throttle stop screw, THROTTLE 5 - STOP SCREWFUEL SYSTEM HIGH ALTITUDE ADJUSTMENT & SPECIFICATIONS Below Batwoon s00n | 3.000-8000% (1,500 m) (1,000-2,500 m) Mainjet #105 #20 oe Pilct screw Factory 3i4 tum opening preset Tho carburetor must be adjusted for high alkitude siding (between 3,000-8,000 11/1 ,000-2,500 m. w STANDARD SETTING: Below 5,000 ft (1,500 m) HIGH ALTITUDE SETTING: Between 3,000-8,000 ft (1,000-2,500 m) ‘The high altitude carburetor adfustmont is porformed as follows: Remove the carburetor (page 4-5) and float chamber Replace the standard main jet with the high alitude type. High Altitucle Main Jet: #120 ‘Assemble and install the carburetor. ‘Turin the pilot screw the specified number of turns from the intial setting q High Altitude Pilot Screw Setting: 3/4 turn in Sian the engine and acjust the ite speed at hich altitude to ensure proper high alttude operation. : {tthe engine must be running to do some work, make ‘sure that the area is well-ventilated. Never run the engine jn an enclosed area. The exhaust contains poisonous ‘carbon monoxide gas that may cause loss of canscious- ness and lead to death CAUTION Sustained operation below 6,000 Tee (1.5007) wih ra oe high aude settings may cause engine overheating era tngine damage ital he otzncardmarot an sero ‘tthe plot Serow the spectted nunbor tte, wert ‘eng bebw® 000 fet (1.500) Standard Main Jet: #125 ve Pict Seow Change Tram igh To Low Athue: 4-17ENGINE REMOVAL/INSTALLATION A0f) 5-05. ENGINE REMOVAL/INSTALLATION Nm 26m 25kgm, Tent) 5-1ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE REMOVAL 5-2 ENGINE INSTALLATION 5:3 54 SERVICE INFORMATION GENERAL The folowing parts or components require engine removal for sarvicing: CCrankshattbalance: Transmission Output gear SPECIFICATIONS Engine oll capacity Front gear case oll capacity (TRX300FW) TORQUE VALUES Engine bracket bott(ront) Engine bracket nut (upper) Engine mounting nut (ront and upper) Engine mounting nut (-eariupper and rear/lower) Grankcase bolt Gearshift pedal bott Foot peg bolt Exhaust mutfler mounting bolt ‘TRX300FW: Front gear case mounting bott(8 mm) (6mm) Section 10 Section 10 Section 10 2.51 (2.8US gt, 2.2 Imp qi) at deassombly 2.2 IR (2.3 US qr 1.9 Imp q) after raining 190 ce (6.4 02) ater drairing 55 Nem (6.5 kg-m, 40 fb) 55 Nem (6.5 kg-m, 40 fb) 55 Nem (5.5 kg-m, 40 fb) 75Nm (7.5 kg-m, 54 fib) 410. Nem (1.0 kgrmm, 7 tb) 16 Nem (1.6 kg-m, 12 fb) 93 Nem (2.3 kg-m, 24 ft4b) 55 Nem (6.5 kgm, 40 ft-lb) 25 Nem (2.5 kg-m, 16 felb) 12.Nom (1.2 kgem, 9 feb)ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL MeVERsE CAS exnaceT MUrTLER Drain the engine oll (page 2-3). TAXG0FW: Drain the front gear case oll (page 2-5) Disconnect the battery negative cable from the engine (under the starter mounting bot) Remove the following: — fuel tank (page 4-3) exhaust mutfier (page 16-7) tight foot peg = neutralreverse switch cover and connectors reverse cable brake pedal (oage 12-29) TRXGOOFW: Remove the following ~ front crive side shaft cover and shalt (page 14-25) —tront gear case (page 14-25) Remove the following ccarburator (Tho throttio and choke cables do not have to be removed.) %, ad ‘ (2 o> ~ swing arm boot band (loosen) = broather tube clamps crankcase breather tube starter motor cablo alternator and igniton pulse generator connectors ‘Support the engine. Remove the following engine mounting bots {front and upper) ‘engine bracket bolts and brackets (front and upper) engine mounting bots (rear/upper and rear/iower, Remove the engine from the right side while disconnecting the drive shaft universal joint from the engine.ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Apply molyodenum disulfide grease to the drive shat splines, Install the engine from the right side while connecting the drive shaft universal joint into the output shaft ‘Support the engine at the position shown. Inetall the following —engina brackets and engine bracket Dolts (upper: from the let side) — engine mounting bolts trom the lott sido Tighten all bolls to the specified torques, TORQUE: Engine bracket bolt (front): 75 N-m (7.5 kgem, 54 ttl) Engine bracket nut (upper): 75 N-m (7.5 kg-m, 54 ft-lb) Engine mounting nut (front and upper): 75 Nem (7.5 kg-m, 54 ft-lb) Engine mounting nut (rear/upper and rearflower): 75 Nem (7.5 kgem, 54 ft-lb) Install tne folowing: breather tube clamps, and tighten TORQUE: 10 Nem (1.0 kg-m, 7 ft-1D) BATTERY, battery ground cablo GROUND Install tha folowing: carburetor (page 4-13) swing arm boot band gearshift pedal, and tighten Le a TORQUE: 16 Nem (1.6 kg-m, 12 ttib) ~ spark plug wire ~crankease breather tube ~starter motor cable alternator and ignition pulse generator connectors 5-4ENGINE REMOVAL/INSTALLATION ~ brake pedal (page 12-30) e291 = fight foot peg, and tighten REVERSE CABLE JM@)g EXHAUST MUFFLER ‘TORQUE: 39 Nim (3.3 kg-m, 24 fb) —neuvralreverse switch cover anc connectors reverse cable exhaust mutfer (page 16-7), and tighten TORQUE: Exhaust muffler mounting bolt 55 Nem (6.5 kg-m, 40 f-lb) ~ fue! tank (page 4-3) TRXSOOAW. — front goar caso (page 14-25) ~ front drive side shaft and cover (page 14-25) ‘Aer installation: + Route the wires and cables propery (page 1-12). * Fi the crankcase to the proper level with the recom mended ail (page 2-2) Fil the front gear case to the proper level with the recom mended oil (page 2-5). Porform the following inspections and adjustments: ~throtte operation (page 3-7) — reverse selector cable (page 3-12) EX ‘Connect the neutral and reverse switch wires propery. IF these wire connections are interchanged, the neutral in- dicator wil come on with the transmission in reverse and the vehicle wil reverse unexpectedly TRXSDOFW,CYLINDER HEAD/VALVES Y2Nm (1.2 kom, 9 Rib) 6-06. CYLINDER HEAD/VALVES SERVICE INFORMATION 61 VALVE SEAT INSPECTION/REFACING 610 TROUBLESHOOTING 62 CYLINDER HEAD ASSEMBLY 613 CYLINDER HEAD COVER REMOVAL 63 CYLINDER HEAD INSTALLATION e14 CAMSHAFT/CAM CHAIN TENSIONER CAMSHAFT/CAM CHAIN TENSIONER LIFTER REMOVAL, 65 LIFTER INSTALLATION e14 CYLINDER HEAD REMOVAL 66 CYLINDER HEAD COVER VALVE GUIDE REPLACEMENT ce, SSSEMBLYANEIALLAHION mn SERVICE INFORMATION GENERAL KE «This section covers cylinder head, valves, camshaft, rocker arm and cam chain tensioner litor service. ‘Those services can be performed with the engine installed in the frame. + Camshaft lubrication oil is fod to the cylinder head through an cil path pipe. Be eure this pipe is not clogged before installation, + Before assembly, apply molybdonum disulide groase to the camshatt journal bearings and rocker arm shafts to provide ital |ubricaton, + Pour clean engine oil into the oll pockets in the cylinder head during assembly to lubricate the camshatt lobes. SPECIFICATIONS Unit mm en) Tren - STANDARD SERVICE LIMIT Gyinder compression 7,250-1 480 KPa (12.5-14.5 kglen?, 178-206 ps) = Camshait | Cam bbe height [IN '35:300-5, 469 (1.4907-1.9964) 35193 (1.98538) x 36.176-05.396 (1.9849-1.0012) 85,006 (1.9762) Jounal. |B 23.954-28.975 (09431-09439) 2490 (0.96) c 29,994-20.955 (0.9429-0.8491) 22,86 (0.940) t 19.954-10.975 79.90 (0.783) R 24.000-24.021 — 24.05 (0.947) eS '24.000-24.02" (0.0446-0 9457) L 20,000-20.021 (0.7874-0.7662) Oraeoae [A 0,025-0.087(0.0070-0.0026) 210 (0.004) ¢ 0.085-0,087 (0.0016-0.0054) 0.12 (0.005) t (0.025-0,007 (0.0070-0.0026) 0.10 (0.008) Gyinder head warpage = 0.10 (0.008) | Rockererm — | .D. 12,000-12.018 (0.4724-0.4731) 12.08 (0.474) Sha 11.986-11.986 (04711-04718) 11.82 (0468) | ‘Armeto-shalt clearance 0,016-0.052 (0.0006-0.0020) 0.08 (0.008), Valve sping Free lenghh | Inner 38.31 (1.508) 353 (1.39) Outer 46.69 (1.844) _ | 43.6 (4-72) Prooad Inner B72 2 08 Ig/Ai.G mm (19.224 = 176 B24) =| ‘Outer | 19.58 = 1.5 kg. 1 nm (48.168 = 3.31 i 38 in) = 6-1CYLINDER HEAD/VALVES ‘Unit: mm (in) TEM __ STANDARD SERVICE LIMIT Valve, valve Stem 0.0. IN - 5.475-6,490 (0.2156-0.2161) 5.45 (0.215) use ex | 8.486-5.470 (02146-02154) 5430214) | Guide. 