A Few Words About Safety Service information ‘The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends fo use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. Ifyou need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommended that you do not use replacement parts of inferior quality For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle Any error or ‘oversight while servicinga vehicle can result in faulty operation, damage to the AWARNING Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed Follow the procedures and precautions in this manual vehicle, or injury to others. and other service materials carefully For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e. g., Hot parts - wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual AWARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this Some of the most important general | ee Ce iy service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise In performing service and repair procedures. Only you can decide whether or not you should perform a given task. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following + Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. + Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, dil, grind, pry or work around pressurized air or liquids, and springs or other stored-eneray components. if there is any doutt, put on eye protection+ Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts, Before you arab something thal looks like it can hurt you, stop and put on gloves. + Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: ‘= Injury ftom moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases {rom batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline of batteries. + Use only a nonflammable solvent, not gasoline, to clean parts, + Never drain or store gasoline in an open container. + Keep al cigarettes sparks and flames away from the battery and all fuel-related parts, ‘Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information thraughout this manual. Of course, it Is not practical or possible to wam you about all the hazards associated with se-vicing this vehicle. You must use your ‘own good judgment ‘You will find important safety information in a variety of forms including: + Safety Labels - on the vehicle + Safely Messages preceded by a safety alert symbol ZS and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. You CAN be HURT if you don't follow instructions, + Instructions - on how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a [NOTICE symbol. The purpose Of this message is to help prevent damage to your vehicle, other property, or the environment. ALL_INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS.1. GENERAL INFORMATION SERVICE RULES MODEL IDENTIFICATION.» GENERAL SPECIFICATIONS. LUBRICATION SYSTEM SPECIFICATIONS - 1-7 FUEL SYSTEM COOLING SYSTEM SPECIFICATIONS CYLINDER HEAD/VALVES ‘SPECIFICATIONS: CLUTCH/GEARSHIFT LINKAGE ‘SPECIFICATIONS. ALTERNATOR/STARTER CLUTCH ‘SPECIFICATIONS. CRANKCASE/TRANSMISSION ‘SPECIFICATIONS. CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS: FRONT WHEEL/SUSPENSION/STEERING ‘SPECIFICATIONS: 1-10 REAR WHEEL/SUSPENSION ‘SPECIFICATIONS HYDRAULIC BRAKE SPECIFICATIONS: BATTERY/CHARGING SYSTEM SPECIFICATIONS: IGNITION SYSTEM SPECIFICATIONS. ELECTRIC STARTER SPECIFICATIONS - LIGHTS/METERS/SWITCHES. ‘SPECIFICATIONS ('04 model LIGHTS/METERS/SWITCHES. ‘SPECIFICATIONS (After 04 model) ~ STANDARD TORQUE VALUES. ENGINE & FRAME TORQUE VALUES. LUBRICATION & SEAL POINT! CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEMS EMISSION CONTROL INFORMATION LABELS «.GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents, Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2, Use the special tools designed for this product to avoid damage and incorrect assembly. 3 Use only matric tools when servicing the motorcycle. Metric bolts, nuts and screws are not™interchangeablo with nglish fasteners, 4, Install new gaskets, O-rings, cotter pins, and lock plates when reassembling, 5, When tightening bolts of nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified, 6. Clsan parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electris! wiras a2 show in the Cable and Harnaes Routing (page 1-23). MODEL IDENTIFICATION ‘06 model: After '04 model: 1-2ime corial number ie etamped on the right side of the eteering head. ‘The engine serial number is stamped on the lower right side of the ‘crankease. ped . The carburetor identification number is stamped on the intake side of ‘the carburetor body as shown. ‘The vehicle Identification Number VIN) Is located on the left side of the steering head on the Safety Certification Label. GENERAL INFORMATION J A VEHICLE IDENTIFICATION NUMBER {VIN} reGENERAL INFORMATION “The color label ie atached 9a ahown. Whon ordering color-coded parte, always specify the designated color code, ‘COLOR LABEL 4GENERAL INFORMATION GENERAL SPECIFICATIONS Trent ‘SPECIFICATIONS DIMENSIONS] Overall Tength 200 Tira (62.7 in} Overall width 740 mmm (28.1 Overall height 41,070 mm (42.1 in) Wheelbase 1.420 mmn (56.9 in) Seat height 780 mm (31.1 Footpeg height 344 mm (13.5 in) Ground clesrance 140 mm (6.5 in) Curb weight os 49 state/Canada type | 200 kg (441 Ibs) model) 202 kg (445 Curb weight (After 201 eg (441 04 model) 203 keg (445 tbs} ‘Maximum woight 7k (384 lbs) sapecity 174 kg (384 ibs) FRAME Frame type Diamond Front suspension Telescopic fork Front axle travel 4108 mm (4:3 in} Rear suspension Swingarm Rear axle travel 427 mm (69 in) Fronttire sieo 1720770 2R Y7MIC (58) Roar tre size ‘180/85 2A 17M/G (73W) Front tire brand ST-56F RADIAL N (Bridgestone) Filot ROAD S (Michelin) Rear tire brand BT-56R RADIAL G (Bridgestone) Pilot ROAD S (Michelin) Front brake Hydraulic double disc Rear brake Hydraulic single dise Caster angie (04 model) 25° 40° Castar angle (After‘04 model) 25°30" Trailjongth 98 mm (3. in) Fuel tank capacity 17 titer (4.49 US gal, 3:741mp gai) Fuel reserve capacity 2.6 liter (0.69 US gal, 0.57 Imp gel) ENGINE ‘ylinder arrangorne ‘ eylindor In-tino, inlined 30° trom Verical Bore and stroke 65.0 X 45.2 mm (2.56 X1.78 in} Displacement 1589 om (38.5 cu-in) Compression ratio 120:1 Valve train Chain driven, DOHC Intake valve opens at 1mm (0.04in) itt | 15° BTDC closes at 1mm (0.04 init | 36" ABDG Exheustvalve opens at 1mm (0.04 in) litt | 38° BBDC closes at Tmm/(.04injiitt | 7°ATDC Lubrication system Forced pressure and wat sump i pump type Trochoid Cooling system Liquid cooled Air fitration. Paper element Engine dry weight 163.2 kg (139.3 tbs) Firing order 4-2-4823 CARBURETOR | Type ‘Constant velocity ‘Throttle bore, 34 mm (1.3 in)GENERAL INFORMATION TEM [DRIVETRAIN Clutch syste Clutch operation system Cable operating Transmission Constant mesh, speeds Primary reduction 1.963 (82/44) Final reduction 2.800 (42/15) Gear ratio Ist 2928 (sia) and 2.082 (29/16) 3rd, 1.847 (28/17) ath 1.368 (26/19) th 1.200 (24/20) eth 1.086 (25/23) Gearshift pattern Loft foot operated return system, 1-N ELECTRICAL Ignition satan Fall tansistorized ignition Starting system Electric starter motor Charging system Triple phase output slternator Rogulator/ectifior SCA shorted/triple phase, full wave rectiics- ton Lighting system BatteryGENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS en nn we owes Lin) Tem ‘STANDARD ae Engine oll capacity ‘River draining SS Mer 7 US qt 31 Imp a = ~ After drainingiiker change | 3.8 iter (40.US qi, 33. impq) | -__ ‘After diss 4.2 liter (4.4 US qt 3.7 Imp qt) — = Recommended engine sit ro Honda GN or HPa(Wtinow = Viscosity: SAE 10W-« ‘Oil pressure a oll presaure switch “490 KPa (5.0 Kgfiem®, 7¥ pal at = 6,000 pmieorcin7e"F) | ‘Oil pump retor ‘Tip clearances | "0.18 (0.008) 20 TOO) (0.15 ~ 0.22 (0,006 — 0.008) 6 03 0.100.008) | | Oil pump drive sprocket collar 0.0. = ‘34.050 - 34.075 (13405 - 1.3476) | ~34.03 (1.340) _| Oil pump drive sprocket LD. _— ‘35.025 — 38.075 (1.3789.- 1.3809) 35.10 (1.382) FUEL SYSTEM | Carbaretor Wentification Except California type: | number (o4mode "| eaioris tye Carburetor identficaiion | Except California Wi umber atir'04 model) |Califgmia ype —| Main jet —_— Slow jet Jet need Pilot screw opening Thigh slttude adjustment Float fava ‘Idle speed Throttle grip free play ma Carburetor vacuum difference Within 30 mm Hig (1.2 in Ha) ‘Base carburetor for synchroni ‘No.3 carburetor COOLING SYSTEM SPECIFICATIONS | Coolanteapacly | Radiator and engine 2Imba) | | Reserve tank gap ter f0.32US at, 0.26 np et) pressure TO8= 197 KPa1.1 1.4 kgliom, 18-20 pal) | Bagin to open ‘BO - 84 °C (176 ~ 183 °F) plone! oe ~Vate i “Recommended aniireca «=~ High qualiyetfvlene lycol antifreeze containing corrasian | protection inhibitors TT metre with soft waterGENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: me {in} Trem ‘STANDARD ‘SERVICE LIMIT | Cylinder compression t360 rpm 7,298 WPS (13.2 kafiem?, 188 pall [0.46 x 0.03 (6,006 6,001) [exam ors 10.22 + 0.03 (0.009 0.001) Camshatt Camm labs height 36.300 (1.4260 - 14257) 3605 [LATS] He i Journal OB: 2.966 (0.9825) Runout 0.08 (0.002) Oil clearance: | { 004 Valve ier | Valve tiiar 0.0: {253978 — 26,983 (1.0298 1.0233) | 297 (1.022) Valve ifr bore 1D- 26010 26.026 (1.0280 = 1.0286) 26008 (1.028) Valve, Vaive stem 03. IN |-3.875 - 3.880 (0.1565 - 0.1571) _ 3.665 (0.1561) valve guide 1 [Valve guide Lo: [000 = 4.012 0.1875 4.04 (0.158) Stem-to-guide clearance .010-0.057 (0.0008 —0.0018) — 0.075 (0.0030) 0.085 (0.0033) —| | Wale gue pseation = L Re “oe i10 035-008) TE T608) ‘Valve spring free length 36.26 (1-506) 3706 Cylinder head warpage 10 (0. CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS ni: mn - Tew STANDARD SERVICE LIMIT] | ean ave fae pay To=2p(ae= 130 e Chit 138) ars nay 2.82 =3.08 (0.115 - 0.127) | 2.610.10) _ = | 0.30 (0.072) omer etter tae 27904-22007 (0.8659 - 0.8660 22017 (00 34978 770 ‘Maiishaft 0.0. at dutch outer guide 21.980 - 21.983 (0.8654 ~ 0.8869) ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Te Starter driven gear TANDARD BYBGS— 51,716 (20354-20367) 1-8GENERAL INFORMATION CRANKCASE/TRANSMISSION SPECIFICATIONS Shi Tor, fork shaft 533-6001 736) 41.967 - 11.968 (0.4707 - 0.472) Transmission 28,000 28.024 (1.1024 - 1.1032) 27.358 - 27.580 (1.1007 = 1.1016) '30:950- 30.876 (1.2189 1.2197) | ~30.94(1.218) 90.020 ~0.082 (0.0009 0.0024) 0.10 (0.004) 0.025 = 0.075 (0.0010 0.11 (6.008) ar bushing Here ser O98 | 2.18 oe | Mainshah OD, 24.367 - 24.960 (0.9830 —0.9835) | 24.96 (0.883) Countershaft 0.5; (O18) 6 (7.101) Bushing to shaft x 3.9002 -0.0018) | 0.68 (0.002) | clearance (0.005 — 0.039 (0.0002 - 0.0075) 0.06 (0.002) CRANKSH. Unit: men Cin} ‘SERVICE Liar Grankshatt = .06 (0.002) (0.020 = 0.045 (0.0008 = 0.008) 0.05 (0.002) = 0.05 (0.002) Fiston, piston (64:870- 64990 (25579-25567) — rings 7,002= 17.008 (0.6684 = 0.6698) 76,984 - 17.000 (0.6651 - 0.6683). ‘0.002 ~ 0.014 (0.0001 - 0.0006) {0.10 =0120 (0.004 = 0.008) i (0.18 030 (0.007 -0.012) 1015 (0.02) 020-070 (0.008 - 0.028) 7.00.08) [70.10 (e.0085 1.10 10.004) 10.10-(0.004) 7. ne tal aa 06708) —| [17.04 (0.6711 '0.10-(0.,004) Toon 016) oa)GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS oe Unit: mm tin) TEM ‘STANDARD: ‘SERVICE UNIT Minimum ire Weed depth — 1.5 (006) Coldtire pressure | Driver only ‘250 KPa (2.50 igor 36 pall | = Driver end pansenger 260 KPa (2.50 baler 36 pal) 1 = Aateranout = ‘exo Wheel rim runout [Radiat = 20008) | Asal = === == [20:08 ah 60g (0.1 02mm Spring free angi BSS 351 513.08) Pipe runout =] a 020 (0.008) ——~| Recommended fork Tuld Pre Honda suspension (uid SSS rz Fluid ievel aos) Fluid capacity aa7 225 om — _ (15.1 3 0.08 US oz, 157 £0.09 imp o2) ‘Spring free Tongih ae — (After '04 model) | Pipe runout = ~Recommonded fork urd Pro Honda suspension Mud SSB = (16.36: 0.08 US 02, 17,000.08 Imp o2) ‘Seeing head beating pro-Toad ‘OS= 13 kat (20-29 1b) = REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm tin) Cc ‘STANDARD ‘SERVICE LIMIT ‘Minimum tre We ——_r = 207008; Cold tire pres- ‘280 kPa (2.90 ktm’, 42 pai L = sure (290 kglen, 2 pal) = [Axio ranout = ‘oz 001) Wheel rim = = ZO TOUR, runout a (“Whos batanes weight — = 609 (2.1 a) max. Drivechain | Sizelink [op | sasvere-TT0LE = __ aK | S25RO-1 === Stack 30 401. ea ("Sheek absarber preload adjuster standard positon | 2nd groove: =GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS BATTERY/CHARGING SYSTEM SPECIFICATIONS _ Unit: rm (in TEM ‘STANDARD SERVICE LMT Front pacified brake Hud i = [Brake aise thickness | 45.18 “pss [Brake cise runout = [0:30 (0.0127 ‘Master cylinder LD: [ye7 (0.60) SS | Calipereylinder (0. | “Upper | “32.03 (1.2697 = = ‘ a Lowor | ~30.2317.180) = [Rear Shocified brake fla ‘bors = 5 5.01020) [aore16) | = [70.30 (0.072) ‘Master cylinder LO 7400 TOESTT I = | Caliper cylinder LD. 3896 1.337) — | IGNITION SYSTEM SPECIFICATIONS _ — re ‘SPECIFICATIONS | Baitory | apaciny T= 8Ah ~Currentieakage ZAM Wattage Fully charged 130-132 (20°Ci68'F) Needs Below 12:3 | charging Normal OSAB- 10h i | Quick {AO ‘Aitomator 54 RW, 000 epee ing oil resistance 20°CI6EF]_ a-190 j [Spare pioa irararay — Spark plug g — 30 (Clanition col peak vortage 100 minimum “Tanition puse generator a “G7 V minimum ignition ting (F'mark) — 7 etoC ELECTRIC STARTER SPECIFICATIONS TEM ‘STANDARD |" Starter ister brush Tength W20= 1301047- 051) a5 (Gi)GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS ('04 model) eM ‘SPECIFICATIONS Bulbs Headlight fi TaV— 55 W to Position git ~Brakerait light [Turn signal tight Fuse 2OAK1, WAXG | “Tachometer peak voltage: an motor ‘Start to close (ON) 105 V minimum 2° (208 FL LL switeh | Stop to open ‘93-87 °C (199-207°F)_ LIGHTS/METERS/SWITCHES SPECIFICATIONS (After ‘04 model) Tem ‘SPECIRCATIONS Bulbs Headlight Hi 12V = 55 W te 12V=58W Postion ight WW -8WX2 = | Brakofa light TeV = 2115 WXE “Turn signal ight Front TwW= 23 WX2 | Rear = 235 WX2 Tpatrument ight teD “Turn signal indicator — LED High bear or LED. ‘Neutral indieator TED ‘Oil pressure ‘Engine coolant temperature indicator LED — Fase ‘Main fuse 308 ‘Sub fuse BAK? AXE | “Tachometer peak voltage 705 V minimum Fan motor switch 1-12GENERAL INFORMATION STANDARD TORQUE VALUES | Tora | 7 FASTENER TYPE Nem ligt, tt FASTENER TYPE Nem (kgm, tote) | ‘Sim hex bolt and nut 305,36) | Smmscrew 4 (04, 28) ‘8mm hex bolt and nut 10(1.0,7) | Smmscrew (09,65) 8 mm hex bolt and nut 22(22,16) | 6 mmifange bolt 1011.0,7) 10mm hex bolt and nut 245.25) | (@mmheadamat fang) 12mm hex bolt and nut 54 (55,40) | 6mm flange bolt 12(1.2,9) | {8 mm head, large flange) | 6mm flangebor 12(1.2,9) (10 mm aad) and nut Simm tangebet and ut 28 (07,20) _ 10 mm flange bolt and nut \0, 29) ENGINE & FRAME TORQUE VALUES + Torque spedifcations listed bolow ars for important festoners. + Others shotia be tightened to standard torque values listed above. Note 1, Apply sealant to the threads. 2 Apply a locting agent tothe threads, 3 Stake. 