| er OO Oe Se ee UU 1. General Information 1-12 General Service Precautions 1-1 Torque Values Features 1-2 Tools 1-14 General Safety 1-3 Lubrication & Seal Points 1-16 Model Identification 1-4 Emission Control Systems 1-18 Specifications 1-5 Cable & Harness Routing ~ 1-19 1-7 | — Symbols and Special NotesGeneral Information FEATURES ENGINE = 4 Stroke OHC Vertical Engine, Aluminium Cylinder With Stee! Liner q alibi 5-Speed Gear Box, | = Automatic Cam Chain Tensioner, Rir Cut Off Valve, for preventing i Air Injection Valve, for reduc mission 200 = Tee nt power fuel cont ile re FRAME BRAKES SUSPENSION UNSTRUMENT CONSOLE d inst OIR FILTER EXHAUST MUFFLER signed powdet coated ELECTRICALS = CDI Copocitive Discharge Ignition) syste : ful > instant starting i for sole riding ad led la all eld a io i i iiPELLYULULULLELLLELELLUEULELELUUULULLOCULLUC UU General Information GENERAL SAFETY poisonous o! can cause loss of nd may lead to death © Petrol explosive under certain conditions so work na well ventilated area with the engine s extremely flammable and is stopped. Do not smoke or allow flames or sporks in the work orea or where petrol is stored Inholed asbestos fibres have been foun cause respiratory disease and concer. N use an cir hose or dry brush to clean brake assemblies. Use on vacuum cleaner of clterncie method designed to minimi hazard caused by eirborne asbestos “ib © The battery gives off explosive gases: keep sparks, flames and cigotettes away. Provide adequate ventilation when charging, © Route all Electrical wire/horness and cables Keep owey them from sharp edges ond area where they might be pinched between moving parts @ Used engine oil ond Dot-4 may cause skin cancer if repeatedly left in contect with the skin for prolonged periods. Although this is unlikely unless you hondle used ail on o | daily bosis, it is still advisable 10 thoroughly | wash your hands with soap and water as soon as possible after handling used oil KEEP OUT OF REACH OF CHILDREN, Icl a rey General Information MODEL IDENTIFICATION2 “ r . - = , > Q » rm rm T~ T T > r ~ rr rr - a 1 a 1 : : rr : a ni - - : :- - > > » > 2 > ’ 2 , > > , > > » > » Lb » » > General Information SPECIFICATIONS tiem 1 Dimensions | Qveol length Orerel wih Wheelbase Ground clearance weight Frome Frame type Front suspension Front axle travel Rear suspension Rear axle travel Front tyre size Reor tyre size Driver only | Cold tyre pressure Driver end | Front Pillion Rear Front brake «STD type. OX type Rear brake Fuel tank capacity Fuel tank reserve capacity Caster angle Trail dength Fork oll capacity Engine | Type Cylinder arrangement Bore and stroke Displocement Compression ratio Valve Yeain Engine oil capacity Lubrication system Oil pump type Air filtration Cylinder compression pressur Intake velve Exhaust valve Open Close Valve clearance Intoke Exhaust Idle speed ] Specifications 2100 mm 130 me 1,335 mr 160 mm 138 kg TubvlarSingle Cradle Frome Telescopic fork 17 mm | Swingarm | 97 mm 2.75 X18 - 42° 100/90 x 18 - 56? 1 | 1.75 kg/em 2.25 ka/em* (33 psi) nal expanding shoes (130mm) Hydraulic dise Internal expanding shoes (130mm) 12.5 litres 255 litres 27° 00 83 mm 142 ce Petrol, air-cooled 4-stroke OHC 15° inclined from vertical 63.5 x 49.5 mm 156.8 cm: as:1 Chain driven Over Head Camshaft 1.2 litre at disassembly 0.9 fitre ot oil change Forced pressure ond wel sump. Trochoid Oiled polyuret 13.0 * 2.0 kg) 01 600 rpm 10° BTDC ot 1 mn lft 25° ABDC of 1 mm lift 30° BBDC ot 1 mm lit (0° ATDC at 1 mm lift 1 foom | 0.10 + 0.02 mm 0.10 + 0.0: 1,400 = 100 rpmGeneral Information | Item Corburettor | Corburettor type dentification sumber Main ie Pilot screw initiol opening Float level Drive train | Clutch system Tronsmission Primary reduction Gear ratio Ist 2nd Bed 4th . 