5 500-5.512 (02166-02170) 6605 (02177) EX §.500-5.512 (0.2165-0.2170) 5525(02177) Serio [IN 0.010-0.097 (0.0004-0,0015) 0.12 (0.006) clearance x '0.080-0.087 (0.0012-0.0022) (014(0.006) | [ave woar wan 12005) : 15,000) TORQUE VALUES Ovinder headcover mm SH bol) 10m 4.0 kgm, 7B) {Erm ange bot) 12 Nem (4.2 kgm, 9 8) Cyinderhead (capri Yorim 40 kgm 20 bib) (gecko bold Bsn @s kgm, 18h) ‘Cam sprocket bott ‘Cam chain tensioner iter (mounting bolt) {sealing bot) il path pipe bolt Carburetor insulator band screw TOOLS ‘Special Pin puller Remover weight Valve guide reamer, 55 mm Common Valve guide diver, 55mm Valve spring compressor 20 Nem (2.0 kg-m, 10 Nem (1.0 kg-m, 10 N-m (1.0 kgm, 42.Nem (1.2 kg-m, AN (0.4 kgm, (07986-MA70100 (97936-3710200, 14 feb) 7 feb) 7 fib) 9 feb) 2.91tb) (079842000001 or 07984-200000D 07742-01010 07757-0010000 Valve seat cuters-these are commercially available in U.S.A. TROUBLESHOOTING Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test or by tracing ‘engine noises to the top-end with a sounding rod stethoscope. ‘Low compression = Valves: Incorrect valve adjustment ~ Burned or bent valve Incorrect valve timing —Week valve spring + Cylinder head: Leaking or damaged head gasket Warped or cracked cylinder head ‘= Cylinder and piston (Section 7) 6-2 High compression + Excessive carton build-up on piston crown or on combustion chamber Excessive noise «= Incorrect valve adjustment ' Sticking valve or broken valve spring ‘= Damaged or worn rockor arm or camehaft ‘= Worn or damaged cam chain ‘= Worn or damaged cam chain tensioner * Worn cam sprocket teeth Poor idling + Compression too lowCYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL === Femove the fofowing: fue! tank (page 4-3) ~cil path pipe (page 8-3) upper engine brackets (page 5-3) we © Flamove the intako and exhaust valve adjusting hole covers. Flemove the timing hole cap. ww Taxsoo: Remove the crankshait hole cap. TAXOOFW: Ramove the reduction chalt cap. TAXsoO: Flotate the crankshaft clockwise, TRXSO0FW: Rotate the starter reduction shaft counterclockwise, using ‘6mm hex wrench ‘Align tho“ mark on the rotor with the index mark. Make sure the piston is at TDC on the compression stroke. If not, rotate the crankshaft 389° (1 full tum) and algn the *T" mark again. Leave bots A Loosen the cylinder head cover bolts in 2 oF 3 steps in a and 8 with the crisscross patiern and remove the cylinder head cover. ‘vind head ee © on Fem he dows pin and the camshal deca. Clean of any calant maser rom the head cover and oylnder head & Pi cen nr currAce DISASSEMBLY Groove sach rocker arm shaft dowelpin wit a rnd and « remove to dowel prs wih the sped ol a Toots: Pin puller 07936-Ma70100 Remover welght 07936-3710200 & foo an [POvER Starr 6-3CYLINDER HEAD/VALVES Removethe rockerarmshats and rocker arms (IN/EX) from the cylinder head cover. Remove the bolt and valve lifter. INSPECTION = 3LPPER, io ‘SURFACE Inepect the rocker arm sipper surfaces for oxcessive wear. ‘Chook the O-rings of the rocker arm shaits for damage or fatiquo. Ingpect the rocker arms and shafts for wear or damage. Ifthe tockor arms require servicing or replacement, inspoct the cam lobes for scoring, chipping or flat spots, Measure the 11D. of each rocker arm, ‘SERVICE LIMIT: 12.05 mm (0.474 in) Measure the ©.D. of each rocker arm shaft SERVICE LIMIT: 11.02 mm (0.489 in) — — OL SEAL e . ; i \eee ET Calculate the rocker arm-to-shatt clearance, SERVICE LIMIT: 0.08 mm (0.003 in) Inspect the valve ier, spring and oll sea for wear or darnage.CYLINDER HEAD/VALVES CAMSHAFT/CAM CHAIN TENSIONER LIFTER REMOVAL REMOVAL Temporenly Remove the cam chain tensioner liter by removing the two leesen the mounting bolts. sealing boo ease removal De net et the bolt fal nto Remove one cam sprocket bok. tha crankcase TRX300: Turn the crankshaft clockwise. TAXOO0FW: Turn the starter reduction shaft counterclockwise, Remove the other cam sprocket bolt lemove the camshaft and cam sprocket, and suepend tho ‘cam chain with a piace of wire to provant it from falling into the crankcase. INSPECTION Using a micrometer, measure the height of each cam lobe and inspect itfor wear or damage. ‘SERVICE LIMITS: IN: 35.199 mm (1.3894 in) EX: 95.006 mm (1.3782 in) Measure the camshatt journal 0. SERVICE LIMITS; Loft: 19.90 mm (0.783 in) Right: 23.90 mm (0.941 in) Center: 23.88 mm (0.940 in)CYLINDER HEAD/VALVES Insiall the cylinder head cover and tighten the head cover bolts in 2 or 3 steps in a crisscross pattern. TORQUES: SmmSH bolt: 10.Nm(1.0korm, 7 feb) ‘6mm flange bolt: 12 Nm (1.2 kg-m, 9 ft-1b) Measure the camshaft joumal bearing .0. as shown, SERVICE LIMITS: Left: 20.05 mm (0.789 in) Right: 24.05 mm (0.947 in) RIGHT CENTER Center: 24.05 mm (0.047 in) Calculate the camshattto-bearing clearance. SERVICE LIMITS: Left: 0:10 mm (0.004 in) Right: 0.10 mm (0.004 in) Center: 0.12 mm (0.005 in) Femave the cam chain tensioner liter sealing bot Discard the gasket a Check the iter oparation: ~The tensioner shaft should not go into the body when itis pushed, When its tured clockwise with a screwdriver, ne ten- zd sioner shaft should be pulled into the body. The shaft should spring out of the body as soon as the screwdriver a is released CYLINDER HEAD REMOVAL peony SS ae REMOVAL Femove the following ~exhaust muffler (page 16-7) cylinder head cover (page 6-3) ~camshafvcam chain tensioner liter (page 6-5) Loosen the carburator insulator band. Remove the cylinder head socket bolis/copper washers ‘and cap nuts in 2 or 8 stops in a crisscross pattern. eemove the eyiinder haad. 6-6CYLINDER HEAD/VALVES Remove the cylinder head gasket and dowel pins. Remove the cam chain guide, DISASSEMBLY amove the carburetor insulator and O-ring trom the cylin: der heed. Meck apart Remove the vale epting cotter, reltiners, springs and deepened ‘aire nth vale prig oomervoes ‘orneyeanbe Pat Ty proven oss of tension, do ot compress the vave jocstone. Springs Mote than necassary to remove the cotiers.. TOOL: Valve spring comprossor 07757-01000 Remove the valve stem seals and valve spring seats. ‘VALVE SPRING COMPRESSORCYLINDER HEAD/VALVES