1 Apply oll tothe throede and flange surface 8 Umut 5. ALOC bolttscrew: replace wth # new one. 7. Apply grease tothe threads @ Apply molydenum disulfide ofl to the threats and seating surface a. crboit ENGINE MAINTENANCE THREAD TORQUE Li OTF | WA rm) | Nem (kgtm, ttt) | REMARKS | ‘Spark plug (04 modal) a wens Spark plug (After 08 mode 4 1 19(1.8,13), | Timing hole cep 5 4“ we(1a,13) | NoTE7 Engine ol fter cartridge 1 2 25(28,18) | NOTE4 oie i | 2 | Bee WBRICATION ew | THREAD] Toru} ‘rest TY | pra. tmm) | Nem kgm, meat) | REMARKS ‘Oi fiter bow 7 2 78(18, 13) | NOTEZ Ol pump driven sproctat bolt 1 ® 15(15,11) | NOTE2 Oil pump assembly bolt 1 6 78(0.80,88) | NOTES Oil cociar sealing bolt 1 ® 49 (60,36) | NOTE? FUEL SYSTEM THREAD TORQUE rem LTV | iam | nem(kgtm mtn) | REMARKS insulator band screw z ¢ = Carburetor rain acrawe 4 ‘ 45(0.5,1.1) ‘Starting enrichment (SE} valve arm screw 2 4 181018, 13) Starting enrichment (SE) valve nut 4 10 181018, 13) Vacuum chamber cover screw 2 4 2:10.21, 15) Airfunnel Helder scrow 16 4 21(0.21, 15) Float chamber screw wis 24 (035,25) ‘Throttle cable holder scrow 2 5 24 (038,28) Throttle postion (TP sensor bracket screw 3 5 34 (0.35, 25) | Carburetor connecting nut, § mm 2 5 51 (082.38) | Carburetor connecting nut, 6 mm 2 6 1011.07) | 1-13GENERAL INFORMATION ‘TOOUNG SvSTEM THREAD TORQUE rem TY | DIA. fmm)_|_ Rem (kgm, wore) | REMARKS Water pump cover Bart z é T3113, 3} NOTES ECT sensor 1 2 2323, 17) Water hess joint i 2 2G022) | = ‘THREAD ‘TORQUE ony DIA. (mm) Nem (kgf-m, Ibf-ft) REMARKS: Drive sprocket spacial bolt T 10 4 (5.5, 40) CYLINDER HEAD/VALVES THREAD ‘TOROUE fre, ITY | DUA. (mm) | Nem (eg, ttre) | REMARKS, Cylinder head seating bor 7 18 "3233, 24) NOTE? bot 10 9 47 (48, 35) NOTES cuum port plug (04 model) 1 5 3103, 22) Cylinder head cover bolt 8 6 1011.0, 7) Camshaft holder flange bolt 20 6 12(1.2, 9) NOTE 4 Cam sprocket bolt 4 7 20 (2.0, 14) NOTE 2 Cam choin tensioner cap nut 1 8 12(1.2,9) Com chain lifter sealing balt 1 6 10(1.0,7) fend valve cover bolt 4 8 13102'9) NoTE® CLUTCH/GEARSHIFT LINKAGE THREAD ‘TORQUE vem QTY | DiA.(mm) | Nem (kgm, tote) | REMARKS ‘Clutch center ook wut 7 20 708(1.0,80) | NOTES@ Clutch spring bot 4 ° 12 (12,3) Shift drum cantor socket bolt 1 8 23,7) NoTE2 Shift drum stopper arm pivot batt 1 6 1211.2,9) Gearshift return spring pin 4 a 233,17) ALTERNATOR/STARTER CLUTCH THREAD TORQUE _ ™ QTY | DIA. (mum)_|_Nem fg, torte) | REMARKS Fiywheel flange bolt tT 7 103 (10.5, 76) NOTE 4 Stetor mounting socket bolt 4 6 12U1.2,9) ‘Alternator wire clamp socket bol 1 6 10(1.0,7) ‘Starter clutch outa tore bolt 6 6 16(.6,12) NOTE 2 ‘CRANKCASE/TRANSMISSION I —a “THREAD ‘TORQUE T eM OY | oa. (mm) | Nem (kgm, tte) | REMARKS ‘Main journal bolt 10 a 2612.7, 20) NOTES Crank ease bot, 10 mim + 10 39 (40, 29) Grenkease bott, 8mm 1 8 24 (24,17) Lower erankease seating bal, 20 mm 1 2 30 (3.1, 22) NOTE 2 Lower erankcase seating bolt 14 mm 1 14 25:25, 18), NoTE2 1-14GENERAL INFORMATION ‘GRANKSHAFT/PISTON/GYLINDER THREAD TOROUE | pean Te LOTY | ota. temm) | mim egtem roe) | REMARKS Connecting rod Baalig ap mut Ts 7 25126, 19) | NOTES IGNITION svSTEM a ‘TOROUE rei |__ Nm (kgfim, tote) | REMARKS _galion pulse panratar ator spediT Bol "596.0, 43) ELECTRIC STARTER THREAD ‘TORAUE = TH ary | ciactnm) | nm tigtm tty | REMARKS | ar oT TarFINAT AOE i 3 1010-7) j LUGHTS/METERS/SWITCHES —S THREAD TORAUE ns | er | cian | tm gto tte T [> Prie [wet 3) | NOTET 1 4 20 (0.20, 1.4) 1 10 1204.2, 9) 1-15GENERAL INFORMATION Insulator clamp (carburetor side}: 1041 mm (0.40.04 in} Insulator clamp (Cylinder hoad side! 41mm (02 + 0.04 in) Exhaust pipe stud bolt: — 21,5 + 0.5 mm (0.85 + 0.04 in) 1-16GENERAL INFORMATION ‘wines | 8 | one tem 7 2 Exhaust pe jolt rut 6 7 z Exhaust pipe mourting nut 1 3 22(2.2,16) Muffler mounting bot 1 a 22 (22,10) Mutter bond bolt 1 2 22(22,16) Grab rail mounting socket bolt 4 a 26 (27,20) Front fender mourting bok 2 6 42102.9) Rearview mirror mounting nut 2 10 24,035, 25) Rear turn signal unt mourting it 2 10 491050, 36) Talight mounting nut 2 6 £9(0.70,5.1 Side cover socket bolt 2 5 (04,3) FUEL SYSTEM “THREAD ‘TORQUE ee ow | omtnm | [Nem (haf, tot) [Ful valve rar 7 22 341, 25) Fuel tank stay nut 2 6 | 42(1.2,9) coouNG sysTEM TORGUE _ Tem any [mieten | REMARKS Fan motor — 7 8,13) | NOTE | Coating fan nut 1 27(028,20) | NOTE? Fan motor mounting nut fa | s | stray | S| ENGINE MOUNTING THREAD TOROUE em OTF | uate) | Nm teat, tote) | REMARKS Front engine hanger nut 2 10 34 (55, 40) Engine hanger bracket bolt 2 8 22 (22,16) Rear engine hanger nut (upper) 1 10 54 (55,40) Rear angine hanger nut lower 1 10 54 (5.5, 40) CCLUTCH/GEARSHIFT LINKAGE Trem avy REMARKS ‘Gearshift pedal Vink aR (goarahif pedal aide) | 1 Goarshit pada! ink bolt (gearshift spindle side) 1 6 20 20,18) FRONT WHEEL/SUSPENSION/STEERING i THREAD TORGUE ——) nares] | mm OY | pia tenm | Nm tem, tin) | REMARKS Handlebar folder bolt 4 3 26 (27,20) Stooring stem nut 1 2 103 (10.5, 76 Steering bearing adjustment nut lock nut 1 26 2 Stooring bearing adjustment nut 1 26 - Fork top bridge pinch bolt 2 . 23123,1) Fork bottom bridge pinch bot 2 70 39 140,20) Front ante batt 1 4 59 60,43) Front axl holder bolt 2 8 22122,16) Front brake die mounting bot 12 8 2012014) | Notes Fork cap (04 model) 2 7 73123,17) Front fork bot (After ‘0¢ model) 2 7 2435, 25.1) Fark socket bolt 2 2 20(20,14 | NOTE? TT e0000——n—nn>na4niaeGENERAL INFORMATION ‘REAR WHEEL/6USPENSION THREAD ‘ToRaUE ren QTY | piA.tmmi_| Nem (kgtm, torn) | REMARKS i an 35 90,68) | NOTES Ree rat dis mounting bolt 4 8 waaay | NOTES Final civensproclet aut 5 2 toa{tie.20) | NOTES ‘Swingarm pivot nut 4 | Me een e) NOTES Drive cal cave bot 2, 2 |. 6 8 (080,65) Drive ein edustr lock nut 2 a 21,15) Rew hock absorbs Upper ousting nit 1) saan — | Notes Faw dhostakenrutioear sroursiog at i io a2) | NOTES HYDRAULIC BRAKE Thien] —roraue ory | em ee tm | REMARKS 2 | 42 (1.2, 8) | 2 | 4 1.5 (0.16, 1.1) | Broke lover pivot tok i a asia) Bate lover pvot rut 1 é 9 (080,43 Front baka light itch crew 1 a Front brake caliper mounting bok 4 a wier2) Nore Front brake elie: pn Bolt A 1 B meat | Nore? | Fe at aan bo : 5 303.3) pin ‘ Padin plug 3 to 25 (025, 18) | Front brats hose damp bot (4 modal) 2 ° tzuizs) | NOTES Front brake Rose damp cap nut Ater‘04 made) | 2 6 121129) | NOTES | Roar master eylinir mounting bo 2 6 “ana oor mastreyiner mounting 2. | Rear master eyincer hose joint screw 1 4 15(08, 1.1) | NOTE? Ison ur od et : 2 ves fae brake caliper mans pin : ‘Rear brake caliper sub slide pin 1 8 23(23, 17) NOTES Gecaeie cee : 6 selosi.es) | NOTES Brate hose ol bot 5 10 348,28) = ~ “ ‘TORQUE — Toa | THREAD] ——rorave trem QTY | aia. (mm)_| Nim kgm, tte) | REMARKS gallon sack euing Bal 3 ¢ eee tieanc ght screw 7 (017, Tailight sow 2 5 1310.17.12) omens THREAD fORQUE eM QTY | pia. tmm)_| nem tage, ttre) | REMARKS i 1 0 wes 77) Side stand pot lock nut 1 iH 39140, 23)GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION. MATERIAL. REMARKS ‘Grankease rating surface Tiguid geafant | {three Bond 12078 or equivalent)(GENERAL INFORMATION LOCATION [Oil pressure switch threads .— Do not apply to the thread head 3-4mm (0.1 -0.2 in) 2 PLACES Ignition pulse generator cover grommet ECT sensor threads Lower crankcase sealing bolt threads Cylinder head sealing bolt threads Alternator caver grammat Cylinder head semi-circular cut-out 5. 10mm (02-0.4in) 5- 10mm (0 ‘Sealant Crankcase mating surface Crankcase mating surface Cylinder had bolt threads and seating surface Camshaft lobesijournats Valve lifter outer sliding surface Valve stem (valve guide sliding surface) Connecting rod small end bore ‘Main journal bearing surface Connecting rod bearing surface (Mais, C5, C8 shifter gear (shift fork grooves) Crankshaft thrust surface Clutch outer sliding surface Starr idlo goat shaft sliding eurtace Welvbdenum disulfide oi (ambxture of V/2engine oil ‘and 1/2 molybdenum disulfide grease ‘Clean anti-ruatoll and apply to the threads and seating surfaceGENERAL INFORMATION LOCATION, ‘MATERIAL REMARKS ‘Clutch center Tock nut threads Engine olf ‘Main journal 8 mm bolt threads and seating surface Connecting rod bolv/aut threads Camshaft holder bolt threads and seating surface | Flywheel bolt threads Oil iter cartridge threads and mating surface | Starter clutch sliding surface Piston surfece | Piston pin bore Piston ring grooves Piston pin surface Piston ting surface Cam chain tensioner collar siding surface Cam chain ensionar and slipper surfaco Clutch friction disc lining surface Oil see! lip without dust lip) Each goat teeth and rotating surface Each bea Each O-ring Other rotating area and sliding surface Timing hole cap threads Mult-purpese grease Each oll geal lips (without dust lip) ‘Cylinder head cover breather plate bolt threads Tocking agent Coating width 65 1 mim ‘Cam sprocket bolt threads Costing width: 6.5 1 mm (Oil pump driven sprocket bolt threads Coating width: 6.5 1 mm ‘Shift drum bearing sat plate bolt threads Coating width: 6.5 1mm ‘Starter clutch outer tone bolt threads Coating width: 6.6: 1 mm ‘Shift drum center bolt threads Costing width: 6.51 mm Mainshaft bearing set plate bolt threads | Coating width: 6.5 1mm Gearshift spindle oil seal set plate bolt threads Coating width: 6.5.4 1mm it iter boss threads il cooler sealing bolt threads 1-21GENERAL INFORMATION MATERIAL Steering head bearing sliding surface Stoering head dust seal lips ‘Swingarm pivot needle bearing Rear wheel sleeve sliding surface oa’ wheel hub Oxing Side stand pivot siding surface Clutch lever pivot sliding surface ‘Throttle pipe sliding area and cable end Footpeg pivot sliding area Goarshift pedal link sting are ‘Swingarm dust see lips Rear brake pedal siding surface Each oil seal fips Eack dust seal lips Multi-purpose grease Engine o ‘Steering bearing adjustment nut threads [pave seats Brake master piston and cups Brake caliper piston and piston seals. ‘ront brake lever pivot and piston tips Roar master eylindor boot inside and push rod tips Brake caliper slide pin surface Brake caliper dust seals si Brake lever adjuster stopper bot hreads Tocking agent Forksocket bolt threads Rear brake caliper bracket retaine joint with brecket Front brake caliper pin bolt A threads Front brake | _ Fan motor switch threa ‘Sealant Handlebar grip rubber inside Honda band Aor equivalent Forkoil seal lips | Pro Honda suspension fluid S58GENERAL INFORMATION CABLE & HARNESS ROUTING “04 modal: LEFTHANDLEBAR SWITCH ‘6P (BLACK) CONNECTOR IGNITION SWITCH 4P (NATURAL) CONNECTOR ‘COMBINATION METER 6 (WHITE) CONNECTOR FRONT TURN ~ <_ SIGNAL ~ CONNECTORS, LEFT HANDLEBAR SWITCH (LUE) CONNECTOR (BLACK) CONNECTOR RIGHT HANDLEBAR SWITCH 9P (BROWN) HEADLIGHT 2° CONNECTOR CONNECTORS ‘After “06 modal: LEFTHANDLESAR SWITCH 6° (BLACK) CONNECTOR IGNITION SWITCH 4P | = (NATURAL| CONNECTOR FRONT TURN SIGNAL CONNECTORS, ‘COMBINATION METER 6P (WHITE) CONNECTOR LEFT HANDLEBAR SWITCH 6 (BLUE) CONNECTOR RIGHT HANDLEBAR SWATCH 2° NATURAL) a {GLAGO CONNECTOR CONNECTOR f RIGHT HANOLEBAR Swarcn a C Lk. Heapuichr 26 (BROWN) CONNECTOR: CONNECTORS.GENERAL INFORMATION "04 model RIGHT HANDLEBAR, ‘SWITCH WIRE CLUTCH CABLE ‘After 04 model: ‘CLUTCH CABLE IGNITION SWITCH WIRE LEFTTURN SIGNAL wireGENERAL INFORMATIONGENERAL INFORMATIONGENERAL INFORMATION “a model:GENERAL INFORMATIONGENERAL INFORMATION “04 model: GROUND TERMINAL CHOKE CABLE IGNITION CoML PRIMARY WIRES CLUTCH CABLE PAIR [PULSE SECONDARY AIR INJECTION) CONTROL VALVE VACUUM (No. 10) HOSE MAIN WIRE HARNESS FAN MOTOR ‘TP (THROTTLE POSITION), Swrreniwne ‘SENSOR WIRE Pama ‘SUCTION HOSE SrAnTeR MOTOR FUEL VALVE VACUUM HOSE 1-2!GENERAL INFORMATION ‘After 04 model: GROUND TERMINAL cHoKecasle = GION col ‘Te (THROTTLE POSITION) ‘SENSOR WIRE JEL VAL 1-30GENERAL INFORMATION ‘pa model GROUND CABLE MAIN WIRE HARNESS ‘TP TROTTLE POSITION) ‘SENSOR WIRE STARTERMOTOR REAR BRAKE LIGHT ‘SWITCH WIRE FUELTANKDRAIN SIDE STAND SWITCH WIRE HOSE FUEL TANK BREATHER HOSE TANK BREATHER HOSE RADIATOR RESEAVE ALTERNATOR WIRE NEUTRAL SWITCH WIREGENERAL INFORMATION ‘After 04 modal GROUND CABLE ‘STARTERMOTOR CABLE TP (THROTTLE POSITION, ‘SENSOR WIRE CLUTCH CABLE MAIN WIRE HARNESS FUELTANKDAAIN HOSE REAR BRAKE LIGHT SWITCH WIRE VEHICLE SPEED SENSOR WIRE RADIATOR RESERVE ‘TANK BREATHER HOSE FUEL TANK BREATHER HOSE SIDE STAND SWITCH WIRE ALTERNATOR WIRE NEUTRAL SWITCH WIRE 1-32GENERAL INFORMATION FUEL TANK CRANKCASE BREATHERHOSE GRATER HOSE SUB AIR PAIR AIR SUCTION {No.16) HOSE OILPRESSU REARBRAKELIGHT ‘SWITCH WIRE GENERATOR WIREGENERAL INFORMATION ‘After 04 model: REAR BF ‘SWITCH WIRE IGNITION PULSE Fuetrane GENERA’ TOR WIRE BATTERY POSITIVE(+) CABLEGENERAL INFORMATION ‘STARTER MOTOR CABLE BATTERY NEGATIVE -) Cal REGULATORRECTIFER 5P CONNECTOR HOSE RADIATOR RESERVE ‘TANK BREATHER ECT SENSOR WIRE 1-35GENERAL INFORMATION PAIR AIR SUCTION (No.16) HOSES No.2 SPARK PLUG WIRE No.3 SPARK PLUG WIRE No.1 SPARK PLUG WIRE No.4 SPARK PLUG WIRE CRANKCASE BREATHER HOSE PAIR CONTROL VALVE VACUUM (No.10) HOSE PAIR AIR SUCTION (No.18) IGNITION COIL PAIRCONTROL, HOSE PRIMARY WIRES. VALVEGENERAL INFORMATION “0d model: PAIR CONTROL VALVE CLUTCH CABLE ‘VACUUM (No. 1¢) HOSE PAIR AIR SUCTION eRe (No.15) HOSE FUEL VALVE CRANKCASE VACUUM HOSE BREATHER HOSE TP (THROTTLE POSITION) ‘SENSOR WIRE CARBURETOR AIR VENT HOSE OILPRESSURE ‘SWITCH ECTSENSOR wine: IGNITION PULSE ‘GENERATOR WIRE NEUTRAL SWITCH WIRE STARTER GROUND CABLE MOTOR CABLE © VEHICLESPEED ‘SENSOR WIREGENERAL INFORMATION ‘tor oF meet: PAIR CONTROL VALVE VACUUM HOSE FUEL CUTOFF SOLENOID VACUUM HOSE PAIR AIRSUCTION cLUTCH CABLE (Nos) HOSE FUEL HOSE Was FUEL VALVE 6 VACUUM HOSE WN c \\ SH | FUEL CUTOFF SOLENOID wax = <5 suction Hose BREATHER HOSE — = teemmornérosmon! SeNSon WIRE Ve OLPRESSURE ( SWITCH > ECTSENSOR =) Ales wre ALTERNATOR WIRE XS Y IGNITION PULSE GENERATOR WIRE NEUTRAL SWITCH WIRE STARTER MOTOR CABLE VEHICLESPEED GROUND CABLE SENSOR WIRE 1-38GENERAL INFORMATION REAR TURN SIGNAL LIGHT CONNECTORS! LICENSE LIGHT CONNECTORS TAIVBRAKE LIGHT 3P. (NATURAL) CONNECTOR REAR BRAKE HOSE 1-39GENERAL INFORMATION CALIFORNIA TYPE: ‘04 model: FUEL CUTOFF SOLENOID VALVE 2P (BLACK) CONNECTOR,GENERAL INFORMATION ‘After 04 model:GENERAL INFORMATION “04 model:GENERAL INFORMATION ‘After 04 model: 1-43GENERAL INFORMATION “04 model: FUEL CUTOFF SOLENOID VALVE WaoHoees: No.6 HOSE AWAY JOINT/ No.7 HOSE No.S HOSES No.6 HOSE No.§ HOSE No HOSE No. HOSE EVAPCANISTER Nos HOSE PURGE VALVE 1-44GENERAL INFORMATION ‘After (04 model: EVAP CAV ‘CONTROL VALVE FUEL CUTOFF ‘SOLENOID VALVE 5-WAY JOINT! No. HOSES. No.7 HOSE EVAP CAV CONTROL VALVE VACUUM HOSE SWAY JOINT B 8 g 2 B g 2 No. HOSE No.4 HOSE EVAPCANISTER PURGE VALVEGENERAL INFORMATION al = ‘SUB-AIR CLEANER, = => HOUSING CRANKCASE FUEL CUTOFF SOLENOD BREATHER HOSE VALVE 2P (BLACK) CONNECTOR FUEL CUTOFF EVAPCAY SOLENOID VALVE WIREGENERAL INFORMATION 1-47GENERAL INFORMATION EMISSION CONTROL SYSTEMS ‘SOURCE OF EMISSIONS. ‘The combustion process produces oxides of nitragen, carbon monoxide and hydrocarbons, Control of oxides of nitrogen ‘and hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subject to suntight. Carbon monaxide does not react in the same way, but tis toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings ss well as other systems, to reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is oquippod with a closed crankcase system to pravent discharging crankcase emissions into the atmosphere. Blow-by gas is raturned to the combustion chamber through the alr cleaner and carburetor body. AIR CLEANER HOUSING (CARBURETOR " rear swingarm and attempting to move the swing farm sido to side, > Replace the bearings if any are looseness is noted. Check the action of the shock absorber by com- pressing it several times. ‘Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired Tighten all quts and bolts. Refor to the shock absorber service (page 15-13). NUTS, BOLTS, FASTENERS Chock that all chassis nuts and bolts are tightened totheir correct torque values (page 1-13). Check that all safety clips, hose clamps and cable ‘stays are In place and properly sscurod. 4-32MAINTENANCE WHEELS/TIRES Tee pressure should be checked whan the tes re cou. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: SRONT [REAR [Teeieag [aso aso, st | 20 vz, 42) | ‘070 zF TeO5S ZA | resize wwe |" Y7MiG (58) (73W) ErseE | — BTSs ce, [Brdaestone | aADIATN | RADIAL Mi ei ROAD'S [Pat ROADS Check the tires for cuts, embedded nails, or other damage. Check the front wheel (page 14-15) and rear whee! (page 18-6) for trueness. Measure the tread depth atthe center ofthe tires, Replace the tires when the tread depth reaches th following limits. (MINIMUM TREAD DEPTH: FRONT: 1.5 mm (0.06 in) REAR: 2.0mm (0.08in) STEERING HEAD BEARINGS Chock that the control cables do not inte handlebar rotation. ‘Support tha motorcycle using a safety stand or hoist securely and raise the front wheel off the ground. ‘Check that the handlebar moves freely from side to side, Ifthe handlebar moves unevenly, binds, or has ver- tical movement, inspact the staering head bearings Ipoge 14-41), 0 with5. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM. OIL STRAINER/PRESSURE RELIEF VALVE--5-6 ‘SERVICE INFORMATION OIL PUMP. TROUBLE SHOOTING OIL COOLER.» OIL PRESSURE INSPECTION + --re-reeoeLUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM EXHAUST CAM SHAFT INTAKE CAM SHAFT PISTON ‘CONNECTING ROD. CRANKSHAFT. — OIL. PRESSURE SWITCH O1L ORIFICE ol cooLeR MANSHAET COUNTERSHAFT Di pune ott nuTé& caRTAIDGE At RELIEF VALVE OIL STRAINER BQLUBRICATION SYSTEM SERVICE INFORMATION GENERAL Used engine oll may cause skin cancer if repeatedly leftin contact with the skin for prolonged periods, Although this is uniikely unless you handle used oil on a daily basi, iti stil advisable to thoroughly wash your hands with soap end water: ‘s00n a8 possible after handling used oil ‘When removing end Installing the ol! pump, use car + If any portion of the oll pump is worn beyond the speci * Aftur the oll pump has beon Installed, check that there are no oll leaks and that oll pressure Is correct SPECIFICATIONS re Engine oll capacity ‘After draining change ‘Recommended engine ail [Oil pressure at oil pressure switch — ‘+ The oill pump can be serviced with the engine installed in the frame. ‘The service procedures in this saction must be performed with the engine oil drained. [STANDARD fier drainingifltar | After disassembly a —_ Pro Honda GN4 or HP4 (Without = 7-490 kPa (6.0 katlem®, 77 pall at 10 allow dust or dirtto entar tne engine. 1d service limits, replace the oll pump as an assembly. Unit: mm tin} TsiiorB7US at 3.1 impql— ier (4 US at 3.3 mp at $2 liter (4 US qt Timp at = ‘molybdenum additives) 4-stroke oil or ‘equivalent motor oil API service classification SG or Higher | JASO T 903 standard: MA Viscosity: SAE 10W-40 | 6,000 mpmn/80°C/176°F) | Oil pump rotor (0.008 0.008) — 67 (0.001 - 0.003), ‘Oil pump drive sprocet collar 0.0. [Coirbup chive sprocket (0. ‘34.050 34.078 (1.3405 ~ 13475) 35.025 — 35.075 (1.3789 - 13808) TORQUE VALUES: Engine oil drain bott 29 Nem (3.0 kgf, 22 thf) Engine oil fiter eartridge 25 Nem (2.5 kgm, 1B IDF) Oil fiter boss i! pump driven sprocket bolt i! pump assembly bolt Oil cooler sealing bott Oil pressure switch Oil pressure switch terminal screw 18 Nem (18 kgf, 13 IbF) 18Nem (15 kgm, 1 bff) 78 Nom (0.80 kgtm, 5.8 bE) 49.Nem (5.0 kgm, 36 IbFft) 12.Nem (1.2 kam, 9 Ibf) 2.0 Nem (0.20 kam, 1.4 IDFA) ‘Apply oll to the threads and flange surface Apply locking agent to the threads ‘Apply locking agent to the threads CT bolt Apply locking agent to the threads Apply sealant to the threads 5-3LUBRICATION SYSTEM TOOLS ll pressure gauge Oil pressure gauge attachment ll Titer wrench (07506-30000, 07510-4220100 O7HAAPI7O101 Ss cx aqiaientcommeriaty avai. | oroquvaiontcommeriay avet- | ora7HAAPs70r00 USA. ony) | oentse thelnUSa. TROUBLE SHOOTING il level too tow * Ollconsumption * External oll leak * Worn piston rings + Improperly instal piston rings * Worn cylinders * Worn stem seals = Worn valve guide Low oil pressure Oil leval low Clogged ol! strainer Internal oil leak * Incorrect oil being used ‘No oll pressure = Olllevel tuo tow Oil pressure reliof valve stuck opan Broken oil pump drive chain Broken oil pump drive or driven sprocket Damaged oil pump Internal oi leak High ol pressure ‘Oil pressure roliot valve stuck closed Clogged oil iter, gallory or metering orifice * Incorrect oll being used i contamination ‘oF filter not changed often enough Worn piston rings it emutsifeation Blown cylinder head gasket ‘Leaky coolant passage * Entry of water 5-4LUBRICATION SYSTEM. OIL PRESSURE INSPECTION UY he ol pressure Check the ol level (page 4-14), Instr ight Sato JOP Remove the bolts and clutch cable guide, the incor sys- tem bare check ing the of pressive BOLTS Romove the rubber cap. Remove the oil pressure terminal switch serew and | RUBBER CAP terminal eyelet. Remove the oil pressure switch. < ‘lL pRessuRE TERMINALEYELET SWITCH Connect an oil pressure gauge and attachment to the oll pressure switch hole. ATTACHMENT Toots: Oi pressure gauge —-_07506-3000001 or equivatent ‘commercially available in USA Oil pressure gauge attach-07510-4220100 or ment equivalent ‘commercially available in usa ‘Warm up the engine to normal operating tempera- ‘ture (approximately 80°C/176°F) and increase the rpm to 6,000 rpm and read the oil pressure, OIL PRESSURE: ‘490 kPa (5.0 kgl/em?, 74 psi) at 6,000epm/ (eorcs176"F) ‘Stop the engine and remove the tools, r Apply 2 sealant to the oll pressure switch threads as ll, PRESSURE GAUGE Do not apply to the shot thread head 3-4mm Inetall and tighten the oil proesure switch to the (0.1-0.2 in) specified torque. ‘TORQUE: 12 Nem (1.2 kgl-m, 9 Ib¢-ft) sa OIL PRESSURE SWITCH 5LUBRICATION SYSTEM ‘Connect the oll prossure switch wire and tighten the oil pressure switch terminal screw to the specified torque. ‘TORQUE: 2.0 Nem (0.20 kgf-m, 14 IbEft) Instal the rubber cap securely, RUBBER CAP screw | <2 Oh pressure TenViNALEVeLST ~ SWITCH | Instal the clutch cable guide and tighten the bolts ine. heck tat thet pressure incestor goes ou after Sne or two sevens. the oi pressure incictor Stays on, stop the engino immediately and deter imine the cause. OIL STRAINER/PRESSURE RELIEF VALVE REMOVAL Drain the engine ol (page 4-15), Romove the exhaust pipe (page2-10). Remove the bolts and oil pan. Romove the pressure relief valve and O-ring. Fomove the oll strainer and packing. (Check the oll strainer for damage or clogging. Clean the oil strainer soreen. © OIL STRAINER/PACKINGLUBRICATION SYSTEM INSPECTION Check the operation of the prossure relief valve by pushing on the piston. Disassemble the relief valve by removing the snap fing. nd, INSTALATION Install the reliaf valve into the crankcase. Apoly fl stat Install the oil strainer into the crankcase while align- Ing its boss with the groove of the crantcase, to the new packing and install it onto the hs Pe I 5-7LUBRICATION SYSTEM ‘Clean the cil pan mating surface thoroughly. Do not apely eat Apply Three Bond 12078 or an equivalent to the: antimore then nec- mating surface. ‘ossary, Carefully instal tho ail pan onto the lower crank- caso. OIL PAN Install and tighten the bolts in crisscross pattern in 2-3steps, {nstall the exhaust pipe (page 3-10), Fi the crankeate with recommenced ol (page 4- Alter installation, check that there ara no oil leaks. OIL PUMP REMOVAL Remove the oll strainer and pressure relief vaive (page 5-6), Remove the clutch assembly (page 10-7). Remove the boltwasher, then remove the oil pump |) dhveldrven sprocket and drive chain ssn assem- i.LUBRICATION SYSTEM the drive sprocket collar trom. the Remove the bolts and oll pump assembly. DISASSEMBLY Remove the oll pump assembly bolt, Remove the oil pump cover and dowel pin, DOWEL PIN lL PUMP CovERLUBRICATION SYSTEM Remove the thrust washer, drive pin, oll pump shaft, outer rotor and inner rotor from the ofl pump, body. ‘OUTER ROTOR INNER ROTOR ‘lt PUMP SHAFT WASHER INSPECTION \¥anysorton ef te Temporarily install the oil pump shaft. ‘al/pump is wom Install the outer and inner rotors into the oll pump TIP CLEARANCE: beyerd the service body. fmt molsco te oi ape Measure the rotor tip clearance. by. SERVICE LIMIT: 0.20 mm (0,008 in} Measure the pump body clearence. ‘SERVICE LIMIT; 0.35 mm (0.016 in) BODY CLEARANCE: Measure the side clearance using a straight edge and fesler gauge SIDE CLEARANCE: ‘SERVICE LIMIT: 0.10 mn (0.004 in}LUBRICATION SYSTEM ‘Measure the oll pump drve sprocket collar 0.0. [SERVICE LIME 34.03 mm (1.240 in) Messure the oil pump drive sprocket LD, ‘SERVICE LIME: 35.10 mm (1382 in) Lo DAIVE SPROCKET DRIVEN SPROCKET ASSEMBLY INNER ROTOR cit puve oor aver oi pune seer fa bower = G urea roron INNER ROTOR: ea onwve i wasn OILPUMPCOVER 7.8 Nim (0.80 kgm, 5.8 Ibi Insta the outer rotor into the ell pump body. Install the inner rotor into the outer rotor {drive pin groove facing the oll pump cover. ith its INNER ROTOR ‘OUTER ROTOR @ oil PUMP BODY - j 5-11LUBRICATION SYSTEM Install the oll pump shaft through the Inner rotor bed pump body " oureR ROTOR INNER ROTOR Install the drive pin into the hole in the pump shaft 8rd align se pin with the groove inthe nner rotor eahown. Install the thrust washer. IVE FIN OIL PUMP SHAFT WASHER Install the dowel pin. Install the oll pump cover. DOWEL PIN 1 PUMP CovER Install and tighten the bolt to the specified torque, TORQUE: 78 Ne (0.80 kgfim, 5.8 tot) Check the oil pump operation by turning the pump shat. ASSEMBLY BOLT necessary, reassemble the oil pump. INSTALLATION {Install the oll pump onto the crenkcase while al ing the pump shaft lug with the water pump shaft froove by turning the oil pumpahatt.LUBRICATION SYSTEM Align th tat sur faces ofthe dian sprocket with tha i pura dive shaft nd, Install and tighten the bolts securely. Apply oll to the drive sprocket and drive chain. ie the dete sarc nd te cots 7 ‘an assembly with the “OUT* mark on the driven ‘sprocket fecing out, ‘Apply a locking agent to the oil pump: driven sprocket bolt threads. Install and tighten the driven sprocket bolt/washer to the opocified torqu TORQUE: 15 Nem (1.5 kgtm, 11 loft) {stall the clutch assembly (page 10-12) After installation, fill the crankcase with recom~ ‘mended oil and check thet there is no oll leaks. ‘Check the oil pressure (page 6-8). Ayam sourwasien 5-13LUBRICATION SYSTEM OIL COOLER REMOVAL Remove the exhaust pipe (page 3-10). Drain the engine oll and remove the oll fiter car- wide (page 4-18) Drain the coolart from the system (page 7-7). ‘ooler watar hose fram the cooler. Remove the bolts andi oll cooler. Remove the joint collars/O-rings from the crank case, Remove the O-ring from the all cooler. O-RING lL COOLER.LUBRICATION SYSTEM DISASSEMBLY Remove the oll cooler cover bolts and sealing washer. OIL COOLER COVERIO-RING BOLT Remove the oll cooler cover and O-ring fs Remove the bolts, washers aid ail cooler. ‘ol COOLER BOLTSWASHERS, Remove the O-rings and joint collars from the oil coolar base, O-RINGSUOINT COLLARS, OIL COOLER BASELUBRICATION SYSTEM. ASSEMBLY OL COOLER BASE lL cooLER ® onns Ol COOLER COVER JOINT COLLAR, PB BWoans Install the joint collars into the oil cooler base holes. Aoply clean engine oil tothe new O-rings and install, eh TB osiesuomr couuars ‘them into the ail cooter base. lL COOLER BASE Install the oll cooler with ite arrow mark facing down. Install the washers and bolts, ten tighten the bolts securely. OL COOLER ‘ARROW MARK BOLTSWASHERS 5-16LUBRICATION SYSTEM Instal a new O-ring to the oll cooler case groove. lL COOLER COVER Assemble the oll cooler case and base, then install ‘the seating washer and bolts. Ol COOLER COVER BOLT Tighten the bolts securely. BOLT/SEALING WASHER —_ INSTALLATION Install a new O-ring into the groove of the oil cooler base. Apply clean engine oil to the new O-rings, and Install them onto the joint collars. Install tha joint collars to the crankcase with its large OD. side facing the cranicase. 5-17LUBRICATION SYSTEM {natall the oll cooler essembly onto the erankease. Install and tightan the oll cooler assembly mounting bolts Connect the water hose to the oil cooler and tighten the band screw securely. 3-10). ‘and fill he crankcase with recommended oll (page 4-15), Fill the cooling system and bleed air (page 7-7). BAND SCREWCOMPONENT LOCATION - ‘SERVICE INFORMATION -- TROUBLESHOOTING AIR CLEANER HOUSING CARBURETOR REMOVAL. 6-10 CARBURETOR SEPARATION -- 612 CARBURETOR DISASSEMBLY. 615 CARBURETOR ASSEMBLY-» 6-20 6. FUEL SYSTEM CARBURETOR COMBINATION CARBURETOR INSTALLATION. PILOT SCREW ADJUSTMENT: HIGH ALTITUDE ADJUSTMENT ‘SECONDARY AIR SUPPLY SYSTEM EVAPORATIVE EMISSION CONTROL ‘SYSTEM (California type only) ~~ FUEL VALVE-~FUEL SYSTEM COMPONENT LOCATION “04 mode!:FUEL SYSTEM ‘After 04 modal: California type: California type:FUEL SYSTEM SERVICE INFORMATION GENERAL * Bending or twisting the contro! cables will impair smooth operation and could causa the cables to stick or bind, result- ing in loss of vehicie control, © Work in a well ventilated arse, Smoking or allowing flames or sparks in the work area or where gasoline is stored can * Seal the cylinder bead intake ports with tape ora clean cloth to keep dirt and debris from entering the intake ports after the carburetor has been removed. * Be sure to remove the diaphragms before cles be damaged. * Before disassembling carburetor, pla drain the carburetor. + The vacuum chamber and float chamber can be serviced with the carburetors assembled. ‘= When disassembling fuel system parts, note the location of the O-rings. Replace them with new ones on reassembly. * Ifthe vehicle is to be stored for more than one month, drain the float bowls may cause clogged lets rosulting in hard starting or poor driveability. * Refer to procedures for fuel reserve sensor inspection (page 20-23). Rofer to procedures for fuel tank removal and installation (page 3-8 * All hoses used in the secondary air supply and evaporative emission control system (California type enly) are num- ‘bored for identification, When connecting one of these hoses, compare the hose number with the Vacuum Hose Rout- ing Diagram Label on frame or page 1-52, for its proper routing. ‘The cerburetor hotes routing for afar ‘04 modal ara differant from for ‘04 model, The removaliinstallation procedures for 04 model are described in this section basically, refer to the cable and harness routing when removing/installing the carburetor for after ‘04 model. ing ‘and fuel pessages with compressed air. The diaphragms might the suitable container under the carburetor drain hose. Loosen the bolt and SPECIFICATIONS rem Carbirior WanWcaiion number foe model) ae ‘Carburetor anicaion number —| Except Cae nia aa — {ater'04 model) [Ceattorns ype] Maier ‘Slow jet Jet noe Piloteerow 1 page Float level 13.7 mm (0.54 in} iia ~ T 1,400 = 100 rpm Tiras grip ee py F=6 mmm WIG= aa] Carburer vasa 2B mmHg (1.2 1 (eeseaton Ne Searbsrator TORQUE VALUES Inula Bi han ‘Soa page 6.24 Carburetor drain screw T8Nm (078k, 1 Io) Staring enrichment (SE) valve arm screw 8 Nem (O.1@kghim, 13 bt) Starting enrichment (SE) valve nut 1.8 Norm (0.18 kgfm, 1.3 bff) Vacuum chamber cover sorow 24 Nan 0.21 kgf, 18th) Airfare holder ecto 2:1 Nem (0.21 gt, 15 ot) Foncunier een Bani (Oa8kghm 2 oF n) ‘Tote cable nolderserow 3.4 Nm (0.35ghm, 25 bt) ‘Thott postion TP sensor bracket screw 3.41Nm(0.38kghm, 25 bt) Carburetor connecting nut rm 5.1 Nim (O.52kgfm, 38 Ibe) Carburetor connecting nut, 6 mm 10. Nem (1.0 kgf-m, 7 Ibf-ft)FUEL SYSTEM. TOOLS | Cerburetor fost level gouge ‘o7401-00%0000 “Pilot serew wrench O7KMA-MINSOTDI or O7MMA-MT30108 (U.S.A. only) or O7MMA-MT3O10A (U.S.A, only) or O7PMW.MZz0114,FUEL SYSTEM TROUBLESHOOTING 6-6 Engine won't start ‘Intake air leak ‘+ Fuel contaminatedideteriorated ‘+ No fue! to the carburetor ~ Fuel strainer