5th Finol reduction Gearshift pottern Electrical system Alternator Bottery capacity Spark plug | Spork plug. sap | Fuse Tans | Heodlight Position light Teiibroke light | Tom signal ight | Speedometer/RPM meter Neutral indicator igh Tum signal indicator tight High beam indicator ight ition timing F mark Full odvence jot Specifications Piston valve (PDD 1A PDCéA 22 mm #105 7/8 turns ov 14 mm Multi-plate, wet 5-speed constont mes 3.333 (70/21 2.769 (36/13) 1.722 (31/18) {1.688 (27/16), ¥-2000 Version} 1.263 (24/19) {1.200 (24/20), ¥-2000 Version} 1.000 (22/22) 0.838 (26/31) 3,285 (46/14) foot operated return system 1-N-2-3 Left col 9 = 2° BIDC of 1,400 rpm 34° + 3° BTDC at 4,000 rpm 130W/5,000 ram 12V 2.54H DPRBEA-9 (NG 2v 3W 2v SW/21 12V 10W x 4 12V 3W x 1 12v aw 12V 1.7W x2 | 12v.1.7wGeneral Information SERVICE LIMITS LUBRICATION, Item Engine oil copacity | At draining A disassembly Recommended engine oil SLETEUUY Standard 0.9 liter 1.2 ier | Hero Hondo 4-svoke genuine ol API service classification: SF Vscosiy: SAE 20W40 Units mm Limit Valve seat width [iaa3 Oi pomp Ouierrotoro-body clearance | 0.15—0.21 Rotor tip O15 7 0.20 7 [Pomp end clearonce [002-009 os ~ a ee eee = r item Stonderd r Cylinder compression [130 = 20 kgteme - | [085 = 26 ps) of 600 rom | ae ceoronee | 20.02 mm al Fr. ooo | [0.10 = 002mm =| Concha Com ob i Intoke | 20891—97.191 30.67 > Exhaust | 30 648—30.888 | lecsom [in emma 2000 a Sho OD. 1.971.995 = Rocker arm-to-shaft clearance 0.005—0.041 5 the Siem OD. invoke | §.450—5.465 - ‘ Bihaus_| 5 - Glide | Intake | 5.475-5.485 ~~ Me [haut 5.755.485 5 iem-io-qvide ceorance | Intake | 0.0100.035 a [haus 0.030—0.055 - ina ves gh [Over [4485 = Pinner [39.2 : 1 . r r r a! ait Ri call Pes 1-7General Information | CYLINDER/PISTON em Cylinder] 1.0. | Out of rovnd I “ Taper eee | Warpoge Piston Piston OD. piston «ing | Piston pin hole L.D. and piston | Paton pi = Jpn Fiston pin OD | Piston-to-piston pin clearance | | Connecting red smell end 1.D. Gylinder-to-piston cleorance | Connecting rod-to-piston pin clearance | Ser | clearance Second | Piston ing end gap | Top | | ee Second (CUUTCH/GEARSHIFT LINKAGE item Lever free ploy | Spring free length | Dise thickness eee ea Oil [side rail Standard | Service Limit Ee 66 O10 oud a1 3a70~08.490 ea 15.002—15.008 15.04 4994--15,000 | 00020014 5010-15028 00010-0040 0.034 0.020 0.070 0.008. | 9.005—0.020 20-035 50.5 20-070 its ice Li | DDD DPD ED PDD DDD DD ppp Dp ppp DD pfs bp ggg PPPs: r » > General Information , r r Item > ~ Shit fork | LD. r a r c r r. r. | F, 7 T C2 a Georto-bushing | M5 r - r Comsat 00. | = r, piacoabch = 3 P = Fee = ¥. ae r "Tato - = » > 2 2 > Bushing OD. > Bushing LO. vb D 2 Mainshaht 00. > 2 , > 2 > Bushing-to , > Runout » 9g end side clearence > Big end radio! clearance Lb a » r re re | CRANKSHAFT /TRANSMISSION/KICKSTARTER | 1, idle geor | Arma, m5 At C2 bushing A kickstorler driven gear idle geor bushing Unit: mm Standard 12.000—12.018 | 12.05 4,935.00 50 11.976—11.994 20.020—20.041 23.020—-23.041 19.520. 20,000—20.021 22.984—23.005 19.479—19.50 19.54) 19.500 [__22.979—23.000 20.010—20.021 20.04 | tes16—16.534 16.60 20.000—20.02 20.10 0.015—0.057 0.10 0.020—0.062 0.10 19.959--19.980 19.97 ar | 19.967—-19.980 [19.92 16.466—16.484 641 0.020 0.062 0.032—0.068 €.096 (0.013—0.047 0.10 0.05—0.30 00.008 0.05 20.000—20.02 0.0: 1995919 8 19.92 Service Limit a aa r~ >General Information FRONT WHEEL/SRARE/SUSPENSION/STEERING i Front axle runout t Front wheel rim runout | Radiat _ Axial [Fork spring free length _ | [Fork tube runout Fork fluid copocity Fork fluid lovel Standard 75 kal/env 25 pai) 75 kgl/em’ (25 psi) 142 env 169 mm from top Front brake lever free play 10—20 Front broke drum 1.0. 