[2 LUBRICATION LUBRIFICATION SCHMIERUNGLUBRICATION (ny CAMSHAFTS \ | 4 /\ + 8) 0 PIPES 7) COUNTERSHAF: (5) OL STRAINER SCREEN 2-0{LUBRICATION | SERVICE INFORMATION 2-1 ENGINE OIL STRAINER CLEANING 23 | | TROUBLESHOOTING 24 OIL PUMP 23 | | ENGINE OIL LEVEL CHECK 2.2 LUBRICATION POINTS 27 | | ENGINE OIL & FILTER CHANGE 22 | SERVICE INFORMATION GENERAL Tain + ifthe engine must be running 10 do some work, make ture the area i well ventilated. Never run the engine nan enclosed are, The exhaust contains poisons carbon monozide gat thet may oause loss of consciousness end lead to death caunon + Used engine ou! may cause skin cancer if repeatedly left in ntact with the ski Jor prolonised per Aichowsh this es unicey untess vou hance used ofl 07 3 daily bask, is sll advisable 10 thoroughly wash Your banel with soy lend wuler as Soan 25 possible after handling used ol * This section describes inspection and replecement of engine oil and ai! Fite, cil strainer cleaning and oil pump serv lL isco SPECIFICATIONS 1.351137 US ee 1124 Imp qu aneroonne singe | TS2RU39 US a 416 ce el ado fer 1 tone | Other viseosities shown in the chart may be used when =e | Ua | re STANDARD Senvice it hil pump tip clearance Ol pump end clearance (9.001 0.604) 08) © 3.5 kp ation at 5,000 rain pr — OR pump delivery TORQUE VALUE 01 crain tote 25 Nem (2.5 kav, 18 (440) TROUBLESHOOTING Gi fevei too tow Low off pressure + Normal eff ecneumption + Fauity ol pump + External ol leaks + Gil puma éeve gear broken + Worn piston rings Oi contamination * Gil oF Fite: nat changed atten enough Faulty head gasket + internal coolant feats Faulty water pump mechenicel seal $ ssSsSsSsSssSSsSSSsSssSsSsssssSsSSSSSSSSSSSS 2-1LUBRICATION ENGINE OIL LEVEL CHECK on tevel ground nv (niet. STICK, Li acy oir Support the metoreycla unig Start the engina and let i ile fr Stop the engine. Check the ol Invle with the dipstick By insert ing tt i until the thraads touch the note Do rot screw the dipstick in when making this check, It the olllovetis below the ower mark on the cipstich, fit to the Upper lovel mark with the recommended ofl through the filer cap hole, ENGINE OIL & FILTER CHANGE NOTE > Change engine oi with the engine werm and the motoroyale fon ts side stand to assure complete acd rapid draiving) Remove the oil filer-cag anid drain bolt Drain the ot Remove the following: oil Filtor spring. Discard the of fiter Install the following spring, new oil fo Cover with = naw Oxing 14) “OUT SIDE" marc | SIDE mark faring outLUBRICATION After the of hes drained, check thet the drain bett seating washer is in good condition, and install the dain bol TORQUE: 25 Nem (2.5 kgm, 18 feb) Nore + Clean the engine of strainer, required, befare filing the crankcase. Fil the crankcase with the coreect quantity of the recommend: i ed ol ‘) ORIN BOLT OWL CAPACITY: 1.92 fit (1.99 U.S. gt, 1.16 Imp at) ot all and oil fiter change RECOMMENDED OIL: Honda 4-stroke Oil ar equivalont API service classification: SE or SF VISCOSITY: SAE 10W- 40 Install the ol filer cap. Start the engine ond let it le for 2-3 minutes Stop the engine and wait a few minutes then che level is at the upper lovel mork with the motoroycla uprsht. Check that there are no ail leak, ENGINE OIL STRAINER CLEANING nore * Perform thie maintononce belore filing the engine with oll Romave the right crankesas cover {page 7 3) Remove the cil evsiner and clean ie Install the ol strainer. Install the sight erankease cover {oage 7-10), Fill the erankcace with recommended ott OIL PUMP REMOVAL Remave the folowieg: Aight ctaakcase cover (page 7-2) = clutch (poge 7-41 primary drive gear (page 7-8) — owe! pin with anc O-ing ‘ll pump dhiven gear. 2-3LUBRICATION Remove the following = oil pump meunting bots. = oil pump. = dows! pins = gasket Disassemble the oll pump. (Clean disassembled paris with noneflammabsie of high Hash point solvent. INSPECTION Tio Claarence Install the innat rotor and outer rotor in the oi pump body Temporarily instal the pump shaft to the pump body end mea. sore tha tip clearance. SERVICE LIM: 0.20 mn {0.008 int Body Cleurance Remave the pump shat. Measure the body clearence. SERVICE LIMIT: 0.25 mm [0.010 in) 2-4LUBRICATION End Clasrance Nescure the end clearance, SERVICE LIMIT: 0.12 men (0.008 tn} ASSEMBLY (1) coveR (2) 00WEL ——(@) INNER. PIN Roror Insta the ienar and outer ratars and the dowel pin io the pura body, Jestall tre puma cover cn the Body, aligning the cover hots with the dowel pin / Pow is) OureR HOLE RoToR — (a) BODY sighton the bolts securely INSTALLATION Instat the dowel pins and a new casket. : 2-5LUBRICATION instal the oll pusmp and tighton the olts securely inctat the pump driven gear on tha rator by alaning their fet surfaces Instat the fotowing: primary drive gear \pege 7-9) = clutch age 7-6) right crankcase cover (page 7-10 (2) FLAT SURFACES 2-6 |LUBRICATION LUBRICATION POINTS Use general purpose grease when not otherwise specitiod here Apply oi or grease to siding surtaces and cables net shown here. CONTROL CABLE LUBRICATION Periodically dieconnect the theatte and clutch cables at their upper ends Ciena the cable end mount in the throttle and the calle ends and reinatal. 1 is not nec essary to ol the cables: a cable Hagins to bind, t must here pease am 7 (21 SWINGARM PIVOT BEARINGS! Sn a)contmo. cases busy Seats (3) Contnot Lever / avers / . / See / 18) BRAKE PEDAL 2) FORK (11) SPEEDOMETER GEAR: DUST SEALS (8) SHOCK ARM PIVOT NEFDLE BEARINGS: SHOCK LINK PIVOT NEEDLE BEARING DUST SEALS/COLLARS 2-7 d