clogged ~ Fuel hose cogged = Fuel vacuum hose clogged = Disconnected fuel valve vacuum hose = Float level misagjusted = Fuel tank breather hose clogged ‘Lean fuel mixture * Fuel jets clogged ‘ Float valve faulty ‘Float level too low + Fuel line restricted * Carburetor alt vent hose clogged. * take air te Throttle valve faulty ‘+ Vecuum piston faulty Rich fuel mixture * Starting enrichment valve ON position, * Float valve faulty * Float level too high Air jets clogged Air cleaner element contaminated * Flooded carburetor Engine stalis, hard to start, rough idling * Ful ine restricted ignition malfunction “uel mixture too leanvrich Fuel contaminated/deteriorated Intake air leak Idle spood misadjusted Float level misadjusted Ful tank breathor hose clogged Pilot sorew misadjusted Slow circuit or starting enrichment circuit clogged + Emission control system malfunction ‘Aftarburn during engine braking is used * Lean mixture in slow circuit * Air cutotf valve malfunction ‘+ Emission conirol system is malfunction = Secondary air supply system faulty = Loose, disconnected or deteriorated hose of the emission control system oF misfiring during acceleration * Ignition system matfunction ‘= Fuol mixture too lean Poor performance (driveabillty| and poor fuel econ- omy * Fuel system clogged * Ignition system matfunction + Emission control system is malfunction = Secondary sir supply system faulty = Loose, disconnected or deteriorated have of the emission control systemFUEL SYSTEM AIR CLEANER HOUSING REMOVAL Remove the following: ~ Fuel tank {page 3-6) = Air cleaner element {page 4-6) ~ Battory (pege 17-6) Disconnect the TP (Throttle position) sensor 3P con- nector, ‘3P CONNECTOR Remove the sub-air cleaner housing clamp screw. Disconnect the crankcase breather hose from the air leaner housing. Castornia yoo Disconnect the No.7 hose from the sub-air cleaner ‘ony housing and remove the sub-air cleaner housing. SUBAIRCLEANER HousiN ee a) Disconnect the PAIR (Pulse secondary sir injection) air suction hose from the air cleaner housing.FUEL SYSTEM. Loosen screws, Remove the alr cleaner housing mounting bolt. Remove the air eleaner housing out of the frame to the lot side. INSTALLATION Install the air cleaner housing into the frame from the left side.FUEL SYSTEM ‘Adjust the carburetor connecting boot band angie ‘5 shown. AND SCREWS 121mm (0.40.08 in) Install and tighten the air ok bolt. 1 housing mounting Connect the PAIR air suction hose to the air cleaner housing.FUEL SYSTEM. ‘Connect the crankcase. breath leaner housing. Caitomia tye ony; Connect the No.7 hose to the sub-air cleaner hous- ing and install the sub-air cleaner housing. hose to the air ‘SUB-AR CLEANER HOUSING Clean the sub-air cleaner element. Install the subalr cleaner housing clamp and tighten the scrow securely. ‘ (eae nouene Connect the TP (Throttle postion) sensor 3° con- netor. Install the following: CARBURETOR REMOVAL Remove the following: Air cleanor housing (nage 67) EVAP CAV control valve (page 6-41) Fuol cutoff solenoid valve (page 6-42) Remove the heat guard rubber.FUEL SYSTEM onsen the carburetor crain screws and catch the fuel with approved gasoline container. Caitornie ype oni Disconnect the No.5 and No.11 hoses from the EVAP canister purge valve. Loosen the carburetor side insulator band screws. Remove the carburetor assembly from the insula- tors. Remove the throttle cables fram the cable holder and disconnect the throttle cables from the throttle drum. 6-11FUEL SYSTEM. ‘Sei the oyinder Disconnect the choke cable from the carburetor. nea intske pots th ape or 9 caan ‘bth to kage are ‘and debris fom cnterng the intake pevtsafer ine car butetor assembly hs been removed. ‘Aftar removing carburetor assembly, do not place it tp side down orthe air intake might be deformed. CARBURETOR SEPARATION + The vacuum chambar serviced without sepa Disconnect the fuel hase from the fuel joint. Disconnect the sub-air cleaner hose from the fuel joints. Disconnect the joints. vent hoses from the air vent AIR VENT HOSES, Calorie ype only: Disconnect the No.6 hoses/S-way joint/3-way joint from the carburetor followin = Disconnect the to No.1 and Nod carburetors hoses from carburetor hose joints. ~ Disconnect the to No.2 carburetor hose from the ‘B.way Joint. = Disconnect the to No.3 carburetor hose from the B-way joint. Disconnect the No.11 hose (to the EVAP canister purge valve) from No.3 carburetor. SWAY JOINT SANAY JOINT 6-12FUEL SYSTEM “Atter‘04 madel Disconnect the PAIR contro! valve vacuum hose 2 from the No.1 carburetor, Disconnect the fuel valve vacuum hose from the No.3 carburetor. FUEL VALVE VACUUM HOSE Remove the starting enrichment (SE) vaive arm ‘screws, washers and spring, Romove the SE valve arm and plastic collars. Loosen the ruts Loosen and remove the carburetor connecting & racy aod acer mm nut and 6 mm nut. nei, Separate the No.3/4 carburetors from the No.t/2 carburetors. AIR JOINT PIPE DOWEL PIN (5 mm) Remove the following: No.2 cerburetor synchronization spring Sway cir joint pipe/O-~ings Dowel pin (5 mm bolt side) Dowel pin (6 mm bolt side) sea DOWEL PN TE)FUEL SYSTEM ‘Separate the No.1 carburetor from the No.2 carbu- retor. Remove the following: ‘No.1 carburetor synchronizstion spring ‘Thrust spring Air joint rubbar pipe ‘Seway air vert joint pipe/O-rings ‘way fuel joint pipe/O-rings Dowel pin (6 mm bolt side) Dowel pin (6 mm bolt side) Remove the screw and TP (Throttle position} sensor from the No.1 carburetor, Do notcfsassere the TP sensor or more Caitome rype oy; Disconnect the No.5 hose from the No.2 carburetor hose joint. ‘Separate the No.3 carburetor from the No.4 carbu- retor. Remove the following: ‘Choke cable holder No.4 carburetor synchronization spring Thrust spring Air joint rubber pipe -way air vent joint pipe/O-1inas Sway fuel joint pipe/O-rings Dowel pin (5 mm bolt side) = Dowel pin (6 mm bolt side) AIR VENT JOINT PPE DOWEL PIN (5 mm) Caer ee FUEL JOINT PIPE _ THRUST ir ae DOWELPIN ‘SPRING = (6mm) Soe SS raleon ee No.2 CARBURETOR AIR VENT JOINT PPE DOWELPIN (5 mm) FUELJOINT PIPE RUBBER PIPE THRUST SPRING DOWELPIN + (6mm) SPRING © * CABLE HOLDERFUEL SYSTEM. ‘04 Catfors ype Disconnect the No.5 hoss from the No carburetor and ster 04 model hose joint. onW No.3 CARBURETOR Remove the screws and throttle cable holder from CABLE HOLDER the No.3 carburetor. No.3 CARBURETOR CARBURETOR DISASSEMBLY AIR FUNNEL Not the ocavon of Remove the scraws and alr funnel holder. ‘ch exrbuoty part ‘20 thy car bo roplacod in oir ‘oreinal locate, screws Remove the air funnel from the holder. Remove the O-ring from the carburetor body. ‘AIR FUNNEL,FUEL SYSTEM ‘SE (STARTING ENRICHMENT) VALVE Remove the SE valve nut. SE VALVE NUT Remove the SE valve and spring, SPRING DIAPHRAGM/VACUUM PISTON Remove the screws and vacuum chamber cover. VACUUM CHAMBER COVER Remove the dischraam spring and diaphream/vec- ‘uum piston from the carburetor body. SPRING DIAPHRAGMIVACUUM PISTON | —_FUEL SYSTEM Temporarily install a 4 mm seraw (example; vac- uum chamber screw) into the jot needle hol JET NEEDLE HOLDER Pull the screw and remove the jet needle holder. + Be careful not to damage the diaphragm. + Do not remove the jet needie holder by pushing the jot nose. Remove the spring, jet needle and washer from the vacuum piston. WASHER SPRING FLOAT AND JETS ‘Remove the screws and flost chamber/O-ring. FLOAT CHAMBER/O-RING Remove the float pin, flast and float valve. {Ingpect the float for deformation or damage,FUEL SYSTEM. Damage tothe plot ‘Soro sat wil cca the aioe scrowis tightened ‘oaiast the sect Inspect the Moot valve seat for scores, scratches, clogging and damage, Check the tip of the float valve where it contacts the vvaive seat for stepped wear or contamination. Replace the valve ifthe tip s worn or contaminated. Check the operation of the float val Remove the following: ~ Main jet = Needle jot holder = Slow jet ‘Turn the pilot screw in and record the number of tums it takes before it seats lightly. Alemove the pilot screw, spring, washer and O-ring. Toot: Pilot serew —07KMA-MN90100 or ‘wrench OIPMAMZ2011A oF = O7MMA-MT30108 (U.S.A. only) or “we. A OIMMA-MT30108 (U.S.A. only) PILOT SCREWSSPRING WASHER RING pect the each jet for woar or damage and reploco voresson eane ree PLOT SCREWISPRINGWASHERO-RING Pay ~ SLOW JET x ~ [NEEDLE JET HOLDER MAIN eT AIR CUT-OFF VALVE (Except 04 California type and after ‘04 model) Disconnect the ai cut-off valve hose, Romove the alr cutoff valve screw. Alf CUT-OFF VALVE TFUEL SYSTEM Remove the air cut-off valve, air jet and O-rings. AIR CUT-OFF VALVE AIR JET Blow open each alr and fuel passages in the carbu- retor body with compressed air,FUEL SYSTEM CARBURETOR ASSEMBLY 7a 2.1. Nem (0.21 kgf, 1.6 tbfft) JET NEEDLE HOLDER Nag JET NEEDLE VACUUM CHAMBER COVER 1.8 Nem (0.18 kgf, 1.2 Ibe) DIAPHRAGM/VACUUM PISTON ‘SPRING ¢— Hower “D+ — 3.4 Nim (0.95 kati, 2.5 IDFA) a 2 ae PILOT SCREW Sty srowser ‘AIR CUT-OFF VALVE (Except “04 California type and after “04 model) AIR JET (Except’04 Califomia type ‘and after ‘04 mods!) | Roar, ——— AIR FUNNEL { x \ sf FLOAT 1, g ‘AIR FUNNEL HOLDER FLOAT VALVE 2.1. Nem (0.21 kgm, 1.6 IbEft) @ 34 Nm 1038 kghm, 25ibh) FLOAT CHAMBER AIR CUT-OFF VALVE (Except ‘04 California type and after 04 model) Install the O-ring onto the air jetand air cutoff valve asshown. AIR CUT-OFF VALVE AIRJET Install the alr jet with its smell end fecing the alr cut- fe off valve. O-RINGSHand a ots wien ira They can = “ipbe sored or seatchod FUEL SYSTEM ir ot and air ext-off valve onto the carbu- ‘ator body. Install and tighten the screw securely. Connect the air cut off valve hose. FLOAT AND JETS Install the following: ~ Stow jet = Neodie jet holder = Main jet sLow Jer NEEDLE JET HOLDER Maine Mee eee atnaremocan °°" °F sain JETINEEDLE JET HOLDER Toot: Plotscrew —7KMALMNO10 or Gronks” SrpMaMaanrin or O7MMA-MT3010B (U.S.A. only} or O7MMA-MT3010A (U.S.A. only) Perform the pilot screw adjustment procedure (page 6-36) if a new pilot screws installed. Install the float and float valve in the carburetor ‘body, then install the flost pin through the body and ‘oat. 6-21FUEL SYSTEM FLOAT LEVEL INSPECTION With the fioat valve seated and the float arm just touching the valve, measure the float level with the special tool as shown. FLOAT LEVEL: 13:7 mm (0.54 in) Tool: Carburetor float level gauge 07401-01000 The float cannot be adjusted. Replace the float assembly ifthe float level is out of specification, FLOAT LEVEL GAUGE Install 8 new O-ring in the float chamber. Install the flost chamber. Install and tighten the flost chamber screws to the specified torque. SCREWS: TORQUE: 3.4 Nem (0.35 kgfm, 25 lb-ft) DIAPHRAGM/VACUUM PISTON Check the condition of the O-ring on the jot needa holder, replace if necessary. ‘VACUUM PISTON, JET NEEDLE Apply oil to the O-ring. Install the washer and jet needie holder and spring ito the vacuum piston. 7a Pras the jet needle holder into the vacuum piston O-RING LUnUL you fect @ click indicating that the O-ring {9 seated into the groove in the vacuum piston. + WasHEA SPRING 6-22FUEL SYSTEM De not inch the daptrag under ‘the chamber cover Install the dlaphragmivacuum piston In the carbure- tor body, aligning the diaphragm tab with the ‘groove of the carburetor body. Hold the vacuum piston almost full open so the dia- phragm isnot pinched by the chamber cover. Install the chamber cover with the spring, ‘careful notte damage the spring. SPRING Align Install and tighten the vacuum chamber cover ‘screws to the specified torque. VACUUM CHAMBER COVER TORQUE: 2,1 Nem (0.21 kafien, 1. ttt) SE (STARTING ENRICHMENT) VALVE Install the spring and SE (Starting enrichment) Install and tighten the SE valve nut to the specified torque. TORQUE: 1.8 Nem (0.18 kgf-m, 1.3 tot)FUEL SYSTEM ‘AIR FUNNEL, Install the air funnel Into the holder as shown. ‘AIR FUNNEL AIR FUNNEL HOLDER Chock that the O-ring is in good condition, replace if necessary. Install the O-ring into the groove of the carburetor body, ‘Align the cut-out on the air funnel with the graove in ‘the carburetor body, then install the air tunnel/ holder. Install and tighten the air funnel holder screws to the specified torque, AIR FUNNEL HOLDER, ‘TORQUE: 2.1 Nom (0.21 kgf-m, 15 tht) screws 6-24FUEL SYSTEM CARBURETOR COMBINATION Always replace the O-ring with new ones. EXCEPT CALIFORNIA TYPE: “0 model shown: ‘8mm NUT ‘Simm NUT AIR VENTHOSES: No: CARBURETOR ‘SUB-AIR CLEANER, 3a SS No CARBURETOR SE VALVE ARM, No.1 CARBURETOR 5.1 Nem (0.52 kgf, 3.8 Ibf-t) 10 Nem (1.0 kgfim, 7 Ibi) woeiZee 3.4 Nem (0.35 kafim, 2.5 Ibf ft) ‘TP SENSOR/BRACKET 6-25FUEL SYSTEM CALIFORNIA TYPE: “04 model shows: 6mm NUT 5mm NUT AIR VENT HOSES. No4 CARBURETOR ‘SUB-AIR CLEANER <4) ass Lenmioseictn S Stor No CARBURETOR Ss. ‘SE VALVE ARM Pe eanoureron No2 caRBneroA 5.1 Nim (0.52 kom, 3.8 bit) 10. Nem (1,0 tg, 7 bff) FUEL HOSES ‘TP SENSOR/BRACKET 3.4Nm (0.35 kgfim, 2.5 tbh)FUEL SYSTEM Install the throttle cable holder to the No.3 carbure- 1oF and tighten the screws to the specified torque. CABLE HOLDER No.3 CARBURETOR TORQUE: 3.4 N-m (0.35 igf:m, 2.5 Ibtt) ‘04 Calforis ype Connect the No.6 hose to the No.3 carburetor hose ‘ad ster 05 made! joint, on Install the following: ‘Dowel pin (6 mm boit sic AIR VENTJOINT PIPE DOWEL PIN (5 mm) = Dowel pin (6 mm bolt side) lia = S+way jue! joint pipelnew O-rings RUBBER PIPE FUEL JOINT PIPE = 3.way alr vent joint pipe/new O-rings = Airjoint rubber pipe = Thrustspeing THRUST = No.4 carburetor synchronization spring SPRING = Choke esbie holder > ‘Assemble the No.3 and No.4 carburetors. ‘DOWEL FIN | == mm) SPRING 7 > ——~ caste Houer Coltomie ype en Connect the No\$ hose to the No.2 carburetor hose joint, No.2 CARBURETOR No.5 HOSEFUEL SYSTEM. Install the TP (Throttle position) senson/bracket aligning its groove with the lug of the thrattle shaft. ‘TP SENSORBRACKET Install and tighten the screw to the specified torque. No.1 CARBURETOR. TORQUE: 3.4 Nom (0.35 kgfim, 2.5 Ibfft) 5 TPSENSORIBRACKET SCREW Install the following: ~ Dowel pin (5 mm bolt side) Dowel pin (6 mm bol side) vay fuel jot pipefnew Cringe ‘3-way air vont joint pipelnew O-rings Air joint rubber pipe eer ‘Thrust spring No.1 carburetor synchronization spring ‘Choke cable holder ‘Assemble the No.1 and No.2 carburetors, AIRVENTJOINTPIPE — DOWELPIN (5 mm) FUEL JOINT PIPE THRUST SPRING DOWELPIN ‘SPRING bem: (6mm) Install the following: = Nou? carburetor synchronization epring AIR JOINT PIPE DOWEL PIN (5 mm) = Sway sir joint pipe/O-rings = Dowel pin (S mmm bolt sida) = Dowal pin (6 mm bolt side) ‘Assemble the No.3/4 carburetors from the No.W/2 ‘carburetors. Bs ? DOWEL PIN (6 mm) 6-28FUEL SYSTEM {Install the 6 mm and & mm carburetor connecting bolts through the carburetors. Check there is no clearance between each of the car~ buretor joints. 0-3mm (0-0. in) Tighten each connecting nuts gradually and alter nately, be sure the bolt thread projections are equal height, Hold the nut and tighten the nut on other side to the specified torque, ‘TORQUE: 5 mm nut: §.1 Nem (052kg-m, 3.8 Ibf-f) ‘Gmm nut: 10 Nem (1.0 kgf, 7 Ibe) Install the spring to the No.2 carburetor body. Install the plastic collars onto the No.2 end No.4 car- buretor bedies. Install the SE valve arm aligning its ends with the SE mye valve heads. Align the spring hook to the SE valve arm hook, 6-2!FUEL SYSTEM Install the plastie washers and tighten the SE valve ‘arm screws to the specified torque. SCREWS TORQUE: 1.8 Nem (0.18 kgfm, 1.3 bE) ‘Ater'04 mode! Connect the PAIR control valve vacuum hose from oni the No.1 carburetor. Connect the fuel valve vacuum hose fram the No.3 carburetor. PAIR CONTROL VALVE VACUUM HOSE Colonia rye onl’ Connect the No.S hosesi6-way joint/3-way joint ‘rom the carburetor following: ‘S.WAY JOINT SAWAY JOINT = Disconnect the to No.1 and No.