130 [Front broke lining thickness 4.0 REAR WHEEL/BRAKE/SUSPENSION — Item Driver only [Cold tyre pressure Driver and pe: Rear axle runout Rear wheel rim rake pedal free ploy | Rear brake drum I.D. [Rear brake lining thickness FOR DX TYPE ONLY : HYDRAULIC BRAKE —— | ltem | Specified brake fluid | Broke dise thickness | [a [(Colipes cylinder 1D. [catier piston 0.0. 1-10 Stendard DOT 3 or DOT 4 B42 25.335—25.368 Service Limit Unit mm Service Limit PELL LL LL LIL LIL LL LLL LPL LDL A LL LLL LL ae |General Information BATTERY CHARGING SYSTEM Item Specifications | moor Dees =| Alternator Copecity 130 Charging coil White—Green 02-070 resistance (20°C/68°F)_| Yellow—Green 01-050 14.0—-15.0 V/5,000 (rpm) Regulotor rectifier regulated voltage IGNITION SYSTEM oo — Spark plus Standard Spark plug gap Peak v Ignition coil primary side 100 V minimum 35 V minimum Ignition timing % BIDC at idle Full advance 34° = ¥° BIDC at 4000 rpm lonition col | Primary coil resistance o8—1 Secondary coil resistance (With plug cop) 12.7 Secondary coil resistonce (Without plug cop) 7.7 — 8.3 KO at 20°C (68°F Exciter coil resistance 2.7 — 64 0 at 20°C (68°F) Ignition pulse generator resistance 180 AAALAC CAAA CAAA TET aa | elGeneral Information TORQUE VALUES STANDARD Torque Torque Fastener Type kgem Fastener Type kg-m 5 mm bolt and aut 0s nny screw 8 mm bolt end nut 22 5mm flange bol (8 mim heo 10 mm bolt ond nut 3.5 6 mm flange bolt (10 mm heod} and mut | |12.mm bolt ond nut 58 8 mm flange bolt and 10 mm flange bolt ond nut 4.0 + Torque specifications listed below and on the next page are fer important fosteners. + Others should be tightened to standard torque volves listed above Notes: 1. Aaply locking agent to the threads ‘Apply il to the threads and seoting surface 3. Unnvt ENGINE Thread Dia.| Torque tem ayy. mm kg-m Remarks ‘Maintenance: Spork plug 12 Valve adjusting hole cop 36 Valve adjusting lock 2 6 Note Cronkshott hole cap 30 Timing hole (clave TYPE} 10. | WRENCH TAPPET COVER sa-201-10 | TO REMOve TAPPET COVER r 11. | GEAR HOLDER SA-202-10 TO HOLD CLUTCH OUTER & GPD : 12. | HANDLE BEARING REMOVER 5A-204-10 | TO HOLD BEARING REMOVER COLLET Fe | 13. | Wetcur soo 205.10 | TOREMOVE BEARING > 14. | BODY FORK SEAL DRIVER $4-215-10 | TO INSTALL FRONT FORK OIL SEAL 15, | WHEEL BEARING REMOVER | -—«SA.217-10 | TO REMOVE WHEEL BEARING FRONT HUBS am 16. | PISTON SLIDE BASE (0-0000024 | TO LOCK PISTON MOVEMENT | > 17. | CUTTER SEAT 45° (INLET/ExHAUST]] 07780-01060 _| VALVE SEAT REFACE a 18. | CUTTER FLAT 32° (INLET) 07780.0012000 _| VALVE SEAT REFACE | — (EXHAUST) 07780-0012001 | VALVE SEAT REFACE : 19. | CUTTER INTERIOR 60" 077800014000 | VALVE SEAT REFACE eee Saree | rE 1-15 oo ee _ oe rmGeneral Information LUBRICATION & SEAL POINTS. ENGINE Location Material Remarks ston ring whole surface Engine « Piston siding surfoc Clutch d Oil hough aiding ores Oil pump roler whole surface i seal lip, Ball bearing rolling surfoce Needle bearing |onting whole surioce | Cam chain whole surface Valve adjusing nut threods Jot iter rotor lock mut threads | Cluch centre lock nul threads | Citnder headcover cop oan hreads | Flywheel boll threads olling surfoc Camshaft cam surface and bearing | Molybdenum disulfide oil | Rocker arm shaft whole surfoce | (mixture of the engine el | Fiston pin whole surtace ond molyodenum disulide Velve stem arease win the vaio 1 1) M3 ond MS gea C1, C2 and C4 geor sliding surfaces lutch outer guide whole surface Moinshaft bearing set p Pulse generator bolt th bolt threads Locking agent (THREEBOND B13 der head cover m Sealont [THREEBOND #215 equivalent Never block the oil passage.