INSPECTION © CYLINDER HEAD Remove carbon deposits trom the combustion chamber. ‘Check the spaik plug hole and valve areas for cracks. ‘Check the cyinder head for warpage with a straight edge ‘and fooler gauge. ‘SERVICE LIMIT: 0.10 mm (0.004 in) ‘Check the cam chain guide for excessive wear or damage. a CAM CHAIN GUIDE » ‘¢ VALVE SPRING FREE LENGTH ‘Measure the tree length of thainnerand outer valve springs, SERVICE LIMITS: Replace the springs if they are shorter than the service limits, VALVE STEN-TO-GUIDE CLEARANCE Inspect each valve for bending, burning or abnormal ster wear. Check valve movement in the guide, measure and record each vaive stem O.D. SERVICE LIMITS: IN: 5.45 mm (0.215 in) EX: 5.43 mm (0.214 in)CYLINDER HEAD/VALVES eam the guides to remove any carbon depesits betore ‘checking cloarances. Insert the reamer from the combustion chamber side of tha head and always rotate the reamer clockwise TooL: Valve guide reamer, 55mm _07984~2000001 or Measure and record each valve guide I.D. SERVICE LIMIT (IN/EX): 5.525 mm (0.2177 in) Subtract each valve stom O.D. from the corresponding uido 1.D. to obtein the stem-to-guide clearance. SERVICE LIMITS: IN: 0.42 mm (0.005 in) EX: 0.14 mm (0.008 in) It the stem-to-quide clearance exceeds the service limits determine ita new guide with standard dimensions would bing the clearance within tolerance. i so, replace any guides as necessary and ream to fit If the stemto-guide clearance exceeds the service fits with new quides also, replace the valves and guides. Roiace the valve seats whenever the valve guides are replaced (page 6-10). VALVE GUIDE REPLACEMENT CCl the replacement vaive guides in the freezer section of a refrigorator for about an hour. Heat the cylinder head to 100-150°C (212-300"F) with a hot plate or oven, Do not use a torch to heat the cylinder VALVE GUIDE DRIVER hhead; it may cause warping, EX To avoid burns, wear heavy gloves when handling the heated cylinder head. ‘Support the cylinder head and drive out the old guides trom the combustion chamber side of the cylinder head. TOOL: Valve guide driver, 5.5 mm o7742-0010100CYLINDER HEAD/VALVES Place @ new O-ring on the new valve guide. Drive guide from the camshaft side of the head. in the Too! Valve guide driver, 5.5mm 07742-0010100 Ingpect the valve guide for damage. Ream the new valve guide after installation, Insert the reamer from the combustion chamber side of the head: always rotate the reamor clockwise TooL: Valve guide reamer, 5.5mm _07984-2000001 or 07984-20000 Clean the eylinder head thoroughly to remove any motal parricles. Roface the valve seat (see below) VALVE SEAT INSPECTION/ REFACING Clean the intake and exhaust valves thoroughly to remove ‘carbon doposts Apply alightcoating of Prussian Biveto the valve seats. Lap the valves and seats usinga rubber hose or other handap- ping tool. Remove and inspect the valves. NOTE “The valves cannot be ground. Ifa valve face is bumed or badly wom crifit contacts tho seat unevenly, replace the valve. Inspect the width of each valve seat STANDARD: — 1.2mm (0.05 in) SERVICE LIMIT: 1.5 mm (0.06 in) tthe seat is too wide, too narrow or has low spots, the seat must be gicund, 6-10 VALVE GUIDE DRIVER SEAT WIOTH oeCYLINDER HEAD/VALVES VALVE SEAT CUTTERS ~ Valve seat cutters, a grinder, or quivalant valve seat reac ing equipment are recommended to correct a worn valve = VALVE SEAT curTer Follow the relacer manufacturer's operating instructions, VALVE SEAT REFACING ROUGHNESS Use a 45 degrees cutter toremove any roughness orirregu- larites trom the seat. NOTE Reface the seat with a 45 degrees cutter whenever a valve guide is replaced. Use a 92 degrees cutterto remove the top 1/4ofthe existing valve seat material OLD SEAT WIDTH S Use a 60 degrees cutter toremove the bottom 1/4 ofthe old seat, Remove the cutter and inspect the area you have relaced. uo seat wioTHCYLINDER HEAD/VALVES Insta a 45 degrees finish cutier and cut the seat to the proper width. Make sure that ll pitting and irregulerties are removes. Refinioh if necessary, ‘Apply a thin coating of Prussian Blue to the valve seat. ross the valve through the valve guide and onto the seat tomako a cloar pattorn NOTE The location ofthe valve seat in relation to the valve face is very important for good sealing. Ifthe comtact areais ioohigh on the valve, the seat must be lowered using a 32 degrees flat cutter. {tthe contact area is toc low on the valve, the seat must be raised using a 60 degrees inner cutter. Refinish the seat tospecifications, using a 45 degrees finish cutter. After cutting the seat, apply lapping compound tothe valve face, and lap the valve using light pressure, {After lapping, wash all residual compound off the cylinder head ana valve. NOTE Do not aliow lapping compound to enter the guides. 4.2mm (0.05 in} “h CONTACT 100 HiGH OLD SEAT WIDTH. CONTACT TOO Low iN OLD SEAT WoT — a 100-147 PING > ;TOOL 6-12© CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY — pe om Inca te valve sping seat anda new stem sea pects Tmthevave Lubriate the vawe stems wih molybdenum asutide t siowy when grease and insert the valve into the valve guide. Lenin ‘osening. Be careful not to damage the stem seal. = 6 | Install the valve springs withthe tghty wound cols facing - e. the cylinder head, i ‘STEM VALVE SPRING SEAL COMPRESSOR Install the vaive spring retainers and cotters. Toprevent oss of tension, de notcompress the vaive spring moro than necessary. TOOL: Valve spring compressor 07757-00100 VALVE SPRING. COMPRESSOR To provent possible valve damage, support the cylinder bhoad above the work surface. Be sure the supports do not. intorfore with valve travel ‘Seat he cotters firmly using two plastichhammers as shown, Hold one hammer on the valve stem and gently tap it with the other hammer Install a new O-ring in the carburetor insulator groove and MAGA instal the insulator with two bolts.CYLINDER HEAD/VALVES CYLINDER HEAD INSTALLATION Make sure that the cam chain is propery installed on the crankshaft drive gear as shown, Plage the bottom ond ofthe cam chain quidainto the groove in tho right crankcase end its bosees in the grooves in the cylinder upper surface. Install ne dowel pins and a new cylinder nead gasket. Install the cylinder head, and tighten the cyiinder head cap nutsashers (9, ©, © and D) and sockst bolts/copper washers ((D, @ and 3) in the sequence shown TORQUES: Cap nut: 40 Nm (4.0 kg-m, 20 ft-1b) ‘Socket bolt: 25 Nim (2.5 kg-m, 18 ft-lb) Tighten the carburetor insulator band screw to specified torque. TORQUE: 4 Nim (0.4 kg-m, 2.9 ftb) Install the folowing: —camshafvieam chain tensioner lifter cylinder head cover (page 6-19) — exhaust muffler (page 16-7) CAMSHAFT/CAM CHAIN TENSIONER LIFTER INSTALLATION CAMSHAFT INSTALLATION Rotate the crankshaft clockwise. Rotate the etarter reduction shaft counterclockwise, using a 6mm hox wrench, Align the “T” mark on the rotor with the index mark. Make sure the piston is at TDC on the compression stoke It not, rotate the crankshaft 360° (1 full tun) and