# carburetors hoses from carburetor hose joints, ~ Disconnect the 16 No.2 carburetor hose from the Sway joint. ~ Disconnect the 10 No.3 carburetor hose from the Sewey joint. Connect the No.1 hose (to the EVAP esnister purge Valve} from No.3 carburator. Connect the relevant hoses to the air vent joints, ‘AIR VENT HOSES. 6-30FUEL SYSTEM ‘Connect the fuel hose to the fuel joi ‘Connect the sub-sir clearer hose to the fuel joints, SUB-AIR CLEANER HOSE. im ‘ 7° FUEL HOSE 6-31FUEL SYSTEM. CARBURETOR HOSE ROUTING (04 MODEL, EXCEPT CALIFORNIA TYPE)FUEL SYSTEM CARBURETOR HOSE ROUTING (‘04 MODEL, CALIFORNIA TYPE) 6-33FUEL SYSTEM CARBURETOR INSTALLATION ‘Connect the choke cable end to the end to the start- ing enrichment valve arm. Connect the throttle cable end to the throttle drum. and install the throttle cablas on to the cable haldar. Cost the inside of the carburetor insulators with clean engine ail for ease of installation. Install the cerburstor assembly onto the carburetor Insulators. “04 model: Adjust the carburetor insulator band angle as ‘shown, After’# modol- Adjust the carburetor Insulator band angle 3 ‘shown. 6-34FUEL SYSTEM. Tighten the connecting boot band screws so that the band ends clearance is 10:4 1 mn (0.4 0.04 in}. 10£1mm (0.4 £0.06 in) Caifomia ype-oay’ Connect the No.5 ard No.11 hoses to the EVAP can- ister purge valve. Remove the heat guard rubber. Ingtall the following: — Fuel cutoff solenoid valve (page 6-42) = EVAP CAV control valve (page 6-41) = Alreleaner housing (page 6-7) Porform following inspections and adjustmants ~ Throttle operation (page 4-5) = Carburetor choke (pace 4-6) = Garburetor synchronization (page 4-17) = Engine idle speed (page 421), = Pilot screw (page 6-35), PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE ‘+ Mako sure the carburetor synchronization is Within specification before pilot serew adjust- ment (page 4-17), ‘+ The pilot screw are factory pre-set. Adjustment is hot necessary uniess the earburetors are aver. hauled or new pilot screws are installed. ‘+ Use a tachometer with graduations of 50 epm or ler that will accurately indicate 60 rpm 98.FUEL SYSTEM ‘Bariage tothe pot sew S0et vill cure plot sorewvis tightened ‘guise thé seat 1. Turn each pilot screws clockwise until it seats Tightly, then back it out the specified number of turn, This I an |nitial setting prior to the final pilot screw adjustment. TOOL: Pilot sorew G7KMA-MIN90101 or wrnch G7PMA-MZZ0T1A or ‘O7MMA-MT30108 (U.S.A. only) or ‘O7MMA-MT3010A (U.S.A. only) INTIAL OPENING: 2.3/8 tums out 2, Warm up the engine to operating temperature and ride the motorcycle fer approximately 10 minutes. 3. Stop the engine and connect # tachometer according tothe tachometer manufacture’s instruction, 4, Start the engive and adjust the idle speod with the throttle step screw. IDLE SPEED: 1,400 + 100 mpm ‘5. Turn the No.3 pilot screw in or out slowly 10 obtain the highest engine speed, 6, Perform step § for ail carburetor pilot screws. 7. Lightly open the throttle 2 - 3 times, adjust the {dle speed withthe throttle stop screw. 8, Turn the No.3 carburetor pilot screw in gradually Lunt the engine epaed drape 50 rpm. 8, Turn the No.3 pilot scrow out to the final opening from the position in step 8. FINAL OPENING: 7/8 tum out 1OAdjust the icle speed with the throttle stop 11.Perform step 8,9 and 10 for the No.1, 2.and4 car- ‘buretor pilot screws. HIGH ALTITUDE ADJUSTMENT These ecsstments rmustbe made at high ata 10 ensure proper high slits operation. When the vehicis is to be operated continuously above 2,000 meters (6,500 feet), the carburetor must bbo readjusted as described ‘below to improve riveabllity and decrease exhaust emissions. Warm up the engine to operating temperature and ‘ide the motorcycle for approximately 10 minutes, Tu each pilot screw to the high at specified below. tude setting Toot: Pilot serew —O7KMA-MN9O101 oF wrench OJPMAMZZO11A or (O7MMA-MT30108 (U.S.A. only) or O7MMA-MT3O10A (U.S.A. only) HIGH ALTITUDE SETTING: 1/2tum in PILOT SCREW WRENCH PILOT SCREWFUEL SYSTEM ‘Adjust the idle spaed ta the specified rpm with the throttle stop screw. IDLE SPEED: 1,400 + 100spm Remove the fuel tank (page 3-8). Dorotatach he Attach a Vehicle Emission Control Information Iabel t=eny ert Update Label on the frame as shown. NOTICE ‘Sustained operation at an altitude lower than 1,500 'm (6,000 foet) with the carburetor adjusted for high altitude settings may cause the engine to idle roughly and stalin trafic. may also cause engine damage due to overheating. When the vehicle is 10 be operated continuousty below 1,500 meters (6,000 fest), turn each pilot screw to be low altitude setting specified below (its original position) LOW ALTITUDE SETTING: 1/2 tum out ‘Aaiust the idle speed to the spacitied rpm (1,400 + 100 rpm). Be sure todo these adjustments at low altitude with the engine at normal operating temperature. Romove tha Vehicle Emission Control Information Update Labal that ie attached on the frame after ‘adjusting for low altitude SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm It up to normal operating temperature, Romove the air clesner element (page 46). Disconnect the PAIR alr suction hose. Check that the PAIR air suction hose port is clean and free carbon deposits, lf the port is carbon fouled, check the PAIR control valve. ~ THROTTLE STOP SCREW UPDATE LABELFUEL SYSTEM "8 mode ony: Aber 84 ee) conv (mec only ‘Afor ‘08 meet nh Disconnect the sir cleaner housing to-PAIR control valve hese (No.15) from the air leaner housing. Disconnect the PAIR control valve vacuum hose {No.10} from the control valve and plug itto keep air from entering. Disconnect the PAIR control valve vacuurn hose ‘rom the No.1 carburetor and plug it to keep air from entering. Connect the vacuum pump to the PAIR control valve. TooL: ‘Vacuum pump Start the engine and open the throtle slightly to be ‘certain that ar is sucked in through the No.15 hose. ifthe air is not drawn in, check the No.15 hose for etogaing. With the engine running, gradually apply vacuum to PAIR control valve. Chock thatthe air intake port stops drawing ar, and that the vacuum does not bise ‘SPECIFIED VACUUM: 40:mm Hig the aic drawn in oF ifthe specified vacuum id not ‘maintained, natal a new PAIR control valve. ifafterburn occurs on deceleration, even wien the secondary air supply system isnormal, checkthe air cutoff valve. PAIR CONTROL VALVE REMOVAL/ INSTALLATION Remove the fuel tank (page 3-8). Remove the ignition coil (page 18-10), Disconnect PAIR control valve-to-air cleaner haus- Ing hose (No.15), Commercially avaitable Disconnect PAIR control vaive-to-cylinder head hhose (No.16). Disconnect PAIR control valve-to-3-way (No.10}. Disconnect PAIR control valve vacuum hose from ‘tha No.1 carburetor. Remove the PAIR control vale. Installation isin he reverse order of removal hose VACUUM PUMP No.1 HOSE PAIR CONTROL VALVE No.0 HOSEFUEL SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) * Refer to hosing diagram on page 1-40 for the hhose connection. EVAPORATIVE EMISSION (EVAP) CANISTER REMOVAL/INSTALLATION Disconnect the EVAP purge control valve-to-canister hhose (No.4). BOLTWWASHER Disconnect the fuel tank-to-Canister hose (No.1). Diesonnoet the Canisterto-open air hose (No.2). Romove the bolts, washers and EVAP canister. Installation isin the reverse order of removs ‘No.2 HOSE EVAP CANISTER EVAPORATIVE EMISSION (EVAP) PURGE CONTROL VALVE REMOVAL/INSTALLATION Remove the alr cleaner housing (page 67) Py Romove the starter motor cable (page 19-8), Disconnect the carburetor-to-EVAP purge control valve hose (No.11). Disconnect the § way joint-to-EVAP purge control valve hase (No.8) Disconnect the EVAP eanister-to-EVAP purge con- ‘trol valve hose (No.4). Remove the EVAP purge control valve. Installation isin the reverse order of removal. ke \P PURGE CONTROL VALVE orFUEL SYSTEM. INSPECTION The EVAP purge control valve should be Inspected it hot start is difficult Remove the EVAP purge control valve (page 6-38). Connect a vacuum pump to the No. hose fiting (output pont} that goes to the § way joint. Apply the specified vacuum fo the EVAP purge control valve. ‘ooL: ‘Vacuum pump Commercially available ‘SPECIFIED VACUUM: 250 mmHg ‘The specified vacuum should be maintained. Replace the EVAP purge control valve if vacuum is ‘ot maintained. Remove the vacuum pump end connect it to the No.7 hose fitting (vacuum port) which goes to the ‘carburetor. Appi the specified vacuum to the EVAP purge control valve. ‘SPECIFIED VACUUM: 250 mmHg “The specified vacuum should be maintained, Roplace the EVAP purge control valve if vacuum is ‘not maintained. Connect the pressure pump to the No.# hose fitting {input port} which goes to the EVAP canister. NOTICE Damage to the EVAP purge control valve may result ‘rom use of a high pressure air source. Use a hand ‘operated air pump only, While applying the specified vacuum to the EVAP purge control valve vacuum port, pump air through the input port. ‘SPECIFIED VACUUM: 250 mmHg ‘Air should flow through the EVAP purge control valve and out the output port that goes to the carbu- retors, Replace the EVAP purge control vaive if air does nat flow out. emove the pumps and Install the EVAP purge con- ‘ol valve in the ravarse order of removal EVAP PURGE CONTROL VALVE To EVAP canister (No.4 hose)(04 mode on Aer 0 model nh ‘84 model ory: Atay 04 mode! FUEL SYSTEM EVAPORATIVE EMISSION. CARBURETOR AIR VENT (EVAP CAV) CONTROL VALVE REMOVALIINSTALLATION Remove the fue! tank (page 3-6). Disconnect the No:4 vacuum port-to-EVAP CAV con- trol valve hose (No 10). Disconnect the No.4 carburetor-to-EVAP CAV con- ‘rol valve vacuum hose. Disconnect tha fuel euteff solenoid valve-to-EVAP CAV control valve hose (No.6), Discunment the EVAP vanister-to-EVAP CAV cuntrul valve hose (No.4), Remova the EVAP CAV control valve from the frame. Disconnect the sub-air cleaner housing-to-EVAP CAV control valve hose (No.7). Installation fe In the reverse order of removal. INSPECTION ‘+ The EVAP CAV control valve should be inspected Ithot start is dificult. Remove the EVAP CAV control valve (page 6-41). Connect » vacuum purmp tothe No.10 hose fitting (vacuum port) that goes tthe No.4 vacuum port. Connect @ vacuum pump to the No.10 hose fitting that goes to the Nod carburetor. ‘Apply the specified vacuum to the EVAP CAV con- trol valve, Toot: Vacuum pump Commercially available SPECIFIED VACUUM: 250mm Hg ‘The specified vacuum should be maintained. Replace the EVAP CAV control valve if vacuum is not maintained. To Sub-air clesner (No.7 hose) To Fust cutoff solenoid valve (Nos hose) “To Vacuum port (0.10 hose) VACUUM PUMP @) roeiarenian LC (CL 6-41FUEL SYSTEM Remove the vacuum pump and connect it to the: No.7 hose fitting that goes to the alr cleaner hous- ing. Apply the specified vacuum to the EVAP CAV control valve, The vacuum should hold steady. Replace the EVAP CAV control valve if vacuum leaks. Remove the vacuum pump and reconnect it to the No.10 hose fitting (Vacuum port Connect the pressure pump to the No.7 hose fiting that goes to the air cleaner housing. NOTICE Damage to the EVAP CAV control vaive may result tram use of a high pressure air source. Use @ hand ‘operated air pump only. ‘While applying the specified vacuum to the EVAP CAV control valve vacuum port, pump air through the alr cleaner housing por. Plug the No.6 hose fitting that goes to the PAIR sole- noid valve. ‘While applying vacuum to the vacuum port, apply ‘should hold steady. Replace the EVAP CAV control valve if pressure is ‘ot retained, Remove the pumps and install the EVAP CAV con- trol valve in the reverse order of removal. FUEL CUTOFF SOLENOID VALVE (‘04 California type and after ‘04 model) REMOVAL/INSTALLATION Remove the fuel tank (page 3-8, Disconnect the fuol cutaff solenoid valve 2P (White) ‘connector. VACUUM PUMP EVAP CAV CONTROL VALVE EVAP CAV CONTROL VALVE 6 en Ssure PUMP ae VACUUM PUMP we PRESSURE PUMP. VACUUM PUMP 2P (WHITE) CONNECTOR _Calis type ory Atte ‘04 mode! (xcept Colfomia ype) only Disconnect the fuel cutoff solenoid vaive-to-EVAP CAV contral valve hose (No.6). Disconnect the fuel cutoff solenoid valve-to-3-way joint (No.6), Disconnect the fuel cutoff solenoid valve-to-5-way Joint hose (No.8). Romove the fuel cutoff solenoid valve, Installation isin the reverse order of removal. Disconnect the fuel cutot solenoid vaive-to-the sub air cleaner hose, Disconnect the fuel cutoff solencid valve-to-3-way joint (No.6) Disconnect the fuel cutoff solenoid vaive-to-the No.3 carburetor hose (fual cutaff solenoid vacuum hose). Romove the fuel cutoff solencid valve. Installation isin the reverse order of removal. INSPECTION Remove the fuel cutotf solenoid valve (page 6-42). Connect @ vacuum pump to the No.S hose fitting that goes to the S-way joint. Apply the specifiad vac- ‘uum to the fual cutoff solenoid valve. Toot: Vacuum pump Commercially available ‘SPECIFIED VACUUM: 250 mm Hg ‘The specified vacuum should be maintained. Replace the fuel curolt solenoid valve It vacuum ts ‘not maintained. Remove the vacuum purrp. Connect the pressure pump to the No.6 hose fitting that goes to the 3-way joint NOTICE ‘Damage to the fuel cutoft solenoid valve may result from use of a high pressure air source. Use @ hand ‘operated air pump only. Pump air through the EVAP CAV control valve port. FUEL SYSTEM = FUEL CUTOFF SOLENOID VALVE No.5 HOSE: FUEL CUTOFF SOLENOID | VACUUM HOSE VALVE To 3-way joint (No.6 hose) PRESSURE PUMP ToEVAPCAV controt valve (No.6 hose)FUEL SYSTEM Remove the pressure pump and connect it to the 'No.