| HREEBOND #1141 Crankcase gasket cut end | Sealant ( Alternator stator wire grommet seating surface | equivalent FRAME Location | Material Remarks ‘© master cylinder piston sliding surface | Silicone grease t broke lever pivot sliding surface liper pin bolt threads Brake caliper pin bolt A threads Handlebor weight mounting screw threads | Locking ogent TB1342 or Locktite - 262 Final driven flange stud bolt gnition switch mounting bolt threads Brake caliper torque nu! threads Front wheel stud bolt threads Brake master piston sliding surfaceCELLULECCULELUCebe cere reece ee erieieny | Location Steering head beoring cone and ball races | Clutch lever pivot sliding surface Swingarm pivot bushing inner surface Swingarm pivot dust seo! lip Broke cam sliding and shoe contocting surface Broke panel anchor pin Wheel dust seal lip Front broke panel oil seal lip Final driven flange dust seal lip Rear brake padel pivot Speedometer geor retainer dust seo! lip Speedometer gear box inside Speedometer cable inside Speedometer pinion teeth and shaft Speedometer gear teeth and inner surface Side stand pivot | Centre stond pivot | Gearshit pedel pivot | Gearshift pedal link joint pin sliding surface |Kickstarter pedal sliding surface, spring and steel ball Front fork oil seal Front broke com fatt seal Rear broke cam felt seal | Air cleaner element urethane foam Air cleaner connecting tube seoting surface Left handlebar grip inside surface Throttle cable inside Throttle cable boot inside Clutch cable inside Front broke cable inside Material Multipurpose grease Fork fluid (ATF or SS Engine oil Cemedine #540 or equivalent Cable lubricant 20) General Information Remarks 2.59 moxGeneral Information EMISSION CONTROL SYSTEMS. SOURCE OF EMISSIONS The combustion process monoxide and hydrocarbons. Controlling hydrocarbon emissions is very important becouse, ur conditions, they react to form photochemical smog subjected to suniight Carbon monoxide does not react in the same way, but it is tox Hero Hon hydrocarbons or Lid., utilizes lean carburettor settings os well as other systems, to reduce carbon monoxide ond CRANKCASE EMISSION CONTROL SYSTEM The en cotmosph ne is equipped with @ closed crankcase system to prevent discharging crankcase emissions into the e. Blow-by gas is returned to the combustion chamber through the air cleaner and carburettor EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) The exhaust emission control system consists of @ secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh cir is drawn into the exhaust port whenever there is @ negative pi in the exhaust system. This charge of fresh air promotes burning of the unburned exhous! gases and changes a considerable amount of hydrocarbons ond carbon monoxide into relatively harmless carbon dioxide and water vapour This model has the pulse secondary air injection (PAIR) ferse ait flow through the system. The PAIR control val ply of fresh air during engine deceleration, thereby preventing oft alve and PAIR check valve. PAIR check valve pre take manifold vacuum and will cut c adjustment to the pulse secondary cir injection system should be mde, clt apeperis\ie'recarnmended| I allel elcid cd ld dd i dd dd i ld 1-18General Information CABLE & HARNESS ROUTING THROTTLE CABLE — CLUTCH CABLE EE ‘SPEEDOMETER CABLE FRONT BRAKE HOSE UULULELEUCETEUUeL err rer tts SWITCH ASSEMBLY WINKER COMBINATION METER CONNECTIONS UGHT CONNECTIONS ULLEUULELUEL A;General Information FRONT - BRAKE HOSE oF CLUTCH CABLE. ¢ CARBURETTOR —_ SPARK cbIUNT ee AIRVENT TUBE PLUG WIRE awreh \ CABLE CARBURETTOR DRAIN TUBE BATTERY )_ CRANKCASE PEATHER TURE BREATHER TUBE oeGeneral Information THROTTLE CABLE ALTERNATOR WIRE PUL UCULUCLELCCUCE CU eee eee eeeGeneral Information ~ LEFT REAR TURN SIGNAL WIRE TAIL LIGHT WIRE BATTERY RIGHT REAR TURN SIGNAL WIRE PPPS Tech el elie el al ll ll ll al dll i lh 1-22 as ee )