align the “T- mark again, TRX300. TRXSO0FW: ace INDEX MARK F MARKCYLINDER HEAD/VALVES ‘Apply molybdenum disulide grease to the camehattjour- rals ofthe cylinder head, and tothe cam lobes, Install the camshaft in the cylinder head, Positon the Install the cam chain over the camshaft as shown ‘cam lobes aown, Raise the camshaft and instal the cam sprocket onto the shoulder of the camshaft with its punch mark facing to the right. Reset the camshaft in the cylinder head. Pull tho sprockot slightly forward off the shoulder, rotate the ‘sprocket until the punch mark ig at the top, and install the ‘cam chain Before positioning the sprocket on the camshatt holder, align the timing marks on the cam sprocket with the upper surlace of the cylinder head. Dono! rotate the crankshaft, Mako sure the “T" mark on the: ‘ywhee! ie stil aligned with the index marker. Reinstall the cam sprocket onto the shoulder of the cam: shaft NOTE It itis dificult to reinstall the cam sprocket, make sure the cam chain is set properiy on the crankshaft cam chain drive gear.CYLINDER HEAD/VALVES Apply locking agant tothe threads of the cam eprocket bos. Tighten the cam sprocket bolt on the punch mark side firs, then tur the crankshaft and tighten the remaining sprocket bolt to the same torque. ‘TORQUE: 20 N-m (2.0 ko-m, 14 ftb) Realign the “T” mark with index mark and recheck the cam sprocket timing marks Fil the oil pocket in the oyinder head fresh cil Apply oil to the cam chain, CAM CHAIN TENSIONER LIFTER INSTALLATION ‘Make a tensioner shaft stopper tool out of a thin piece of ‘tee! (I mim thick) using the diagram. (CAN SPROCKET BOLTS 15mmCYLINDER HEAD/VALVES ‘Turn the tensioner shat clockwise with the stopper tool 1o retractthe tensioner, then insert the stopper fully tohold the tensioner in the fully retracted position, Install a new gasket on the cam chain tensioner litter. Install the cam chain tensioner iter with its groove facing up. Tighten the cam chain tensioner iter mounting bolt. TORQUE: 10 Nm (1.0 kg-m, 7 feb) Remove the holder tool trom the tensioner liter Instal and tighten the bolt with 2 now gasket to tho tensioner. Tighten the Dott fo the specttied torque, Ail TORQUE: 10 Nem (1.0 kg-m, 7 ftb) CYLINDER HEAD COVER ASSEMBLY/INSTALLATION ASSEMBLY CYLINDER HEAD COVER INTAKE ROCKER =x (wos) INTAKE. ROCKER ABN ‘SHAFT pees —__\ fF 0 < Pi can (Moss) EXHAUST ROOKER, ABM SHAFTCYLINDER HEAD/VALVES Install tne ol seal, return spring, valve liter and vaive liter Dott. VALVE LIFTER Note that intake rockor arm has an “" mark on its side as shown. INTAKE ROCKER ARM Caretly iceniy the exhaust sie pars: ROS ~The rocker arm has the decompression lug as shown, ~The rocker arm shaft has two holes as shown, (MoS.) Sema ‘Apply ol to tho O-rings of the rocker arm shafts. Apa vecppcneer: cigs Wi esi eee tua: Instal the rocker arms and shafts, aligning the grooves on the shafts with the head cover mounting holes. 6-18~ © D0 not zoo sealant the camshaft journals, CYLINDER HEAD/VALVES Insert new dowel pins in the head cover. ‘Apply tquid sealant to the mating surtaces of the cylinder é read cover ONG wwso Aoply moWfadenum sulle greaso to he camshat jour nalset he cylinderheadcoverandtotherocker arm sipper btacos SEALANT INSTALLATION Installthe dowelpins and the camshaft side cap on the cylin der heed. Position the camshaft so that both cam lobes taca down as shown by rotating the crankshaft. Install the cylinder head cover boits A and B onto the cylin- der head cover. Install the cylinder head cover. Install anew copper washer on tho flange bott thats desig nated by the “W" mark Tighten the cover boltsin2or3 stepsin a crisscross pattern, starting with the center bolt, ‘TORQUES: 6 mm flange bolt: 12 Nem (1.2 kg-m, 9 fttb) 6mm SH bolt: 10 Nem (1.0 kg-m, 7 ftp) ‘Adjust the valve clearance (page 3-8), Install the following, valve adjusting holo covers engine brackets (upper) (page 5-4) ~cil path pipe (page 825) — uel tank (page 4-3) 6-19CYLINDER/PISTON7. CYLINDER/PISTON ‘SERVICE INFORMATION wa PISTON 73 TROUBLESHOOTING A PISTON/CYLINDER INSTALLATION 75 CYLINDER 72 SERVICE INFORMATION SPECIFICATIONS Unit: mm eM STANDARD SERVICE LMT Oyinder [1 74.000-74 010 (2.9194-2.9136) 74.10 (2.917) Taper = 0.61 (0.004) | ‘Out of round = 0.01 (0.004) | [ Warpage across top T = 0.01 (0.004) aero 8 TGC ETE TTD a0 a) — piston pin Piston pi bore | _____17.000-17.006 (0.5694-0.6696) 17.08 0.671) Piston pn 0.0 16.904-17.000 (0,5601-0.6603) 76.96 (0.668) Piston-o-pn clearance (0,002-0.014 0.0001-0.0006) 0.02 (9.001), Paton irgtong | TOP 0.92-005 (0.001-0.002) 0.09 (0.604), geov coarance | SECOND, T.o15-0.085 0.0006-0.0078) 0.09 (0.004) Paton ng ‘(TOP 0.15-0.30 0.006-0.012) 05 (002) fend gap SECOND (0.25-0.49 (0.010-0.016) 06 (002) ‘oll 7K 03) =| = Oyinderto-piston clearance {1645-00050 (0.0006-0.000) 010 (0008), [Connecting fod smal end LD. 617.094 (0,6899-0.6706) 7.10 (0.670) TORQUE VALUE Oyfinder mounting bot 10 Nem (1.0 kgm, 7b) TROUBLESHOOTING Low or unstable compression Overheating + Wor cylinder or piston rings ‘+ Excessive carbon build-up on the piston head or combustion + Cylinder head and valves (Section 6) chamber wall Excessive amoke Knocking or abnormal noise + Wom cylinder, piston or piston rings + Worn pision and oyinder + Improper installation of piston ngs + Excesswva carton bule-up * Scored or scratched pieton or cylinder wall TACYLINDER/PISTON CYLINDER 7-2 REMOVAL Remove the cylinder head (page 6-8), Remove the cylinder mounting bolts and cylinder Remove the cylinder gasket and dowel pins. INSPECTION Inspect the cylinder bore for wear or damage. ‘Measure the cylinder 1D. in X and ¥ axis at three levels, “Take the maximum reading to detormino the cylinder wear. ‘SERVICE LIMIT: 74.10 mm (2.917 in) Calculate the piston-te-eylindor clearance. Take the maxi- ‘mum reading to dotormine the clearance. Refer to page 7-4 for measurement of the piston O.D, SERVICE LIMIT: 0.10 mm (0.004 in) Caleulate the taper and out of round at three levels in X and Y axis, Use the maximum reading to determine the service limit SERVICE LIMITS: Taper: (0.10 mm (0.003 in) ‘Out of round: 0.10 mm (0.008 in) “The cylinder must be rebored and an oversize piston fttod Ifthe service limits are exceeded “The tollowing oversize pistons are availabe: (0.25 mm (0.010 In), 0.50 mm (0.029 in), 0.75 mm (0.030 in) and 1.00 mn (0.040 in) Tho piston-to-cylinder clearance for th oversize piston ‘must be: 0.015-0.050 mm (0.0006-0 0020 in} MIDDLE BorrowCYLINDER/PISTO! Inspect the top ot the cylindar tor warpage. ‘SERVICE LIMIT: 0.10 mm (0.004 in) PISTON REMOVAL Dorot et ine Remove the piston pin clip with pliers, {ips fal ints pportthe piston, press the piston pin outof the piston and. {he erankcate. remove the piston NOTE ‘Always support the piston when pressing out the piston pin to prevent damage to the big-end bearing. INSPECTION Donot damage Remove the piston rings, as shown, the piston ings turing rernova Romeve any carbon deposits from the piston ring grooves, using an old piston ring as