é hose fiting that goes to the EVAP CAV control valve. NOTICE Damage to the fuel cutoff solenoid valve from use of a high prosoure ait source. Us ‘operated air pump only. Pump air through the 3-way joint port. Connect the 12V battery to the fuel cutoff solenoid valve 2P (Black) connector terminals. Connect 8 vacuum pump to the No.6 hose fitting that goes to tho EVAP CAV control valve. Apply the specified vacuuim to the fuel cutoff solenoid valve. ‘SPECIFIED VACUUM: 260 mm Hg ‘The specified vacuum should be maintained. Replace the fuel cutoff solenoid valve if vacuum is ‘ot maintained, Remove the pressure pump and connect it to the 'No.S hose fitting that goes to the S-way joint. NOTICE Damage to the vel cutoff solenoid valve may result ‘rom use of @ high pressure alt source. Use a hand ‘operated air pump only. Pump air through the 3-way joint port Replace the fuel cutoff solenoid valve if necessary. Remove the pressure pump and install the fuel cut- ‘off solenoid valve in the revarse order of removal. FUEL VALVE INSPECTION Remove the fuel tank ipage 3-6), Connect the fuel hose to the fuel valve and place a suitable gasoline container under the fuel hose. Turn the fuel valve on, Ifthe fuel flows out of the fuel hose, replace the fuel valve diaphragm. Connect @ commercially available vacuum pump to the fuel vaive vacuum hose. Fuol should flow out from the fuel hose whan vac- ‘uum is applied If the fuel flow is restricted, replace the fuel valve diaphragm. FUEL CUTOFF SOLENOID VALVE ToS-way joint (No.6 hose) ToEVAP CAV control valve (No.6 hoso} To EVAP CAV control valve (No.6 hose) 2P (BLACK) CONNECTOR BATTERY To S-way joint (No.5 hose) PRESSURE PUMP. CONNECTOR FUEL VALVE. vacuulFUEL SYSTEM REMOVAL Drain the fuel from the fuol tank, Remove the screws and diaphragm cover. DIAPHRAGM COVER Remove the spring and diaphragnvspacer. Be eae DIAPHRAGMISPACER SPRING Felco the Ga Check the diaphragm for tears or other damage. piaym cow. Replace if necessary. DIARIAGM song, daptragry spacer as a st ‘Loosen the nut and remove the fuel valve assembly from the fuol tank. FUEL VALVEFUEL SYSTEM Femove the fuel stviner and O-ring from the fuol valve. FUEL VALVE ASSEMBLY Install a new Oring and fuel strainer onto a fuel valve, STRAINER {nstall the fuel valve into the fuel tank. Tighten the fuel valve nut tothe specified torque, FUEL VALVE TORQUE: 24 Nem (3.5 kgm, 25 IbE-) Install the diaphragm/spacer, spring and diaphragm ‘over so that theair vent hole ofthe spacer and vac- DIAPHRAGMISPACER VACUUM PIPE ‘bum pipe of the cover facing to the same divection 38 the fuel pipe ofthe fuel valve body. 6-46FUEL SYSTEM Install and tighten the screws securely, Install the fue! tank (page 3-6). Fill the fuol tank and make sure there are no fuel leaks.7. COOLING SYSTEM ‘SYSTEM FLOW PATTERN SERVICE INFORMATION ‘TROUBLESHOOTING. - SYSTEM TESTING: COOLANT REPLACEMENT -- THERMOSTAT. RADIATOR RADIATOR RESERVE TANK WATER PUMPCOOLING SYSTEM SYSTEM FLOW PATTERNCOOLING SYSTEM SERVICE INFORMATION GENERAL Removing the radiator cap while the engine is hot can slow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool cawn before removing the radiator cap. NOTICE Using coolant with silicate inhibitors may cause premature wear of water pump seals or blocksge of radiator passages. Using tap water may cause engine damage. ‘Add cooling system at the reserve tank. Do not remove the radiator cap except to reill or drain the system, ‘= All cooling system services can be done with the engine in the frame, + Avoid spiling coolant on painted surfaces. * ‘After servicing the system, check for leaks with a cooling system tester ‘= Rafer to tha fan motor switch inspection and ECT sensor inspection (page 20-19) ‘SPECIFICATIONS CC eM T ‘SPECIFICATIONS — —_ ‘Coofant capacity Radiator and engine “Zier (2.43 US at, 2.02 Imp at) { Reserve tank (0.30 liter (0.32 US qt. 0.26 Imp qt) (Radiator ap relief pressure - - TO8= 137 kPa (1.)- 7.4 kgticm?, 16 - 20 pal) “Thermostat Begin to open 80-= 84 °C (176 = 183 F) Fully open 95°C (2037) Valve lift — emi (63 in} minima Recommended antifraare High qualiivathviene glycel antifreare containing corrosion protection inhibitors — ft |" Standard coolant concentration TORQUE VALUES Water pump cover bolt 13.Nem (13 kgm, 9 bE) CT bolt ECT sensor 23. Nem (2.3 kgm, 17 Ibe Water hase joint 29 Nom (3.0kgfm, 22 Ibe Fan motor switch 38 Nem (1.8kgfm, 13 IbhA) Apply sealant to the threads Fan motor mounting nut 8.1 Nem (0.52 kgm, 3.8 IbtA) Caaling fun nut 2.7 Nim (0.28 kgtm, 2.01BLF) Apply # locking agant to the theoadeCOOLING SYSTEM TROUBLESHOOTING Engine temperature too high ‘+ Faulty temperature gauge or ECT sensor ‘Thermostat stuck closed * Faulty radiator cap * Insufficient coolant ‘+ Passage blocked in radiator hoses or watar jacket * Airin system ‘= Faulty cooling fan motor ‘© Faulty fan motor switch ‘Faulty water pump Engine temperature too low ‘Faulty temperature gauge or ECT sensor Thermostat stuck open ‘+ Faulty cooling fan motor switch Coolant teak ‘Faulty water pump mechanical seal Deteriorated O-rings Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hase connection ar clamp Damaged or deteriorated hoseCOOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the screw and redistor cap. RADIATOR CAP Test the coolant gravity using a hydrometer (sea below for ‘Coolant gravity chart’). For maximum corrosion protection, 2 50 - 60% solu- tion of ethylene glycol and distilled water is recom- ‘mended (page 7-6). Look for contaminstion and replace the coolant if necessary. a0 )45-|-s0 (00a) | ca) | (22) T oa 1.008 | 1907 001 [0889/0387 1015, 1008 | 7.007 | 1005 | 8 | 1025 | 1024 Loa 11S | Love 1012 [i033 1031 1023.| L02T | 1019 Tost | 102e'| 1025 ‘1038 | 1.035 | 1032) aa .043 [1080 | 1083 1087 10% 3/1060 | 1 1065 1059 - 1 1067 [4077 [1.074 | 1071 | 75COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Before nstaling the Remove the radiator cap (page 7-5). cap th ote, Pressure test the radiator cap. ‘were esirg Replace the raditor cap iit does not hold pressure, (S085. Grif ralief pressure is too high or too low. Wmust hold speed pressure for atleast 6 seo- [RADIATOR CAP RELIEF PRESSURE: 108-137 kPa (11-14 kgf/em?, 16-20 psi) RADIATOR CAP TESTER Pressure the radiator, engine and hoses, and check {or leaks. NOTICE Excessive pressure can damage the cooling system ‘components. Do not exceed 137 kPa (1.4 kgtem, 20 pail ‘Repair or replace components if the system will not hold specified pressure for at least 6 seconds. COOLANT REPLACEMENT PREPARATION + The offo ulation of rust or if there is a chang ‘mixing proportion during usage. Therefor nose of coolant das best performance change the coolant regularly | | ANTIFREEZE 28 specified in the maintanance schedule. SOLUTION + Mix only distilled, low mineral water with the antifreeze. | RECOMMENDED ANTIFREEZE: (ETHYLENE LOWMINERAL | High quality ethylene glycol antifreeze containing GLYCOL BASE ORDISTILLED | corrosion protection inhibitors SOLUTION) WATER | RECOMMENDED MIXTURE: (Distilled water and antifreeze) cooLaNt 7-6COOLING SYSTEM Then tiaie REPLAGEMENT/AIR BLEEDING R072" 26 Remove the screw and raator cap. ‘checking coat teva, pce mmo na 8 ‘capstone 9 tt ove sre. Remove the drain bolt on the water pump cover and drain the system coolant Roinstall me drain bot with the new sealing washer. Tighten the water pump drain bolt securely, Remove the rear fender (page 3-8). Remove the fuse box. resarve tank with water. Connect the siphon hose to the reserve tank. Fill the system with the recommended coolant through the filer opening up to filler neck.COOLING SYSTEM Remove the radiator reserve tank cap end fill the © ‘reserve tank to the upper level ine. . FILLER CAP ‘Blood air from the system as follow: 1. Shift the transmission into neutral. Start the engine and letit idle for 2-3 minutes. 2. Snap the throttle 3— 4 times to blead air from the system, 3. Stop the engine and add coolant up to the proper level if necessary. Reinstall the rediator cap. 4. Chack the lavel of cootant inthe reserve tank and {il to the upper level If iis low. THERMOSTAT REMOVAL Drain the coolant ipage 7-7). Remove the bolts and thermostat housing protec- tor. Remove the bolts, protector bracket and thermostat / ie hhousing cover. Remove the O-ting fom the thermestat housing ‘cover. Remove the thermostat from the housing 7-8COOLING SYSTEM INSPECTION Wear insulated gloves and adequate eye protection. Keep flammable materials sway from the electric THERMOSTAT heating lament. Visually inspect the thermostat for damage. Do net let the ther» Heat the water with an electric heating element to masta or thar gperating temperature for § minutes. rmometertouchthe Suspend the thermostatin heated water to check its pan oryou wilget operation ‘ols0"80°9. Replace the thermostat if the valve slays open at room temperature, or ift responds at temperatures ‘other than those specified. ‘THERMOSTAT BEGIN TO OPEN: 80-84 °C (176-188 °F) VALVE LIFE: ‘8mm (03 In) minimum at 95 °C (203°F) INSTALLATION Mako sure the thermastat air bleed hole facing up. Install a new O-ring to the thermostat housing cover groove 7-9COOLING SYSTEM Insta the tharmosta housing cover anto the hous- Inwal he thermostat Rousing protector bracot. Install and tighten the bolts securely. Install the thermostat housing protector and tighten’ tha bolts securely. Fil tho system with recommended coolant and bleed the air (page 7-7) RADIATOR REMOVAL Remave the fuel tank (page 3-8), Drain the coolant (page 7-7), Disconnect the radiator sub-harnass 3P (Black) con- pector. Disconnect the siphon hose, Loosen the hose band scraw and disconnect the upper radiator hose from the right side of the radia- tor,COOLING SYSTEM ‘Loosen the hase band screw and disconnect the lower radiator hose from the left side of the radia: tor. Mr. Afwr ‘04 meal Disconnect the fan motor switch connector. PAN MCTOR SITE oie Remove the radiator mounting bolts and collars. Slide the radiator to the right, then release the /|BOLTSICOLLARS, Sronwnat om the frame bose aR TY Becrstlnerto Remove the radiator assembly. image tb radon GROMMET/BOSS ——s DISASSEMBLY Release the hooks from the tabs on the radiator and remove the radiator gril. RADIATOR GRILL. HOOKS Flomove the bolts and radiator grill side covers, SIDE COVER BOLTS 7-11COOLING SYSTEM ‘bémoda/eni Disconnect the fan motor switch connecter and ‘olaase the sub-hamess fram the clamp. Remove the bolts, ground eyalet and cooling fan motor assembly. CONNECTOR GROUND EYELET IH FAN MOTOR ASSEMBLY Remove the nut and cooling fan. COOLING FUN. Remove the nuts and fan motor from the fan motor a: shroud. FAN MOTOR FLANGE NUTS. Refer to the fan motor switch information. 7-12COOLING SYSTEM ASSEMBLY “04 model: DP wouter ses 7 ; RADIATOR GALL 18Nem (1.8 kgfm, 13 bf) FAN MOTOR SHROUDCOOLING SYSTEM Install the fan motor onto the fan motor shroud and — tighten the nuts to the specified torque. FLANGE NUTS ‘TORQUE: 5.1 Nem (0.52 kgf-m, 3.8 Ibfft) Install the cooling fan onto the fan motor shaft by aligning the flat surfaces. COOLING FUN Apply a locking aga the colin an ut tread tnfal and ightos to nu to the specie torque, COOLING ay TORQUE: 2.7 Nem (0.28 kgf-m, 2.0 bff) Install the cooling fan motor assembly onto tho radi- ator, CONNECTOR Route the ground eyelet propery. Install and tighten the bolts securely. ‘cAmede!riy| Install the radiator sub-harness connector to the fan ‘motor bracket. Connect the fan motor switch connector. GROUND EVELET B FAN MOTOR ASSEMBLY 7-14COOLING SYSTEM Install the radiator grill side covers. Install and tighten the bolts securely. SIDE COVER ail BOLTS Install the radiator grill while aligning the tabs to hooks on tha radiator. RADIATOR GRILL INSTALLATION Bo cofatulnot:2 Install the radiator assembly, aligning its grommet damage the asst with the Fame boss. “°° Install the collars end bolts, then tighten the bolts || securely, Connect the lower radistor hose and tighten the hose band screw securely. Alter ‘04 modes Connect the fan motor switch connecter. ; ony FAN MOTOR SWITCH | CONNECTORCOOLING SYSTEM Connect the upper radistor hese and tighten the hose band screw securely. Connect the siphon hose to the radiator securely. ‘Connect the radiator sub: Fill the system with recommended coolant (pege 7-8), Install the fuel tark {page 3-8). RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the rear fender (page 38) Remove the fuse box. Disconnect the siphon hose. Remove the bolt and radiator reserve tank, Jostllation isin the reverse order of removal. fill the system with recommended coolant (page 7-6).COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Inspect the inspection hole for signs of coolant leak- age. Hthore fe leakage, the mechanical soo! ia defective and replace the water pump as an assembly, WATER PUMP = / 7 INSPECTION HOLE REMOVAL Drain the coclant (page 7.7) Loosen the hose band screws, Disconnect the lower radiator hose and bypass hose from the water pump cover, a Seen Remove the two SH bolts, two flange bolts and ‘water pump cover. Remove the O-ring from the water pump body. Loosen the hose band screw and disconnect the oil ‘cooler watar hase from the water pump body. mae “4 ‘JL COOLER WATER HOSE Remove the water pump body from the crankcase, Cs Q‘COOLING SYSTEM. INSTALLATION ‘Apply engine oil to @ new O-ring and install it onto the stepped portion of the water pump body. Install the water pump into the crankcase while aligning the water pump shaft groave with the pump shaft end by turning the water pump impel ir, Connect the oll cooler water hose to the water ‘pump and tighten the band screws securely. Align the mounting bolt holes in the water pump and crankcase and make sure the water pump is. securely installed. Apply grease to a new O-ring and install it into the ‘groove in the water pump body. Install the water pump cover, two SH bolts and two flonge bolts. Tighten the flange bolts to the specified torque, ‘TORQUE: 13 Nem (1.3 kam, 9 ttt) ‘Tighten the two SH bolts securely. Connect the lower radiator hose and bypass hose, then tighten the band screws securely. Fill the system with recommended coolant and bleed the air (page 7-7),8. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION.» vw 82 ENGINE REMOVAL ++ +7 SERVICE INFORMATION +--+ snnte 8B ENGINE INSTALLATION w=-vvssnvnernesense 8-1ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION "04 model shown: 20 Nom (2.0 kghm, 14 Ibfift) o| A\\ 54Nom (55 kom, a0 oF) 54 Nm (6.5 kafim, 40 IFA) 22 Nem (2.2 kgm, 16 Fmt)ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL ‘+ Ahoist or equivalent is roquired to support the motorcycte when removing and installing the engine. ' A floor jack or other adjustable suppor is required to support and manouver the engine. NOTICE ‘Do not use the oll fter as a jacking point, the engine will be damaged, ‘+ The following components can be servicad with the engine installed in the frame. coolerall pump, = Weter pump = Cylinder headivaives = Clutch/gearshift linkage = Alternator/starterelutch ‘= The following components require engine removal for service, = Crankshetttcansmission ~ Pistonleyiinder SERVICE DATA TEM T ‘SPECIFICATIONS Engine dry weight "63.2 kg (139.3 Ibs) [engine ot espaeny [iter aisassembly | ~aziner a Us at 3.7m ao — Coolant capacity Radiator and engine | 23 ier (2.43 US at, 2.02 imp at TORQUE VALUES Drive sprocket special bott 54 Nim (8.5 kgm, 40 IDF) Front engine hanger nut 54 Nem (5.8 kgfm, 40 Ibf) Engine hanger bracket bolt 22Nem (2.2 kgtm, 16 IDF) sngine hanger nut (upper) 5A Nim (5.6 kafom, 40 IbF-A) Rear engine hanger nut (lower) 54 Nim (6.5 kgf, 40 IDF) Gearshift pedal link bolt (gearshift spindle side) 20 Nem (2.0 kgfm, 14 IbF-R) Swingarm pivot nut 88 Nim (8.0 kgf, 65 Ibf-) Starter motor terminal nut WON-m (1.0 kgtim, 7 Ib)ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the following: 7 Side coverage 8) = Fuel tank (page 3-6) = Exhaust pipe (page 3-9) = Carburetor (page 8.10) = Radiator (page 7-10) Remove the following (California type only): ~ EVAP purge control valve (page 6-39) ~ EVAP canister (page 6-33) Drain the engine oll (page 4-15), Drain the coolant (page 7- Turn the ignition switch OFF and disconnect the bat- tery negative cable, Remove the bolts and drive sprocket cover. Loosen the drive sprocket special bolt while apply- ing the rear brake with the rear whe ‘ground, Loosen the drive chain (page 423). Support the motoreycla securely using a hoist or equivalent, Remove the drive sprocket special bolt, washer and drive sprocket. Remove the spark plug caps and ignition coll assembly (page 18-10).ENGINE REMOVAL/INSTALLATION Remove the bolts and clutch cable quide, then dis- connect tha clutch cabo ‘rom the clutch arm. Disconnect the following connectors: ~ ECT sensor 3P (Natural) connector = Engine sub-harness 3P (Natural) connector = Ignition pulse generator 2P (Blue) connector TONITION PULSE GENERATOR 2P (BLUE) ALTERNATE /3P (NATURAL) Alternator 3 (Natural) connector Vehicle speed sensor 3P (Natural) connector eeraencon Bene, Remove the wire band. Remove the terminal nut and starter motor cable from the siarter motor. Remove the bolt and ground cable eyelet. ‘STARTER MOTOR —— a Remove the bolt and gearshift pedal link. GEARSHIFT PEDAL LINK e&ENGINE REMOVAL/INSTALLATION Do rot use theo! Place a floor jack or other adjustable support under tite as 9 aching the engine. pont the 270 “Remove the front right engine hanger boltinut at willbe damaged. erro te it right engine hanger bolvnut and Romove the Its and engine hanger bracket Remove the front feft engine hanger bolwrut and distance calla Remove the swingarm pivot nut. 'SWINGARM PIVOT NUT Remove the [eft pivot bracket mounting bolts Slightly pull the pivot bracket outward and tit it so ‘that the lower engine hanger bolt can be removed. 8-6ENGINE REMOVAL/INSTALLATION Femove the rear lower engine hanger bolvnut and vance collar. BOLTNUT Remove the rear upper engine hanger bolt/nut and distance collar. Carefully lower the adjustable support, hen remove the engine from the frame, ENGINE INSTALLATION + Note the sirction of re hanger bots. '* The jack height must be continually adjusted to stoss from the mounting fasteners. the wire and cables property (page 1-23). Install the engine into the frame. Install the rear upper engine hanger bolunut and istance colar 72 REAR UPPER ENGINE HANGER BOLT/NUTENGINE REMOVAL/INSTALLATION Install the rear lower engine hanger bolvinut and distance collar. — REAR LOWER ENGINE HANGER BOLT/NUT. Install the left pivot bracket, then tighten the bracket bolts securely. Install_ and tighten the swingerm pivot nut to the specified torque. TORQUE: 88 Nm (9.0 kgm, 65 Ib) Install the front laft engine hanger boltnut and dis ‘ance collar.ENGINE REMOVAL/INSTALLATION Tnotall the front right engine henger bracket end tighten the bolts to the specified torque. TORQUE: 22 Nem (2.2 kgm, 16 tht) Install the front right engine hanger bolUnut and dis tance collar. W ronan | GER Beaceer [FRONT RIGHT ENGINE S HANGER BOLTINUT, ‘Tighten the front right engine hanger nuts to the specified torque. TORQUE: 54 Nem (5.5 kgm, 40 Ibe) Tighton tho rear lower engine hanger nut to the Yana 2 Bares ae RETAINER CYLINDER HEAD INSPECTION ‘CYLINDER HEAD ‘Avoid camaping the Remove carbon deposits from the combustion basket surface. chamber, being careful not to damage the gaskot surface. Check the apart plug hole and valve arse for ora Check the cylinder head for warpage with a straight e0ge and fesler gauge. SERVICE LIMIT; 0,10 mn (0.004 in) VALVE LIFTER BORE Inspect each valve lifter bore for scratches or abnor- ‘mal wear. ‘Measure the each valve lifter bore I.D. ‘SERVICE LIMIT, 26.04 mm (1.025 in)VALVE LIFTER Inepect each valve lifter for scratches or abnormal Measure the each valve titer 0.0. ‘SERVICE LIMIT, 25.97 mm (7.022 in) VALVE SPRING ‘Measure the valve spring free length. SERVICE LIMITS: IN: 3705 mm (1.46 in} EX: 3795 mm (1.46 in} Replace the springs if they are shorter than the ser- vice limi. CAM CHAIN TENSIONER/CAM CHAIN GUIDE Inspect the cam chain tensioner and cam chain ‘Quide for excessive waar or damage, replace if nec- essary, VALVE/VALVE GUIDE ‘Chock that the valve moves smoothly in the guide. Inspect each valve for bending, burning or abnor- ‘mal stem wear. Check valve movement in the guide, measure and record esch valve stem 0.0. SERVICE LIMITS: IN: 3.985 mm (0.1861 in) EX: 3955 mm (0.1857 in) CYLINDER HEAD/VALVES VALVE LIFTER VALVE SPRING CAM CHAIN GUIDE ~ CAM CHAIN TENSIONER, VALVE >} ooCYLINDER HEAD/VALVES Ream the guides to remove eny cerbon deposits bbefore checking clearances. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clock- wise, ‘ToL: Valve guide reamer, 4.0 mmO7MMH-MIV90100 or ‘O7MMH-MV90108 (USA. only) Measure and record each valve guide LD. SERVICE LIMITS: IN/EX; 4.04 mm (0.158 in) ‘Subtract each valve stem 0.0. trom the correspond- ‘the stern-to-guide clearance. Fatoce the valve seats wheraver che its, determine if a new guide with standard dimen- valve gudes ae sions would bring the clearance within tolerance. if replaced 20 0, replace any guides as necessary and resmto fit. 20), If the stem-to-guide clearance is out of standard with the new guides, replace the valves and guides. VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about one hour Heat the cylinder head to 100 - 150°C (212 - 300°F) ‘with a hot plate or oven. NOTICE Do not use a torch to heat the cylinder head; it may cause warping. ‘Support the cylinder head and drive out the va ‘guides from combustion chamber side of the cylin- dor he TOOL: Valve guide driver, 4.0 mm — O7GMD-KT70100 Drive in the guide to the specified depth from the top of the cylinder head. ‘SPECIFIED DEPTH: 3.10 ~ 13.30 mm (0.516 -0.524 in) EX: 11.30 - 11.50 mm (0.445 - 0.453 in) ToL: Valve quide driver, 40mm — 07GMD-KT70100 Let the cylinder head coo! to room temperature.CYLINDER HEAD/VALVES Uso.cuting oon Ream the new valve guids after installation. tho rearer durng Insert the reamer from the combustion chamber this acevaton side of the head and slso always rotate the reamer clockwise. TOOL: Valve guide reamer, 4.0 mm O7MMH-MVS0100 or ‘O7MIMH-MVSO108 (USA. only) Clean the sylinder head thoroughly to ramova any metal partictes. Reface the valve seat (page 9-20). VALVE SEAT INSPECTION/REFACING ‘Clean the intake and exaust valves thoroughly to remove caibon deposit. HAND-LAPPING TOOL ply @ light coating of Prussian Blue to the valve ats. ‘Tap the valves and seats using a rubber hose or ‘other hanclapping tool, Remove the valve and inspect the valve seat face. ‘The valve seat contact should be within the specl- fied with and even all around the circumference. | STANDARD: 0.90110 mm (0.035 ~0.063 in) SERVICE UMIT: 15 mm (0.06 in) ‘ IE the seat width fs not within speciation, reface | the valve seat (page 8:20) SEAT WIDTH Inspect the valve soat face for: + Uneven seat width: ~ Replace the valve and reface the valve seat, + Damaged face: ieplace the valve and reface the velve seat, DAMAGED FACE UNEVEN SEAT WIDTH 9-19(CYLINDER HEAD/VALVES ‘ground. fa valve fon burned or badly worn ort ‘conc the seat tneveniy, reciace the waive Follow the racing manufacturer's opening msi tis. Fetace the se6t with 0 at-dogr0e ‘utter whenever 8 valve guid is replaced. * Contact area (too high oF too low) ~ Reface the vaive seat. VALVE SEAT REFACING Valve seat cuttersigrinders or equivalent valve seat fefacing equipment are recommended to correct Ifthe contact area is too high on the valve, the seat must be lowered using a 32" flat cutter. Wthe contact area is tao low on the valve, the seat ‘ust be raised using » 60° interior cutter, Use a 45-degree cutter to remove any roughness or Irregularities from the seat. TooLs: ‘Seat cuttor, 275 mm (IN) 07780-01020 ‘Seat cutter, 26.5 mm (EX)07780-0010100 Cutter holder, 40mm 07781-0010500 or equivalent commercially available in U.S.A. TOO Low TOO HIGH Cy Os [ CONTACT TOOWIGH OLD CONTACT TOO Low - Nes SEAT WIDTH oun: ere L80° ROUGHNESS 9-20CYLINDER HEAD/VALVES Use a 32-dagros cutter to remove the top 1/4 of the existing valve seat material, Toots: \ Flat cutter, 27 mm (IN) 07780-0013300 Flat cutter, 24 mm (EX) 07780-0012500 AQ SAT WT ‘Cutter holder, 4.0mm 07781-01050 or Se equivalent commercially : ‘alle In USA. wt Use a 60-degree cutter to remove the bottamn 1/4 of the old seat. Toots: “ow sear woth Anterior cutter, 26 mm (IN) 07780-0014500 Interior cutter, 22 mm (EX)07780-0014202 — Gutter holder, 4.0mm —07781-0610500 or ‘equivalent commercially available in USA. ow f\ Using @ 46° seat cutter, cut the sest to the proper width. Make sure that all pitting and irregularities are removed, Refinish if necessary. After cutting the seat, apply lapping compound to esti ‘the valve face, and lap the valve using light pres- teas NOTICE © Excessive lapping prossure may deferm or dam- age thesoat. = * Change the angle of lapping tool frequently to ~ prevent uneven seat wear. * D0 not allow lapping compound to enter the guides. After lapping, wash all residual compound off the cylinder head and vaive. _HAND-LAPPING TOOL 9-21CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY nh (CARBURETOR INSULATOR VALVE LIFTER ‘SHIN: COTTERS: senna reranen —O) vases 9) @ omen SPRING SEAT VALVE GUIDE EXHAUST VALVE 7” INTAKE VALVE Clean the cylinder head assembly with solvent and. blow through all oil passages with compressed air. Blow through all oil passages in the cylinder head with compressed air, Install the special too! or equivalent (page 9-15) into [Pow the valve lifter bore. TooL: ‘Tappet hole protector OTHMG-MR70002 (Not avallable in US.A.) 29 eal sy TAPPET HOLE PROTECTORS * nes VALVE SPRING Lubricate the velve stems with molybdenum oil solution, Insert the valve Into the valve guide while tuming it RETAINER, slowly to avoid damage ta the stem seal.CYLINDER HEAD/VALVES Greaze he coters te ease insalon Suppo the cy ler haad above ne Work bench su face 1 prevent pos: sole valve damege {Install the vaive spring with the tightly wound coils facing the combustion chamber. VALVE SPRING Install the vaive spring retainer, ‘COMBUSTION CHAMBER SIDE Install the valve cotters using the special tool as shown. > ATTACHMENT. NOTICE To prevent loss of tension, do not compress the valve spring more than necessary. Toots: \Valve spring compressor 07757-00100 ‘Valve spring compressor attachmert07958-KM30101 ‘Tap the valve stems gantly with two plastic ham- mers as shawn to seat the cotters firmly. PLASTIC HAMMERS COTTERS Install the insulators aligning the their grooves with the bosses on the cylinder head. 9-23CYLINDER HEAD/VALVES Tighten the band screws vo thet the band ends clearance is 41 mm (0.2+ 0.04 in). BAND SCREW Install and tighten the spark plugs. ‘TORQUE: 12 Nem (1.2 kgf-m, 9 ott) 421mm (0.2 +0.04 in) CYLINDER HEAD INSTALLATION Install the timing sprocket by aligning the wide teeth between the erankshoft and sprocket Wiining sprocker St) Install the cam chain to the timing sprocket teeth. Install the cam chain guide, collar and tighten the bolt securely. Install the ignition pulse generetor rotor cover (page 188), BOLT/COLLAR,CYLINDER HEAD/VALVES Testa I ping and a new cylinder head loatal the dowel pi and» new oy gee DOWEL PINS Install the cylinder head onto the eylinder block. ‘Apply ll tothe threads and soating sutac ofthe 8 mm bolte/washors and i Tighten the 9 mm bolts ina crisscross pattern in 2— ox ‘3 steps to the specified torque. TORQUE: 47 Nem (4.8 kgf, 35 tt) Install and tighten the 6 mm bolts securely, ‘04 modetony: ‘Connect the vacuum hoses to the cylinder head. Connect the bypass hose to the cylinder head and tighten the band screw securely.CYLINDER HEAD/VALVES ‘Connect tha ECT sensor 3P connector. '3P CONNECTOR Install the eam chain tensioner slider. INER LIFTER ac Ingtall the cam chain tensioner slider cap nut with the new sealing washer ‘Tighten the cam chain tensioner slider cap nut to ‘the specified torqus TORQUE: 12 Nem (1.2 kgm, 9IbFft) Install the cam chain tensioner lifter onto the eylin- der head with new gasket. Install new saaling washers ard tighten the mount- ing bolte cocuroly. Install the following: = Camshaft (page 9-27) = Radiator (page 7-15) = Thermostat housing (page 7-9) = Carburetor (page 6-34) = Exhaust gystem (page 2-9) sockersouts & seauinc WASHERS EBON, cea ASCYLINDER HEAD/VALVES CAMSHAFT INSTALLATION Install the shims ‘and save iors 9 hel rina xa Apply molybdenum oll solution to the outer surface of the each valve lifter. Install the shims and vale lifters into the valve bores. ae, ‘VALVE LIFTER ee lifter If the cam sprockets are removed, install the cam ‘sprockets onto the camsnatts. * Install the intake cam sprocket with the timing mark (IN) facing outward and the No cam lobes {facing up as shown, * Install the exhaust cam sprocket with the timing mark (EX) fecing outward and the Nod cam lobes facing up as shown, EXHAUSTCAM INTAKE CAM ‘SPHOCKET SPROCKET ‘+ The marks on the camshaft have the following INTAKE CAMSHAFT "EX" MARK = "EX": Exhaust camshaft IN’ MARK EXHAUST CAMSHAFT Clean and apply a locking agent to the cam sprocket bolt threads. Install the cam sprocket bolts.CYLINDER HEAD/VALVES “Turn the crankshaft clockwise and mark on lign the “T™ 2 ignition pulse generator rotor with the / INDEX MARK ignition pulse generator rotor ‘Apply molybdenum oll solution to the camshaft journals of the cylinder head and camshaft holder. Install the cam chain over the cam sprockets and then install the intake ond exhaust camshafts. ‘Make sure that the timing marks on the cam sorock- is are facing outward and flush with the cylinder head upper surface as shown. CAM CHAIN INTAKE CAMSHAFT ‘= Tho marks on the camshaft holder have the fol- Jowing meanings. INTAKE CAMSHAFT HOLDER ~ "IN": Intake camshaft holder ~ "EX": Exhaust camshaft holder IN" MARK EXHAUST CAMSHAFT HOLDER. Apply molybdenum cil solution to the camshaft \ journats of the cylinder head and camshaft holder. CAMSHAFT HOLDERS Install the camshaft holder onto the camshafts. 9-28CYLINDER HEAD/VALVES Install the cam chain guide 8, ‘Apply engine oll to the threads and seating su of the camshaft holder bots, {¢ suro the dowel Finger tighton the bolts. ons te com Tighten the all camshaft holder bolts in the numeri- Shiite alr Corder mah on te cena Hol holes the cylinaer TORQUE: 12 Nem (1.2 kgfim, 9 Mf-t) bed. CAM CHAIN GUIDEB. Install and tighten th bolt securely. {In case the cam sprockels were removed, tighten the cam sprocket bolts to the specified torque. TORQUE: 20 Nem (2.0 kgfim, 14 Ibttt) Turn the crankshaft clockwise one full turn (360°) |) ‘and tighten the other cam sprocket bolts, Remove the stopper tool from the cam chain tensioner lifter.CYLINDER HEAD/VALVES Install a new sealing washer and tighten the sealing bolt. BoLT CAM CHAIN TENSIONER LIFTER Recheck the valve timing. SEALING WASHER CYLINDER HEAD COVER ASSEMBLY ‘Install the eylinder head packing into the groove of the cylinder head cover. COVER PACKING CYLINDER HEAD COVER 9-30CYLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION Apply sealant to the cylinder head semi-circular cut- outs os shown fozsoamn Install the cylinder head cover onto the oylinder head. CYLINDER HEAD COVER ‘wetall he washers with thelr “UP* ak facing Up. Install and tighten the cylinder head cover special bolts to the specified torque. ‘TORQUE: 10 Nim (1.0 kgm, 7 thf)CYLINDER HEAD/VALVES Install the heat guard rubber. Install the crankease breather hose. CRANK BREATHER HOSE ‘Connect the air suction hoses to the PAIR reed valve ‘overs. Install the ignition coil (page 18-10). CAM CHAIN TENSIONER LIFTER 9-32 REMOVAL Remove the cam chain tensioner sealing bolt and sealing washer. BolT CAM CHAIN TENSIONER LIFTER Turn the tensioner shaft fully in (clockwise) and ‘secure it using the stopper too! (page 8-8) to prevent damaging the cam chain. Remove the socket bolts, sealing washers and cam chain tensioner lifter. Remove the gastet. er SOCKET BOLTS/SEALING WASHERS OS ameCYLINDER HEAD/VALVES INSTALLATION ‘Note ne instalation. Install @ new gasket onto the cam chain tonsionor cirection of te gas- lifter. wot Inszal the socket bolts with new seating washers. ‘Tighten the socket bolts securely. Remove the stopper tool Install a new sealing washer and tighten the sealing bolt to the specified torque. Install the removed parts in the reverse order of removal. ‘TORQUE: 10 Nem (1.0 kgm, 7 thee) 9-33CYLINDER HEAD/VALVES PAIR REED VALVE REMOVAL Disconnect the PAIR reed valve Remove bolts and PAIR reed valve cover ir suction {No.16) hose from the cover. ‘Check the PAIR reed valve for wear or damage, 2 ‘place ifnecessery. Remove the port plates from the eylinder head INSTALLATION Install the port plates to the cylinder head cover. 9-34CYLINDER HEAD/VALVES install the PAIR reed valves to the cylinder head jalve cover. bolts to the specified torque. TORQUE: 13 Nem (1.3 kgtm, 9 Ibtt) Connect the alr suction (No.1) hose to the PAIR reed valve cover. 