shown,CYLINDER/PISTON “Temperatiy inctal the piston rings to their proper position with the mark facing up. Measure the piston ring-to-groove clearance with the rings, pushed into the grooves. SERVICE LIMITS: Top: 0.09 mm (0.004 in) ‘Second: 0.09 mm (0.004 in) Inspect the piston for wear or damage. ust inermgs_ Insert each piston rig squarely into the bottom ofthe cylin into te eyinder der and measure the ting end gap. withthe top ofthe ‘poion tbo cure i Poon eesey SERVICE LIMITS: inimecyinder Top: 0.5mm (0.02 in) Second: 0.8 mm (0.62 in) Measure the diameter of the piston at 10 mm (0.4 in) from the bottom and 90 degrees to the piston pin hove. ‘SERVICE LIMIT: 73.90 mm (2.908 in) Measura tne piston pin bore on bath sides. SERVICE LIMIT: 17.04 mm (0.671 in)CYLINDER/PISTON Measure the pston pin ©.D. at three places, SERVICE LIMIT: 16.96 mm (0.568 in) Calculate the piston-to-piston pin clearance, ‘SERVICE LIMIT: 0.02 mm (0.001 in) ‘Measure the connecting rod small end |.D. SERVICE LIMIT: 17:10 mm (0.673 in) PISTON/CYLINDER INSTALLATION Do rot darnage the rings while ‘nstalin, Clean the piston ring grooves thoroughly Apply oil tothe piston rings Do rct mix the top and second rings: the top ring is narrower inwicth than the second ring. TOP RING Install the piston sings with the markings (T or R) facing up. Ct FING Aitor installation, the rings should rotate freely in the ring ed grooves. RAIL Space the piston ring end gaps 120 degrees apat. Do not seacen f Ot, algn the gaps in the of rings sie ri. soe AA EZ vr rns ZA sco. wns 7-5CYLINDER/PISTON Apply molybdenum disufide grease to the outer surface of the piston pin Position the piston “IN* mark on the intake valve sido. Do not et the Install the piston and piston pin, using new piston pin clips, ‘lp fl nto {he crankcase. D9 net algn the piston pin clivend gap with the piston cut-out. Be carefulnot to. Clean of any gasket material from the eylinder base ané ‘amragethe crankcase upper surlaces. gasket surace ‘Apply quid sealant to the crankcase joints. Install a new gasket and dowel pins. ‘Avoid piston ring Coatthe cylinder bore and piston with engine oil and instal damage during the cylinder. instalation Do rot let the cam chain fal inte the crankcase. 7-6CYLINDER/PISTON Tighten the cylinder mourting bots TORQUE: 10 Nim (1.0 kg-m, 7 4D) Install the cylinder head (page 6-14). 77CLUTCH/OIL PUMP/KICK STARTER wennczken, o See s2Nam (1 2k, fsb) ; as S yeep tion, oun a0tem xno 2k, one) saueanen i) Ry 8-08. CLUTCH/OIL PUMP/KICK STARTER SERVICE INFORMATION ‘TROUBLESHOOTING RIGHT CRANKCASE COVER REMOVAL CENTRIFUGAL CLUTCH’ PRIMARY DRIVE GEAR CHANGE CLUTCH at a2 83 aa ez REVERSE LOCK MECHANISM ‘Ol PUMP KICK STARTER RIGHT CRANKCASE COVER INSTALLATION a7 818 21 8.23 SERVICE INFORMATION GENERAL, + This section covers removal and instalation of the centnfugal clutch, change clutch, oll pump and kick starter. These parts can be serviced with the engine installed in the frame. SPECIFICATIONS Unit: mm (a) [ TEM ‘STANDARD SERVICE LIMIT Change Spring fee tength 32.1 (1.26) 31.01.22) ay Dio thickness 262 2.78 (0.103-0.109), 2.3 (0.09) Disc warpage = (0:20 (0.008) Plate warpage = (0.20 (0.006) Giutch outer guide 0D. 27.950-27.980(1.1007-1.1016) | _27.02(1.000) _| Giutch outer guide 1D. 22.000-22.021 (0.8861~0.8670) 22.05 (0.868) Mainshait OD. (euter guide) '21.972-21.998 (0.8850-0.8659) 21.03 (0.863) Centrifugal Drum io. 140.0 (6.51) 1402 (6.52) etucn Weight ining thickness 300.12) 20 (008) [ouch song nelant 3.10.12) 2.95 (0.116) ‘Chich weight sping ee ngth 21.8 (0285), 22.5 (0.89) Kee ‘Shaft o0. 23 859-23.980 (0.9438-0.9441) 23,90 (0.981) sate Pinion 1D. 24,000-24.021 (0.9449-0.9457) 24.10 (0.949) Primary Crankshaft oD. 26 969-26 980 (7.0614~1.0622) 26.93 (1.060) ceive caae Gear 10. '27,000-27.024 (1.0630-1.0696) 27.06 (7.085) Oi pump Body clearance 0.15-022 (0.008-0.008) (0.25 (0.010) Tip deerance 0.15 (0.006) MAX 0.20 (0.008) ‘Sido clearance 0102-0.08 (0.001-0.003) _ 0.10 0.004) 8-1CLUTCH/OIL PUMP/KICK STARTER TORQUE VALUES CCantritugal clutch tock nut 120 Nm (12.0 kg-m, 87 tb) ~ Apply locking agentStako/Lofthand threads Ghange cluich lock nut +10 Nem (11.0 kg-m, 60 tht) ~ Apply locking agentStake Guten spring bolt 32 Nm (1.2 kgrm, 9 feo} Reversaineuiral rotor bolt 42 Nim (1.2 ka-m, 9 fh) ~ Apply locking agont i pipe bolt (BLACK) 42 Nm (1.2 kgrm, 9 f+) Right crankcase cover bot 40 Nm (1.0 kgm, 7 feb) Fight foot peg bott 38.Nm (33 kgm, 24 fp) Oil path pipe bot 12 Nem (1.2 kg-m, 9b) Kick starter ratchet guide bot 12 Nem (1.2 ke-m, 9 fo) Oil pump assembiy bolt 7 Nem (0.7 kg-m, 5.1 fb) TOOLS Special Bearing remover. 17 mm 07996-3710300 Remover handle 07936-3710100 Remover weight 07996-3710200 Clutch hotder O7GMB-HA70100 Guth canter older 07HG8-001000A tachment, 28x 90 mm 07946-1870100 Clutch puter (07933-HBSOCOA ‘Common Driver 07748-00100 atachment, 42 x 47 mm 07746-0010300 Pot, 17 mm 077460040400 TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch, (Clutch slips when accelerating + Faulty clutch iter * Discsipiates won Weak springs Clutch will not disengage + Faulty clutoh liter mochanism + Plates wrapped ‘The vehicle ereops with clutch disengaged + Faulty centrtugal clutch + Plates warped Clutch operation feels rough + Outor drum slots rough Hara to shitt * Incorrect clutch adjustment «+ Faulty clutch lifter mechanism Low oll pressure «Faulty oll pump + Oil pump drive gear broken 8-2CLUTCH/OIL PUMP/KICK STARTER RIGHT CRANKCASE COVER \ REMOVAL REMOVAL Shift the ansmission into neutral and din the oil rom the engine (page 2-9) ww Remove the following oll path pipe bots and ol path pipe ~ switch cover neutral, reverse and oll temperature switch wires -bolt from the reverse stopper shaft, and reverse stopper wv lever = ight ctankcase cover bott and reverse cable holder ster O7 erty RIGHT CRANKGASE COVER TAXS00W. ~ sk plate —~@ yy OS =rght tect pag Lo ~kick starter pedal 195-97: Remove the twelve right crankcase cover bolts. ‘Ator'97: Remove the thitoon right crankcase cover bolts. Remove the rght crankcase cover. NOTE e Bo caf notto remove the Kok Sarer mechanism and reverse stopper sht rom the crakease a3 You Remove the gaskat and dowel pins. OWL PATH FIPE ‘SEALING \ WASHER INSPECTION ‘Make sure that the oll path pipe and its bots are not ciogged . ‘and that tha sealing washers are in good condition. fo % ? - Seana WASHERS OIL PATH PIPE BOLTS 8-3CLUTCH/OIL PUMP/KICK STARTER Check the kick starter pedal and reverse stopper shaft oil s0ale for woar or damage, Turn tha cranksnatt bearing inner race with your finger. The bearing should tum smoothly and quietly. Also check thatthe bearing outer race flrs ightly in the crankcase cover. Replace itt necessary. BEARING REPLACEMENT Flemove the crankshaft bearing from the right crankcase cover with the following tools, TooLs: Bearing remover, 17 mm 07938-3710300 REMOVER HANOLE [CRANKSHAFT BEARING Romover handle (07936-3710100 a Remover weight (07938~3710200, Drive @ new crankshaft bearing into the cover, with its sealed side facing out, using the foliowing tools. TooLs: Driver (07749-00100 Attachment, 42 x 47 mm (07748-0010300 Pitot, 17 mm (07748-0040400 CENTRIFUGAL CLUTCH/ PRIMARY DRIVE GEAR CENTRIFUGAL CLUTCH REMOVAL Flemove the right crankcase cover (page 8-3) Unstake the cantrfugal clutch lock nut with dail or grinder, Be carelul that metal particles do not enter tho clutch and that the threads of the erankshalt aro not damaged. 8-4© © The ook nuthas Hold the centrifugal clutch weight assembly with a otutch le-nancttnreads. holder and remove the lock nut by turning it clockwise. TOOL: Clutch holder 07GMB-HA70100 Discard the lock nut. Remove the look washer. Remove the centitugal clutch woight assembly using the special tool and remove the clutch drum, TooL: Clutch puller 07833-HB3000A Remove the separator plate. CLUTCH/OIL PUMP/KICK STARTERCLUTCH/OIL PUMP/KICK STARTER 8-6 PRIMARY DRIVE GEAR REMOVAL move the following: ~cantrtugel cutch (page 8-4) change clutch (page 8-12) cil pump (page 8-18) Remove the primary drive gear and washer from the crank. shat. INSPECTION © One-way clutch Hold the clutch drum and rotate the clutch weightassembly, ‘You chould only bo able to tum it counterclockaise. Flemove the clutch weight assembly and one-way cluteh from the clutch drum, (Check the rollers for excessive wear. © Drive plate boss ‘Check the dive plate boss for excessive wear or damage. © Weight fining Moacure the weight lining thicknoss as shown. SERVICE LIMIT: 2.0 mm (0.08 in) For replacement, see page 8-7. uinine‘© Clutch Drum Check the inside ofthe centrifugal clutch crum or scratches or excessive wear. Replace if necessary. Measure the ID. of the clutch drum. ‘SERVICE LIMIT: 140.2 mm (5.52 in) ‘© Weight Spring/Cluteh Spring Remove the E-dips, outside washer, clutch spring, and Inside washer. Remove the weight springs and clutch weights from the dive plate. Measure the height of the clutch spring ‘SERVICE LIMIT: 2.95 mm (0-116 in) Replace the spring if itis shorter than the service limit. CLUTCH/OIL PUMP/KICK STARTER WASHER Eup CLUTCH WeIckT WEIGHT SPRINGCLUTCH/OIL PUMP/KICK STARTER ‘Check the weight springs for wear or damage, and replace if necessary. ) ‘Measure the length of the waight spring ‘SERVICE LIMIT: 22.5 mm (0.89 in) Replace the springs i ney are longer than the servica lim, ) ‘© Primary drive gear Inspect me primary drive gear for damage or excessive wear ‘Measure the primary crive gear |.D. ‘SERVICE LIMIT: 27.05 mm (1.065 in) ‘© Crankshaft at the primary drive gear Mecsure the crankshaft ©.0. at two lecatione as shown. ‘SERVICE LIMIT: 26.93 mm (1,060 in) PRIMARY DRIVE GEAR INSTALLATION Instal the following, — washer and primary drive goar to the crankshaft ~oil pump (page 8-20) —change clutch (page 6-15) 8-8CLUTCH/OIL PUMP/KICK STARTER CENTRIFUGAL CLUTCH WEIGHT ASSEMBLY WASHER 27 x 40 mm) prve Pare custo 420/N-m (12.0 kg-m, B7 fb) LOCK NUT (20 mm) WEST (CEFT-HAND THREADS) euro Paany SPRING oave Gm, = vock = % ovtawar wasten & Siren (20mm). \ weer SraIna nde WASHER ede WASHER wciiing Wie cleh wags an spas onthe ive Pe. ee toe OUT SDE" crak tro intl te scng_ instal ho inside washer a oki sping i raat sng WASHER cuuTcH sPANe face owas , ; ye cetovars tll the ouside washer with the locating pins facrg out. iP LOCATING PINCLUTCH/OIL PUMP/KICK STARTER Bocareiul not to Place the clutch weight assembly in a vise and tighten the damage the clutch jaws just enough to compress the clutch spring, WeIgM @5S27Y. neta the E-clips wth their dished sides against he washer ‘and their gaps aligned with the locating pins. Inspect the one-way clutch for smooth operation and check the rollers for excessive wear. Install the one-way clutch in the clutch drum with its “OUT SIDE" mark facing out. Install the centrifugal clutch weight assembly in the clutch rum, rotating the weight assembly counterclockwise. CENTRIFUGAL CLUTCH INSTALLATION Install the separator plate. E-CLIP tocarmorn 8-10CLUTCH/OIL PUMP/KICK STARTER Install the centrtugal clutch weight assembly and clutch ‘frum to the crankshatt using the following method’ Align the spines of the drive piate and crankshatt Rotating the clutch outer, align the splines of tho primary drive gear and clutch outer FT-SIDE” mark facing out Install the lock washer with ts "OU 0 CHEN SHAT (Py Apply locking agent to the new fock nut. ‘The ock mut Hold the centnfugal clutch waight assembly with te clutch ‘nas fef-nand holder and tighten the lock rut by turing ft counterclockwise, threads TORQUE: 120 Nem (12.0 kg-m, 67 ft-1b) TOOL: Clutch holder 07GMB-HA70100 Stake the lock nut and install the right crankcase cover (page 6-28).CLUTCH/OIL PUMP/KICK STARTER CHANGE CLUTCH REMOVAL Remove the following: fight erankcase cover (page 8-3) ~centrfugal clutch (page 6-4) clutch lavar (page 8-17) Remove the clutch bolts, loosening them in a crisscross pattern in 2 or 8 stops. Romove the liter plate end clutch springs. LUnstake the clutch center lack nut witha drill or grinder. Be: Careful tat metal panicles do not enter the clutch and that the threads of the mainshaft are not damaged Inetall the clutch contor holder and lock nut wrench as shown, and remove the clutch lock nut Toots: Clutch center holder 07HGB-0010008 Discard the lock nut. Remove the washer, clutch center, discs, plates and pres- sure plate es an assembly.CLUTCH/OIL PUMP/KICK STARTER Remove the thrust washer and cluich outer. Remove the clutch outer guide from the mainshatt. INSPECTION ‘© Clutch tifter bearing Turn the lifter bearing innor race with your finger. The: bearing should tumn smoothly and freely without excessive play. Also check thatthe Dearing autar race fits tightly in the Clutch liter plate, Replace if necessary. Drive the beating out of the clutch liter plate. Drive a new bearing into the plate. TooLs: Driver 07743-00100 Attachment, 28 x 30 mm 07948-1870100 © Cluteh spring ‘Measure the spring free length of all 4 springs, SERVICE LIMIT: 31.0 mm (1.22 in) 8-13CLUTCH/OIL PUMP/KICK STARTER © Cluteh center (Check the grooves of the clutch center for damage or wear caused by the clutch plate. Replace # necessary. © Clutch dise Replace the clutch discs if they show signs of scoring orcis- coloration. Measure the disc thickness. SERVICE LIMIT: 2.3 mm (0.09 in) © Clutch plate (Check for plate and disc warpage on a surface plate using a feeler gauge and surlace plate, ‘SERVICE LIMIT: 0.20 mm (0.008 in) © Clutch outericiutch outer guide Check the slots of the clutch outer for damage or wear ‘caused by the clutch discs. Replace if necessary. Measure the 0.0. and |. of the clutch outer guide. ‘SERVICE LIMITS: 0.0. 