9-3510. CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION SERVICE INFORMATION.» ‘TROUBLESHOOTING --» RIGHT CRANKCASE COVER REMOVAL. 10-6 CLUTCH... GEARSHIFT LINKAGE. RIGHT CRANKCASE COVER INSTALLATION. 10-1CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 2) 12Nem(1.2 kgm, 9 iat) 20 N:mw (2.0 kat'm, 14 tot)CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL ‘+ This section covers sarvico of the clutch, gearshift linkage, shift drum and shift forks. All service ean be done with the ‘engine installed in the frame. ‘+ Transmission oll viscosity and laval have an affect on clutch disengagamant. When the clutch does not disengage cr the ‘motorcycle creeps with clutch disengaged, inspect the transmission oil level before servicing the dutch system, SPECIFICATIONS Unit: mm tin) ree SERVICE LNA | ‘Clutch lever free play —— = Ciuich [Spring free Fengih 48.5 (1383) aS TT) ickness 2.6 (0.10) — [Plate warpage 0.30 (0.0%2) [Gate outer aude T [22017 (0.8668), - 6. Mainshafi OD. at cuteh outer guid — 3 TORQUE VALUES ‘Giutch center tock nut 108 nm (LOKgEm, Bo IDI) Apply ollto he thread Stake the nut {Clutch spring bott 12m (12kgtm, 9 ER) Shift drum center socket bolt 23Nm(23kgim, 17 [bE Apply locking agentto the threads ‘Shift drum stopper arm pivot bolt 42.Nem (1.2katm, 3 IDFA Gearshift spindle return spring pin 23.Nem (23 kgm, 17 IbFf) Gearshift pedal ink bolt 26 Nem (2.7 kgm, 20 bE) (goarshift pedal side) pedal link bolt 20 Nem (2.0 kgf, 14 fbf) spindle side) 10-3CLUTCH/GEARSHIFT LINKAGE fr Holder plate O7HGB-0010108 or ‘Attachment, 37 X40 mm ‘0746-0010200 ‘9748-0010300 10-4 Pilot, 35 mm 9746-0040800CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Clutch lover too hard to pull in ‘= Damaged, kinked or dirty dutch cable ‘Damaged clutch ifter mechanism + Faulty clute lifter bearing * Clutch liter piece installed improperly Clutch slips when accelerating Incorrect clutch adjustment Worn clutch disc ‘Weak clutch springs ‘+ Transmission oil mixed with molybdenum or graphite additive Clutch will not disengage or motorcycle creeps with clutch disengaged * Incorrect clutch adjustment ‘* Clutch lifter piece installed improperly Hard to shift Incorrect clutch adjustment Improper oil viscosity Bont chit fork Bent shift fork shaft Bent fork claw. Damaged shift drum cam groove Loose stopper plate bolt Damaged stopper plate and pin * Damaged gearshift spindle Transmission umps out of gear + Worn shift drum stopper arm Weak or broken shift arm return spring Loose stopper plate bolt Bent shift ferk shaft Damaged shift drum cam groave Damaged or bent shift forks ‘Worn gear engagement dogs or slots Gearshift pedal will not return ‘= Weak or broken gearshift spindle return spring ‘= Bont gearshift apindle(CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine ol (page 4-15). Remove the bolts and clutch cable holder, then dis ‘connect the clutch cable from the clutch arm, Remove the bolts end right crankcase cover. Remove the dowel pins and gasket. Clean ony gasket olf from the right crankcase cover ‘mating surfaces. CLUTCH LIFTER LEVER Remove the clutch lifter piece, Remove the clutch lifter arm, return spring ond washer from the right crankcase cover. Check the lifter arm spindle for wear, damage or bending. ‘Check the return spring for fatigue or damage. Chock the needle bearings for woar, damage or loose Check the oi! see for fatigue or damage. O1SEAL v6 °° °° .”°™©}— OCCCLUTCH CLUTCH/GEARSHIFT LINKAGE REMOVAL Remove the right crankcase cover (page 10-6), — Remove the clutch iter tod from te iter bearing. PRESSURE PLATE Remove the clutch spring bolts, springs and lifter plate. Unstake the clutch center lock nut. Set the clutch center holder onto the clutch center. Install an finger tighten the four fifter plate bolts, Hold the cluteh cantar holder and remove the look ut. TooL: Clutch center holder 07JMB-MNSO3O1 or Holder plata (O7HGB-0010108 or O7HGB-OOI0I0A ana Holder collar"A" —_O7HGB-0010208 or O7HGB-0010208,(CLUTCH/GEARSHIFT LINKAGE Remove the lock washer and thrust washer aan Remove the following: Eight clutch plate Eight clutch discs cturch pisces CLUTCH Disc B SPRING SEAT Remove the pressure plate and washer. poewal PRESSURE Ingort a 5 mm pin (or suitable tool Into the holes in the primary driven gear and sub-gear to align the ‘gear teeth, ull the clutch outer guide out by pinching the ribs ‘on the clutch outer guide and sliding the guide for- ward.CLUTCH/GEARSHIFT LINKAGE Remove the clutch outer from the mainshaft by positioning the projections of the crankcase between the teeth of the primary driven gears. INSPECTION (Clutch liter bearing ‘Turn the inner race af the lifter bearing with your finger. “The bearing should turn smoothly and quietly with- out excessive pli Replace if necessary. ‘Clutch spring Feplce the ctich Measure the clutch spring free length, soot CLUTCH SPRING be ‘SERVICE UMIT: 475 mm (1.87 In} Clutch center Check the grooves of the clutch center for damage ‘or wear caused by the clutch plates. (CLUTCH CENTER, Replace if necassary.CLUTCH/GEARSHIFT LINKAGE epee the cue ses and plates 3 epics the clutch ses aa plates as asst Clutch lifter rod Check the clutch lifter rod for wear or dama CLUTCH LIFTER ROD (Clutch dise Replace the clutch discs if thay show signs of scor- ing of discoloration. CLUTCH DISC Measure the dise thickness of each disc. ‘SERVICE LIMIT: 2.6 rm (0.10 in) Clutch plato Chock each dise plate for warpage on a surtace plate sing a fesler gouge. ‘SERVICE LIMIT: 0.30 mm (0.012 in) (CLUTCH PLATE Clutch outer/eluteh outer guide Check the slots of the clutch outer for damage or wear caused by the clutch discs. NEEDLE BEARING CLUTCH OUTER Check the serrated teeth of the primary driven gear for wear or damage. Chock the neadle bearing for wear or damage. Replace if necessary, PRIMARY DRIVEN GEAR 10-10CLUTCH/GEARSHIFT LINKAGE ‘Measure the 0.0, and .D. of the clutch outer guide, # cuuTcH ‘SERVICE UMITS: OUTER GUIDE (0.0. 34.965 mm (1.3766 in) LD: 22.017 mem (0.8668 in) ‘Mainshaft ‘Measure the mainshaft 0.D. at clutch outer guide sar es sliding surface. ‘SERVICE LIMIT: 21.95 mm (0.864 in) CLUTCH OUTER NEEDLE BEARING REPLACEMENT Pross the noedie bearing out of the clutch outer Using the special tools. NEEDLE BEARING TooLs: Driver (07748-00100 ‘Attachment, 37X40 mm 07746-0010200 Pitot, 38 mm, (0746-0040800 Press a new needle bearing into the clutch outer so. that the casing of the needle bearing is flush with NEEDLE BEARING: DRIVER the inner edge of the clutch outer, ny Toots: Driver (07743-0010000 Attachment, 42X47 mm _07748-00%0300 Pilot, 35 mm (0748-0040800 [ATTACHMENT/PILOTCLUTCH/GEARSHIFT LINKAGE INSTALLATION ‘Apply molybdenum disulfide oll to the clutch outer inaedia bearing, Install the clutch outer onto the mainshatt by post tioning the projections of the crankcase between the teeth of the primary driven gears. Align the primary drive gear and sub-gear teeth ‘with a 5 mm pin (or suitable tool). Agply molybdenum disulfide oil to the clutch outer gui Install the clutch outer quide with the ribbed side {acing out, Bo sure the clutch outer sits securely onto the posi- tioning tabs of the oll pump drive sprocket. Attor installing the clutch outer guide, ramova the 5 ‘mm pin (or suitable tool) from the primary driven, gear. Install the thrust washer onto the mainshatt. Coat the clutch discs and plates with clean engine CLUTCH PLATES {Install the clutch dise B (larger LD. disc) to the clutch MUDEEH SPRING center side. ‘Stack the clutch discs and plates alternately. CLUTCH Discs CLUTCH Disc B SPRING SEAT~ 01 uri ENTER 10-12‘notall the epring eoat clutch canter as shown. Install the pressure plate to the clutch center align ing the punch marks on the pressure plate and clutch center. Install the clutch center assembly Into the clutch outer. Install the outer clutch disc (clutch disc 8) in the ‘shallow slot on the elutch outer. Install the thrust washer. w. Install the lock washer with its “OUT SIDE" mark fac- [J "OUT SIDE" MARK ing out.(CLUTCH/GEARSHIFT LINKAGE ‘Aaply engine oil to the threads and seating surface ofa new clutch center lock nut and instal it. Sot the clutch center holder onto the clutch canter. Too ‘Clutch conter holder Holder plate Holder collar“ Install and finger tighten the four lifter plate bolts, Hold the clutch center and tighten the clutch center Fook nut, ‘TORQUE: 108 Nm (1.0 kgm, 80 tht) Bessrefolnet to ‘Stake lock nut into the mainshaft groove with ‘damage the punch. rmainshat threads, Install the clutch springs onto the pressure plate bosses. Install the clutch lifter plate and lifter rod, CLUTCH CENTER HOLDER Lock NUT cw \ \eeNe Lock NUT TCH GENTER HOLDER 10-14CLUTCH/GEARSHIFT LINKAGE Install and tighten the bolts in a crisscross pattern in 2-~3 stops, then tighten the bolts to the specified torque. TORQUE: 12 Nem (1.2 kaf-m, 9 IDF) Install the right crankcase cover (page 10-18). GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL Remove the following: ~ Right crankcase cover (page 10-6) = Clutch assembly (page 10-7) Remove the bolt and gearshift peda fink. Pull the gearshift spindle assembly and thrust washer out of the crankcase. Remove the shift drum center socket bolt, shift drum center and dowel pin. 10-15CLUTCH/GEARSHIFT LINKAGE 10-16 Remove the following pivot bott (GEARSHIFT LINKAGE INSPECTION Chock the gearshift spindle for wear, damage or bending. sen * meas RETURN SPRING Choo the return spring for ftigue or damegs. GEARSHIFT SPINDLE Chock the needle bearing for wear or damage. Check the oll seal for fatigue or damage. GEARSHIFT LINKAGE INSTALLATION Inszall the following: ~ Wesher = Return spring Stopper arm = Stopper arm pivot bolt Tighten the stopper arm pivot bolt to the specified torque. TORQUE: 12. Nem (1.2 kgfim, 8 IFA)CLUTCH/GEARSHIFT LINKAGE Install the dowel pin onta the shift drum. Algn the doweienn Install the shift drum center while holding the stop- ‘nthe shit um per arm using a screwdriver as shown. wth the wide roave onthe htt ‘hum corte ‘Apply @ locking agent to the shift drum center ‘sockat bolt threads Install and tighten the socket bolt to the specified torque. TORQUE: 23 Nim (2:3 kgm, 17 Itt) Inetall tho thrust washer and ge assembly into the crankcase wi ‘Spring ends with the crankcase stopper pin. Install the gearshift pedal link aligning its slit with the punch mark on the gearshift spindle. Install ang tighten the bolt to the specified torque, TORQUE: 20 Nem (2.0 kgt-m, 14 IDE) Install the clutch assembly (page 10-121. 10-17CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER INSTALLATION ‘Note the return spring direction and install the lifter ‘arm with the spring and washer. Apply grease to tha clutch lifter piece and install it, ‘Apply a sealant to the mating surfaces of the erank- ‘pase as shown. Install the two dowel pins and new gasket. the right crankcase cover. Connect the clutch cable to the clutch lifter arm and ‘set the bracket, then install and tighten the securely. Pour the recommended engine oil (page 4-14), RIGHT CRANKCASE cover a re 10-1811. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION: ‘SERVICE INFORMATION -« ‘TROUBLESHOOTING... ALTERNATOR COVER REMOVAL. STATOR FLYWHEEL REMOVAL - ‘STARTER CLUTCH~. FLYWHEEL INSTALLATION. “11-10 ALTERNATOR COVER INSTALLATION 11-11ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION 103 Nem (10.5 kgf, 76 Ib) 11-2ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION GENERAL * This soction covers service of the alternator stator, flywheel and starter clutch, All sarvico can be done with the engine Installed in the frame, ‘= Refer to procedures for alternator stator inspection (page 17-8). * Refer to procedures for starter motor servicing (page 18-6). ‘SPECIFICATIONS _ — 0 —_ ‘Starter driven gear boss OD. ‘BL6BO— 51718 (2.0384 - Z036T) ‘51.684 (2.0348), TORQUE VALUES Flywheel fange bolt 103N'm (10.5 kafim, 76 Ibf‘t) Apply oil tothe threads and flange surface Stator mounting socket boit 12m (1.2 kgf, 9 bE) Alternator wire clamp socket bolt 10 N-m (1.0 kgf-m,7 Ibfst) Stater clutch outer torx bolt 16 Nem (1.6 kgm, 12 bf) Apply @ locking agent to the threads TOOLS 07725-04000, 07733-0020001 "Flywheel halder “Rotor puler | || or equivatent commercially avail- | oF 07833-2950000 (U-S.A. only) | ablein USA, TROUBLESHOOTING Engine doos not turn * Faulty starter oluteh * Damaged reduction gearshaftALTERNATOR/STARTER CLUTCH STATOR REMOVAL Remove the alternator wire grommet from the alter- nator cov Remove the socket bolt and alternstor wire clamp. ‘GROMMET Remove the socket bolts and stator. INSTALLATION Install the stator into the alternator cover. Install and tighten the siator mounting socket bolts to the specified tarque. TORQUE: 12 Nim (1.2 kgf-m, 9 Ibtt) Apply sestant to the wire grammet, then install the ‘wire grommet into the aternator groove securely. Install the wire clamp and tighten the socket bolt to the specified torque. TORQUE: 10 Nem (1.0 kgf-m, 7 Ibf) wire CLAMPALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL Remove the alternator cover (page 11-4). Hold the flywheel using the flywheel holder, then remove the flywheel bolt. hea ff FLYWHEEL BOLTAVASHER a mi ToL: Flywheel holder 07725-0040000 or equivalent commercially available inUSA. Remove the washer. Remove the flywheel using the special tool. Toot: Rotor puller 07733-0020001 or (07733-3950000 (U.S.A. only) Remove the woodruff key. Romove the starter reduction gear shaft and reduc- tion gear. 11-6ALTERNATOR/STARTER CLUTCH ‘Check the starter reduction gear and shaft for wear ‘or damage. REDUCTION GEAR REDUCTION GEAR SHAFT STARTER CLUTCH INSPECTION Check the operation of the one-way clutch by turn- ing the driven gear. You shauld be able to turn the driven gear counter: clockwise smoothly, but the gear should not turn clockwise. 6 j DISASSEMBLY Romove the starter driven gear by turing it eoun- terclocwise. a "s TORX BOLTS Hold the flywheel with a flywheel holder, and remove the starter clutch outer tarx bok, Toot: Flywheel holder 97725-0040000 or equivalent commercially available inUsA. FLYWHEEL HOLDER Remove the starter one-way clutch sssembly from the flywheel. FLYWHEEL, ‘ONE-WAY CLUTCH ASSEMBLY 11ALTERNATOR/STARTER CLUTCH INSPECTION (Check the starter driven gear for abnormal wear or damage. Measure the starter driven gear boss O.D. ‘SERVICE LIMIT: 51.684 mm (2.0348 in) ‘STARTER DRIVEN GEAR Check the one-way clutch sprag for wear, damage fr irregular movement. ‘ONE-WAY CLUTCH Replace if necessary. Check the one-way clutch roller contact surface of the clutch outer for wear or damage. Replace if necessary. CLUTCH OUTER ASSEMBLY CLUTCH OUTER, FLYWHEEL, ‘STARTER DRIVEN GEAR B one way cuutcs AWM 16 1m (1.6 4am Y2 RDALTERNATOR/STARTER CLUTCH ‘Apply engine olf to the one-way clutch contacting surfaces, Ty oneway cuuTeH Install the one-way clutch into the starter clutch ‘outer withthe flange sida facing the flywheel. CLUTCH OUTER Install the starter one-wey clutch assembly onto the flywheel. FLYWHEEL, ONE-WAY CLUTCH ASSEMBLY Apply @ locking agent to the starter clutch outer tone bolt threads, 2p TOP BOLTS Hold the flywheel with a flywheel holder, and tighten the starter clutch outer torx bolts. = ‘Toot: Flywheel holder 07725-0040000 or equivalent commercially aval InUSA, TORQUE: 16 Nem (1.6 kgl-m, 12 ttt) Install the starter driven gear into the one-way Clutch white turning it counterclockwise. Recheck the one-way clutch operation. You should be able to turn the driven goar counter- clockwise smoothly, but the gear should not turn clockwise