27.92 mm (1.099 In) 1.D. 22.05 mm (0.668 in) 8-14CLUTCH/OIL PUMP/KICK STARTER ‘© Mainshatt at ie clutch outer guide Measure the 0.D. of the mainshett ‘SERVICE LIMIT: 21.93 mm (0.863 In) INSTALLATION ‘Apply molybdenum disulfide grease to the inner and outer surfaces of the clutch outer guide, Install the clutch outer guide on the mainshatt. Install the clutch outer and thrust wasner. Coat new clutch discs with engine oi GIGHIEGRE RAE. Assomblothechichpressure plate, discs, platesandaiten | LOCK NUT Conor, aninsta hem nthe uth ote, CLUTCH CENTER Stack the cscs and plates altemately a sure the clutch center and pressure plate grooves are propery alignec WASHER (22x45 ne) (CLUTCH PLATE (6 pcs) CLUTCH DISC (6 pee) SPRING WASHER 8-15CLUTCH/OIL PUMP/KICK STARTER Install ho washer onthe mainshalt with #5 “OUT-SIDE a mark facing out Scien ‘Apply locking agent to the new lock aut Hold the elutch conter and tighten the lock nut. ‘TORQUE: 110 Nem (11.0 kg-m, 80 fb) TooLs: Clutch contor holder (07HGB-001000A IoLuTcH CENTER HK (OLDER ‘Stake the clutch center lock nut Install the clutch springs, lifer plato and bot. Tighten the bolts ina crisscross pattern in 2 or 3 steps. TORQUE: 12 Nim (1.2 kg-m, 9 fb) Install the following: ~ clutch lever (page 8-17) ~ centrifugal elutch (page 8-10) ~ ight crankcase cover (page 6-23) UFTER PLATECLUTCH/OIL PUMP/KICK STARTER foLuroH LEVER} REVERSE LOCK MECHANISM ae € REMOVAL Remove the following: right crankcase cover (page 8-3) ‘washer and clutch lever washer and reverse stopper shaft ~rotor bolt, reversa/neutral rotor and reverse lock plate Remave the washer and spring fromthe reverse stopper shaft Chock al parts for excessive wear or damage, and replace ‘tnecessary. INSTALLATION Assemble the reverse stopper shaft and apply oll fo the shaft pivot Install the reverse stopper st Install the reverse lock plate pins with their thicker sides towards the drum, then install the reverse lock plate. Install tne reverseineutral rotor with its projacton tacing down, Apply locking agent to the rotor bolt and tighten it to the specified torque. TORQUE: 12 Nm (1.2 kg-m, 9 ftb) ‘Align the index marion the crankcase with the punch mark ‘on the clutch lever and instal the clutch lever. Install the thrust washer. Install the right crankcase cover (page 8-28).CLUTCH/OIL PUMP/KICK STARTER OIL PUMP REMOVAL/DISASSEMBLY Remove the following: ‘contrfugal clutch (page 8-4) change olutch (page 8-12) Remove the O-ring, oll pipe mounting bots, cil pine bot (BLACK) and pipe. Remove the oil pump mounting botts. Remove the oil pump, primary drive gearand thrust washer, lamove the O-ring and two dowel pins trom te crankcase. Disassemble the oil pump. INSPECTION ‘Mako eure that the cl pipe and oil pipe bolt are not clogged, ourire ie oe ‘Thoroughly clean all the components, BODY CLEARANCE, Install the outer and innor rotors into tho body and tempo: ‘afl ineort the oil pump driven gear shatt Measure the pump rotor clearance SERVICE LIMIT: 0.25 mm (0.010 in) 8-18CLUTCH/OIL PUMP/KICK STARTER Measure the pump rotor tip clearance, SERVICE LIMIT: 0.20 mm (0.008 in) Remove the oll pump driven gear shaft from the oil pump body and measure the pump side clearance. Boece ‘SERVICE LIMIT: 0.10 mm (0.004 in) ASSEMBLY INNER ROTOR, PUMP COVER oars tran @) aD @o @ pom 696 Gam wAsnen — RETURN = (14.124 1.0 mm) xamae SPRING quan sur ans © ars ane Aol meter die gosto sine sioct ne Ue’ ahchcnd the aidng ace ofmokcesttor LAY Dn — ° we) « Ist otc stator pion on he shat en insta he washer and snap ring, Insiall the ratchet on the shaft while aligning their punch marks. WASHER! SNAP RING. 8-21CLUTCH/OIL PUMP/KICK STARTER Install the ratchet spring and spring seat, snap ring and washer. ‘SPRING SEAT WASHER: ; » RATCHET ‘SNAP FING. SPRING Instal the retum spring and collar, abgring tre groavetin the. a colar with the end of the return spring, COLLAR ALIGN Install the washer. RETURN SPRING INSTALLATION Temporanty instal the kick starter pedal onto the shaft Hook the retum spring onto the crankcase, Installthe kick starter assembly by turing clockwise about a half-tum and abgning the raichet mith the ratchet quice Mako sure thatthe punch mark on the ond of the epindle is facing up. @ Install the right crankcase cover (page 8 8-22CLUTCH/OIL PUMP/KICK STARTER RIGHT CRANKCASE COVER INSTALLATION CLUTCHUFTER ASSEMBLY LIFTER CAM BALL RETAINER, RIGHT CRANKCASE COVER. ‘Apply oil to the clutch adjusting bolt Inctal the O-ring andthe clutch adjusting bolt while aligning the groove of the clutch iter with the crankcase cover pin. Install the washer and nut, INSTALLATION Install the dowel pins and now gasketCLUTCH/OIL PUMP/KICK STARTER Apply grease to the clutch iter cap. Install the ball retainer and spring to the clutch liter cam srs} 4 CLUTCH LIFTER CaP CLUTOM UFTER CAM Aoply oil to the clutch lever, LIFTER PLATE BALL RETAINER Install the clutch ifter cam and ball retainor tothe clutch liter plate as shown, NOTE ‘Make sure the clutch lever points toward the center of ‘lutci as shown, ‘CLUTCH LIFTER CAM, Install the right erankease cover. Atter'97 only RIGHT ORANKCASE COVER '95-97- Install the twelve right crankcase cover bolt, C8 6 / Afer'97, Install the thiteen right crankcase cover bolts. (RS) Tighten the bots in a crisscross patter in 2 or 3 steps f& x SS. TORQUE: 10 Nm (1.0 kg-m, 7 ft1b) BOLTS Connect the snitch connectors refer "N' tothe neutral wich and “Rt to the their marked codes: ferse switch. ay Ifthe neutral and revorse switeh wire connections are in terchanged, the neutral incieator will come on whon tho transmission fs in reverse. Connect he ol temperate swich wire Rote the wres along the cyankcase cover ‘property. ‘OIL TEMPERATURE SWITCH 8-24CLUTCH/OIL PUMP/KICK STARTER Install the clamp and cable hoicer with the rignt crankcase cover bolts. Tighten the bolts. REVERSE STOPPER LEVEL TORQUE: 10 Nim (1.0 kg-m, 7 45) amp the wire win the ciamp and cable holder as shown. Install the reverse stopper lover with its “OUT” mark facing ‘out Install and tighton tho revoree stopper shalt bolt Install the switch cover and the right foot peg. Tighten the foot pog bolt TORQUE: 33 N-m (3.3 kg-m, 24 ft-1b) TRXSGOFW: Install the skid plat. Install the kick starter pedal tothe shaft, aligning the punch marks of the pedal and shaft Inctall the cil path pipe at the top using a special bot, lock washer and a new sealing washer {Attach tne lower end of the ol path pipe using a special bolt and new sealing washers. Torque the special bolts, TORQUE: ll path pipe bolt (oil contro! bo! 42.Nem (1.2 kgem, 9 feb) Secure the oll path pipe using the mounting bot as shown. Tighten the bolt securely ‘Adjuet the clutch and reverse cablo (pages 3-14 and 2 Fil the engine with of (page 2-3). ‘Check the clutch and gearshift pedal for smooth operation. Maka sure there are no oil leaks. PIPE BOLTS i] 8-25ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE 16Nen (1.8 ko-m, 1b) 9-0 HON (11.0 kgm, 80 fb) 10K (1.0 Kam, 7H)9. ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION 9-1 FLYWHEEL/STARTER CLUTCH 97 TROUBLESHOOTING 9-1 GEARSHIFT LINKAGE 940 STARTER REDUCTION GEAR 9-2 LEFT CRANKCASE COVER LEFT CRANKCASE COVER REMOVAL 4 INSTALLATION a SERVICE INFORMATION GENERAL “This section covers the removal and installation of the starter recuction gear, altemater, ignition pulse genaretor, starter clutch end gearshit linkage. “+ Refer to section 17 for pulse ganerator inspection, and to section 18 for alternator inspection, TORQUE VALUES TOOLS = prance es os TROUBLESHOOTING Engine does not turn + Faulty one-way starter clutch + Starter reduction goar broken Transmission jumps out of gear + Shift drum stopper arm broken Hard to shitt + Shift drum cam plate damaged Gearshift pedal will not return + Weak or broken shift retin spring + Shit spindle binding with case 1ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE STARTER REDUCTION GEAR REMOVAL Remove the starter reduction gear cover bolts and cover, Remove the gasket and dowel pins. Remove reduction goars A/B and C, the washer and the shafts INSPECTION Inspect the starter reduction gear teeth for wear or damage. Check the reduction gear bearing for excessive play or damage. Replace it necessary aoe BEARING REPLACEMENT Remove the gear cover protector by removing tne serews. Remove the reduction gear bearing by neatng the cover slightly and then tapping the area around the bearing with 2 soft haimmer. Crs To avoid buns. near aw gloves when herding the pnoreTOn read redcton cover Drive the new boarng int the later rducton gear cover B Aven Toots: Driver orr4e-cor0000 oe Attachment, 2426 mm o7r46-0010700 NOTE Do not use a pilot when driving the bearing because the pilot contacts the cover bofore the bearing seats, Install the gear cover protector with screws 9-2ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE INSTALLATION = ISTARTER REDUCTION SHAFT Apply oll to all gear teeth and shaft jaumals of the erank- case. Install the starter reduction shatt {Install the starter reduction gear C and thrustwasner on the shat Install the starter reduction shaft A and starter reduction gear AB. ‘ —. ® ISTARTER REDUCTION GEAR AB Install the dowel pins and new gasket.ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE Install the starter reduction gear cover and tighten the bolts to the specified torque TORQUE: 10 Nem (1.0 kgm, 7 ft4b) REDUCTION IGEAR COVER LEFT CRANKCASE COVER REMOVAL COVER REMOVAL Dain the oll rom the engine (page 2-3) Remove the following: TAXSOOFW: — skid plate TAXSOOFW. ~‘ront drive side shaft cover and shatt (page 14-25) —lelt foot peg ~ gearshift pedal —startor reduction goar (page 9-2) Disconnect the ignition pulse generator and alternator connectors, Remove and save the plastic clip securing the wires a Remove the left crankcase cover mounting bolts and cover, —— LEFT CAN KCASE coven) NOTE Be careiul not to pull the gearshift spindle out of the ‘crankcase whan removing the crankcase caver.ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the gasket and dowel pins. oF am. DOWEL PINS INSPECTION os Inspect the gearshit spindle ol seal for wear or damage ALTERNATOR-IGNITION PULSE GENERATOR REPLACEMENT t Remove the wire clamp by removing the bot. Remove the three stator bolts and stator. Remove the igntion pulse generator mounting screws, ALTERNATOR STATOR) ame Release the ignition pulse generator wie fram the clampon ‘the ignition pulse generator. 4 eee CONNECTOR Pulthe Disconnect theigrition pulse generatcr wireconnector trom comector, the ignition pulse generator. {0 net pus ‘ne wire. wiRE 9-5ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE Move the wite ube and keep the distance between the: ‘terminal insulator and wire tube at 40 mm (1.6 in). Clamp tho ignition pulse gonorator wito socuroly as shown. NEW IGNITION PULSE GENERATOR a nm (1819) cLAMP Push the wire tube into the ignition pulse generator clamp. ‘Connect the ignition puise generator wire connector on the ignition pulse generator terminal. ‘ConNecTOR Apply sealant to the groove in the let crankcase cover and insert the wre grommet Apply lacking agent to the attaching screws and instal the slaior, ignition pulse generator and wire ciamp securely Tighten the screws and bolts to the specified torque. TORQUE: Ignition pulse generator: 6 N-m (0.6 kgm, 4 ft-lb) Alternator stator: 10 Nom (1.0 kg-m, 7 f-b) 9-6ALTERNATORI/STARTER CLUTCH/GEARSHIFT LINKAGE FLYWHEEL/STARTER CLUTCH FLYWHEEL REMOVAL Hold the flywheo! with the flywheel holder, and remove the bolt and washer. TOOL: Flywheel holder or ‘commercially strap wrench available Remove the flywheel with the starter driven gear. TOOL: Rotor puller 07933-3950000 Remove the needle bearing, washer and woodruff key. STARTER CLUTCH INSPECTION/ DISASSEMBLY Check the operation of the one-way clutch by turing the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should nat turn counter- clockwise. 9-7ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE Inspect the starter driven gear testh for damage or abnor ‘mal wear. NEEDLE BEARING Chock the neodie bearing for damage. ‘STARTER ORIVEN GEAR. —— Flomove the one-way clutch rom the flywheel using an im- pact drivor and torx driver bit TOOL: Torx driver bit, 730 ‘commercially available Check the one-way clutch rollers for wear or damage. STARTER CLUTCH ASSEMBLY teh (.6kg¢m, 12) 6) aw FLYWHEEL Washer ew! (26x40 26mm) NEEDLE BEARING STARTER DRIVEN cLurcH Sure: GEAR ONE-WAY CLUTCH Apply ol to the one-way clutch rolls. Insiall the one-way clutch in the clutch outer.ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE ‘Assemble tho one-way clutch outer and the flywheel. CLUTCH OUTER NOTE ‘Make sure the lange side of the one-way cluich is facing toward the tlywneet [Apply locking agent to the threads of the torx bolts Install and tighten the torx bolts. TORQUE: 16 Nim (1.6 kg-m, 12 tt1b) TOOL: Torx driver bit, T30 ‘commercially avaliable Install the starter driven gear into the one-way clutch by ‘turning it clockwise. FLYWHEEL INSTALLATION Clean any cil rom the crankshaft Install the washer with its chamfered surface facing out Install the needle bearing, Install the woodrutf key.ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE Install the fywhoo! with the starter driven gear, aligning the koy-way in the flywheel with the key on the crankshaf Install the washer and flynhee! bolt Hold the flywheel! with the flywhes! holder and tightan the bot TORQUE: 110 N-m (11.0 kg-m, 80 ft-lb) TooL: Flywheel holder or ‘commercially ‘strap wrench GEARSHIFT LINKAGE REMOVAL Remove the following: ~ lott crankcase cover (page 9-4) ~ tight crankcase cover (page 8:3) ~ clutch lever (page 8-17) Pull he gearshift spindle out of the crankcase. Be caretuinot Remove the guide plate bolls and guide plate assembly. to drop any components i Disassemble empenents 1 Disascomblo thom. 9-10ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE Feemove the collars, dowel pine and bearing stopper plate. L DOWEL PIN | Remove the stopper arm bolt, stoppar arm and raturn spring RETURN SPRING Remove the shift drum center bolt, shift drum center and done pin, INSPECTION GEARSHIFT SPINDLE Inspect he gearsit spinde fr distortion Ye Cook the return spring for woar or damage AETURN SPRING 9-11ALTERNATOR/STARTER CLUTCH/GEARSHIFT LINKAGE Check the ratchet pawis, plungers and springs for wear or damage RATCHET PAN a a, la eo Intl the oprings, lunges and ratchet paws tothe crum

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